Machine Translated by Google

Machine Translated by Google

Version Date: 20231231

Version Name: CF400-8 CF400-8F (6AQ2-00WX01-11) Maintenance Manual - 20231231

Official website: www.cfmoto.com

Machine Translated by Google

Preparation Instructions Table of contents

This maintenance manual describes in detail the CF400-8, CF400- Maintenance 1

8F maintenance and adjustment instructions, disassembly and installation procedures, inspection and maintenance information 2

Maintenance points, troubleshooting methods and maintenance technical data, Maintenance plan 3
Detailed graphic information is provided to guide the operation. Technical 4
The first three chapters mainly introduce general work items, tools used, information 5
The vehicle structure and basic technical parameters, inspection and adjustment points, Seat exterior parts 6
Maintenance and repair essentials, etc. 7
Fuel system Lights, instruments,
Chapter 4 and later introduces the disassembly and installation of various parts of the vehicle. 8
switches Electrical
Installation, adjustment, maintenance and fault diagnosis methods, etc. 9
system Cooling
The copyright and final right of interpretation of this manual belong to Zhejiang Chunfeng Power Co., Ltd.
system Exhaust 10
Co., Ltd. Without obtaining the approval of Zhejiang Chunfeng Power Co., Ltd.
system Front wheel, rear wheel, brake system 11
Without the written permission of the Company, any
Shock absorber, rear fork Engine 12
No part of it may be copied, translated, or reproduced in any form or
assembly Direction 13
electronic images may not be transmitted or disseminated by any means;
, and lower connecting plate
handlebar Upper 14
Files and recordings, etc.
combination Electrical schematic diagram Appendix A
Although great efforts have been made to make this manual as complete as possible,

good and accurate, but any bias in this publication

No responsibility is assumed for errors or omissions.

As the vehicle is improved, this manual may differ from the actual vehicle.

Any discrepancies will be changed without further notice.

The penalty is based on the actual vehicle and is not applicable to pre-production products.

This publication is for reference only.

If you have any objections, please contact your dealer to obtain the latest

Improved product information.

The information contained in this publication is based on the information available at the time of publication.

Get the latest product information. Illustrations in this publication

and photos are for reference only and do not represent actual models, components,

Parts, etc.

The contents in this manual are subject to change due to vehicle improvements, etc.

Subject to change without prior notice. Repair and maintenance

The actual status of the vehicle shall prevail.

Zhejiang Chunfeng Power Co., Ltd.

December 2023
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Unit symbol comparison table

A ampere) lb pound

ABDC after bottom dead center m rice

AC min
ATDC After Top Dead Center N Newton

BBDC before bottom dead center Pa Pascal

BDC Down to Point PS Metric horsepower
BTDC before top dead Psi pounds per square inch
center ÿC degrees Celsius r Revolutions

DC Direct Current rpm revolutions per minute

F Farad TDC Top Dead Center
degrees Fahrenheit ÿF feet ft Total TIR indicator reading
grams hours litres V volt
WWatt
gh ÿ Ohm
L in inch
US gal US gallon US qt US quart
oz HP Imperial horsepower
ounce cm Hg centimetre pint
of mercury cu in cubic inch mL milliliters
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Foreword This manual is designed for use by trained mechanics in a repair shop. However, the detailed information and basic information in this manual are

sufficient to enable the owner to perform basic maintenance and repair work on the motorcycle himself. To achieve more comprehensive maintenance and repair

results, a mastery of basic mechanics, the correct use of tools and an understanding of repair procedures are necessary. If you lack practical experience or are

unsure of the maintenance and repair work, all adjustments, maintenance and repair work must be performed by a qualified mechanic. In order to improve work

efficiency and avoid major mistakes, read this manual before operating to make yourself thoroughly understand the repair procedures, and then work carefully in

a clean area. Once special tools or equipment are specified, do not use makeshift tools or equipment instead. Only the use of appropriate tools or equipment

can ensure the mechanical performance of the vehicle, and the use of substitute tools will seriously affect the safety of operation. During the warranty period, we

recommend that all repairs and scheduled maintenance be carried out in accordance with this repair manual. If the owner performs maintenance or repairs

without following the procedures in this repair manual, we will not be responsible for any consequences.

To obtain a longer service life for this vehicle.

Follow the regular maintenance chart in this service manual.

Perform unscheduled maintenance in special

cases. Use appropriate tools and our company's original

accessories. The special tools, meters and testers necessary for CFMOTO motorcycles introduced in this service manual are listed in the parts catalog as

necessary original

accessories. Carefully follow the procedures in this manual. Do

not take shortcuts. Be sure to keep complete records of maintenance and repairs with specific dates, and indicate when new accessories were replaced.

How to use this manual In

this manual, the product introduction is divided into its main systems. These systems make up the chapters of this manual. The catalog has shown all the

systems of this product and can help you locate the specific chapters of the system. Each chapter has its own sub-catalog. For example: if you want to find

information about ignition coils, use the catalog to locate the electrical system chapter; then, find the ignition coil section in the catalog on the first page of the

chapter.
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Whenever you see the following warning and caution symbols, pay attention to its instructions! Always follow these safe operating and maintenance methods.

Danger: Indicates a situation where the operator or surrounding personnel may die if no action is taken.

WARNING: Indicates a situation where operator injury or component damage may occur if no action is taken.

CAUTION: Indicates a situation where precautions must be taken to avoid damage to components.

NOTE: Indicates information that makes a procedure easier or clearer. No symbols are used.

Note: The

vehicle disassembly steps do not include electrical components, guards and engines by default. Electrical components, engines and other contents will be disassembled and inspected in

separate chapters. All

connectors are disconnected by default during the disassembly process.

The guide lines without serial numbers in the pictures indicate the disassembly direction.
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Repair Information

1.1 Operation precautions.................................................................................. 1-2

1.2 Disassembly and assembly precautions............................................................
1-4 1.3 Number engraving position........................................................................... 1-8

1-1
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CFMOTO
1.1 Operation Precautions Danger:

Warning: When the engine is just stopped, the temperature of the engine
Since the exhaust gas contains harmful components, it is prohibited to
and muffler is still very high. Be careful not to touch them with bare hands to
operate the engine for a long time in a closed place or a place with poor
avoid burns. Please wear long-sleeved work clothes and gloves when performing
ventilation.
maintenance.

Warning: Battery solution (dilute sulfuric acid) is a strong corrosive

Warning: Coolant is toxic, please do not drink it, and do not let it get
agent. If it comes into contact with the skin or eyes, there is a risk of burns
on your skin/eyes/clothes. If it gets on your skin/clothes, please rinse it with
and blindness. If it comes into contact with the skin or eyes, please rinse it
soapy water immediately. If it gets on
, your eyes, please rinse them with
immediately with plenty of water and go to the hospital for treatment. In
plenty of clean water and go to the hospital for treatment. If you drink the
addition, if it comes into contact with clothes, please rinse it with plenty of
coolant by mistake, please spit it out/rinse your mouth immediately and go
water to avoid skin burns. Batteries and battery solution must be kept strictly
to the hospital for treatment. The coolant must be kept strictly and must
in a safe place where children cannot reach them.
be placed in a safe place where children cannot reach it.

1-2
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Repair Information

WARNING: Wear work clothes appropriate to the job. Danger: Gasoline is flammable so the work area must be strictly

(Overalls, etc.)/Hat/Safety boots, if necessary, and safety boots, if necessary, and No fireworks allowed. Be careful not only about open flames but also about electric sparks.

Wear dust glasses and dust masks/gloves and other safety protective equipment. In addition, there is a risk of explosion due to the evaporation of gasoline.

Protective products to protect your body. Work in a location with good wind.

Danger: When charging the battery, it will produce flammable and explosive hydrogen. Warning: When more than two people are working together, they must constantly

Gas will
, explode if there is fire or electric spark near it., Hail to confirm
, safety.

Danger. Please charge in a well-ventilated place.

Danger: When inspecting, be careful not to let the rear wheels or clutch

Rotating and movable parts such as devices may pinch your hands and clothes.

1-3
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CFMOTO
1.2 Precautions for disassembly and
ÿ Please clean the dirt/dust on the vehicle before maintenance.
assembly ÿ Parts/lubricants/greases must be genuine "Spring
Breeze" parts or recommended products.

ÿ Gaskets/O-rings/piston pin retaining rings/split pins etc. must be replaced with new

ones after disassembly. ÿ If the retaining

ÿ During disassembly, the components of each system should be sorted and stored
ring is opened too wide during disassembly, it will deform and easily fall off after
separately so that each component can be put back to its original position.
reassembly. Please do not use a retaining ring that has loosened/lost its elasticity.

ÿ After disassembly and inspection, parts should be cleaned and the cleaning agent

should be blown away with compressed air before measurement. Apply lubricating oil
ÿ During disassembly, necessary locations should be inspected and relevant data
to the moving surface before assembly.
measured so that the state before disassembly can be restored during assembly.

1-4
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Repair Information

ÿ If the screw length is unknown, insert the screws one by one and arrange them ÿ Fasteners such as bolts/nuts/screws must be pre-tightened first, and then

in order before screwing them in, making sure that each screw is screwed in the tightened diagonally from large to small and from inside to outside with the

same amount. specified tightening torque.

ÿ Rubber parts should be checked for aging when disassembling, and replaced ÿ Be sure to apply or inject the recommended grease in the designated areas.

in advance if necessary. In addition, since rubber parts are not resistant to

corrosion by gasoline/kerosene, try not to let volatile oils/greases adhere to them.

ÿ When removing a pressed-in ball bearing, if you use a disassembly method

that applies force to the ball, the removed bearing must not be used again.

ÿ If you need to use special tools for work, you must use the correct special tools

1-5
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CFMOTO
ÿ Turn the inner or outer ring of the ball bearing by hand to confirm whether the rotation is ÿ When assembling single-sided dustproof bearings, pay attention to the installation direction.

flexible and smooth. • Replace the When assembling open-type or double-sided dustproof bearings, install them with the side

bearing if the axial or radial looseness is too large. • Clean the bearing with oil engraved with the manufacturer's logo and size facing outwards.

if it feels uneven. If it is still not repaired after cleaning, replace it (double-sided dustproof type

cannot be cleaned). • Replace the bearing if it is pressed into the machine body or

shaft and the pressed part

is not tight.

ÿ When installing the circlip, place the chamfered side in the direction of force. Do not use a

circlip that has become loose and has lost its elasticity. After assembly, turn the circlip to

confirm that it is securely installed in the groove.

ÿ When the ball bearing is cleaned and blown with compressed air, do not let the bearing race

rotate. If the bearing race is allowed to rotate, its high-speed rotation speed will exceed the

limit, which may damage the bearing. Apply engine oil or grease to the bearing before

assembly.

ÿ Brake fluid and coolant will damage painted surfaces/plastic parts/rubber parts, etc. Do not

allow them to adhere to such parts. If they do adhere, rinse them immediately with water.

ÿ After assembly, be sure to check whether all fastening parts are tightened and whether

the operation is normal.

1-6
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Repair Information

ÿ The oil seal should be installed with the side with the manufacturer's logo ÿ When installing pipe parts, insert the pipe to the root of the joint. If there is a

facing outward (the direction pipe clamp, install it in the concave mark of the pipe. Replace the pipe that is

without oil). • When assembling, be careful not to curl the oil seal lip and not to not tight during installation.

let burrs scratch the oil

seal lip. • Apply grease to the oil seal lip before assembly.

ÿ The gasket material attached to the joint surface of each engine case must be

cleaned before assembly. The bumps on the contact surface must be evenly

ÿ Do not allow dust, dirt, etc. to enter the engine and the brake hydraulic system. polished and removed with an oilstone.

ÿ When assembling protective cap parts, if there are grooves, be sure to insert

ÿ Do not twist or bend cables excessively. Deformed or damaged cables may the protective caps into the grooves.

cause malfunction or breakage.

1-7
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CFMOTO
1.3 Number Engraving Location

1 3

1 Frame number 2 Engine number 3 Vehicle nameplate location

1-8
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02 Maintenance plan

2.1 Daily Maintenance Table.................................................................................. 2-2

2.2 Maintenance Table During the Running-in Period................................................... 2-3

2.3 Maintenance Table after Running-in Period.................................................................. 2-4

2-1
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CFMOTO

Maintenance information

Precautions
ÿ = Severe use item. When the vehicle is subjected to severe use, the vehicle maintenance interval is shortened by 50%.

ÿ = Have the affected component or system repaired by an authorized dealer.

2.1 Daily maintenance table

Pre-ride maintenance items

project
Hours Months km Remark

Fuel System
Fuel tank fuel
- daily - Check for damage and aging.
pipe electrical system

Switch
- Daily -
examine.
lights and speakers
- life -

2-2
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02 Maintenance plan

2.2 Maintenance table during the running-in period

Maintenance interval during the running-in period

project (Perform maintenance on the item that reaches the maintenance interval first)

Hours Months km Remarks

engine
ÿ Oil and oil filter Idle speed - - 1000 replace.
ÿ - - 1000
Coolant - - 1000 examine.

Throttle - - 1000
system Electrical
ÿ Function of electrical - - 1000
equipment - - 1000 examine.

Battery fuse or overload - - 1000

protector Brake
Brake - - 1000
disc Brake - - 1000 examine.

pad Brake fluid level - - 1000

- - Check for damage

ÿ Brake pipe 1000
Injury, whether it is sealed.

Brake pedal - - 1000 Check free travel.

wheel
Tire status Tire
- - 1000
examine.
pressure
- - 1000
Suspension

Check for oil leaks. (Press

According to need and purpose of use
ÿ Rear shock absorber and front fork
- - 1000
Front fork and rear shock absorber

Maintenance

cool down

Coolant level - - 1000

ÿ Coolant ÿ - - 1000
examine.
Radiator fan function - - 1000
Cooling - - 1000
hose direction
ÿ Steering bearings,
- - 1000 examine.

others

- - Using the diagnostic tool

ÿ Fault diagnosis interface 1000
Pick.
Lubricate and check its flexibility
ÿ All moving parts - - 1000
sex.
ÿ Bolts and nuts - - 1000 Check whether it is firm.
- - Check for damage
ÿ Cable 1000
Injury, bend and its setting.

2-3
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CFMOTO
2.3 Maintenance table after the running-in period

Maintenance interval after the running-in period

project (Perform maintenance on the item that reaches the maintenance interval first)

Hours Months km Remarks

engine
Engine oil and oil filter - 6M 5000 replace.
Clutch idle - - 10000
- - 10000 examine.
- - 10000
ÿ Coolant - 24M 30000 replace

Throttle - - 10000 examine.

system Throttle valve body - - 5000 Cleaning

- - 10000 examine.
ÿÿ Air filter element - -
24M
- - replace.
ÿ Spark plug ÿ 10000
Valve clearance - 40000 examine.

Electrical
ÿ Electrical equipment - 12M 10000
function - 6M 5000 examine.

battery fuse or overload protector - 6M 5000

Check for damage
ÿ Cable - 12M 10000 Injury, when laying
No bend.
brake
- 12M 10000
Front and rear brake system
- 24M 20000
- 12M 10000
Brake disc - 24M 20000
examine.
- 12M 10000
ÿ Brake pads - 24M 20000
- 12M 10000
Brake fluid level - - 20000
- 24M 20000
Brake pedal - Check free travel.
12M 10000
- 24M 20000 Check for damage
ÿ Brake pipe - 12M 10000 damage, whether it is sealed.
ÿ Brake fluid 24M - replace.
wheels
- 12M 10000
Tire condition - 24M 20000
- 12M 10000
Tire pressure - examine.
24M 20000
- - 10000
ÿ Wheel bearings - - 30000

2-4
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02 Maintenance plan

Maintenance interval after the running-in period

project (Perform maintenance on the item that reaches the maintenance interval first)

Hours Months km Remarks

Suspension

- - 5000
ÿ Suspension system
- - 10000 examine.
- - 15000
- 12M Check for oil leaks.
10000
(As needed and used
ÿ Rear shock absorber and front shock absorber
- Use the purpose of the front fork and
24M 20000
Rear shock absorber maintenance)
- - 10000
ÿ Rocker arm - - examine.
30000
cool down

- 12M 10000
Coolant level - 24M 20000
- 12M 10000
ÿ Coolant - 24M 20000
examine.
- 12M 10000
ÿ Radiator fan function - 24M 20000
- 12M 10000
ÿ Cooling hose - 48M 30000
Frame
Frame
- - 30000 examine.

steering
- 12M 10000
ÿ Steering bearing - examine.
24M 20000
Chain
- 12M 10000
ÿ Chain, rear sprocket and engine sprocket - examine.
24M 20000
other
- 12M 10000 Read using diagnostic tool
ÿ Fault diagnosis interface - 24M 20000 Pick.
- 12M 10000 Lubricate and check its
ÿ All moving parts - 48M 30000 active.
- 12M 10000
ÿ Bolts and nuts - Check for firmness.
48M 30000
- 12M 5000 Check for damage
ÿ Cable - Injury, stuck, pulling
24M 15000
Is it flexible?
- 12M 10000 Check for cracks,
ÿ All hoses and sleeves - Sealed and arranged
48M 30000
is it right or not.

2-5
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03 Technical Information

3.1 Main parameters of the vehicle.................................................................. 3-2

3.2 Main parameters of the engine.................................................................. 3-3
3.3 Maintenance parameters..........................................................................................
3-4 3.3.1 Front wheel..................................................................................................
3-4 3.3.2 Rear wheel..................................................................................................
3-4 3.3.3 Braking system...................................................................................
3-4 3.3.4 Lights, instruments, switches................................................... 3-4 3.4
Maintenance parameters..........................................................................................
3-5 3.4.1 Valve mechanism + cylinder head..................................................................
3-5 3.4.2 Lubrication system..........................................................................................
3-6 3.4.3 Cylinder + piston + piston ring + crank connecting rod.................. 3-6
3.4.4 Clutch + transmission.................................................................. 3-7 3.4.5
Cooling system................................................................................ 3-7 3.4.6
Intake system.......................................................................................... 3-7
3.4.7 Electrical system..........................................................................................
3-7 3.5 Tightening torque.................................................................................. 3-8
3.5.1 Vehicle tightening torque table................................................. 3-8 3.5.2
Engine fastener torque table................................................................ 3-9 3.6
Lubrication requirements...................................................................... 3-11

3-1
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CFMOTO
3.1 Main parameters of the vehicle

project parameter

450MT
model
CF400-8 CF400-8F

Overall 2210 mm

length 870 mm

Overall 1390 mm 1380-1430mm

width 1505 mm

Overall height 272MQ-B

Wheelbase Engine 449CC

model Integer gasoline

displacement Fuel type 185kg

Vehicle curb weight Number of passengers 2 persons (including driver)
Front wheel 90/90-21
Tire specifications
rear wheel 140/70 R18

Ground clearance 220 mm

Minimum turning diameter 5400 mm

Vehicle dry mass 175kg

Right 35º
Steering Steering angle
Left 35º

Front Hydraulic disc

Braking device type
and Hydraulic disc
rear Front Telescopic
Buffer device Suspension method
wheel Rear wheel Cantilever
Frame type Split cradle type

Item standard

Fuel tank capacity 17.5 L

Injector Model: F01R00MH06

Test voltage: DC13.5V±0.3V
Oil supply device
Output pressure: 0.40MPa ± 0.01MPa
Fuel Pump
Output flow: ÿ 20 L/h
Working current: ÿ 2.2 A

3-2
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03 Technical Information

3.2 Main engine parameters

Item Type/Specification

Type Vertical, in-line twin-cylinder, four-stroke, water-cooled

Cylinder bore × 72.0mm ×55.2mm

stroke Integer 449CC

displacement 11.5:1

Compression ratio Engine 1350r/min±135r/min

idle speed Electric start

Starting system Maximum net power 32.5kw, 8500rpm

and corresponding speed Maximum 44N•m, 6250rpm
torque and ECU Ignition

Electrical System corresponding speed Ignition BN8RT1/0.8mm ~ 1.0mm

control method Permanent magnet three-phase AC generator

Spark plug type/gap Paper filter element

Combustion System
Unleaded gasoline 95 (V) or above

Gas distribution system Magneto type DOHC/Chain Drive

Air filter type Pressure splash lubrication

Gasoline distribution Rotor type

method Lubrication method Oil pump type Filter

Full
type
flow filter + paper filter element
Lubrication system
First choice: SAE 10W-40 SJ JASO MA2

Engine oil brand Second choice: SAE 10W-30 SJ / SAE 10W-50 SJ / SAE 20W-40 SJ / SAE
20W-50 SJ JASO MA2

Cooling method Closed coolant circulation cooling

cooling system
Coolant type Clutch -35ºC Anti-rust and Antifreeze

type Speed change Wet multi-disc manual clutch

method Speed Six-speed international standard gear

reducer Gear shift 6 gears

method/sequence Primary Mechanical reciprocating/1-0-2-3-4-5-6-5-4-3-2-0-1

transmission ratio 2.088

transmission
1st 2.929
system Second-rate

gear 2.056
transmission class
2nd 1.579
Gear Ratio pass
gear 1.333
move
3rd 1.154
Compare

gear 4th gear 5th gear 6th gear 1.037

Net mass 47.3kg

output type Chain drive

Engine output Rotation direction In forward gear, looking from the left end of the engine, counterclockwise

3-3
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CFMOTO
3.3 Maintenance parameter table

3.3.1 Front wheel

standard Limits of use

Project: Front axle bent - 0.2 mm
Longitudinal 0.8 mm 2.0 mm
Rim runout
Front wheel
and 0.8 mm 2.0 mm
transverse residual
- 1.6 mm
tire -
groove air pressure 225 kPa

3.3.2 Rear wheel

project standard Limits of use

Longitudinal 0.8 mm 2.0 mm

Rim runout
and 0.8 mm 2.0 mm
rear wheel
transverse residual grooves
- 1.6 mm
tire 225kPa -
Air pressure

3.3.3 Braking system

Item Limits of use

Standard -
Front (hand) brake free
Front brake
travel Brake 4 mm
disc wear Rear (foot) brake 5mm~10mm 4.5 mm 10mm~20mm -
Rear brake
free travel Brake disc wear 5 mm 4 mm

3.3.4 Lights, instruments, switches

project standard

Main fuse, 30 A
fuse
auxiliary 1×25A 3×10A 3×15A 2×5A
fuse, led
headlight, led
Lighting position light, led
tail light, turn led
signal light, license plate light led

3-4
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03 Technical Information

3.4 Maintenance parameter table

3.4.1 Valve mechanism + cylinder head

project Standard Limit value notes

In- value 0.10mm~0.15mm -
Valve clearance (cold) -
0.25mm~0.31mm
Valve guide and valve stem 0.01mm~0.037mm 0.075mm
Fit clearance 0.03mm~0.057mm 0.095mm
Valve guide aperture row, in-row, 4.500mm~4.512mm 4.540mm
in- 4.475mm~4.490mm 4.465mm
Valve stem diameter
row, and in-row 4.455mm~4.470mm 4.445mm
Valve spring free length 36.8mm 35mm
When compressed to 33mm, the elastic force is -
Valve spring force -
106N~124N When compressed to 25mm, the
elastic force is 423N~467N Inlet 33.850mm
Cam height
33.945mm~34.055mm Outlet 32.945mm~33.055mm 32.850mm
Camshaft journal and camshaft
Inlet and 0.028mm~0.071mm 0.13mm
outlet bearing hole clearance

Camshaft journal diameter inlet and outlet 23.950mm~23.972mm 23.920mm

Camshaft bearing hole diameter inlet and outlet 24.000mm~24.021mm 24.050mm

Camshaft runout ÿ 0.02mm 0.1mm

3-5
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CFMOTO

3.4.2 Lubrication system

Project Standard Limit value notes

Oil pump inner and outer rotor value 0.08mm~0.15mm 0.25mm
clearance Oil pump outer rotor and oil pump
0.15mm~0.193mm 0.25mm
The gap between the body pores

1.4 bar at 1500 r/min -

hydraulics pressure
2.4 bar at 6000 r/min SAE
Oil Type 10W-40 SJ JASO MA2 Oil -

replacement and filter 2500 mL -

Oil quantity
Engine overhaul 2700 mL -

3.4.3 Cylinder + Piston + Piston Ring + Crank Connecting Rod

project standard value Limit value Remark

1.43MPa~1.55MPa -

Clearance between cylinder piston and cylinder 0.033mm~0.052mm 0.10mm

From piston bottom edge
Piston skirt diameter 71.960mm~71.975mm 71.910mm
Measured at 10mm
Cylinder bore diameter 72mm~72.019mm 1 72.065mm
ring 0.15mm~0.30mm 2 rings 0.55mm
Piston ring opening clearance 0.10mm~0.30mm Oil ring 0.55mm
0.20mm~0.70mm 1 ring 0.85mm
0.02mm~0.06mm 2 rings 0.15mm
Piston ring/piston ring groove clearance 0.02mm~0.06mm Oil ring 0.15mm
0.01mm~0.15mm 1 ring -

0.97mm~0.99mm 2 rings 0.93mm

Piston ring thickness 0.97mm~0.99mm Oil ring 0.93mm
1.38mm~1.50mm 1 ring -

1.01mm~1.03mm 2 rings 1.10mm

Piston ring groove width 1.01mm~1.03mm Oil ring 1.10mm
1.51mm~1.53mm -

Piston pin hole diameter Piston 17.002mm~17.008mm 17.035mm

pin diameter Connecting 16.992mm~16.997mm 16.980mm
rod small end hole diameter 17.015mm~17.025mm 17.035mm
Connecting rod big end side 0.15mm~0.30mm 0.50mm
clearance Crankshaft main journal 33.985mm~34.000mm 33.965mm
diameter Crankshaft main journal radial 0.028mm~0.060mm 0.070mm
clearance Crankshaft connecting rod 34.985mm~35.000mm 34.955mm
journal diameter Connecting rod big end 0.04mm~0.06mm ÿ 0.07mm
radial clearance Crankshaft runout 0.02mm 0.05mm

3-6
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03 Technical Information

3.4.4 Clutch + Transmission

Item standard value Limit value notes
Clutch friction plate assembly ÿ
-
-
Quantity 3
Clutch friction plate assembly ÿ
-
-
Quantity 3
Clutch friction plate assembly thickness 2.9 mm ~3.1 mm 2.8 mm
Driven plate
-
-
ÿ 1
Quantity
-
-
Driven 4
plate ÿ Quantity Clutch friction plate or driven plate thickness
ÿ 0.15mm 0.30mm
Surface
area Clutch spring free length 42.5mm~43.5mm 41.5mm
Shift fork claw thickness 4.93mm~5.00mm 4.83mm
Gear fork slot width 5.10mm~5.17mm 5.27mm

3.4.5 Cooling system

Item Standard value/parameter Thermostat opening Limit value notes

temperature 80ÿC~84ÿC Thermostat valve lift 95ÿC, ÿ 8 mm Radiator -

cap opening pressure 135kPa~160kPa (standard value 140kPa) B to shell -

end resistance -

A. C terminal resistance
-
Water temperature (ÿC)
(ÿ) (kÿ)
-20 - 13.71~16.94 -
The resistance of the water temperature sensor is
25 - 1.825~2.155 -
Water temperature correspondence
50 176~280 80 63.4~81.4 - -
110 24.6~30.6 -35ÿC High- 0.303~0.326 -
grade antifreeze, anticorrosion, 0.1383~0.1451 -

Coolant Type high boiling point coolant -

3.4.6 Air Intake System

Item Parameter Remark

Throat size (mm) value ÿ39 mm

Idle speed (r/min) 1400 r/min ± 140 r/min

3.4.7 Electrical system
project Parameter Value Remark

Model BN8RTI
spark plug
Electrode gap 0.8mm~1.0mm
Spark characteristics ÿ8mmÿ100kPaÿ
Primary 0.8ÿ~1.4ÿ
Ignition coil resistance
12.5kÿ~13.5kÿ
Magneto coil resistance Secondary Trigger 400ÿ
Magneto maximum output power 350W (7000r/min)
Regulated 13.5V~15.0V
voltage Ignition coil secondary ÿ27kV
voltage Trigger peak voltage ÿ20V (1300r/min)

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3.5 Tightening torque

The torque of common standard fasteners is as follows:

Type Torque N•m 5mm bolts, nuts Type Torque N•m(kgf•m)

5 5mm screw 4
6mm bolts and nuts 10 6mm screw 9
8mm bolts and nuts 20~30 6mm flange bolts and nuts 12
10mm bolts and nuts 30~40 8mm flange bolts and nuts 20~30
12mm bolts and nuts 40~50 10mm flange bolts and nuts 30~40

3.5.1 Vehicle tightening torque table

For places not listed in the table below, tighten according to the standard torque.

Note: 1: Threaded part, apply thread glue on the joint surface

2: Self-locking bolts should be replaced when disassembled

Installation type Quantity Tightening torque N•m

location Engine front left mounting M10×1.5×60 1 50~55
bolt Engine front right mounting M10×1.5×30 1 50~55
bolt Engine center right mounting M10×1.5×30 1 50~55
bolt Engine center left mounting M10×1.5×60 1 50~55
bolt Engine rear mounting nut M10×1.25 1 45~50
Subframe upper mounting bolt M10×1.25×25 2 50~55
Subframe lower mounting nut M10×1.25 2 50~55
Front M16×1.5 80~85
wheel axle Rear wheel axle nut M16×1.5 11 105~110
20~25 (on the upper plate shock absorber
Upper connecting plate locking screw M25×1.5 1
Before tightening the locking screw)

Upper connecting plate steering column locking bolt M8×25 Upper and lower 20~25
connecting plate shock absorber locking screw M8×30 Front shock absorber 1 20~25
locking front wheel axle bolt M8×25 Rear shock absorber upper mounting 6 20~25
bolt M10×1.25×50 Rear shock absorber lower mounting nut M10×1.25×50 21 45~50
Triangular rocker arm lower mounting nut M12×1.25 Triangular rocker arm upper 1 45~50
mounting nut M12×1.25 Tie rod welding assembly mounting bolt M10×1.25×130 1 50~55
Front brake caliper mounting bolt M10×1.25×60 Handlebar support mounting 1 50~55
bolt M10×1.25×60 Handlebar pressure block mounting bolt M8×25 Rear fork shaft 1 45~50
fastening bolt M12×1.25×35 Front left/right footrest bracket mounting bolt M8×20 2 45~50
Rear left/right footrest bracket mounting bolt M8×20 Rear handrail mounting bolt 2 45~50
M8×20 Clutch handle gland bolt M6×20 Note: Except for the nut, the bolts 4 20~25
above need to be glued with thread glue when assembling 2 105~110
2 20~25
4 20~25
4 20~25
2 7~9 (without glue)

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03 Technical Information

3.5.2 Engine fastener torque table

Quantity Thread Specification Torque Value (N•m) Remark

Project Crankcase bolts 3 M6 10

Apply appropriate amount of engine oil and MoS2 lubricant to the threads.
Crankcase bolt 13 M8 8 ÿ 20 ÿ 27
Grease mixture (weight ratio 10:1)
Apply appropriate amount of engine oil and MoS2 lubricant to the threads.
Crankcase bolt 6 M9 8 ÿ 20 ÿ 35
Grease mixture (weight ratio 10:1)
Left bearing baffle fixing bolt 2 M6 10 Apply thread locker
Right bearing baffle fixing bolt 2 M6 10
Shift fork 1 M14×1.25 5
shaft cover oil nozzle 2 M5 5.4
Oil pressure switch 1 Main R3/8 20 Threads coated with silicone sealant
oil channel cone plug 1 Oil R23/8 20 Apply thread lock glue
filter mounting bolt 1 Shift M20×1.5 M8 25
positioning torsion spring pin M6 20 Apply thread lock glue
1 Right side cover fixing bolt 11 10
Timing observation hole M12×1.5 4
cover 1 Oil filling plug 1 3/4ÿ Tight hands

Filter cover 1 Left side M35×1.5 M6 10

cover fixing bolt 11 Magneto M6 10
stator bolt 3 Trigger bolt 2 M5 10 Apply thread locker
Pressure plate bolt 1 5 Apply thread lock glue
Cylinder head cover bolt M6 10
4 Labyrinth cover bolt 3 M6 10
M6 10
New bolt 20 ÿ 54 Apply appropriate amount of engine oil and MoS2 lubricant to the threads.
Cylinder head bolt 6 M10
Old bolts 20 ÿ 49 Grease mixture (weight ratio 10:1)
Cylinder head bolt 2 Cylinder M6 10
head shock absorber bolt 1 M6 10
Water temperature sensor M12×1.5 M6 15
1 Thermostat cover bolt 3 10

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Items Quantity Thread Specification Torque Value (N•m) Remark

Spark plug 2 Cylinder M10×1 15

head bolt 2 Camshaft seat R23/8 20 Silicone sealant for threads
bolt 12 Tensioner assembly M6 5 ÿ 8 ÿ 12
bolt 2 Throttle body connecting M6 10
pipe bolt 3 Timing sprocket bolt 4 M6 10
Threaded pin 1 Magneto rotor M6 10
assembly fixing M8 20
1 M12×1.25 155
bolt
(20 N•m±2 N•m) Apply appropriate amount of engine oil and MoS2 to the threads

Connecting rod bolt 4 M8×0.75 +(100° ±5° ) Grease mixture (weight ratio
10:1)
Clutch pressure plate bolt 3 M6 10
Clutch fixing nut 1 M14×1.25 Output sprocket nut 1 125
M20×1.5 Positioning star wheel bolt 1 M6 125
Positioning rocker arm screw 1 M6 Gear 10 Apply thread lock glue

sensor bolt 2 M6 Speed drum limit screw 1 10

M6 Oil pump sub-assembly bolt 4 M6 Oil filter 10 Apply thread lock glue

1 M20×1.5 Water pump assembly bolt 4 M6 10

Drain bolt 1 M12×1.5 Oil pan fixing bolt 13 10
Starter motor bolt 2 17 Oil the sealing ring
10
35
M6 10
M6 10
M5 4.5~6
Other unfilled bolts M6 8~12
M8 18~25

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03 Technical Information

3.6 Lubrication requirements

The operating cables, bearings and rotating parts should be lubricated according to the

following table . Oil

PartsSide bracket rotating

partSteering column

bearingRear fork needle

roller bearingTriangular rocker

arm needle roller bearingTie rod welding

assemblyNeedle roller

bearingFront wheel left/right oil Lithium grease

lubricating
sealRear brake GB/T5671
pedal rotating

partRear

wheel right oil sealSprocket

seatOil seal cableWindshield

bracketMoving partFront

pedal rotating partRear pedal rotating partShift lever rotating part

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04 Seat Cushion

4.1 Seat Cushion Removal..................................................................................

4-2 4.2 Seat Cushion Installation........................................................................... 4-2

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4.1 Seat Cushion Removal

Place the vehicle on a flat surface and park it; Insert key

1 into the seat cushion lock and turn the key clockwise to release the seat cushion; Lift

the front part

of seat cushion 2 ; Remove the

seat cushion diagonally to the rear. 2

4.2 Seat Cushion Installation

Place the seat cushion flat on the vehicle along the longitudinal direction of the vehicle body, with the

front rubber pad of the seat cushion placed on the sheet metal (see picture a), and the rear end raised;

Press down the front end of the seat cushion and push it forward slightly so that the
E
raised fixing point A at the rear of the fuel tank is buckled into the seat cushion slot 1
H
(see picture E); Press down the middle of the seat cushion and slowly push it forward so G
that the seat cushion tongue 2 is buckled into the seat hook B at the rear of the fuel tank ,

and the seat cushion tongue 3 is buckled into the frame fixing hook C (see pictures F and G); F

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04 Seat Cushion

Continue to push the seat cushion diagonally downward until it is in place. Finally, press the

rear end of the seat cushion to buckle the lock tongue 4 into the seat cushion lock D (see

picture H). The seat cushion

1 4
is installed. After installation, grab the seat cushion and shake it slightly left and right to

confirm whether it is installed in place. 2

3

C D
A B
C

Note: If not installed properly, the seat cushion may be loose. Pull up the seat cushion to

check whether it is locked properly.

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05 Appearance parts

5.1 Front fender assembly .................................................................................. 5-2 5.1.1

Front fender trim panel........................................................................... 5-3
5.2 Handlebar Guard.................................................................................. 5-3 5.3 Front
Windshield.......................................................................................... 5-4
5.4 Body guard assembly.................................................................................. 5-4 5.4.1
Radiator left guard and left turn signal lamp.................................. 5-4
5.4.2 Radiator Right Guard and Right Turn Signal Light.................................. 5-5 5.4.3
Fuel Tank Upper Guard.................................................................. 5-6
5.4.4 Left body guard plate.................................................................................. 5-6
5.4.5 Right body guard plate.......................................................................................... 5-7
5.5 Headlights.................................................................................................. 5-9 5.6
Instruments......................................................................................................... 5-9
5.7 Radiator Front Guard.................................................................................. 5-10 5.8
Rear Hub Guard Assembly........................................................................... 5-10
5.8.1 Rear Armrest Cover.................................................................................. 5-10
5.8.2 Rear Armrest.......................................................................................... 5-10
5.8.3 Rear left decorative panel.................................................................. 5-11 5.8.4
Rear right decorative panel........................................................................... 5-11
5.8.5 Taillight upper guard.................................................................. 5-11 5.8.6 Rear
fender assembly........................................................................... 5-11
5.9 Small Sprocket Cover.................................................................................. 5-12 5.10
Engine Guard.......................................................................................... 5-12
5.10.1 Left engine guard plate.................................................................. 5-12 5.10.2
Right engine guard plate........................................................................... 5-12
5.10.3 Engine lower guard plate.................................................................. 5-12 5.11
Rear fork guard plate........................................................................... 5-13

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5.1 Front fender
assembly low fender 1

Disassembly Remove the three bolts on the left and right sides 1 ;
1

Remove the front fender 2 ;

1
2

Installation

Install in the reverse order of disassembly.

High mudguard

Disassembly Remove the 4 bolts 2

1 ; Remove the front fender 2 ;

Installation

Install in the reverse order of disassembly. 1

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05 Appearance parts

5.1.1 Removal of the front

fender
trim Remove
screw 1 ; Remove the left front fender.trim 2
1
2

Remove screw 3 ;
.
remove the front fender right decorative panel 4

3
4

Installation

Install in the reverse order of disassembly.

5.2 Handlebar guard

removal

Rotate and remove the two rearview

mirrors 1 ; Remove the two step screws 2 ;

Remove the left hand guard 3 ;

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Remove the right hand guard 4 ;

Installation

Install in the reverse order of disassembly.

5.3 Removal of the front

windshield Remove the four hexagon socket step

.
screws 1 ; Remove the front windshield 2

1 1

1 1
2
Installation

Install in the reverse order of disassembly.

5.4 Body Guard Assembly 5.4.1

Radiator Left Guard and Left Turn Signal Light

Removal Remove the three bolts 1 ;

1

Remove the two self-tapping screws 2 ;

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05 Appearance parts

Remove the left radiator guard plate according to the direction shown in

the figure 3 ; disconnect the turn signal

harness 4 ; remove the

4
bolts 5 ; remove the left turn signal 6 ;
65

Installation 3
Install in the reverse order of disassembly.

5.4.2 Removal of the right radiator guard and right turn signal

lamp

Remove the three bolts 1 ;

Remove the two self-tapping screws 2 ;

Remove the right radiator guard plate according to the direction shown in

the figure 3 ; disconnect the turn signal

4
harness 4 ; remove the
56
bolts 5 ; remove the right turn signal 6 ;

3
Installation

Install in the reverse order of disassembly.

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5.4.3 Removal of the upper guard

plate of

the fuel tank Open the fuel

3
tank cover 1 ; Insert the key to open the fuel

tank lock; Remove the three screws

2
2 ; Remove the fuel tank lock 3 ; 1
2

Remove the two bolts 4 ; remove

5
the two plastic clips 5 ; remove the upper 5
guard plate of the fuel tank 6 ;

6
Installation

Install in the reverse order of disassembly.

5.4.4 Removal of the left guard

plate of

the vehicle body Remove the three

bolts 1 ; Remove the plastic buckle 2 ;

1

Remove the two bolts 3 ;

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05 Appearance parts

Remove the 4 bolts 4 ;

Remove the left guard plate assembly 6 of the vehicle body ;

Installation

Install in the reverse order of disassembly.

5.4.5 Removal of the right guard

plate of

the vehicle body Remove the three

bolts 1 ; Remove the plastic buckle 2 ;

2

Remove the two bolts 3 ;

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Remove T-BOX 4 ;

Remove 4 bolts 5 ;
5

5
5

Remove the right guard plate assembly 6 of the vehicle body ;

Installation

Install in the reverse order of disassembly.

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05 Appearance parts

5.5 headlight

Disassembly Remove the six screws

1 ; Remove the two bolts 3 ;

Remove the headlight assembly 2 ;

1 1

Installation
3
Install in the reverse order of disassembly.

5.6 Instrument

disassembly Remove the three nuts

1 ; Disconnect the main wiring harness 2 ;

1

2
1

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Remove instrument 3 ;

Installation

Install in the reverse order of disassembly.

5.7 Radiator front guard plate removal

Remove
1 1
the 4 bolts 1 ; Remove the radiator

front guard plate 2 ;

Installation 2
Install in the reverse order of disassembly.

5.8 Rear wheel hub baffle assembly 5.8.1

Rear armrest cover plate removal

Remove

the 4 bolts 1 ; Remove the rear

armrest cover plate 2 ;

12

Installation

Install in the reverse order of disassembly.

5.8.2 Rear armrest

removal

Remove the two bolts 1 ; Remove

the two bolts 2 ; Remove the rear

armrest 3 ;
1
twenty three

Installation

Install in the reverse order of disassembly.

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05 Appearance parts

5.8.3 Removal of the rear left

decorative

panel Remove the two bolts 1 ;

Remove the two expansion screws 3 ;

Remove the rear left decorative panel 2 ;

Installation 3
Install in the reverse order of disassembly.

5.8.4 Removal of the rear right

decorative

panel Remove the two bolts 1 ;

Remove the two expansion screws 3 ; 1

Remove the rear right decorative panel 2 ;

Installation

Install in the reverse order of disassembly.

5.8.5 Removal of the upper taillight

guard

Remove the stepped screw 1 ;

Remove the two self-tapping screws 2 ; 1

2
Remove the upper taillight guard 3 ;

Installation

Install in the reverse order of disassembly.

5.8.6 Rear fender assembly removal

Remove

the 4 bolts 1 ; Remove the rear

fender assembly 2 ;

11
Installation

Install in the reverse order of disassembly.

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5.9 Disassembly of small

sprocket

cover Remove the three hexagon socket screws

1 ; Remove the small sprocket cover 2 ;

2

Installation

Install in the reverse order of disassembly.

5.10 Engine guard plate 5.10.1

Removal of the left engine guard plate 2

Remove

the two step screws 1 ; Remove the left

engine guard plate 2 ;

Installation

Install in the reverse order of disassembly.

5.10.2 Removal of the right engine guard

plate

Remove the two step screws 1 ; Remove the

engine guard plate 2 ; 2

Installation

Install in the reverse order of disassembly.

5.10.3 Removal of engine lower guard

plate

Remove the four bolts 1 ; Remove

the engine lower guard plate 2 ;

1 1

Installation

Install in the reverse order of disassembly.

2

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05 Appearance parts

5.11 Rear fork guard removal Remove

the two

hexagon socket step screws 1 ;

Remove the hexagon socket step screw 2 ; remove the rear

fork guard 3 ;

Installation

Install in the reverse order of disassembly.

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06 Fuel System
6.1 Fuel Evaporation System.................................................................................. 6-3
6.2 Fuel Tank Removal.................................................................................. 6-3
6.3 Oil Pump Assembly.................................................................................. 6-4
6.4 Oil Level Sensor Assembly.................................................................. 6-4

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Danger:

Fuel is flammable. Please repair the fuel system in a ventilated area. The engine must be shut down in advance and the engine and muffler must be completely

cooled. Smoking or other pyrotechnic activities are strictly prohibited in the refueling area or fuel storage area. Do not tilt

or invert the fuel tank to prevent the overflowing fuel from flowing onto the high-temperature

components. Fuel is toxic and harmful to health. Do not allow fuel to come into contact with the skin, eyes and clothing. Do not inhale fuel vapor.

If fuel comes into contact with the skin, rinse the contact area with plenty of water

immediately. If fuel comes into contact with the eyes, wash them immediately with

water and go to the doctor. If fuel comes into contact with clothing,

change the clothing in time. If you swallow fuel by

mistake, go to the doctor immediately. Handle fuel properly to avoid harm to the environment.

warn:

Please use genuine parts for maintenance work, otherwise the normal operation of the electronic fuel injection system cannot

be guaranteed. During the maintenance process, it is forbidden to disassemble the

electronic fuel injection parts. During the maintenance process, the

electronic fuel injection parts should be handled with care. When disconnecting or connecting the connector, be sure to turn off the ignition

switch, otherwise the electronic fuel injection parts will be damaged. When removing the electric fuel pump from the fuel tank, do not energize the fuel

pump to avoid sparks and fire. The fuel pump is not allowed to be tested in a dry state or in water, otherwise its service life will be shortened. In addition, the positive and

negative poles of the fuel

pump cannot be connected in reverse. The fuel supply pressure of the electronic fuel injection system is high (about 400kPa), and all fuel pipes are made of high-pressure

resistant oil pipes. Even if the engine is not running, the oil circuit maintains a high oil pressure, so be careful not to disassemble the oil pipe easily

during the maintenance process. When checking the ignition system, spark detection should be performed only when necessary, and the time should be as short as possible.

The throttle should not be opened during the detection, otherwise a large amount of unburned gasoline will enter the exhaust pipe and damage the three-way

catalytic converter. When the fuel system needs to be repaired, the fuel system should be depressurized before removing the fuel pipe. The depressurization method is as

follows: Remove the fuel pump relay, start the engine and let it idle until the engine extinguishes itself. The removal of

the fuel pipe and the replacement of the fuel filter should be carried out by professional maintenance personnel in a well-ventilated place.

When connecting the battery, the positive and negative poles of the battery must not be connected incorrectly to avoid damaging the electronic components.

This system uses the negative pole grounding. It is not allowed to remove

the battery cable when the engine is running. Before implementing electric welding on the whole vehicle, the positive and negative battery cables and the

electronic control unit must be removed. Do not use the method of piercing the skin of the wire to detect the electrical

signals input and output of the components. Establish environmental protection awareness and effectively deal with the waste generated during the maintenance process.

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06 Fuel System
6.1 Fuel evaporation system disassembly

Remove

the fuel vapor desorption pipe 1 on both sides of the throttle valve ; Remove

the carbon canister 3 from the carbon canister fixing seat 2.

1
Installation: Install in the reverse order of disassembly;

6.2 Fuel tank disassembly

Remove

the two bolts 1 ; Lift the rear

of the fuel tank 2 ; Note:

Prevent the rubber pad from being lost.

Disconnect the oil tank leakage pipe 3 ;

Remove the high-pressure fuel pipe assembly

4 ; remove the entire fuel tank assembly.

Danger: Do not invert the fuel tank to prevent fuel leakage.

Warning: When installing the fuel tank, first install the quick connector of

the high-pressure fuel pipe and check that the pipes are not squeezed or

damaged.

Installation: Install in the reverse order of disassembly; 4

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6.3 Fuel pump assembly

Depressurize the fuel system; Ensure

that the static electricity of the vehicle is released by grounding;

Disconnect the cables associated with the fuel pump;

Disconnect the quick connector and use a towel to prevent fuel leakage; After removing all the

connecting wires and connectors under the fuel pump, clean the bottom of the fuel tank and the

fuel pump to prevent foreign matter from entering the fuel tank; Note: Too much

foreign matter in the fuel tank will cause premature wear of the fuel pump or block the fuel coarse

filter. Remove bolts 1 to 5 in sequence ; 2

Carefully remove fuel pump 6 ; Note: There will still be a 1 3
certain amount of fuel in the removed old fuel

pump, and the old fuel pump should be transferred to an appropriate container in time. Check 6
whether there is any debris in the fuel tank. Before reinstalling the new fuel pump, the inside of
5
the fuel tank should be thoroughly cleaned with clean fuel. Do not use water or other chemical
4
reagents to clean the inside of the fuel tank. Installation Put the fuel pump seal ring from bottom to

top on the installation position of the fuel pump assembly, and then correctly position the fuel

pump in

the installation hole of the fuel tank assembly. Note: The arrow of the fuel pump is always aligned

with the positioning mark of the fuel tank. Place the fuel pump screw cap at the joint of the fuel

pump assembly and

the fuel tank assembly. Install bolts 1 to 5 in sequence ; reconnect the quick connector, cables

and

other components, and start the power supply to test whether the fuel pump starts normally.

6.4 Disassembly of the oil level sensor assembly

Remove

the four bolts diagonally 1 ; Carefully remove

the float ball assembly 2 ;

Installation

Installation is carried out in the reverse order of disassembly; 1 1

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06 Fuel System

Inspection Check whether the fuel tank has dents, cracks or other damages. If found, replace the fuel tank components in time.
Check whether the hose has cracks, aging, oil leakage, etc. If found, replace it in time. Installation

Installation should be carried out in the reverse order of disassembly.

Note: When installing the fuel tank, there must be no squeezing, excessive bending, etc. between the pipes and cables.

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07 Lamps, Instruments, Switches

7.1 Maintenance Information .................................................................................. 7-2 7.1.1

Operation Precautions........................................................................... 7-2
7.1.2 Maintenance criteria.................................................................................. 7-2 7.2
Lamp fault diagnosis.......................................................................................... 7-2
7.3 Ignition Lock.................................................................................................. 7-3 7.4
Front Brake Light Switch.......................................................................................... 7-3
7.5 Handle Switches.................................................................................. 7-4 7.5.1 Left
Handle Switch........................................................................... 7-4
7.5.2 Right Handle Switch.................................................................................. 7-5 7.5.3
ABS Switch......................................................................................................... 7-5
7.6 Instruments.................................................................................................. 7-6 7.7 Oil
Level Sensor.......................................................................................... 7-7
7.8 Battery.................................................................................................. 7-8 7.9 Grounding
Wire.......................................................................................... 7-9
7.10 Intelligent Vehicle Connectivity Terminal.................................................................. 7-9

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7.1 Maintenance Information

7.1.1 Operation Precautions Warning:

·When checking the battery, check whether the battery is abnormal. ·The switch

conduction test can be checked and measured when the switch is installed on the vehicle body. ·After the

inspection and maintenance of each part, the cables and cables must pass correctly according to the cable and cable wiring diagram.

7.1.2 Maintenance criteria

project

Primary insurance
fuse
Secondary insurance Standard 30A 2×5A 3×10A 3×15A
1×25A Low beam
Headlight LED: 15W High
beam LED: 26W
Lighting
Turn signal Position light LED:
9.9W LED: 1.5W×4 Rear
taillight
position light LED: 2.3W Brake light LED: 4.4W

7.2 Lighting fault diagnosis The light

does not light up when the switch is turned on, and the high and low

beams cannot be

switched. Possible reasons:

1) The fuse is blown. 2)

The switch is damaged. 3) The battery is low or the

wiring is bad. 4) The related connectors are abnormal, such as the pins are pulled out,

bent or not plugged in

properly. 5) The headlamp controller is

faulty. For

headlamp

disassembly, please refer to 05 Appearance Parts Headlamp Disassembly Section

Use a cross screwdriver on the right side of the vehicle headlight to directly

adjust gear 1 to adjust the up and down angle of the low/high beam.

Note: The headlight is an LED light and must be replaced as a whole if the main

body is damaged.

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07 Lamps, Instruments, Switches

7.3 Ignition lock

Check

and pull out the connector connecting the ignition switch 1 and the main cable, and

check the connection of the ignition switch.

1
Ignition switch

position/line color red black key can be pulled out • • can not

can

7.4 Front brake light switch Unplug

the front brake light wiring switch plug 1 Check the front brake light wiring Check the

front brake light wiring: 1. When the front brake handle is

squeezed: the brake light is on 2. When the front brake

handle is released: the brake light is off

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7.5 Handle switch

7.5.1 Left Handle Switch

Disconnect the left handlebar switch harness from the main cable connector.

Check the on-off status of each switch. 1

Dimmer switch 1
color
Function
G/ L
W• •
• •

Menu switch
color
2
Function
GB/WL/B GR/R L/WG/W
ÿ•• • 2
SET • • •
BACK • ÿ • • •
••
R 3

Steering switch 3
color
4
Function
GR SB
O• •
• •

Horn switch 4 color

Function
G/ LG
W• •

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07 Lamps, Instruments, Switches

7.5.2 Right-hand switch

Disconnect the right-hand switch harness from the main cable connector.
Check the on-off status of each switch.
1

Flame-out and start switch 1

Function
color
B/BR BR/B Y/R

• •
• • •
2

Warning switch 2

Function
color
O GR SB
(press) • (pop) • •

7.5.3ABS switch
Disconnect the connector connecting the ABS switch harness to the main cable.

Check the on-off status of each switch.

1
ABS switch
Function
color
L/Y G/B
(press) • (pop) •

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7.6 Instrumentation

18 34
1 17

No. Pin Function 1 Keyless Serial number Pin Function Number Pin Function

system indicator light 4 Oil 2 EFI fault light 3 ABS warning light

pressure signal 7 Position 5 Fuel level signal (450ÿ high resistance) 6 High beam signal

light signal 8 Right turn signal 11 9 Left turn signal

10 Handle switch: return 13 Handle switch: Confirm 14 12 Handle switch: Down

Handle switch: up 16 Electric Negative power 15 Negative pole of power supply

door lock 19 supply 17 Positive 18 Oil level signal (90ÿ small resistance)

Vehicle speed power supply 20 Start 21 Gear signal 6

signal 22 Gear signal ground signal 23 Gear 24 Gear signal 3

5 25 Gear signal 2 signal 4 26 Gear 27 Gear position signal N

28 ABS off signal 31 signal 1 29 Mode 30 12V power output

Ambient temperature sensor selection 32 Ignition off switch signal 33 CAN-L

34 CAN-H

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07 Lamps, Instruments, Switches

7.7 Fuel level sensor

removal
Refer to Chapter 06 Fuel
.
system Remove the 4 nuts and take out the fuel level sensor 1
1

Check
whether the oil level sensor seal is deformed/damaged/hardened,
if so, replace it; Check
the resistance value of the oil level sensor at the high and
low poles;
Resistance value: High:
(10±1.5)ÿ Low: (450±5)ÿ

Connect the oil level sensor harness to the main circuit, turn on the ignition switch,

slowly swing the oil level sensor float up and down, and check the swing of the oil

gauge pointer on the instrument; if the pointer fails to

reach point F or E, the oil gauge is defective and should be replaced with a new

one; if

the pointer is unstable when swinging, the oil level sensor is defective and should

be replaced with a new one.

Note: After installing the oil level sensor, check for oil leakage.

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CFMOTO
7.8 Battery

Warning:

1. Even if the battery is not in use, it loses charge every day. 2. The state of

charge and charging method are very important to the service life of the battery. Using high charging current to quickly charge will have a negative

impact on the service life. 3. If the charging

current, charging voltage and charging time are exceeded, the battery will be damaged. 4. If the battery is

low due to repeated starting of the vehicle, it must be charged immediately. 5. Leaving the battery in a discharged

state for a long time will cause deep discharge and sulfation, which will damage the battery. 6. The battery does not require maintenance,

and there is no need to check the acid level. 7. It is not allowed to remove

the battery cable when the engine is running. 8. It is prohibited to use

the method of piercing the surface of the wire to detect the electrical signals input and output of the

components. 9. Establish environmental protection awareness and effectively handle the waste generated during the maintenance process.

Remove the battery

and take off the

seat cushion; Unfasten the rubber strap that

secures the battery; Remove the negative bolt 1 and the

3
positive bolt 2 ; Remove the.battery 3

Warning: When removing the battery, you must first remove the negative cable.

This will cause the battery to short circuit.

1

When
charging, switch off all electrical consumers
2
and the engine;
Remove the battery; Connect the charger to the battery and
switch it on; After charging, switch off the charger and disconnect it from
the battery.

Note: If the vehicle is not in use, recharge its battery every 3 months.

Check the charging

voltage. The battery must be fully functional and fully charged. Start

the vehicle and measure the voltage. The

measuring point is positive (+) and the measuring point is

grounded (-).

5000rpm Charging voltage 13.5V~15.0V

If the displayed value is less than the specified value:

Check the connector from the engine to the rectifier-regulator;

Check the connector from the rectifier-regulator to the cable

harness; Check the electronic winding of the

engine. If the displayed value is greater than the

specified value: Replace the rectifier-regulator.

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07 Lamps, Instruments, Switches

7.9 Grounding wire

Grounding wire 1 is located at the upper front of the left side of the

frame. Grounding wire 2 is located at the lower middle of the left

side of

the frame. Check and turn off the engine and all

electrical equipment; Check whether the grounding wire

harness is abnormal; Check whether bolts 1 and 2 are loose.

7.10 Intelligent vehicle connection terminal

reference 05 Appearance parts

The intelligent vehicle connection terminal (T-BOX) is located in the front right guard plate;

Take out the intelligent vehicle connection

terminal 1 ; Check the connection of the connector.

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CFMOTO
Intelligent vehicle connection terminal (T-BOX) fault code

sequence DTC Possible fault

DTC meaning Failure maturity conditions Fault clearing conditions Repair suggestions
Number Display Code reason

1. Ignition state shall be IGN ON;

Vehicle 1.battery
B111716

power voltage >= Check

(demo)

2.The engine status is not in Cranking; Battery

supply 10V, and keep the power
(FV only) voltage
voltage status at least supply
3.Power supply voltage <= 9V, too low
below at t >= 1000ms; battery;
and keep the status at least at t >=
threshold
1000ms;"
1. Ignition state shall be IGN ON;
1.battery
B111716

Check
2.The engine status is not in voltage >= 10V, Battery System power
supply power
1 Cranking;(FV only) and keep the voltage too low
supply
3.Power supply voltage < 9V, status at least too low
battery;
and keep the status at least at t >= 500ms;
at t >= 1000ms;
1. Ignition state shall be IGN ON;
1.Battery
B111717

Check
2.The engine status is not in System voltage <= 15V, Battery and
power supply power
2 Cranking;(FV only) keep the voltage status at
Pressure too high supply
3.Power supply voltage > 16V, least too high
battery;
and keep the status at least at t >= at t >= 500ms;
1000ms;
1.Ignition state shall be IGN 1.Refer
the ON; Check
U007388

CAN bus.
BusOff fault Is the CAN
BICAN Total 2.Power supply voltage is in circuit bus
3 demature range of short
BusOff 9-16V; or circuit
definition in or EMC?
3.BusOff fault definition Refer to open
ISO-11898-1;
to ISO-11898-1 is met;
1. Ignition state shall be IGN ON;

2.Power supply voltage is in the

range of 9-16V; 1. Received Check
U118287

CAN bus.
3.The condition of diag enable MMI (CANID = 0 Is the CAN
MMI Node circuit bus
4 time=1.5s is met; x 151) short
Communication lost or circuit
4.Lost MMI(CANID=0x151) message at or EMC?
open
message time >= 10 times the least once;
transmission cycle and Lost
MMI(CANID=0x151) message
time >= 500ms;

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07 Lamps, Instruments, Switches

1. Ignition state shall be IGN ON;

2.Power supply voltage is in the

range of 9-16V; 1.Received Check
U11C087

CAN bus.
3.The condition of diag enable BCM (CANID = 0 Is the CAN
BCM Node circuit bus
5 time=1.5s is met; x 130) short
Communication lost or circuit
4.Lost BCM(CANID=0x150) message message at or EMC?
open
time >= 10 times the transmission least once;
cycle and Lost BCM(CANID=0x150)
message time >= 500ms;
B1A4087

Harness damage
KL15 is powered on. KL15 is powered on and KL30 is disconnected for more than KL15 Power on KL30
6 Bad, malicious
KL30 Disconnect 30s Connection takes more than 1s
destroy

1.Power supply voltage is in the

1. Received Check
U220D00

range of 9-16V; CAN bus.

and sent ring Is the CAN
Network Management 2.Nmrxcount >4 or line circuit bus
7 message short
return fault Nmtxcount >8; or circuit
successfully at or EMC?
3.tLimpHomeDTC >= open
least once;
2000ms.

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Electrical System

8.1 Diagnostic Tools.................................................................................. 2

8.2 Charging System.................................................................................. 3
8.2.1 Magneto coil resistance...................................................................................3

8.2.2 Performance of magneto without load..................................................................3

8.2.3 Starting relay..................................................................................................4

8.2.4 Rectifier and Voltage Regulator..................................................................................5

8.3 Electronic fuel injection system.................................................................. 6

8.3.1 Structure of the EFI system...................................................................................6

8.3.1.1 Sensors..................................................................................................6

8.3.1.2 ECU ..................................................................................................................6

8.3.1.3 Actuator..................................................................................................6

8.3.2 Precautions for maintenance of electronic fuel injection system...................................................7

8.3.3 Structure and performance of EFI components................................................................8

8.3.3.1 ECU ..................................................................................................................8

8.3.3.2 Throttle body assembly..................................................................................9

8.3.3.3 Intake air pressure temperature sensor...................................................................10

8.3.3.4 Water temperature sensor..................................................................................12

8.3.3.5 Oxygen sensor..................................................................................................13

8.3.3.6 Trigger.................................................................................................................14

8.3.3.7 Fuel pump assembly..................................................................................15

8.3.3.8 Injector..................................................................................................16

8.3.3.9 Ignition coil..................................................................................................17

8.3.4 UP6.0 Fault Codes..................................................................................................18

8.4 Common Fault Diagnosis........................................................................ 20

8.5 Diagnose engine faults based on symptoms.................................................. 23

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CFMOTO
8.1 Diagnostic Tools

CFMOTO DSCAN Aftermarket Diagnostic Instrument

Function : Read/clear EFI system fault codes, observe data flow, update ECU

program, etc.

Diagnostic instrument digital multimeter

Function: Check the voltage, current, resistance and other characteristic

parameters in the EFI system

8-2
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Electrical System

8.2 Charging System

8.2.1 Magnetic Motor Coil Resistance

Measure the resistance between the stator coils of the three-phase magnetic

motor. If the resistance is within the specified range, it means that the magnetic

motor is good; otherwise, it is abnormal and needs to

be replaced with a new part. Normal magnetic

motor coil resistance range: 0.55ÿ~1.5ÿ

(yellow-yellow); Insulation resistance: ÿ ÿ (yellow-

ground); Check whether the stator coil and the stator center are

insulated; When checking, the multimeter should be set to 1×10ÿ.

8.2.2 Performance of magneto without load Start

the engine and let it run at 5000r/min, then use a multimeter to measure the

voltage between the three output wires of the magneto stator coil. If the voltage

meets the following range requirements, the magneto is in good condition;

otherwise, it is abnormal and needs to be replaced with a new part; When the

magneto

is without load, the voltage between the coils is ÿ 50V (AC) at 5000r/min; When

measuring, set the multimeter to the AC voltage

range.

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CFMOTO
8.2.3 Starting relay Load DC12V

voltage on the positive and negative contacts of the starter relay control circuit coil,

and then use a multimeter to measure whether the contacts are connected; If the

relay contacts make a

ticking sound and the multimeter makes a continuous ticking sound, it means that

the two contacts are connected; otherwise, it means that they are not connected;

When the DC12V voltage

is not loaded on both ends of the coil, the two contacts are not connected; The

above two items

can confirm whether the relay is in good condition. When measuring, the multimeter

should be set to the diode position;

Warning: The voltage applied to the relay coil should not exceed two minutes,

otherwise the coil will overheat and burn out.

When using a multimeter to measure the resistance between relay coils, if the

resistance is not within the specified range of 3ÿ~5ÿ, it is necessary to replace it

with a new one;

when measuring, the multimeter should be set to the 1×10ÿ range.

The auxiliary relay

A
applies DC12V voltage to the positive and negative poles of the auxiliary relay

control circuit coil, and uses a multimeter to measure whether the A and B contacts

are connected. When measuring, the multimeter is set to the diode gear. If the

contacts make a ticking sound and the multimeter makes a continuous beeping

sound, it means that the two contacts are connected; otherwise, it means that they

are not connected;

When the DC12V voltage is not loaded on both ends of the coil, the two contacts

are not connected;

The above two items can confirm whether the relay is in good condition. When

measuring, the multimeter should be set to the diode B

gear; The normal coil resistance range is 90ÿ~100ÿ.

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Electrical System

8.2.4 Rectifier and Voltage Regulator

AC

Connection Diagram circuit diagram

8-5
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CFMOTO
8.3 Electronic fuel injection system

8.3.1 Structure of electronic fuel injection system

8.3.1.1 The sensor 8.3.1.3 The actuator

converts various non-electrical physical quantities of the engine into executes the instructions of the electronic control unit ECU. The actuator

electrical quantities and provides various information to the electronic is the hands and feet of the electronic control unit. The main

control unit. It is the eyes and ears of the electronic control unit. It actuators are: • Fuel pump assembly (provides high-

includes the following sensors: • Intake pressure pressure fuel) • Injector (injects fuel quantitatively to make the fuel

sensor (load information) • Intake temperature and pressure sensor atomization better) • Ignition coil (provides high-voltage ignition energy

(air density information) • Throttle position sensor (load information, load to the spark plug) • Idle speed control (provides idle air intake)

range information, acceleration

and deceleration information) • Trigger

(crankshaft phase information) • Water temperature

sensor (engine temperature information) • Mileage

sensor (output shaft speed information) •

Gear position sensor (gear position information) • Oxygen sensor (excess

air coefficient, i.e., ÿ greater than 1 or less than 1 information)

8.3.1.2 ECU

Electronic Control Unit, the brain of the entire EFI system. It analyzes and

processes various information provided by sensors and sends the

conclusions to the actuator in the form of instructions, so that the engine

can run in the best state.

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Electrical System

8.3.2 Precautions for EFI system maintenance • Please • Idle speed adjustment is completely completed by the electronic fuel injection system and does not

use genuine parts for maintenance work, otherwise the normal operation of the EFI require manual adjustment.

system cannot be guaranteed; • During the

maintenance process, it is forbidden to disassemble the EFI components When the fuel system needs to be repaired, the fuel system should be depressurized

Operation; before removing the fuel pipe. The depressurization method is as follows: remove

• During maintenance, the EFI parts should be handled with care; • When the fuel pump relay, start the engine and let it idle until the engine extinguishes itself .

disconnecting or connecting the connectors, be sure to turn off the ignition switch,

otherwise the EFI parts will be damaged; • When removing the

electric fuel pump from the fuel tank, do not energize the fuel pump to avoid generating Only professional maintenance personnel can perform this work in

electric sparks and causing fire; • The fuel pump is not allowed to be tested in places with good wind. • When connecting the battery, the positive and negative poles

a dry state or in water, otherwise its service life will be shortened. In addition, the of the battery must not be connected incorrectly to avoid damaging the electronic

positive and negative wires of the fuel pump cannot be connected in reverse • components.

The fuel supply pressure of the EFI system is high This system uses the negative pole for grounding. • When the engine is running, it is

(about 400kPa), and all fuel pipes are made of high-pressure resistant oil pipes. not allowed to remove the battery cable. • Before welding on the vehicle, the positive

Even if the engine is not running, the oil circuit maintains a high oil pressure, so and negative battery cables and the electronic control unit must be removed.

be careful not to disassemble the oil pipe easily during maintenance. • When

checking the ignition system, spark detection should only be performed when • Do not pierce the wire to test components.

necessary, and the time The electrical signals input and output of the device;

should be as short as possible. The throttle should not be opened during the detection, • Establish environmental protection awareness and effectively handle waste generated

otherwise a large amount of unburned gasoline will enter the exhaust pipe and during maintenance.

damage the three-way catalytic converter;

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CFMOTO
8.3.3 Structure and performance of EFI components
8.3.3.1 ECU
The electronic control unit is the brain of the entire electronic fuel injection system. It analyzes and processes the various information provided by the sensors.

The conclusions drawn are sent to the actuator in the form of instructions, so that the engine can run in the optimal state.

ECU pin functions:

Serial number pin function Serial number pin function Serial number Pin Function

1(M1) Oxygen sensor heating 2 2(L1) Oxygen sensor heater 1 3(M2) Ignition coil 1

4(L2) 5(M3) Ignition Ground 6(L3) Carbon canister valve fuel evaporation control

7(M4) Ignition coil 2 8(L4) Non-continuous power supply 9(K1) Intake air pressure sensor

10(J1) Sensor ground 1 11(H1) Intake air temperature sensor 12(G1) Throttle position sensor

Engine coolant temperature sensor

13(F1) 14(E1) Main relay 15(D1) CAN communication line low

16(C1) CAN communication line high 17(B1) Stepper motor phase D 18(A1) Stepper motor phase C

19(K2) Oxygen sensor 1 20(J2) Sensor 2 21(H2) 2 cylinder ignition diagnosis

22(G2) Empty 23(F2) Side support switch 24(E2) Flame-out switch

25(D2) Empty 26(C2) Start relay 27(B2) Stepper motor phase A

28(A2) Stepper motor phase B 29(K3) Empty 30(J3) 5V power supply

31(H3) Empty 32(G3) Non-continuous power (power after lock) 33(F3) Continuous power

34(E3) 35(D3) Neutral switch 36(C3) 1 cylinder ignition diagnosis

37(B3) Clutch switch 38(A3) 39(K4)

40(J4) 41(H4) 42(G4) Engine speed sensor B terminal

43(F4) Engine speed sensor A terminal 44(E4) 45(D4) Fan relay

46(C4) Oil pump relay 47(B4) Injector 2 48(A4) Injector 1

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Electrical System

8.3.3.2 Throttle body assembly

Connect the air filter and the engine, control the opening and closing angle of the

throttle valve plate through the motor, and transmit the angle signal to the ECU

through the throttle position sensor 1 .

The right picture is the wiring diagram with ECU

BR/

GR/
LG/
GR/

LG/
BR/

R
Y

R
Y
R
R

A CB

30

12
10

ECU

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CFMOTO
8.3.3.3 The intake air pressure and temperature

sensor monitors the pressure of the intake pipe and provides the ECU with engine

load information.

The right picture is the wiring diagram of the sensor and ECU

A BCD
GR/
LG/

BR
W/
GR/

R/
LG/

R
Y

B
BR
W/
R/

R
Y
B

10
11

ECU 30

8-10
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Electrical System

The following figure is the corresponding diagram of pressure

and output voltage; Monitoring pressure range: (10~115) kPa

5 4.65
Voltage
Output
Uout
in
V

0.4

0 0 10 115
Absolute Pressure Pabs in KPA

The following figure is the temperature-resistance characteristic table of the sensor

60000

50000

40000

30000

20000

10000

-10000
Temperature (°C) Nominal resistance (OHM)

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CFMOTO
8.3.3.4 Water temperature sensor

This sensor is two sets of negative temperature coefficient (NTC) thermistors,

whose resistance value decreases as the coolant temperature rises, but not

in a linear relationship. One set is provided to the ECU to monitor the thermal

state of the engine. The other set is provided to the instrument to monitor the

water temperature.

A and C form a group, providing water temperature signals to the ECU;

through the ECU, providing water temperature signals to the instrument.

The picture on the right is the wiring diagram of the sensor and ECU.

GR/

LG/
C AB

Y
GR/

LG/
W

Y
13
10

ECU ÿ

The table on the right is the characteristic table of terminals A and C and temperature, and the signal is Temperature range° CB to shell resistance (ÿ) -20±0.1 25±0.1 80±0.1
transmitted to the ECU. 110±0.1 13.71~16.94

1.825~2.155

0.303~0.326

0.1383~0.1451

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Electrical System

8.3.3.5 Oxygen sensor This

sensor is used in the feedback system of the electronically controlled fuel injection device
1 2

to achieve closed-loop control and improve the ECU's control accuracy over the air-fuel
3 4
ratio. It is installed on the

exhaust pipe to measure the oxygen content in the exhaust gas and determine whether

the gasoline and air are completely burned, so as to ensure that the three-way catalytic

converter has the maximum conversion efficiency for HC, CO and NOX in the exhaust gas.

Function of each pin: 1.

Output signal positive 2. Output

signal negative 3. Heating ground

negative 4. Heating power 2

positive

The right picture is the wiring diagram of the oxygen sensor and ECU

LG/

SB/

LG/
LG/

SB/
LG/

BR
W/

W/
O
R
Y

Y
B

B
B
SB/

SB/

LG/

LG/
LG/
W/

BR
O
R

B
Y

AC BD ACBD

1
2
8
10 ACB D ACBD

ECU 19
20

GR

GR
tÿ tÿ
ÿ ÿ
ÿ ÿ

Oxygen sensor 2 Oxygen sensor 1

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CFMOTO
8.3.3.6 The trigger

provides the engine speed signal to the ECU, and the ECU determines

the ignition angle, injection phase, etc. based on this signal.

The picture on the right is the wiring diagram of the trigger and ECU;
trigger Magneto

BA

B/
L/
Y

L
43
42

Measure the trigger

resistance value; Set the multimeter to

1×100ÿ; Trigger coil resistance: 260ÿ~300ÿ (20° C) If the trigger

resistance is not within the above range, replace it with a new one.

Measure

the trigger peak voltage value

Connect the multimeter and peak voltage adapter as shown in Magneto

the right figure: + Probe: Green

Trigger resistor
(B) lead - Probe: Blue (A) lead

Note: When using a peak voltage adapter, refer to the relevant

instruction manual.

Peak voltage meter

Set the multimeter to the AC V

position; Set the gear to neutral and the ignition switch to "ON";

Press and hold the start button to let the engine run for a few seconds,

and then measure the peak voltage

of the trigger coil; Repeat the measurement several times to measure

Magneto
the

highest peak voltage of the trigger coil; Trigger peak voltage:

Trigger peak voltage
ÿ 20V (1300r/min) If the trigger peak voltage is not within the above

range, replace it with a new one.

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Electrical System

8.3.3.7 Fuel pump assembly The fuel

pump assembly and its connection circuit diagram with the fuel pump relay and ECU are

shown in the figure on the right; This fuel pump

assembly integrates the fuel pump, plastic bracket, coarse filter, fine filter and pressure

regulating valve. The working process is to pump fuel from the fuel tank to the engine at

a certain oil pressure and flow rate; The function definition of each

pin is: 1 : Ground 2 : Connect to

the output end

of the fuel pump relay Performance parameters:

Pressure regulating
2
valve opening pressure: (0.4±0.007)MPa Flow rate: 80L/h
1

This fuel pump assembly is installed in the fuel tank; do

not operate the fuel pump assembly in a dry state (no load) to avoid damage; handle it

with care during

installation or removal and do not drop it on the ground; the battery supplies power to the

fuel

pump assembly through the fuel pump relay, and the relay connects the fuel pump

only when starting or the engine is running.

Measure the oil

pressure: Connect the oil pressure gauge to the oil outlet of the fuel pump assembly and

lock it with a clamp to ensure that there is no leakage at

the joint; Connect the circuit according Oil pump relay Auxiliary relay
Fuel Pump Start relay

to the figure on the right; After closing the ignition switch and the flameout switch, the

BR
L/
fuel pump will work for 5 seconds and then stop. At this time, measure whether the oil
W/
O/
W

Y/
R
BR
W/
Y/

B/
L/

L/
R

B
L

pressure reaches the specified pressure value. If so, it means that the fuel pump is in

G/
B/

R
Y
good condition; otherwise, it means that the fuel pump is abnormal and needs to be

replaced with a new part; The normal pressure holding value after the oil pump stops

running is 0.2MPa (ÿ5 minutes). Start/Stop Switch

Battery + pole
Y/

W/
L

O/
W
B

Pressure relief treatment of fuel lines: The 46

8

ECU26

fuel supply pressure of the electronic fuel injection system is high, and all fuel pipes are

made of high-pressure resistant oil pipes. Even if the engine is not running, the oil circuit

maintains a high pressure, so during the maintenance process, be careful not to

remove the oil pipes easily; When repairing a

fuel system that needs maintenance, the fuel system should be pressure-relieved before

removing the oil pipes. The method is as follows: Remove the fuel pump relay, start the

engine and run it at idle speed until the engine runs until it shuts down by itself.

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CFMOTO
8.3.3.8 Injector One end

of the injector is installed on the injector seat, and the other end is connected

to the oil pipe through the injector cap. It injects fuel within the specified time
1 2
according to the instructions of the ECU, thereby providing fuel to the engine

and atomizing it. This injector adopts four-hole injection. After fixing the

retaining spring, the , Do not rotate.

function definition of each pin

is: 1 : + pole connected to the fuel

pump relay 2 : - pole connected to the ECU

Injector resistance 12ÿ±0.6ÿ(at 20°C)

081701

+ Connect to
1 oil 2 - Connect to ECU
pump relay

The right picture is the wiring diagram of the injector and ECU

SB/

SB/
W/

W/
W
B

B
SB/

SB/

W/
W

B
B

AB AB

47
48

ECU8

Injector 1 Injector 2

Installation of fuel

injector: The fuel injector must be installed by hand, and it is forbidden to hit it

with

hammers or other tools; When removing and reinstalling the fuel injector, the O-

ring

must be replaced; When removing the fuel injector, if necessary, perform

pressure relief first; After installing the fuel injector, perform a sealing test to

ensure that there is no leakage.

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Electrical System

8.3.3.9 Ignition coil

The ignition coil converts the low voltage electricity of the primary winding into the secondary winding.

The high voltage electricity with resistance is discharged through the spark plug to produce sparks,

The fuel and air mixture in the gas cylinder;

123
Function of each pin:

1. Signal;
2. Grounding;
3. Power supply;

The right picture is the connection diagram of the ignition coil and ECU

Ground 1

G3

G4
W/

W/

W/

W/
B

V
W/

W/
W/
Y

B
V
A C3 A B C3
1 B2 1 2
3
7
8

ECU A
1
B
2
C
3 A
1
B
twenty three
C
YBR YBR

Ignition coil 1 Ignition coil 2

Measure the secondary ignition voltage:

Connect the engine according to the EFI schematic diagram; 1

Connect the peak voltage meter as shown in the right figure;

Start the engine;

After starting, the secondary ignition voltage should be >15000V;

3
2
4

Ignition coil parameter table: 1 Peak voltage meter 3 Battery

2 ECU 4 Spark plugs

value
quantity

Minimum Typical maximum unit

Rated voltage 14 V

Operating 6 16.5 V

resistance voltage Primary resistance 0.74 0.76 0.78 ÿ

(20° C to
Secondary Obstruction 10.1 10.6 11.1 kÿ
25° C)
Primary current 7 A

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CFMOTO
8.3.4 UP6.0 fault code

Serial number fault code description

P0030 00 1-way oxygen sensor heating control circuit fault

1 P0031 00 1-way oxygen sensor heating control circuit voltage is too low

2 P0032 00 1-way oxygen sensor heating control circuit voltage is too high

3 P0050 00 2-way oxygen sensor heating control circuit fault

4 P0051 00 2-way oxygen sensor heating control circuit voltage is too low

5 P0052 00 2-way oxygen sensor heating control circuit voltage is too high

6 P0053 00 2-way oxygen sensor heating internal resistance is unreasonable

7 P0059 00 Intake pressure sensor 2 signal is unreasonable

8 P0130 00 1 road oxygen sensor signal is unreasonable

9 P0131 00 1-way oxygen sensor signal circuit voltage is too low

10 P0132 00 1-way oxygen sensor signal circuit voltage is too high

11 P0133 00 1-way oxygen sensor has a delayed response to both rich and lean mixtures

12 P0134 00 1-way oxygen sensor circuit signal circuit fault

13 P0150 00 2-way oxygen sensor signal is unreasonable

14 P0151 00 2-way oxygen sensor signal circuit voltage is too low

15 P0152 00 2-way oxygen sensor signal circuit voltage is too high

16 P0153 00 2-way oxygen sensor has a delayed response to both rich and lean mixtures

17 P0154 00 2-way oxygen sensor circuit signal fault

18 P0122 00 Throttle position sensor 1 signal circuit voltage is too low

19 20 P0123 00 Throttle position sensor 1 signal circuit voltage is too high

twenty one
P0105 00 Intake air pressure sensor signal fault

twenty two P0106 00 Intake air pressure sensor signal exceeds limit

twenty three P0107 00 Intake air pressure sensor short circuit to ground

twenty four P0108 00 Intake air pressure sensor short circuit to power supply

25 P0111 00 Intake air temperature sensor signal is unreasonable

26 P0112 00 Intake air temperature sensor signal circuit voltage is too low/exceeds the limit

27 P0113 00 Intake air temperature sensor signal circuit voltage is too high

28 P0116 00 Engine coolant temperature sensor signal is unreasonable

29 P0117 00 Engine coolant temperature sensor circuit voltage is too low

30 P0118 00 Engine coolant temperature sensor circuit voltage is too high

31 P0119 00 Engine coolant temperature sensor signal is discontinuous

32 P1116 00 Engine coolant temperature exceeds limit

33 P0201 00 1 cylinder injector control circuit open

34 P0261 00 1 cylinder injector control circuit short circuit to ground

35 P0262 00 1 cylinder injector control circuit short circuit to power supply

36 P0202 00 Cylinder 2 fuel injector control circuit open

37 P0264 00 Cylinder 2 fuel injector control circuit short circuit to ground

38 P0265 00 Cylinder 2 fuel injector control circuit short circuit to power supply

39 P2300 00 1 cylinder ignition coil short circuit to ground

40 P2303 00 2 cylinder ignition coil short circuit to ground

41 P0300 00 Multiple cylinder misfire

42 P0301 00 Misfire in one cylinder

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Electrical System

43 P0302 00 Cylinder 2 misfire

44 P0322 00 Speed sensor signal fault
45 P0413 00 Secondary air supply solenoid valve circuit open
46 P0414 00 Secondary air supply solenoid valve circuit voltage is too low

47 P0412 00 Secondary air supply solenoid valve circuit voltage is too high

48 P0411 00 Secondary air system flow detection fault

49 P0441 00 Carbon canister solenoid valve flow is incorrect

50 P0444 00 Carbon canister solenoid valve circuit open

51 P0458 00 Carbon canister solenoid valve circuit voltage is too low

52 P0459 00 Carbon canister solenoid valve circuit voltage is too high

53 P0480 00 Cooling fan control circuit open

54 P0691 00 Cooling fan control circuit voltage is too low
55 P0692 00 Cooling fan control circuit voltage is too high
56 P0501 00 Vehicle speed sensor signal fault
57 P0506 00 Idle speed control speed is lower than target idle speed

58 P0507 00 Idle speed control speed is higher than target idle speed

59 P0511 00 Stepper motor drive control circuit fault

60 P0615 00 Start control circuit open
61 P0616 00 Starting control circuit voltage is too low
62 P0617 00 Starting control circuit voltage is too high
63 P0627 00 Fuel pump relay control circuit open
64 P0628 00 Fuel pump relay control circuit voltage is too low
65 P0629 00 Oil pump relay control circuit voltage is too high
66 P0650 00 MIL lamp driver circuit fault
67 P0560 00 System battery voltage signal is unreasonable
68 P0562 00 System battery voltage is too low
69 P0563 00 System battery voltage is too high
70 P1098 00 Tipping sensor signal voltage is too low
71 P1099 00 Tipping sensor signal voltage is too high
72 P2177 00 The air-fuel ratio closed loop control self-learning value exceeds the upper limit

73 P2178 00 The air-fuel ratio closed loop control self-learning value exceeds the lower limit

74 P2179 00 The air-fuel ratio closed loop control self-learning value exceeds the upper limit

75 P2180 00 The air-fuel ratio closed loop control self-learning value exceeds the lower limit

76 P0602 00 Electronic control unit coding fault

77 P0604 00 Electronic control unit RAM fault
78 P0605 00 Electronic control unit ROM fault
79 U0198 00 TOX CAN communication failure
80 U0155 00 ECU and IPC (Instrument Panel Control Module) communication is abnormal
81 U0073 00 CAN bus off fault
82 U0121 00 ECU and ABS control module communication lost
83 P0508 00 Idle actuator control circuit short circuit to ground
84 P0509 00 Idle actuator control circuit short circuit to power supply
85 P0511 00 Idle actuator control circuit fault
86 P0511 00 Idle actuator control circuit fault

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CFMOTO
8.4 Common fault
diagnosis of engine body

Fault phenomenon cause of issue Treatment measures

Cylinder pressure

is too low 1. Cylinder wear 2. Replace

Piston ring wear 3. Cylinder gasket Replace

leaks 4. Valve guide wear or valve Replace

seat is not suitable 5. Spark plug is loose 6. Starting motor rotates too slowly Repair or Replace

7. Valve timing is incorrect 8. Valve Tighten

clearance is not suitable Spark plug does not ignite Check Electrical Part Adjust

or ignites weakly The engine cannot start Adjust

or 1. Spark plug gap is incorrect and starting is

difficult 2. Spark plug is wet or dirty 3. Ignition

coil is faulty 4. Trigger is open or
short-circuited 5. Magneto failure Throttle valve body Adjust or replace Clean
lacks fuel 1. Fuel
tank vent is blocked 2. Injector is blocked or faulty 3. High- Dry or Replace Replace Replace

pressure fuel pump does not work 4. High- Replace

pressure fuel pump pressure is low 5. High-pressure

fuel pump filter is blocked

Clean or replace Clean

or replace Check or

replace Check or

replace Clean or replace

1. Improper valve clearance adjustment 2. Adjust,

Unsuitable valve seat 3. Defective valve replace or trim Replace,

guide 4. Worn rocker arm or rocker arm shaft replace

5. Dirty spark plug 6. Incorrect spark plug gap 7. or trim

The engine has no idle speed or the
Faulty ignition coil 8. Clogged Replace,
idle speed is unstable
idle valve inlet and exhaust pipe 9. Faulty replace or trim Replace

magneto or trim

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Electrical System

Fault phenomenon cause of issue Treatment measures

1. The valve spring force is weakened 2. The Replace

camshaft is worn 3. The spark Replace

plug is dirty 4. The spark Clean or Replace

plug gap is too small 5. The valve timing Adjust or Replace

Engine instability at medium and high speeds
is incorrect 6. The ignition coil is Adjust

faulty 7. The high-pressure fuel pump Replace

does not provide enough fuel pressure 8. The air filter Adjust or Replace

is too dirty Clean or Replace

1. Excessive lubricating oil 2. Check oil level and drain excess oil Replace

Piston ring wear 3. Valve guide Replace

The engine exhaust has blue or wear 4. Cylinder wall wear or Replace

black smoke scratches 5. Valve stem wear 6. Valve stem oil Replace

seal damage Replace

1. Improper valve clearance 2. Weakened Adjust

valve spring force 3. Incorrect valve timing 4. or

Cylinder wear 5. Piston ring wear 6. replace

Improper valve seat 7. Dirty Adjust

spark plug 8. Improper spark or

plug clearance 9. Clogged injector replace Replace or

nozzle 10. Insufficient fuel repair Clean or

Lack of engine power
supply pressure from high-pressure fuel replace Clean or

pump 11. Dirty air filter 12. Worn rocker replace Clean or

arm or camshaft 13. Leakage in intake pipe 14. Too replace Adjust or

much lubricating oil replace Clean or

replace

Replace Tighten or

replace Check oil level and change

1. Carbon deposits on the top of the

Clean,
piston 2. Too little or too much lubricating oil
check and add or reduce,
3. Oil pump failure 4. Oil line
replace,
Engine overheating blockage 5. Intake pipe
clean,
leakage 6. Unsuitable lubricating
tighten or replace,
oil 7. Cooling system failure
change oil

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Fault phenomenon cause of issue Treatment measures

Abnormal valve

noise 1. Valve clearance is too large 2. Adjustment

Valve spring is worn or broken 3. Rocker arm or camshaft Replacement

is worn Replacement

Abnormal noise from the

piston 1. Piston wear 2. Cylinder Replace

wear 3. Carbon deposits in the Replace

combustion chamber 4. Piston pin or Clean

pin hole wear 5. Piston ring or ring groove wear Replace

Replace

Abnormal noise in the timing chain 1.

Chain stretch 2. Sprocket wear Replace chain and sprocket

3. Timing chain tensioner working Replace chain and sprocket

Engine abnormal noise abnormally Repair or replace

Abnormal clutch noise

1. Clutch gear wear and damage 2. Clutch buffer rubber Replace the clutch gear Replace

aging and damage the clutch gear

Abnormal

crankshaft noise 1. Abnormal Replace

bearing noise 2. Crank pin bearing wear or sintering 3. Too Replace

large clearance Replace

Abnormal noise in the

transmission system 1. Gear wear or damage Replace

2. Main shaft or counter shaft wear 3. Bearing Replace

wear 4. Bushing wear Replace

Replace

1. The clutch active plate is worn or damaged 2. The clutch driven Replace

Clutch slipping plate is worn or damaged 3. The clutch spring force is weakened Replace

Replace

Ignition system:

Fault phenomenon cause of issue Treatment measures

1. Faulty igniter 2. Spark plug burnout 3. Replace

Spark plug gap is too large or too Replace

small 4. Carbon deposits on spark plug 5. Faulty magneto 6. Adjust

Insufficient battery voltage or failure 7. Clean

No spark or spark is too Faulty ignition coil 8. Faulty trigger coil 9. Replace

weak Faulty trigger gap is too large or too small 10. Other Charge or Replace

circuit faults Replace

Replace

Adjust

Check

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Electrical System

8.5 Diagnosis based on engine fault symptoms

Before starting the troubleshooting steps based on the engine fault symptoms, you should first perform a preliminary inspection:

1. Confirm that the engine fault indicator light is working properly. 2. Use

a fault diagnosis instrument to check and confirm that there is no fault information record. 3.

Confirm that the fault phenomenon complained by the owner exists and confirm the conditions for the occurrence of the fault.

Then do a visual inspection:

(1) Check if there is any leakage in the fuel line; (2) Check if the vacuum line is

broken or kinked, and if the connection is correct; (3) Check if the intake line is blocked, leaking, flattened

or damaged; (4) Check if the high-voltage wire of the ignition system is broken or aged, and if the

ignition sequence is correct; (5) Check if the grounding point of the wiring harness is clean and firm; (6) Check if the connectors of each sensor and actuator are loose or in poor

contact. Important: If the

above phenomenon exists, repair the fault phenomenon first, otherwise it will affect the subsequent fault diagnosis and repair

work.

Diagnostic Help:

1. Confirm that the engine has no fault record; 2. Confirm that

the complained fault phenomenon exists; 3. During the

inspection and repair process, do not ignore the impact of vehicle maintenance, cylinder pressure, mechanical timing, fuel conditions, etc. on the system; 4. Replace the ECU

and conduct a test.

If the fault phenomenon can be eliminated at this time, the fault location is in the ECU. If the fault phenomenon still exists at this time, replace the original

ECU, repeat the process and perform the maintenance work again.

Common faults and repairs:

1. When starting, the engine does not turn or turns slowly. 2. When

starting, the engine can be dragged but cannot be started successfully. 3. It is difficult to

start with a hot engine. 4. It is

difficult to start with a cold engine.

5. The speed is normal, but it is difficult to start at any time. 6. Starting

is normal, but the idle speed is unstable at any time. 7. Starting is normal,

but the idle speed is unstable during the warm-up process. 8. Starting is

normal, but the idle speed is unstable after the warm-up is completed.

9. Starting is normal, but the idle speed is unstable or stalls under partial load (such as turning on the headlights).

10. Starting is normal, but the idle speed is too

high. 11. The speed cannot be increased or it stalls when

accelerating. 12. Slow response

when accelerating. 13. Powerless and poor performance when accelerating.

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CFMOTO
(1) When starting, the engine does not turn or turns
slowly. Common fault locations: 1. Battery; 2. Starter motor; 3. Wiring harness or ignition switch; 4. Engine mechanical parts.

General diagnostic

process: No. Operation step Test result Subsequent steps Use a multimeter to check the voltage between the two terminals of

the battery to see if it is around 8V to 12V when the engine is started. No Replace the battery Yes Next
1
step Turn on the ignition switch, the flameout switch, and the side support switch to check if the voltage at the

12V. No Repair the switch or replace the wiring harness Keep the ignition ECU32 pin is around
2
switch in the start position and use a multimeter to check if the voltage at the positive terminal of the starter motor is above

8V. No Repair or replace the wiring harness Yes Repair or replace the starter motor Remove the
3
starter motor and check the working condition of the starter motor. Focus on checking whether it is open circuit or

step is to replace the lubricant with the appropriate grade. If the fault only stuck due to poor lubrication. No The next
4
occurs in winter, check whether the resistance of the starter motor is too large due to improper

step is to inspect the internal resistance of the engine Check whether the selection of engine lubricant. No The next
5
mechanical resistance inside the engine is too large, causing the starter motor to not rotate or rotate

slowly. No Repeat the above steps

6

(2) When starting, the engine can be dragged but cannot be

successfully started. Common fault locations: 1. No oil in the fuel tank; 2. Fuel pump; 3. Trigger; 4. Ignition coil; 5. Engine mechanical parts.

General diagnostic

process: No. Operation Step Connect the fuel pressure The next step after the test results is
gauge (access point to the front end of the fuel inlet pipe of the fuel injector), turn
1 on the ignition switch, repeat several times if necessary, or start the engine to check

whether the fuel pressure is around 300kPa. Connect the electronic No, check the oil supply

fuel injection system diagnostic instrument, observe the "engine speed" data item, system is the next
2
start the engine, and observe whether there is a speed signal output. Unplug the step. No, check the speed sensor
ignition high-voltage wire, connect the spark plug, make the spark plug electrode
circuit is the next step.
3 about 5mm away from the engine body, start the engine, and check whether there

is a blue and white high-

No Check the ignition

voltage fire. Check the pressure of the engine cylinder and observe whether the system Yes Eliminate engine
4
engine cylinder has insufficient pressure. mechanical failure
Connect the electronic fuel injection system adapter, turn on the ignition switch, and
No The next step is Diagnosis Help
5 check whether the power supply of ECU32, 32 pins is normal; Check whether the

grounding of ECU5, 6 pins is normal. No Repair the corresponding circuit

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Electrical System

(3) It is difficult to start a hot

engine. Common fault locations: 1. Water in the fuel; 2. Fuel pump; 3. Engine water temperature sensor; 4. Ignition coil.

General diagnostic

process: No. Operation Step Connect the fuel pressure What are the next steps for the test

gauge (the access point is the front end of the injector fuel inlet pipe), start the results? Is the oil
1
engine, and check whether the fuel pressure is around 300kPa. Pull out the supply system repaired?

ignition high-voltage wire, connect the spark plug, make the spark plug electrode
is the next step
2 about 5mm away from the engine body, start the engine, and check whether there

is a blue and white high- No Repair the ignition system

voltage fire. Unplug the engine water temperature sensor connector, start the
Repair the circuit or replace the sensor
engine, and observe whether the engine starts successfully at this time. (Or connect
3
a 300 ohm resistor in series at the engine water temperature sensor connector
No Next step
instead of the engine temperature sensor, and observe whether the engine

starts successfully at this time.) Check the fuel condition and observe whether the Yes Change fuel No
4
fault Next step Yes
phenomenon is caused by just refueling. Connect the EFI system adapter, turn on Diagnosis Help
5 the ignition switch, and check whether the power supply of ECU32, 32 pins is
No Repair the corresponding circuit
normal; Check whether the grounding of ECU5, 6 pins is normal.

(4) Difficulty in starting a

cold engine. Common fault locations: 1. Water in the fuel; 2. Fuel pump; 3. Engine water temperature sensor; 4. Fuel injector; 5.
Ignition coil; 6. Throttle body and idle bypass airway; 7. Engine mechanical parts.

General diagnostic

process: No. Operation Step Test Result Subsequent Steps Connect the fuel pressure gauge (the access point is the front end of the

injector fuel inlet pipe), the next step is to start the engine and check whether the fuel pressure is around
1 300kPa. Pull out the ignition high-voltage wire, connect the spark plug, make the
No Repair the oil supply system
spark

plug electrode about 5mm away from the engine body, start the engine, and is the next step
2 check whether there is blue and white high-voltage fire. Unplug the engine

temperature sensor connector, start the

No Repair the ignition system

engine, and observe whether the engine starts successfully at this time. (Or

connect a 2500 ohm resistor in series at the engine water temperature sensor Repair the circuit or replace the sensor

3 connector instead of the engine temperature sensor, and observe whether the

engine starts successfully at this time.)

No Next step

Yes Clean the throttle and idle air passage

4 Gently pull the accelerator and observe whether it is easy to start.
No Next step Is the
Remove the fuel injector and use a special fuel injector cleaning faulty replacement No
5
analyzer to check whether the fuel injector is Next step Is the
leaking or blocked. Check the fuel condition to see if the fault is fuel replacement No
6
caused by Next step Is the
refueling. Check the pressure of the engine cylinder to see if there is engine mechanical fault eliminated No
7
insufficient pressure in the engine cylinder. Next step

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CFMOTO
(5) The speed is normal, but starting is difficult at any time.
Common fault locations: 1. Water in fuel; 2. Fuel pump; 3. Engine water temperature sensor; 4. Injector; 5. Ignition coil; 6.
Throttle body and idle bypass air duct; 7. Intake duct; 8. Ignition timing; 9. Spark plug; 10. Engine mechanical part.

General diagnostic process:

Serial number Steps Next steps after test results

Intake system inspection
1 Check whether the air filter is blocked and whether there is any air leakage in the intake duct.
No Next step
Connect the fuel pressure gauge (the connection point is the front end of the injector fuel inlet pipe), is the next step
2
Start the engine and check whether the fuel pressure is around 400kPa. No Repair the oil supply system
Pull out the spark plug cap, connect the spark plug, and make sure the spark plug electrode is 1/2" away from the spark plug.
is the next step
3 The engine body is about 5mm, start the engine and check whether there is
No Repair the ignition system
Blue and white high pressure fire.

Check the spark plug of the cylinder to see if its model and gap meet the requirements. is the next step
4
specification. No Adjustment or Replacement

Unplug the engine water temperature sensor connector, start the engine, and observe Repair the circuit or replace the sensor
5
Check whether the engine starts successfully at this time. No Next step
Clean the throttle valve and idle air passage
6 Gently pull the accelerator and observe whether it is easy to start.
No Next step
Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
7
Check whether the device is leaking or blocked. No Next step
Check the fuel condition and observe whether the fault phenomenon is caused by refueling. Is the fuel changed
8
Later caused. No Next step

Check the pressure of the engine cylinder and observe whether the engine cylinder is Eliminate engine mechanical failure
9
Is there insufficient pressure? No Next step

(6) The engine starts normally, but the idle speed is unstable
at any time. Common fault locations: 1. Water in the fuel; 2. Injector; 3. Spark plug; 4. Throttle body and idle bypass air duct;
5. Intake duct; 6. Idle air control valve; 7. Ignition timing; 8. Spark plug; 9. Engine mechanical part.

General diagnostic process:

Serial number Steps Next steps after test results

Intake system inspection
1 Check whether the air filter is blocked and whether there is any air leakage in the intake duct.
No Next step
Clean or replace
2 Check whether the idle air control valve is stuck.
No Next step
Check the spark plug of the cylinder to see if its model and gap meet the requirements. is the next step
3
specification. No Adjustment or Replacement

Check whether there is carbon deposit on the throttle body and idle bypass air passage. Yes Cleaning
4
elephant. No Next step
Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
5
Check whether the device is leaking, blocked or has excessive flow. No Next step
Check the fuel condition and observe whether the fault phenomenon is caused by refueling. Is the fuel changed
6
Later caused. No Next step

Check the pressure of the engine cylinder and observe the pressure of the engine cylinder. Eliminate engine mechanical failure
7
Is there a large difference in force? No Next step
is the next step
8 Check whether the mechanical ignition timing of the engine is within the specification.
No Check ignition timing

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Electrical System

(7) Starting is normal, but the idle speed is unstable during warm-up.

Common fault locations: 1. Water in fuel; 2. Engine water temperature sensor; 3. Spark plug; 4. Throttle body and idle speed sensor
Air duct; 5. Intake duct; 6. Idle air control valve; 7. Engine mechanical part.

General diagnostic process:

Serial number Steps Next steps after test results

Intake system inspection
1 Check whether the air filter is blocked and whether there is any air leakage in the intake duct.
No Next step
Check the spark plug of the cylinder to see if its model and gap meet the requirements. is the next step
2
specification. No Adjustment or Replacement

Remove the idle air control valve and check the throttle body, idle air Cleaning related parts
3
Check whether there is carbon deposit on the control valve and idle bypass air passage. No Next step

Unplug the engine water temperature sensor connector, start the engine, and observe Repair the circuit or replace the sensor
4
At this time, is the engine idling unstable during the warm-up process? No Next step
Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
5
Check whether the device is leaking, blocked or has excessive flow. No Next step
Check the fuel condition and observe whether the fault phenomenon is caused by refueling. Is the fuel changed
6
Later caused. No Next step
Check the pressure of the engine cylinder and observe the pressure of the engine cylinder. Eliminate engine mechanical failure
7
Is there a large difference in force? No Next step

(8) Starting is normal, but the idle speed is unstable after warm-up.

Common fault locations: 1. Water in fuel; 2. Engine water temperature sensor; 3. Spark plug; 4. Throttle body and idle speed sensor
Air duct; 5. Intake duct; 6. Idle air control valve; 7. Engine mechanical part.

General diagnostic process:

Serial number Steps Next steps after test results

Intake system inspection
1 Check whether the air filter is blocked and whether there is any air leakage in the intake duct.
No Next step
is the next step
2 Check the spark plug to see if its model and gap meet the specifications.
No Adjustment or Replacement

Remove the idle air control valve and check the throttle body and idle speed control valve. Cleaning related parts
3
Check whether there is carbon deposit on the throttle and idle bypass air duct. No Next step
Unplug the engine water temperature sensor connector, start the engine, and observe Repair the circuit or replace the sensor
4
At this time, is the engine idling unstable during the warm-up process? No Next step
Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
5
Check whether the device is leaking, blocked or has excessive flow. No Next step
Check the fuel condition and observe whether the fault phenomenon is caused by refueling. Is the fuel changed
6
Later caused. No Next step
Check the pressure of the engine cylinder and observe the Eliminate engine mechanical failure
7
Is there a large difference in pressure? No Next step

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(9) The engine starts normally, but becomes unstable at idle speed or stalls when the engine is under partial load (e.g., with the headlights on).

Common fault locations: 1. Idle air control valve; 2. Fuel injector.

General diagnostic process:

No. Operation Step Test Result Subsequent Steps

Remove the idle air control valve and check the throttle body and idle speed adjustment. Cleaning related parts
1
Check whether there is carbon deposit on the air filter and idle bypass air duct. No Next step

Observe whether the engine output power increases when the load is turned on. Yes to step 4
2 Use the electronic fuel injection system diagnostic instrument to observe the ignition advance angle, injection pulse width and No Next step
Changes in air intake volume. No Repair of Air Conditioning System

Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
3
Check whether the device is leaking, blocked or has excessive flow. No Next step
Connect the EFI system adapter, turn on the ignition switch, and check Is a diagnostic aid
4 Check whether the power supply of ECU32 and 32 pins is normal;
No Repair the corresponding circuit
Check whether the grounding of ECU5 and 6 pins is normal.

(10) Starting is normal, but the idle speed

is too high. Common fault locations: 1. Throttle body and idle bypass air duct; 2. Injector seat; 3. Idle air control valve;
4. Engine water temperature sensor; 5. Ignition timing.

General diagnostic process:

Serial number Steps Next steps after test results

Yes Adjustment
1 Check if the throttle cable is stuck or too tight.
No Next step
Intake system inspection
2 Check the air intake system and the connected injector seats for leaks.
No Next step
Remove the idle air control valve and check the throttle body, idle air Cleaning related parts
3
Check whether there is carbon deposit on the control valve and idle bypass air passage. No Next step
Unplug the engine water temperature sensor connector, start the engine, and observe Repair the circuit or replace the sensor
4
Check whether the engine idle speed is too high at this time. No Next step
is the next step
5 Check whether the mechanical ignition timing of the engine is within the specification.
No Check ignition timing

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Electrical System

(11) The engine speed fails to increase or the engine stalls during acceleration.

Common fault locations: 1. Water in the fuel; 2. Intake pressure sensor and throttle position sensor; 3. Spark plug; 4.
Throttle body and idle bypass air duct; 5. Intake duct; 6. Idle air control valve; 7. Injector; 8. Ignition timing;
9. Exhaust pipe.
General diagnostic process:

Serial number Steps Next steps after test results

Intake system inspection

1 Check if the air filter is clogged
No Next step

Connect the fuel pressure gauge (the connection point is the front end of the injector fuel inlet pipe), is the next step
2 Start the engine and check the fuel pressure at idle.
No Repair the oil supply system
About 300kPa.

Check the spark plug of the cylinder to see if its model and gap meet the requirements. is the next step
3
specification. No Adjustment or Replacement

Remove the idle air control valve and check the throttle body and idle air Cleaning related parts
4
Check whether there is carbon deposit on the control valve and idle bypass air passage. No Next step
Check the intake pressure sensor, throttle position sensor and their wiring. is the next step
5
Is the road normal? No Repair the circuit or replace the sensor
Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
6
Check whether the device is leaking or blocked. No Next step
Check the fuel condition and observe whether the fault phenomenon is caused by refueling. Is the fuel changed
7
After No Next step
is the next step
8 Check whether the engine's ignition sequence and ignition timing are in compliance with the specifications.
No Check ignition timing
is the next step
9 Check whether the exhaust pipe is exhausting smoothly.
No Repair or replace the exhaust pipe

(12) Slow response when

accelerating. Common fault locations: 1. Water in the fuel; 2. Throttle position sensor; 3. Spark plug; 4. Throttle body and idle side
Air duct; 5. Intake duct; 6. Idle air control valve; 7. Fuel injector; 8. Ignition timing; 9. Exhaust pipe.

General diagnostic process:

Serial number Steps Next steps after test results

Intake system inspection
1 Check if the air filter is clogged.
No Next step
Connect the fuel pressure gauge (the connection point is in front of the fuel inlet pipe of the injector
is the next step
2 end), start the engine, and check the fuel pressure at idle condition.
Around 300kPa. No Repair the oil supply system

Check the spark plug of the cylinder to see if its model and gap meet the requirements. is the next step
3
specification. No Adjustment or Replacement

Remove the idle air control valve and check the throttle body, idle air Cleaning related parts
4
Check whether there is carbon deposit on the control valve and idle bypass air passage. No Next step

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Serial number Steps Next steps after test results

is the next step

5 Check whether the throttle position sensor and its circuit are normal.
No Repair the circuit or replace the sensor
Remove the fuel injector and use a special fuel injector cleaning analyzer to check the Replacement of faulty
6
Check whether the lubricator is leaking or blocked. No Next step

Check the fuel condition and observe whether the fault phenomenon is caused by Is the fuel changed
7
Caused by oil. No Next step

Check whether the engine ignition sequence and ignition timing meet the specifications. is the next step
8
Fan. No Check ignition timing
is the next step
9 Check whether the exhaust pipe is exhausting smoothly.
No Repair or replace the exhaust pipe

(13) Lack of power during acceleration and poor performance.

Common fault locations: 1. Water in fuel; 2. Throttle position sensor; 3. Spark plug; 4. Ignition coil; 5. Throttle
Valve body and idle bypass air duct; 6. Intake duct; 7. Idle air control valve; 8. Injector; 9. Ignition timing;
10. Exhaust pipe.

General diagnostic process:

No. Operation Step Test Result Subsequent Steps

Check for clutch slippage, low tire pressure, brake drag Yes Repair
1
Lag, tire size imbalance fault. No Next step
Intake system inspection
2 Check if the air filter is clogged.
No Next step
Connect the fuel pressure gauge (the connection point is the front end of the injector fuel inlet pipe),
is the next step
3 Start the engine and check whether the fuel pressure is within
About 300kPa. No Repair the oil supply system

Pull out the ignition high-voltage wire, connect the spark plug, and make sure the spark plug electrode is
is the next step
4 The engine body is about 5mm, start the engine and check the high pressure
Is the fire intensity normal? No Repair the ignition system

Check the spark plug of the cylinder to see if its model and gap meet the requirements. is the next step
5
specification. No Adjustment or Replacement

Remove the idle air control valve and check the throttle body, idle air Cleaning related parts
6
Check whether there is carbon deposit on the control valve section and idle bypass air passage. No Next step
is the next step
7 Check whether the throttle position sensor and its circuit are normal.
No Repair the circuit or replace the sensor
Remove the injector and check the injection with a special injector cleaning analyzer. Replacement of faulty
8
Check whether the device is leaking or blocked. No Next step

Check the fuel condition and observe whether the fault phenomenon is caused by refueling. Is the fuel changed
9
Later caused. No Next step
is the next step
10 Check whether the mechanical ignition timing of the engine is within the specification.
No Check ignition timing
is the next step
11 Check whether the exhaust pipe is exhausting smoothly.
No Repair or replace the exhaust pipe

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cooling system

9.1 Cooling System Schematic Diagram..................................................................

2 9.2 Disassembling the Cooling System Assembly..................................................
3 9.3 Engine Coolant..................................................................................................
4 9.4 Checking the Sealing of the Cooling Circulation..................................................
4 9.5 Checking and Cleaning the Radiator and Water Pipes.................................
5 9.6 Checking the Fan Motor................................................................................
6 9.7 Checking the Coolant................................................................................. 6
9.8 Adding Coolant.................................................................................................
7 9.9 Replacing the Coolant................................................................................. 7

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cooling system

9.1 Cooling system schematic

6 7

1 Radiator assembly 2 Auxiliary water tank assembly 3 Water pump assembly 4 Radiator water outlet pipe

5 Radiator water inlet pipe 6 Fan motor assembly 7 Engine assembly

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Danger:

Coolant is toxic and harmful to health. Do not allow

coolant to come into contact with skin, eyes or clothing. If coolant is

swallowed, seek medical attention immediately. If it comes

into contact with skin, immediately rinse the contacted area with plenty of clean water. If coolant

comes into contact with eyes, immediately rinse the eyes thoroughly with water and then seek medical attention. If

coolant is spilled on clothing, change the clothing. Rusty and corroded

residues in the engine and radiator must be handled in accordance with regulations, as the chemicals in them are harmful to the human body.

Warning:

If tap water is added to the cooling system, scale will accumulate inside the cooling system. When the temperature is below zero, ice will form and seriously affect the operation

of the cooling system. Bottled antifreeze sold on the

market has anti-rust and corrosion agents added. When it is diluted, it will lose its anti-rust and corrosion capabilities. The dilution concentration of the antifreeze must be

consistent with the manufacturer's instructions. When adding coolant to the

cooling system, its color is green and contains ethylene glycol. When the ambient temperature is -35°C, please use a coolant with a freezing point below -35°C. Warning:

The coolant will be very hot and under pressure when the vehicle is running. Do not open the radiator,

radiator hose, auxiliary water tank or any other cooling system parts before the engine or cooling system has completely cooled down. In case of burns, rinse the wound with

running cold water for

more than 10 minutes until the wound is no longer painful and seek medical attention immediately.

9.2 Disassembling the cooling system assembly

Place a basin under the water pump; Remove the

drain bolt 1 ; Drain the coolant;

Loosen the ring 2 ;

Remove the water

outlet pipe 3 ; Note: After

removing the water outlet pipe, a small amount of coolant will continue to flow out of

the pipe. Note: The

cooling system has a certain pressure, and the coolant will spray a long distance after 1 3
2
removing the drain bolt.

Loosen the hoop 4 ;

remove the water inlet pipe 5 ;

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cooling system

Loosen the clamp 1 ;

remove the auxiliary water tank siphon 2 ;

Remove the bolts 3 on both

sides ; remove the .

radiator

4 and install it in the reverse order of disassembly.

3
4
9.3 The coolant used in
the engine cooling system is a mixture of 51.5% water,
46% ethylene glycol and 2.5% additives. This mixture
has good anti-corrosion and heat absorption functions.
Its freezing point is -35ÿ. If the engine works in an
environment below -35ÿ, use a coolant with a freezing
point of -40ÿ
or -50ÿ. Warning:
Use a mixture of high-quality distilled water and ethylene glycol
antifreeze. Do not mix with ethanol mixture or other brands of
antifreeze; the
mixing ratio should not exceed 60% or be less than
50%; do not use anti-leak additives.

Mixing ratio freezing point

9.4 Checking the sealing of cooling cycle Checking 50% -30°C

the radiator cap Remove 55% -40°C
the radiator cap; Use a
60% -55°C
pressure gauge to test the opening pressure of the

radiator cap; If the radiator cap cannot meet the pressure requirement, (°C)
replace it with a new one. The
opening pressure of the
0
-10
radiator cap is 135kPa~160kPa 1.35kgf/
-20 -30
cm2 ~1.6kgf/cm2
-40
-50
Freezing point

-60
19.58psi~23.2psi
-70
Standard
value: 140kPa Mixing ratio 0 20 40 60 80 100
1.4kgf/cm2 20.3psi Sealing check Connect the tester to the auxiliary water tank connection port;

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warn:

Do not open the radiator cap before the engine has cooled down to avoid burns from high temperature steam.

Pressurize to 135 kPa and maintain for 10 seconds;

If the pressure drops within 10 seconds, it indicates that there is a leak in the cooling cycle. At this time, check the entire cooling cycle and replace any ,

leaks with new ones.

NOTE: When removing the tester, cover the radiator cap with a rag to prevent coolant from splashing.

NOTE: Do not test the pressure above the radiator cap opening pressure.

9.5 Inspection and cleaning of radiator and water pipes

Radiator inspection and cleaning

Use high-pressure gas to remove sand and dirt from the surface of the radiator;

Use a small screwdriver to repair the heat sink.

Radiator water pipe inspection

Check the radiator water pipe for leaks and damage, and replace it with a new one if any leaks or damage is found.

Check the radiator water pipe clamps and replace them with new ones if they are found to be tightened incorrectly.

After checking the radiator and water pipes,, check the coolant , Add coolant if necessary.

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cooling system

9.6 Fan Motor Inspection Remove

1
bolt 1 ; remove fan

motor assembly 2 ; turn the blades by

hand to check their flexibility and integrity. If the blades are stuck or damaged,

replace the fan motor assembly 2 with a new one; the battery voltage is 12V, the

motor is 2
running at full speed, and the current on the ammeter does not exceed 5A. If the

motor does not rotate or the current exceeds the specified value, replace the fan

motor assembly 2 with a new one ;

Installation

Installation is carried out in the reverse order of disassembly;

9.7 Coolant Check Prop

the vehicle up on level ground with side
stands; After confirming that the coolant has cooled completely,

check the coolant level in the auxiliary water tank; If the coolant
A
level is in area A:
drain excess coolant to area B; If the coolant level is in area
B
B: the level is appropriate; If the coolant level is in area C or is
not visible: add the same coolant to area B.
C
Warning: The coolant will be very hot and under pressure when the vehicle

is running. Do not open the

radiator, radiator hose, auxiliary water tank or any other cooling system parts

before the engine or cooling system is completely cooled. In case of burns, rinse

the wound with running

cold water for more than 10 minutes until the wound is no longer painful and seek

medical attention immediately.

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9.8 Coolant Addition Open

the auxiliary water tank cap and add the same coolant to area B. Warning: If

you need to add coolant frequently, or the coolant in the auxiliary water

tank is often sucked dry, there may be a leak in the cooling system. Contact

your dealer to check the cooling system. Only CFMOTO original coolant

is recommended. Mixing different coolants may cause engine damage.

Contact your dealer to replace the coolant.

9.9Preconditions for replacing

coolant : On a level surface, use a vehicle stand to prop up the vehicle or fix 1
the vehicle on a level operating table so that the vehicle is perpendicular to

the ground; 1. Place a

basin under the water pump; 2. Remove the

drain bolt 1 ; 3. Loosen the

radiator pressure cap; 4. Drain the

coolant (make sure that the coolant in the auxiliary water tank is also drained);
2
5. Install the

drain bolt;

6. Open the radiator pressure cap 2 ; 7.

Use a funnel to add coolant from the radiator port to the radiator neck; 8.

Start the

vehicle to warm up for 2~3 minutes (do not cover the radiator pressure cap

during the vehicle start-up); 9.

After the engine is warmed up, add coolant from the radiator port to the

radiator

neck; 10. Cover the radiator pressure cap

2 ; 11. Start the vehicle until the fan runs, and observe the auxiliary water

tank at the same time to confirm whether the coolant in the radiator flows into

the auxiliary water tank through the auxiliary

water tank connecting pipe; 12. If no coolant flows out, repeat the above

steps 6~11 (make sure the engine has cooled

down); 13. If coolant flows out, add coolant to the auxiliary water tank to

between the upper and lower limit lines. 14.

After the engine cools down, check the liquid level of the auxiliary water tank.

If the liquid level is lower than the lower limit line, add coolant to between the

upper and lower limit lines. If the liquid level is higher than the upper limit

line, draw out excess coolant to restore the liquid level to between the upper and lower limit lines.

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10 Exhaust system

10.1 Disassembly of engine guard plate, exhaust pipe, and cylinder welding assembly...
10-2 10.1.1 Engine guard plate................................................................................ 10-2
10.1.2 Exhaust Pipe.................................................................................. 10-3 10.1.3
Cylinder Welding Assembly............................................................ 10-4
10.2 Exhaust Pipe Inspection.................................................................. 10-4

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Danger: The temperature of the muffler is very high after the engine is running. When disassembling and repairing the muffler, the vehicle must not be parked near

flammable and explosive materials, which may ignite or detonate flammable and explosive materials. The muffler and other high-temperature parts must not be operated

before the vehicle cools down, which may cause serious burns to the operator or

surrounding personnel. The muffler will emit toxic and harmful gases, so it must not be operated in a closed environment or without effective ventilation. The toxic and

harmful gases emitted by the muffler may cause poisoning or even death to surrounding personnel.

10.1 Disassembly of engine guard, exhaust pipe and cylinder welding

assembly 10.1.1

Remove the hexagon socket

bolt 1 of the engine guard ;

remove the right engine guard 2 ; the 2

operation of the left engine guard is the same as above

Remove the four bolts 3 ;

remove the engine lower guard plate 4 ;

3 3

Remove the hexagon socket bolt 5 ; 5

remove the guard bar 6 .

6
5

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10 Exhaust system
10.1.2 Disconnect the

oxygen sensor connector 1 from the exhaust

pipe ; Note: Mark the oxygen sensor terminals so that they correspond to the “L” and “R”

markings on the connector.

Remove the locking nut 2 ;

2 2

Remove bolt 3 ; remove

clamp 4 ;

3
4

Remove the exhaust pipe assembly 5 ;

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10.1.3 Loosen the clamp 1 of the cylinder

welding assembly ;

Remove the hexagon socket bolt 2 ;

Remove the cylinder welding assembly .

3. Note: When disassembling, hold the tail of the cylinder steady to prevent it from falling 2
suddenly.

3 1

10.2 Exhaust pipe inspection

Check the exhaust pipe for damage. If the exhaust pipe is damaged, please replace it with a new one in

time. Check the graphite sealing sleeve ÿ 2 of the

exhaust pipe . Check the exhaust

gasket 1. If corrosion, cracks or deformation occur, please replace it with a new

one in time. Check the buffer sleeve 3. If cracks, corrosion, etc. occur, please replace it with a new one in time.

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11 Front and rear wheels, brake system

11.1 Front brake caliper.................................................................................. 11-2 11.2 Front

wheel......................................................................................................... 11-2

11.3 Rear Wheel.................................................................................................. 11-2 11.4 Rear

Brake Caliper.......................................................................................... 11-3

11.5 Brake Master Cylinder.................................................................................. 11-4 11.5.1

Rear Brake Master Cylinder........................................................................... 11-4

11.5.2 Handbrake master cylinder assembly.................................................. 11-4 11.6 Tire

inspection.......................................................................................... 11-5

11.6.1 Front Wheels.................................................................................. 11-5 11.6.2 Rear

Wheels.......................................................................................... 11-5

11.6.3 Spokes.................................................................................. 11-6 11.6.4 Air

Pressure.......................................................................................... 11-7

11.6.5 Tire Surface.................................................................................. 11-7 11.6.6 Wheel

Bearings...................................................................................... 11-8

11.6.7 Wheel Rim.................................................................................. 11-8 11.7 Brake

System Inspection........................................................................... 11-9

11.7.1 Inspection of the parking brake master cylinder.................................................. 11-9

11.7.2 Inspection of the rear brake master cylinder........................................................ 11-10

11.7.3 Inspection of brake lines.................................................................. 11-12 11.7.4

Inspection of front and rear brake calipers and brake discs........ 11-12

11.8 Free travel.................................................................................. 11-13 11.8.1 Free travel

of the front brake handle.................................................. 11-13

11.8.2 Rear Brake Pedal Free Travel.................................................. 11-13

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Note: Before removing the tire, reinstall the center support/side support or use

a bracket to support the vehicle so that the front wheel/rear wheel is off the

ground. 11.1 Front brake caliper

1
Remove the hexagon socket bolt

1 ; Remove the wheel speed 3

sensor 2 ; Remove the hexagon

socket bolt 3 ; Remove the right front brake caliper 4 ;

4
2

11.2 Front wheel

disassembly Loosen the hexagon

socket bolt 1 ; Remove the front wheel shaft and

.
push it out 2 ; Remove the front wheel 3

2
1
3

Prevent the front wheel bushing 4 from being lost;

11.3 Rear wheel

2
disassembly Remove the rear wheel axle

fastening nut 1 ; remove the chain adjustment block 2

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11 Front and rear wheels, brake system

Push out the rear wheel axle 3 ;

push the rear wheel 4 toward the front of the vehicle

body; remove the chain 5 from the sprocket;

3 1
4
5

Remove the rear wheel 4 ;

prevent the sprocket seat 6 from falling from the left. Warning:

When removing the rear wheel, tilt the tire slightly to the right to prevent the sprocket seat from falling

and causing injury.

Prevent the rear wheel left shaft sleeve 7 and the rear wheel right shaft sleeve 8 from being lost.

7 8

11.4 Rear brake caliper removal Remove

the rear

brake caliper 1 from the stop block 2 ;

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11.5 Brake Master

Cylinder 11.5.1 Rear Brake 2 1

Master

Cylinder Removal

Remove bolt 1 ; remove rear .

brake oil cup 2 Remove right foot pedal
4
fixing bolt 3 ; remove right foot pedal fixing bolt 4

Warning: The brake oil cup cannot be turned upside down to prevent air from

entering the brake line and causing brake system failure.

3

Remove the main brake pump fixing bolt 1 ;

remove the main brake pump pin 2 ;

remove the main brake pump pin shaft

3 ; remove the main brake pump 4 ;

1 4

11.5.2 Disassembly of the handbrake

master

pump assembly Remove

bolt 1 ; remove the gland

.
2 ; remove the handbrake master pump assembly 3
3

1
Warning: The brake oil cup cannot be turned upside down to prevent air from 2
entering the brake line and causing brake system failure.

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11 Front and rear wheels, brake system

11.6 Tire inspection warning:

When removing tires, a dedicated tire pressing machine must be used. When

removing tires, avoid the area near the valve stem to prevent damage to the tire

pressure

sensor. 11.6.1

Check the spoke 1 of the front wheel for damage such as twisting, breaking,
1
cracking, etc. If damaged, replace with a new

spoke; Check the spoke spring ring for deformation or misalignment. If the spring ring

is deformed or misaligned, it may cause the rim to leak and be damaged. Replace the

rim if necessary;

If equipped with a tire pressure sensor:

Check whether the tire pressure sensor valve stem 2 is damaged or leaking. The

vehicle uses a tire pressure sensor. If the valve stem is damaged or the tire pressure

display is abnormal, replace it with a new tire pressure sensor.

11.6.2 Check the

spoke 1 of the rear wheel for any damage such as twisting, breaking, cracking, etc.

If there is any damage, replace it with a new

spoke. Check the spoke spring ring for any deformation or misalignment. If there is

any deformation or misalignment, it may cause the rim to leak or become damaged.
1
Replace the rim if necessary.

If equipped with a tire pressure sensor:

Check whether the tire pressure sensor valve stem 2 is damaged or leaking. The

vehicle uses a tire pressure sensor. If the valve stem is damaged or the tire pressure

display is abnormal, replace it with a new tire pressure sensor.

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11.6.3 Spokes

When replacing tires, check the tread runout. If the tread runout is greater

than 1.0, adjust the spoke nuts. Check

the spokes for looseness or breakage. If so, replace with new spokes. Check

the spoke nut torque (torque:

4N•m~6N•m). If the torque is incorrect, confirm the torque and adjust the

runout to less than 1.0.

Inspection

method: Use a torque wrench to check the torque value of each spoke nut,

which should be ÿ 4N.m. If you don't have a torque wrench, you can use a

screwdriver or other tool to knock on the spokes to check. A crisp sound

means that the spoke tension is sufficient, a low and hoarse sound means

that the tension is insufficient, and the loose steel wire can be felt directly by hand.

Adjustment

method: For spokes with insufficient tension, first use a 2mm hexagonal

screwdriver 1 to unscrew the set screw 2 from the spoke nut. Then use a

T40 plum wrench 3 to re-tighten the spoke nut corresponding to the spoke,
2
and use a torque wrench to check that the torque is between 4-6N•m. Finally,

re-install the set screw and tighten it.

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11 Front and rear wheels, brake system

Check whether the six buffer rubber blocks 3 are aged or

damaged; If the buffer rubber blocks are aged or damaged, directly replace the
4
buffer rubber

blocks; Check whether the sprocket seat 4 and the rear sprocket are worn

or damaged; If the sprocket seat or the rear sprocket is worn or damaged, directly
3

replace the sprocket seat or the rear sprocket.

11.6.4 Air pressure

Remove the tyre valve cap; Measure 1

the tyre pressure using a tyre pressure gauge 1 when the tyre is cold ; Air

pressure Single

Front person 225kPa

wheel 250kPa

Rear wheel If necessary, adjust the tyre pressure according to the

specification; Install the tyre valve cap.

11.6.5 Tire surface Remove

any embedded stones1 or other foreign particles2 from the tire tread ; Check

whether there are cracks, cuts or

dents on the tire tread; Check whether there are bulges or protrusions on the tire
2
tread .

Bulges or protrusions indicate that there is damage inside the tire; If the above

damage occurs, replace the tire to avoid rapid expansion of

tire damage and the emergence of danger.

1

Check the degree of tire wear. When the tire surface wear exceeds the limit of use,

it will be punctured and fail. Generally, 90% of tire failures occur during the last 10%

of the tire's service life. Therefore, continuing to use the tire when the surface is

worn to the smooth surface will cause unsafe factors. When the tire pattern is worn

to the height of the

wear bump 3 , the tire must be replaced.

3

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11.6.6 Wheel bearings Support

the vehicle to lift the front wheel off the ground;

Push and pull wheel A forward and backward to check if the front wheel bearing is

damaged; Gently and quickly rotate front wheel B to check if the wheel rotates smoothly and

whether there is any noise during

rotation; If the above phenomenon is found, replace the front wheel bearing;

A
B

Prop the vehicle up to lift the rear wheels off

the ground; push and pull wheel A forward and backward to check if the rear wheel

bearing is damaged; gently and quickly rotate rear wheel B to check if the wheel rotates smoothly

and whether there is any noise

during rotation; if the above phenomena are found, replace the rear wheel bearing.

B A

11.6.7 Check the wheel

rims to see if they are dented or damaged . 1 If the wheel

rims are dented or damaged, you need to thoroughly check the front or rear wheels and replace

them if necessary.

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11 Front and rear wheels, brake system

11.7 Braking System Inspection

WARNING: Brake fluid can

irritate the skin. Keep brake fluid out of the reach of children. Do not

allow brake fluid to come into contact with skin, eyes or clothing. Wear protective clothing and goggles when handling. If brake fluid is

swallowed, seek medical attention immediately. If it

comes into contact with skin, immediately rinse the contacted area with plenty of clean

water. If brake fluid comes into contact with eyes, immediately rinse the eyes thoroughly with water and

then seek medical attention. If brake fluid is spilled on clothing, change the clothing.

11.7.1 Check the brake fluid level before

inspecting the handbrake master

pump. Straighten the handlebar so that the handbrake oil cup is parallel

to the ground. Check the brake fluid level in the

oil cup. If the fluid level is higher than the oil cup pad, release a certain amount of brake

fluid to the space between the oil cup

pad and the MIN. If the fluid level is between the oil cup pad and the MIN, the fluid level

is appropriate. If the fluid level is lower than the MIN, add brake fluid to the space between

the oil cup pad and the MIN.

Brake fluid replacement

Remove the two screws 1 ;

Remove the oil cup cover

2 ; Remove the oil cup

1

gasket 3 ; Note: The oil cup gasket may be dented due to the negative pressure
2
caused by the reduction of brake fluid during daily use, which will not affect normal

use, but the oil cup gasket still needs to be restored during installation.

Open the rubber cover of the

bleed bolt; Connect a clean plastic hose to the other end of the ,

bleed bolt 4 and place it in the container;

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Repeatedly hold and release the A brake handle until it feels very hard,

then hold the

brake handle tightly; Slightly loosen

the bleed bolt 4 ; Wait until the brake fluid stops

discharging/the brake

feels soft; Tighten

the bleed bolt; Add brake fluid; Repeat the steps from "hold and release

the handle" to "re-tighten the bleed bolt" until A

fresh brake fluid is sprayed out. Warning: Always ensure that the

brake fluid level is not lower than LOWER to prevent air from entering

the brake system and avoid damage to the

brake system that could cause casualties. Warning: If there is air in

the brake system, the brake fluid must be replaced repeatedly until there

is no air in the discharged brake fluid.

Add brake fluid

to the area between the UPPER and LOWER reservoirs;

Install the oil cup gasket

3 ; Install the oil cup

cover 2 ; Install two screws .1

1

11.7.2 Checking the brake fluid

level after the rear brake
master pump has been overhauled Straighten the vehicle so
that the rear brake oil cup is parallel
to the ground; Check the brake fluid level in the oil cup; If the level is
higher than UPPER, release a certain amount

of brake fluid to between UPPER and LOWER; If the level is between

UPPER and
LOWER, the level is appropriate; If the level is lower than LOWER, add brake fluid to
Between UPPER and LOWER.

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11 Front and rear wheels, brake system

Brake fluid replacement

Remove the oil cup cover fixing screw 1 ;

Remove the oil cup cover

2 ; Remove the oil cup

1
gasket 3 ; Note: The oil cup gasket may be concave due to the negative pressure

generated by the reduction of brake fluid during daily use, which will not affect normal
2
use, but the oil cup gasket still needs to be restored during installation. 3

Open the bleed bolt rubber sleeve

3 ; connect a clean plastic hose to the other end of the bleed ,
bolt 4 and place it in the container;

3
4

Repeatedly press and release the brake pedal A until it feels very hard,
then press the
brake pedal tightly; Slightly loosen
the bleed bolt 4 ; Wait until the brake fluid stops
discharging/the brake
feels soft; Tighten the bleed bolt; Add brake fluid between
UPPER and LOWER; Repeat the steps from "press and release the
pedal" to "retighten the bleed bolt" until fresh
A
brake fluid is sprayed out. Warning: Always ensure that the brake A
fluid level is not lower than LOWER to prevent air from entering the
brake system and avoid damage to the brake

system that could cause casualties. Warning: If there is air in the

brake system, the brake fluid must be replaced repeatedly until there is
no air in the discharged brake fluid.

Add brake
fluid to the area between UPPER and LOWER

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Install the oil cup gasket

3 ; Install the oil cup cover

2 ; Install the plate oil cover fixing screw 1 ;

2
3

11.7.3 Brake line inspection Check

the brake hoses, joints and pipes for damage, cracks and leaks. If not properly

maintained, the high

B
pressure in the brake pipes can cause fluid leakage A or hose bursting. Bend and A
twist the rubber hoses when checking the

brake lines. If any cracks B , bulges C , or leaks are found, replace the hoses and

pipes. Tighten all brake hose connection bolts and brake pipe joint nuts. Check

the brake hose lines.

If the brake hose lines are not correct, reset the brake hose lines.
C

11.7.4 Inspection of front and rear brake calipers and brake

discs Remove the

brake calipers; Check the

minimum thickness of each brake pad; Minimum friction

pad thickness: 1.3mm When the brake pad is

worn to the minimum thickness, it must be replaced. Both brake caliper pads

need to be replaced at the same time; Check whether the brake pad is

missing, has deep scratches or other damage. If so, replace it with a new one. 1.3mm

Both brake caliper pads need to be replaced at the same time.

Warning: Do not drive the vehicle immediately after replacing a new brake

disc or brake friction pad; the brake pad needs to be run-in by operating (holding

and releasing) the front brake handle several times until the brake disc and brake

caliper engage well.

Check the

minimum thickness of the front brake disc;

The minimum front brake disc thickness is

4mm; The minimum rear brake disc thickness

Front: 4mm
is 4mm; The brake disc must be replaced before it wears to the minimum
Rear: 4mm

thickness; Check whether the brake disc has missing pieces, deep scratches or

other damage, if so, replace it with a new one.

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11 Front and rear wheels, brake system

11.8 Free travel

11.8.1 Free travel of front brake handle
Check the free travel of the front brake .
handle 1 Free travel: 5mm~10mm

11.8.2 Free travel of rear brake pedal

Check the free travel of the rear brake .
pedal 1 Free travel: 10mm~20mm

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12 Shock absorber, rear fork

12.1 Left and Right Front Shock Absorbers.................................................. 12-2 12.2

Chains......................................................................................................... 12-2
12.3 Rear Fork Assembly.................................................................................. 12-3
12.4 Rear Shock Absorber.......................................................................................... 12-3
12.5 Transmission Chain.................................................................................. 12-4
12.5.1 Transmission Chain Inspection............................................................ 12-4
12.5.2 Adjusting Chain Slack.................................................................. 12-6 12.6
Front Shock Absorber Inspection............................................................ 12-7
12.7 Rear Shock Absorber Inspection.................................................................. 12-8

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12.1 Front work of left and right front

shock absorbers

Remove the front wheel (see Chapter 11 for details)

1

Disassembly

Remove the hexagon socket bolts 1 of the upper and lower connecting plates ;

Remove the left and right front shock absorbers 2 .

2

Bolt torque: 20N•m~25N•m

1
Installation

Install in the reverse order of disassembly

12.2 Chain front

work Remove
1
the rear wheel (see Chapter 11 for
details) Remove the shift lever connecting rod
fixing bolt 1 ; Remove the left rear fork fixing
2

bolt 2 ; Remove the left

bolt 3 ; Remove the
4
left foot pedal 4 ; Reinsert bolt 2 ;

Flip up the locking washer

2 ; remove the nut

1 ; remove the locking washer 2 ;

2
1

Push chain 1 forward;

disengage chain
1 ; prevent the chain from falling on the ground or coming into contact
with other dirt. If the chain is dirty, use professional chain cleaning
agent and chain oil to clean and lubricate the chain when reinstalling it.

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12 Shock absorber, rear fork

12.3 Rear fork assembly Remove

1
the oil cup fixing bolt 1 and remove

the right rear fork bolt 2 ; Remove the right

bolt 3 ; Remove the right foot

pedal 4 ;

Remove the left rear fork bolt 5

Remove the bolt and nut assembly 6 ;

pull out the rear fork shaft 7 ;

remove the rear fork assembly 8

12.4 Rear shock absorber 8

front work

Remove the rear fork assembly (see this section for details)

1
Disassembly Disassemble bolt and

nut combination 1 Remove bolt and

nut combination 2 Bolt torque: 20N•m~25N•m

Installation

Install in the reverse order of disassembly

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12.5 Transmission chain 12.5.1

Transmission chain inspection Squeeze

the pin head 1 to make it flat; Set the cutting and 2

riveting pins 2 according to the diagram ;

Tighten the pin holder with the bolt until it contacts the chain pin;

Make sure the cutting pin is aligned with the center of the chain pin;

Use spanner 3 to rotate the pin seat clockwise to remove the chain pin.

Drive chain installation

Engage the new drive chain link on the drive chain and replace the old drive chain link;

Remove the drive

1 2
chain from the new drive chain; Apply lubricating oil to the

chain pin 2 and the seal 1 ; Engage the drive chain with the rear

sprocket; Insert the chain pin in the drive 3

chain link; Install the seal 1 ; Install the chain

plate with the mark 3 facing

1
outwards; Push the chain plate to fix it by hand or with

pliers; Use the seal to prevent the lubricating oil from leaking

from the chain, and ensure that the seal is installed correctly;

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12 Shock absorber, rear fork

A fixer 4 and a plate fixer 5 are arranged on the pin seat ;

Install the retainer to the chain;

Rotate the pin holder by hand until the retainer contacts the chain;

Use a wrench to rotate the pin holder clockwise until the two pins of the chain

enter the grooves of the

retainer 4 ; remove the retainer 4 ;

Set the fixer 5 and the cutting and rivet pin 6 according to the diagram ;

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Rotate the pin holder until the rivet pin contacts the chain pin;

Turn the wrench clockwise until the tip of the rivet pin touches the chain pin; rivet;

the rivet method for

other chain pins is the same.

After

checking the riveting, check whether there are cracks in the riveted parts of the 1
chain pins. Measure the outer diameter 1 and width 2 of the chain pins and

chain plates ; Chain

pin outer diameter standard: 5.45mm~5.55mm

Chain plate outer width

standard: 17.25mm~17.45mm If the reading exceeds

2
the specified length, cut and re-rivet the chain link.

120603

12.5.2 Adjusting the chain tension Checking

the chain tension Put the

vehicle in neutral

gear; Support the vehicle with a

side stand; In the natural state, the distance between the chain and the lowest point of

the rocker

arm shall not exceed 30mm; Pull down the chain, and the distance between the chain and
40mm 30mm
the lowest

point of the rocker arm shall not exceed 40mm; If the chain tension does not meet the
Measuring position
requirements, adjust it to the standard value. Note: The degree of chain wear is not always

uniform, rotate the rear wheel several times and repeat the tension measurement at different positions.

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12 Shock absorber, rear fork

Adjusting the tension of the drive chain: Loosen

the rear axle nut 1 ; Loosen the left and right

locking nuts 3 ; Turn the left and right adjustment

4

bolts 2 to adjust the chain tension; Make sure that the marks on the left and right chain tensioners

4 are in the same relative position as the reference marks; Make sure that the tensioner is tight against

the adjustment bolt; Tighten the left and right

locking nuts 3 ; Tighten the rear axle nut (90 N•m).

132

12.6 Inspection of front shock absorber Check

the

appearance of the front shock absorber for damage, cracks or other damages. If so, replace the parts;

Clean the dust and mud on the front shock absorber;

Hold the handlebar and press it down several times to check whether

the compression and rebound of the front shock absorber are normal.

Installation

Install in the reverse order of disassembly.

Warning: When installing the front shock absorber, the upper end surfaces 4 of the two front

shock absorber inner tubes must be flush, and the number of scale lines exposed on the upper end of 4
the front shock absorber inner tubes must be the same.

Adjustment:

The front shock absorbers have been adjusted to the best condition when the vehicle leaves the factory,

which is suitable for most situations.

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Restoration damping

adjustment The restoration damping end is engraved

with the word TEN. Restoration damping affects the reaction speed of shock absorber

rebound. The higher the restoration damping gear 1 , the slower the suspension rebound

speed. The lower the restoration damping gear, the faster the suspension rebound speed.

Initial gear: 10 gears, total gear: 20 gears ±2 gears

1
Use a flat-blade screwdriver to rotate the gear counterclockwise (S direction) and record the

number of times to reduce the restoring damping; use a flat-blade screwdriver to rotate the

gear clockwise (H direction) and record the number of times to increase the restoring

damping.

Reverse rotation according to the recorded rotation times to restore the factory settings; or

rotate counterclockwise (S direction) to the minimum, then rotate clockwise (H direction) to

the shock absorber 10th gear. Contact your dealer to adjust the damping,

do not adjust it by yourself. Front shock absorber oil: KHL15-10 Front shock absorber

oil volume: 365±2mL

Compression damping

adjustment The word COMP is engraved on the compression

damping end. Compression damping affects the reaction speed of the shock absorber when it is

pressed down. The higher the compression damping gear 2 , the slower the suspension presses

down. The lower the compression damping gear, the faster the suspension presses down.

Initial gear: 10 gears, total gear: 20 gears ±2 gears 2

Use a flat-blade screwdriver to rotate the gear counterclockwise (S direction) and record the

number of times to reduce compression damping; use a flat-blade screwdriver to rotate the

gear clockwise (H direction) and record the number of times to increase compression

damping.

Rotate in the reverse direction according to the recorded number of rotations to restore the

factory settings; or rotate counterclockwise (S direction) to the minimum, then rotate

clockwise (H direction) to the shock absorber 10th position. Contact your

dealer to adjust the damping, do not adjust it by yourself.

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12 Shock absorber, rear fork

12.7 Rear shock absorber inspection

Check

the rear shock absorber for damage, cracks or other damage. If so, replace

the parts. Clean the dust and mud on the

rear shock absorber. Press down the seat cushion

several times to check whether the compression and rebound of the rear

shock absorber are normal.

Adjustment The rear shock absorber spring preload can be adjusted to suit the rider's weight

and riding conditions. Follow the steps below

to adjust the spring preload Use special tool 1 to

turn counterclockwise in direction a to reduce spring preload. Use special tool 1 to turn

clockwise in direction b

to increase spring preload.

a

b 1
1
Note: The rear shock absorber has been adjusted to the best condition when the vehicle

leaves the factory, which is suitable for most situations.

Danger: This component contains high-pressure nitrogen. Improper handling may

cause explosion. Read the relevant instructions and do not put it into fire, open holes

or open it.

Restoration damping

adjustment Restoration damping affects the reaction speed of shock absorber rebound. The

higher the restoration damping gear 1 , the slower the suspension rebound speed. The lower

the restoration damping gear, the faster the suspension rebound speed. S H

Initial gear position: 10 gears, total gear position 20 gears ±2 gears. Turn the

adjustment knob clockwise (H direction)

at the angle shown on the right. Turn the gear position and record the number of times to

increase the return damping. Turn the adjustment

knob counterclockwise (S direction) to turn the gear position and record the number of times

to reduce the return damping. 1

Restoring the damping to factory settings Rotate

in the reverse direction according to the recorded number of rotations to restore the factory

settings; or rotate counterclockwise (S direction) to the minimum, then rotate clockwise (H

direction) to the shock absorber 10th gear. Contact your dealer to adjust the

restoring damping, do not adjust it by yourself.

Danger

This component contains high pressure nitrogen. Improper handling may

cause explosion. Read the relevant instructions. Do not put it into fire, open holes
or open it.

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Seat height

adjustment Remove the lower bolt and nut combination 1 of the rear

shock absorber ; Move the rear shock absorber 2 from the high seat installation

point A of the triangular rocker arm to the low seat installation point B of the triangular

rocker arm , and the seat cushion height will drop by

15mm~20mm; Install the lower bolt and nut combination 1 of the rear shock absorber ;
2
Rear shock absorber nut torque: 45N•m~50N•m

15mm~20mm B

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13 Engine
13.1 Preparation Instructions.................................................................. 13-4

13.1.1 Unit Conversion Table................................................................................... 13-4

13.1.2 Warning Statements.................................................................................. 13-4

13.2 Maintenance Information.................................................................. 13-5

13.2.1 Engine Appearance................................................................................... 13-5

13.2.2 General Precautions.................................................................................. 13-6

13.2.3 Fuel and Oil Selection.................................................................................. 13-6

13.2.4 Engine Running-in.................................................................................. 13-7

13.2.5 Engine-specific maintenance tools.................................................................. 13-8

13.3 Engine Disassembly.................................................................................. 13-13

13.4 Air Intake System.................................................................................. 13-19

13.4.1 Air Filter Assembly.................................................................................. 13-19

13.4.2 Throttle Valve Body Assembly.................................................................. 13-24

13.5 Engine Disassembly.................................................................................. 13-27

13.5.1 Mounting the Engine.................................................................................. 13-27

13.5.2 Draining the Engine Oil.................................................................................. 13-27

13.5.3 Removing the Starting Motor.................................................................................. 13-27

13.5.4 Removing the Thermostat.................................................................................. 13-28

13.5.5 Removing the Water Pump.................................................................................. 13-28

13.5.6 Removing the Cylinder Head Cover.................................................................. 13-29

13.5.7 Removing the Right Side Cover.................................................................................. 13-30

13.5.8 Removing the Clutch.................................................................................. 13-30

13.5.9 Removing the Shift Lever Assembly, Shift Positioning Components and Positioning Star Wheel... 13-32

13.5.10 Removing the Oil Pump.................................................................................. 13-33

13.5.11 Removing the Cylinder Head................................................................... 13-35

13.5.12 Disassembling the Magneto and Dual Gears.................................................. 13-38

13.5.13 Disassembling the Cylinder Block................................................................... 13-39

13.5.14 Removing the Piston.................................................................................. 13-41

13.5.15 Removing the Oil Pan.................................................................................. 13-41

13.5.16 Removing the Oil Passage Cover Assembly.................................................................. 13-42

13.5.17 Binning.................................................................................................. 13-42

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13.6 Engine Overhaul and Reassembly................................................................... 13-47
13.6.1 Crankcase Assembly.................................................................................. 13-47

13.6.1.1 Main bearing/balance bearing selection................................................... 13-47

13.6.1.2 Crankcase.................................................................................. 13-53

13.6.1.3 Right Side Cover.................................................................................. 13-55

13.6.2 Cylinder head cover sub-assembly.................................................................................. 13-56

13.6.3 Cylinder head sub-assembly................................................................................ 13-58

13.6.4 Cylinder Block.................................................................................................. 13-69

13.6.5 Piston/Piston Ring/Piston Pin.................................................................. 13-70

13.6.6 Valve transmission subassembly.................................................................................. 13-74

13.6.7 Crankshaft and connecting rod.................................................................................. 13-79

13.6.8 Clutch.................................................................................................. 13-83

13.6.9 Shifting Gears and Speeds.................................................................. 13-86

13.6.9.1 Spindle combination.................................................................................. 13-86

13.6.9.2 Sub-axis combination.................................................................. 13-89

13.6.10 Lubrication System................................................................................... 13-95

13.6.10.1 Lubrication Oil Circuit Diagram.................................................................. 13-95

13.6.10.2 Oil Pump.................................................................................. 13-96

13.6.10.3 Oil Pump Cover/Oil Pressure Limiting Valve................................................ 13-96

13.6.10.4 Oil channel cover assembly................................................................... 13-98

13.6.11 Water Pump Assembly................................................................................... 13-98

13.6.12 Electric Start.................................................................................................. 13-99

13.6.13 Magneto Stator.................................................................................. 13-101

13.6.14 Rear Balance Shaft Assembly.................................................................. 13-102

13.7 Engine Assembly.................................................................................. 13-103

13.7.1 Installing the Rear Balance Shaft Assembly................................................... 13-103

13.7.2 Installing the Speed Shift Hub, Positioning Star Wheel, and Positioning Rocker Arm... 13-104

13.7.3 Installing the Countershaft Assembly.................................................................. 13-106

13.7.4 Installing the Shift Fork Shaft Assembly and Shift Fork................................................ 13-107

13.7.5 Installing the Spindle Assembly.................................................................. 13-108

13.7.6 Installing the Shift Lever Assembly.................................................................. 13-108

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13 Engine
13.7.7 Installing the crankshaft connecting rod assembly and the front balance shaft assembly... 13-109

13.7.8 Crankcase Assembly..................................................................................13-112

13.7.9 Installing the Oil Pump Sub-Assembly and Oil Pressure Switch...................................................13-114

13.7.10 Installing the Water Pump Assembly..................................................................13-115

13.7.11 Installing the Oil Pan..................................................................................13-116

13.7.12 Installing the Oil Passage Cover Assembly...................................................13-117

13.7.13 Installing the Oil Filter..................................................................13-117

13.7.14 Installing the Cylinder and Piston Assembly...................................................13-117

13.7.15 Installing the Timing Chain Assembly...................................................13-119

13.7.16 Installing the Cylinder Head Assembly..................................................................13-119

13.7.17 Installing the Magneto Rotor Assembly.................................................. 13-121

13.7.18 Installing the left side cover assembly.................................................................. 13-122

13.7.19 Installing the Inlet and Exhaust Camshaft Assemblies................................................... 13-122

13.7.20 Installing the Hydraulic Tensioner Assembly.................................................. 13-124

13.7.21 Installing the Cylinder Head Cover Assembly.................................................. 13-124

13.7.22 Installing the Starter Motor.................................................................. 13-125

13.7.23 Installing the Clutch.................................................................................. 13-125

13.7.24 Installing the Right Side Cover Assembly....................................................... 13-128

13.7.25 Installing the Gear Position Sensor Assembly.................................................. 13-130

13.7.26 Installing the Throttle Body Assembly and the Fuel Distribution Pipe Assembly................................................................................... 13-131

13.7.27 Installing the Output Sprocket Assembly.................................................. 13-132

13.7.28 Adding Engine Oil, Checking Oil Quantity, and Testing Oil Pressure................................... 13-132

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13.1 Preparation Instructions

This engine maintenance manual details the maintenance and adjustment procedures, disassembly and assembly essentials, inspection and maintenance points,

troubleshooting methods and maintenance technical data of the 272MQ-B engine, and is accompanied by detailed graphic materials to guide the operation. Read this manual

carefully and perform engine operations in accordance with the specifications.

13.1.1 Unit conversion table

items Unit conversion

1kgf/cm2 =98.0665kPa
pressure 1kPa=1000Pa
1mmHg=133.322Pa=0.133322kPa
Torque 1kgf·m=9.80665N·m
1mL=1cm3 =1cc
volume
1L=1000cm3
force 1kgf=9.80665N

13.1.2 Warning Instructions

Whenever you see the following warning and caution symbols, you must pay attention to its instructions! Always follow these safe operating and

maintenance methods.

Danger

Indicates a situation where the operator or surrounding personnel may die if no action is taken.

warn

Indicates a situation where operator injury or component damage may occur if action is not taken.

CAUTION indicates a situation where precautions must be taken to avoid damage to components.

NOTE

indicates information that makes a procedure easier or clearer. No symbols are used.

However, please note that the "Warnings" and "Cautions" contained in this maintenance manual cannot cover all potential hazards during engine use

and maintenance. Therefore, in addition to the relevant provisions of "Warnings" and "Cautions", maintenance personnel must also have basic mechanical safety

knowledge. If you are not sure about completing the entire maintenance operation process, please consult a more experienced, senior technician.

The contents of this manual are subject to change due to engine improvements etc. without prior notice.

The actual condition of the engine shall prevail.

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13 Engine
13.2 Maintenance Information

13.2.1 Engine Appearance

Magneto side

Engine No.

Clutch side

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13.2.2 General precautions

WARNING Correct maintenance procedures are very important for the safety of maintenance personnel and the reliability and

, work together, they should pay

safety of the engine. When two or more people

, to start the engine indoors, you must ensure

attention to each other's safety. When you need

, use toxic or flammable items, you must strictly follow the manufacturer's
that the exhaust gas is discharged outdoors. During work, if you
instructions for use and ensure
that the workplace is well ventilated.
Do not use gasoline as a cleaning fluid. To avoid burns, do not touch the uncooled engine, oil and
exhaust system parts. If the fuel, lubrication and exhaust systems have been repaired, they must be checked for markings
and leaks. To protect the natural environment, engine oil and replaced parts should not be disposed of at will.

Warning During maintenance, if parts need to be replaced, genuine parts or recommended products from Zhejiang Chunfeng Power
Co., Ltd. must be used. For
disassembled parts that need to be reused, keep them in order so that they are not messed up during assembly. Ensure
that special tools are used according to the requirements specified in
the maintenance manual. Ensure that the parts used for assembly are clean, and lubrication
must be lubricated where lubrication is required. Use
special lubricants, adhesives and sealants. When tightening bolts, screws and nuts, tighten the large ones first and tighten
them from the inside out to the specified torque. Use a torque wrench to tighten bolts with torque requirements. If grease and oil are
stuck on the threads, they must be wiped off. After disassembly, the parts should be inspected and
cleaned before measurement. After assembly, check the tightening
and operation of the parts. Do not use disassembled oil seals, gaskets, self-locking nuts, locking washers, cotter pins, circlips and ,
other parts. Replace them with new ones during assembly.

13.2.3 Fuel and Oil Selection

Only
use 92# or above unleaded gasoline.

The
preferred engine oil is SAE 10W-40 SJ JASO-MA2, and the second choice is SAE 10W-30 SJ / SAE 10W-50 SJ depending on the temperature
/ SAE 20W-40 SJ / SAE20W-50 SJ JASO-MA2.

Viscosity Grade

temperature

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13 Engine
13.2.4 Engine running-in

The engine has many parts that move relative to each other, such as pistons, piston rings, cylinder blocks, and meshing transmission gears.

Therefore, it is necessary to perform a standardized run-in at the beginning of its use. Running-in can make the moving parts adapt to each other, correct the

working clearance, and form a good smooth friction surface that can withstand heavy loads. Only engines that have been run-in have excellent performance

and reliability. The

recommended running-in time is 1000km, and the specifications are as follows:

General

requirements: 1. After the engine is working, the throttle should be rotated slowly and not suddenly. 2.

Try to drive on roads with better conditions. It is not suitable to drive on hills or bumpy roads for a long time. 3. Keep the lubricating oil

passage unobstructed. 4. Avoid sudden

acceleration or high-speed operation of the engine when there is no load. 5. During the

running-in period, maintenance should be carried out according to daily maintenance and regular regulations, and faults should be

eliminated in time. 6. After the running-in is completed, the engine oil, filter element, coarse filter screen must be replaced, the spark plug electrode and valve

clearance must be checked, and the whole machine must be inspected, adjusted and maintained in accordance with the requirements of the manual before it can gradually enter the normal driving

0km ~ 500km: Avoid continuous operation at ÿ50% throttle. Change the vehicle speed constantly and do not operate at a fixed throttle position. Avoid

sudden acceleration and change the throttle slowly. Cool the engine for 5 to 10 minutes after every hour of operation.

500km ~ 1000km: Avoid prolonged operation at more than 3/4 throttle.

Note: During the running-in period, perform maintenance according to the daily maintenance regulations and eliminate any faults in a timely manner. After the running-in period is

completed, the entire machine must undergo a 1000km running-in maintenance before entering the normal driving stage.

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13.2.5 Engine-specific maintenance tools

Oil filter special wrench

0700-070200-922-001

Rear balance shaft positioning and anti-rotation tooling

0SQ0-000000-922-005

Magneto rotor removal tool

0SQ0-031000-922-002

Clutch master and slave hub anti-rotation tooling

0SQ0-050000-922-001

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13 Engine

Output sprocket stop wrench

0MQ0-062030-922-001

Magneto rotor stop tooling

0SQ0-031000-922-001

Valve stem seal punch

0700-022400-923-002

Valve spring compression

clamp 0180-022006-922-001

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Oil level sight glass punch

0SQ0-013100-923-001

Right side cover needle roller bearing punch

0SQ0-013000-923-003

Right cover oil seal punch

0SQ0-013000-923-002

Countershaft oil seal punch

0SQ0-010001-923-001

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13 Engine

Case oil hole joint (used to test oil pressure)

0SQ0-000000-922-014

Bearing 6204 pressure head

0SQ0-011101-921-002

14×24×6 Oil seal punch

0SQ0-011101-923-001

HK1412 Needle Roller Bearing Punch

0SQ0-011101-923-002

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Timing sprocket anti-rotation tooling

0SQ0-000000-922-004

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13 Engine
13.3 Preparation for Engine

Disassembly

Remove the seat cushion; (Refer to the Seat

Cushion section) Remove the fuel tank; (Refer to the Fuel

System section) Remove the relevant body panels; (Refer to the Appearance

Parts section) Drain the coolant.

The main work

ÿÿThe range is Euro 5 status Operation steps:

ÿ Loosen the clamp 1 , unplug the secondary air supply ;

2
outlet pipe 2 ÿ

4
Loosen the clamp 3 and remove the crankcase ventilation pipe 4 ;
1

Loosen the hoop 1 ;

Remove bolt 1 ;
and remove air filter assembly 2;

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Loosen the nut 1
1 ; rotate the clutch release lever 3 clockwise and release 2
the clutch
cable 2 ; hang the clutch cable aside;

Push the protective cap 1 backwards and remove the positive wire

fixing nut; Hang the positive wire

1
aside; Remove the bolt 2 and hang the ground wire aside;
2

Remove bolt 1 and ;

remove the left engine guard plate 2 ; 1

Remove bolt 1 ;

remove the right engine guard plate 2 ; 2

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13 Engine
Remove bolt 1 and ;
remove the engine lower guard plate 2 ;

1 2

Remove bolts 1 and 2, and take ;

off the right front footrest bracket assembly 3 and the rear brake pedal 3
assembly 4 ;

2
1

Remove bolt 1 , disconnect the shift lever assembly 2 from the

engine;
remove bolt 3 and bolt 4 ; remove
3
the left front pedal bracket assembly 5 and the shift lever assembly 2 ;

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Remove the exhaust system 1 ; (refer to the exhaust system section)

1 2

Remove bolts 1 and 2 and ;

remove sprocket cover; 3

Remove nut 1 ; 1 3
Remove anti-loosening ;
;
washer 2 Remove output sprocket assembly 3

Remove bolt 1 and ;

remove the welding assembly 2 of the left engine guard bar ;

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13 Engine
Remove bolt 1 and ;
remove the welding assembly 2 of the right engine guard bar ;

1 2

Loosen the clamp 1 ;

Unplug the radiator water outlet pipe 2 ;

2

Loosen the clamp 1 ;

Unplug the radiator water inlet pipe 2 ;

Loosen the clamp 1 , pull out the tube ;

2 and remove the throttle cable from the engine 3 ;

2
Disconnect all electrical connectors connected to the engine;

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Remove bolt 1 ;
Remove bolt and nut 2 ; 1

Remove bolt 1 ;
Carefully remove the engine and transfer it to a workbench.

Install the engine

Install the engine to the vehicle in the reverse order of removal.

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13 Engine
13.4 Intake System 13.4.1

Removal of Air Filter

Assembly Remove the
seat cushion; (refer to the seat cushion
section) Remove the fuel tank; (refer to the fuel
system section) Remove the relevant body covering parts; (refer to the exterior parts section)

ÿÿThe range is Euro 5 status Operation steps:

ÿ Loosen the clamp 1 , unplug the secondary air supply ;

2
outlet pipe 2 ÿ

4
Loosen the clamp 3 and remove the crankcase ventilation pipe 4 ;
1

Loosen the hoop 1 ;

Remove bolt 1 ;
and remove air filter assembly 2;

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Remove the filter

;
element and remove the screw 1

1
Remove the air filter cover 1 ;

1
Remove the filter element wedge 1 ;

Take out the filter ;

element 1 and clean the air filter housing.
1

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13 Engine
Check the air filter housing.

Check the upper housing 1 , lower housing 2 and outlet pipe 3 for cracks or other
1
4
damage. If any of them has problems, please replace them as a whole. Check

the crankcase ventilation

pipe 4 for aging or other damage. If so, replace it with a new one.

2
3

Check whether the sealing ring 1 is hardened or otherwise damaged. If so,

replace it with a new one.

1

1
2

Check whether the air filter cover 1 and the intake pipe 2 are cracked or otherwise

damaged. If so, replace them with new ones.

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Check and clean the filter

element Check and determine whether the filter element can continue

to be used. Preliminarily determine the usability of the filter element

according to the following standards:

1. The filter element must not be deformed. 2. The filter element must not be

contaminated by water or oil. (If a certain amount of oil or water is found in the air

filter, please stop the air filter element replacement work immediately, replace the

entire air filter and check whether the engine is abnormal)

3. The filter element must not be damaged. 4. The

filter element must not have other visible abnormalities. If the filter element

cannot be used anymore, replace it with a new one and perform the installation

steps. If the filter element can be

used anymore, perform the filter element cleaning steps: Use a soft brush to brush

away the dust on the air inlet end of the filter element; Use

compressed air to blow away the dust from the air outlet end of the filter element;

Use compressed air to blow the air inlet end of the filter element from the side.

Warning:

Using compressed air vertically from the air inlet end of the filter element will blow

dust into the filter pores of the paper filter element, causing the filter element to be

blocked and affecting the air intake efficiency.

Install the filter

element Install the cleaned filter element or a new filter element 1 into the air filter

housing;

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Install the filter element wedge 1 ; 1

Install the air filter cover 1 ;

Mounting screw 1 .

Install the air filter

assembly Install the air filter assembly in the reverse order of removal.

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13.4.2 Disassembly of the throttle valve body

assembly Loosen the ring hoop 1 of the

2
throttle valve body

assembly ; Remove the throttle valve body assembly 2 ;

2
Remove bolt 1 and ;
take off the throttle body connecting pipe assembly 2 .

Disassemble the throttle body assembly,

remove bolt 1, and ;

remove the fuel distribution pipe assembly 2 ;
1

Remove screw 1 ;
remove intake air temperature pressure
sensor 2 ; remove 5
screw 3 ; remove throttle position
sensor 4 ; remove
1
screw 5 ; remove idle stepper motor 6 . 6
4

2
3

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13 Engine
Check the throttle valve body assembly

to see if the throttle valve body is cracked or otherwise damaged. If so, replace it

with a new one.

For details on the inspection of the idle stepper motor, throttle position sensor, and

intake air temperature and pressure sensor, refer to the electrical section.

Dismantle the fuel distribution

pipe 2
assembly and push both sides of the circlip 1 with your thumbs to remove the circlip 1.

;
Remove the injector 3 from the fuel distribution pipe 2 ; for detailed

maintenance of the injector, refer to the electrical section.

Assembly: Install the injector 3 onto the fuel distribution pipe 2 , and then install the

retaining ring 1. The boss of the fuel distribution pipe must be inserted into the
3
groove of the retaining ring 1 .

Check whether the 1

throttle body connecting pipe 1 is cracked or otherwise damaged.
If so, replace it with a new one.

Check whether the O-ring 2 is broken, hardened or otherwise

damaged. If so, replace it with a new one.

Assemble the throttle valve

body assembly Install the idle
stepper motor 6 ; Install the screw 5 ; (torque:
2N•m~3N•m) Install the throttle position 5
sensor 4 ; Install the screw 3 ; (torque: 3N•m~4N•m)
Install the intake air temperature pressure
1
sensor 2 ; Install the screw 1 ; (torque: 3.5N•m~4.5N•m)
6
4

2
3

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CFMOTO
Install the fuel distribution pipe
assembly 2 ; Install bolt 1. (Torque: 10N•m)
1

2
Install the throttle valve body
assembly Install the throttle body ;
connecting pipe assembly 2 Install bolt 1 ; (torque: 10N•m)

2
Install the throttle valve assembly 2 and ;
tighten the clamp 1 .

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13 Engine
13.5 Engine disassembly
13.5.1 Fixing the engine Fix
the engine firmly on the disassembly table. Warning

The
engine must be firmly fixed on the disassembly table to prevent
the engine from falling and injuring the staff or causing damage to
the engine.
The engine must be completely cooled or special protective clothing
must be worn before disassembly and maintenance can be
carried out to avoid burns.

13.5.2 Drain the engine

oil Place a container under the disassembly table to receive the
engine oil; Remove the M12 magnetic drain bolt 1 and
washer 2 ; Drain all the engine oil; 1 2

Use the oil filter wrench A A

.
(0700-070200-922-001) to remove the oil filter 3.

Warning: When disassembling, it is necessary to add a buffer layer,

such as a rag, between the special wrench and the oil filter to prevent
damage to the oil filter.

13.5.3 Remove the starter

2
motor Remove the M6×25 bolt 1 ;
Remove the starter motor 2 .

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CFMOTO
13.5.4 Remove the

thermostat Remove the M6×22 bolt

1 ; Remove the thermostat cover 2 ;

1
1

Remove the thermostat cover seal 3 ;

Remove the thermostat 4 .

13.5.5 Remove the water

pump. Remove the M6×42 bolts 1 diagonally and crosswise .

.
Remove the water pump 2.
1

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13 Engine
13.5.6 Remove the cylinder head

cover and remove the M6×12 bolt 1 ;

Remove the pressure plate 2 ;

Pull out the ignition coil 3 ;

Remove the spark plug 4 ;

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CFMOTO
Remove the M6 cylinder head cover bolts 5 and their sealing rings diagonally and

crosswise; 6

Remove the cylinder head cover 6 .

13.5.7 Remove the right side Bolt with 5×2 O-ring

cover and remove the M6×25 bolts 1 diagonally and crosswise ;

Rotate the clutch control shaft counterclockwise to disengage it from the clutch

lever;

Remove the right side cover 2 .

13.5.8 Dismantle the

clutch Remove the M6×35 bolt 1 ;
1

Remove the clutch spring pressure plate 2 ;

2

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13 Engine
Remove the clutch spring 3 ;

Pull the pull rod 4 and pull out the pressure plate fitting 5 ;

6 7 6

Remove the friction plate/driven plate

assembly; Check the friction plate/driven plate assembly in the

following order: Friction plate assembly II 6 -- driven plate I 8 -- friction plate assembly

II 6 -- driven plate II 9 -- friction plate assembly I 7 -- driven plate II 9 -- friction

plate assembly I 7 -- driven plate II 9 -- friction plate assembly I 7 -- driven

plate II 9 -- friction plate assembly II 6 -- disc spring 10 -- disc spring seat 11

Use cable ties to tie up the friction plate/driven plate

combination;

11 10 9 8

Use clutch master and slave hub anti-rotation tool A (0SQ0- 050000-922-001)

to fix the center sleeve;

A

Remove the M20×1.5 nut 12;

13
Remove the elastic washer 20 13;

12

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CFMOTO

Remove the center sleeve 14 and the 25.2×39×2 gasket underneath it ;

14

15

Remove the primary driven gear assembly 15;

16

Remove the clutch sleeve 16;

Remove the 25.2×46×5.8 washer 17.

17

13.5.9 Removing the shift lever assembly, shift positioning components and

positioning star wheel

2
Remove the ÿ14 shaft retaining ring 1 and the 14×28×1 washer 2 ;

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13 Engine
Remove the shift lever assembly 3 ;

Remove the M6×16 hexagon socket head screw 4 ;

Remove the shift positioning component 5 ;

5

Remove the M6×16 bolt 6 ;

7
Remove the positioning star wheel 7 ;
6
8
Remove the speed hub bushing 8 .

13.5.10 Disassembling the Oil Pump

1
Remove the ÿ11 shaft retaining ring 1 ;

Remove 11×20×1 washer 2 ;

Remove the oil pump gear 3 ; 2

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CFMOTO
Remove the P4×21.8 needle roller 4 and the 11×20×1 washer 5 ;

4
5

Remove the M6×22 bolts 6 diagonally ;

7 6
Remove the oil pump cover 7 ;

8
8
Remove the P4×7.8 needle roller 8 ;

remove the oil pump inner rotor, oil pump shaft and P4×15.8 needle roller

assembly 9 ;

Remove the oil pump outer rotor 10.

10

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13 Engine
13.5.11 Removing the cylinder head

Remove the timing observation hole cover 1 ;

Remove the filter cover 2 ;

Rotate the crankshaft counterclockwise 3 so that the mark on the magneto rotor

"I" is aligned with the center of the notch of the timing sight hole on the left cover;

At the same time, the "IN" mark on the intake timing sprocket is parallel to the upper plane

of the cylinder head, and the "EX" mark on the exhaust timing sprocket is parallel to the

upper plane of the cylinder head, as shown in the right figure;

Remove the M6×20 bolt 4 ;

Remove the hydraulic tensioner assembly 5 ;

4 5

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CFMOTO

Remove the M6×22 bolt 6 ;

Remove the transition joint assembly 7 ;

Remove the M6×65 bolt 8 ;

8
9
Remove the chain guide block 9 ;

10

Remove the M6×45 bolts 10 diagonally and crosswise ;

Remove the intake camshaft seat assembly 11; 11

10
Remove the exhaust camshaft seat 12;

12

10

13

Remove the intake camshaft assembly 13;

Remove the exhaust camshaft assembly 14;

14

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13 Engine
Remove the M6×90 bolt 15;

15 16
Remove the M10×150 cylinder head bolts 16 and their washers diagonally and crosswise ;

Shake the cylinder head left and right to make it easier to remove. Be careful not to shake

it too much, otherwise the positioning pins will fall off.

Hook the timing chain to prevent it from falling into the case;

Remove the shock-absorbing bolt 17 and its sealing gasket;

17

Lift the cylinder head 18 and hook the timing chain 19 from the gap to prevent the chain

from falling into the case;

Remove the cylinder head 18;

18

19

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CFMOTO

20
Remove and discard the cylinder head gasket 20;

Remove the chain guide 21.

twenty one

13.5.12 Disassembly of the magneto and duplex gear

Remove the M6×30 bolts 1 diagonally and crosswise ;

Remove the left side cover 2 ;

Use the magneto rotor stop fixture A (0SQ0-031000-922-001) to fix the magneto

rotor; A

4
Remove the M12×40 bolt 3 and the 12.5×33×5 washer

4;
3

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13 Engine
Use magneto rotor removal tool B (0SQ0-031000-922-002) B
to push out the magneto rotor and starting gear
assembly 5 ;

Remove the intermediate gear shaft 6 and the double gear 7 .

13.5.13 Disassembly of cylinder block

Gently shake the cylinder body 1 to loosen it, and pull the cylinder body 1

upwards ; 1
Warning:

When the piston is about to leave the cylinder body, hold the piston with your hand

to prevent it from colliding with the box body. If necessary, use dust-free paper to

isolate the piston from the crankcase.

Remove and discard the cylinder block gasket 2 ;

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CFMOTO

Remove the threaded pin 3 ;

Remove the tensioning plate 4 ;

Remove the M6×12 bolt 5 ;

Remove the timing chain support plate 6 ;

6
5

Remove the timing chain 7 .

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13 Engine
13.5.14 Removing the piston

Turn the crankshaft and adjust the piston to a position suitable for disassembly; 3
adjust the opening of the piston pin retainer to the position of the piston notch;
1
use needle-nosed pliers to remove the piston pin retainer 1 and discard

it; push out the piston pin 2 from the other

side ; remove the piston 3 ;

Both pistons are removed in the same manner.

13.5.15 Removing the oil pan

Turn the engine over;

Remove the M6×25 bolts 1 diagonally and crosswise ;

Remove the oil pan 2 ;

Remove the ÿ8×12 cylindrical roller 3 ;

3
Remove the filter assembly 4 .

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CFMOTO
13.5.16 Remove the oil channel cover assembly.

Remove the M6×18 bolts 1 diagonally and crosswise .

.
Remove the oil channel cover assembly 2.

13.5.17 Binning

Remove bolts 1 to 22 in sequence;

twenty one
20
1~6:
M9×108 combination bolt
11
8 10

7 , 9 , 13:
M8×105 combination bolt
7 9
twenty two

3 1 5
8 , 10, 16, 17:
M8×55 bolt

4 2 6
11, 18, 19:
M8×45 bolt

12
13 12, 15:
M8×45 combination bolt

14
14:
15
M8×55 combination bolt

20, 21, 22:

16 M6×30 bolt
17
18 19

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13 Engine
Remove the lower crankcase 23;

twenty three

When disassembling, use a rubber hammer to gently tap the crankcase protrusion 24 to

make it easier to separate the upper and lower crankcases;

twenty four

twenty four

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CFMOTO
Make sure the balance bearing 25 and the main bearing 26 remain in the lower crankcase;

25

26

Remove the front balance shaft assembly 27, crankshaft connecting rod assembly 28,

countershaft assembly 29, and main shaft assembly 30;

27

28

30

29

Remove the throttle plug 31;

remove the P4×7.8 needle roller 32; remove

the 6×16.2 positioning pin 33; remove the 6205

bearing retaining ring 34; remove the 62-28 bearing

retaining ring 35;

31

34 32

33

32 35

Remove the M6×16 bolt 36;

Remove the right bearing baffle 37 (clutch side); 37

36

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13 Engine
A : Push the rear balance shaft assembly 38 toward the clutch side and remove the

rear balance shaft bearing 6204 (clutch side);

C
B : Lift the rear balance shaft gear end;
C : Remove the rear balance shaft assembly 38; B
A

38

Remove the fork shaft cover 39;

Remove the 15×1.9 O-ring 40;

40 39

42
Push the shift fork shaft assembly 41 in the

direction A ; remove the shift forks (left and right) 42 and the shift fork (center)
A
43;

remove the shift fork shaft assembly 41;

43
41

Remove the M6×25 bolt 44;

45

Remove the gear position sensor assembly 45;

44

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CFMOTO
Remove the 31.5×2.5 O -ring 46;

Remove the ball contact 47 and the contact spring 48 from the speed change hub;

48
46

47

Remove the M6×16 bolt 49 and the 6.3×16.3×1.2 washer 50;

remove
the speed hub 51 and the 16005 rolling bearing 52 from the clutch 51
side.

52

50

49

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13 Engine
13.6 Engine Overhaul and Reassembly
13.6.1 Crankcase Assembly
1
1. Upper crankcase
2. Lower crankcase 3

3. Left cover 4.
Right cover 5.
4
Oil pan 2

13.6.1.1 Main bearing/balance bearing selection 220315011ABABA

Crankshaft main bearing seat hole/front balance shaft bearing seat hole

The crankshaft main bearing seat hole and the front balance shaft bearing seat hole 2 1
are grouped according to the following table. The grouping marks are engraved on

the lower crankcase. The

positions are shown in the example on the

mark right.

A Crankshaft main bearing seat hole

1. Crankshaft main bearing seat hole diameter
B (new part) Diameter 1 37 mm~37.008 mm 37.009 mm~37.016 mm
2. Front balance shaft bearing seat hole diameter

Front balance shaft bearing seat hole

(new part) Marking diameter 2 A 29
mm ~ 29.006 mm B 29.007 mm ~ 29.013 mm

Example tag "220315011ABABA" description:

From left to right:

The first character A: indicates that the grouping mark of the balance shaft

bearing seat holes on the left side (magneto side) is

A; The second character B: indicates that the grouping mark of the balance shaft

bearing seat holes on the right side (clutch side) is

B; The third character A: indicates that the grouping mark of the crankshaft main

bearing seat holes on the left side (magneto side)

is A; The fourth character B: indicates that the grouping mark of the crankshaft

main bearing seat holes in the middle

position is B; The fifth character A: indicates that the grouping mark of the

crankshaft main bearing seat holes on the right side (clutch side) is A.

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CFMOTO
Main bearing

The main bearing center wall thickness et grouping is shown in the table below.

Main bearing (new)

Color coding central wall thickness et

Red 1.486 mm~1.490 mm

Black 1.491 mm~1.494 mm

et
Blue 1.495 mm~1.498 mm

Balance bearing

The grouping of the center wall thickness et of the balance bearing is shown in the table below.

Balance bearing (new)

Color coding central wall thickness et

Red 1.484 mm~1.488 mm

Black 1.489 mm~1.492 mm

blue 1.493 mm~1.496 mm
et

Crankshaft: Status 1
Crankshaft main journal

The condition of the crankshaft is shown in the figure on the right.

Crankshaft: Status 2

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13 Engine
Crankshaft main journal diameter 1 group is shown in the table below;

Crankshaft main journal (new part)

mark Diameter 1
1 1 1
B 33.985 mm~33.992 mm

A 33.993 mm~34.000 mm

Magneto side Clutch side

Crankshaft: Status 1

The grouping mark positions are shown in the figure on the right, from left to right:

Main journal grouping marks on the magneto side, middle side, and clutch side

remember;

Measure the crankshaft main journal diameter. If it is smaller than the maintenance limit,

Replace with new parts.

Crankshaft main journal diameter

Maintenance limit 33.965 mm

Main journal grouping mark

Crankshaft: Status 2

Main journal grouping mark

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CFMOTO
Crankshaft Grouping
2 3
Check the tooth surface of the balance shaft driving gear 1 and output gear 2

Is it seriously worn or otherwise damaged? If so, replace it with a new one

Crankshaft assembly.

The crankshaft is divided into the balance shaft driving gear 1 and the output gear 2

There are two groups, A and B. Each gear has a group mark engraved on it.
3 .

The crankshaft must be mated to the correct primary driven gear on the clutch and the correct driven gear on the balance shaft. These gears are also

There are two groups, A and B, and they are marked with grouping marks. The following table shows the correct pairing method.

Crankshaft gear Clutch Primary driven gear Front balance shaft driven gear Rear balance shaft driven gear
A B B B
B A A A

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13 Engine
Front balance shaft journal

The front balance shaft journals are grouped according to diameter 1 ;

1 1
Front balance shaft journal (new part)

Mark 1 2 diameter

25.987 mm~25.993 mm

25.994 mm~26.000 mm

Clutch side Magneto side

The grouping mark position is shown in the example on the right, and the grouping of the journals on both sides

The marks are engraved on the adjacent balance weights;

Measure the journal diameter of the front balance shaft 1. If it is smaller than the maintenance

If it fails to meet the limit, replace with new ones.

Front balance shaft journal diameter Grouping Mark

Maintenance limit 25.967 mm

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CFMOTO
Front balance shaft assembly group
2
Check whether the tooth surface of the balance shaft driven gear 1 is damaged or not.

Excessive wear, if there is any abnormality, replace the front balance shaft assembly with a new one

Piece.

The front balance shaft assembly is divided into A and B according to the balance shaft driven gear 1.

Group A and B. Group mark 2 is engraved on the balance shaft driven gear

On wheel.

Crankshaft assembly and front balance shaft assembly

The crankshaft assembly and the front balance shaft assembly are matched according to the following table

assembly:

Crankshaft assembly Front balance shaft assembly

Grouping Mark Grouping Mark

A B

B A

Matching tile

Notice

Before aligning the bearings, first ensure that the crankshaft assembly and the front balance shaft assembly

The pairing of components meets the above requirements.

The crankcase and main bearing are assembled in pairs according to the following table:

Crankshaft main bearing seat hole Crankshaft main journal Main bearing

mark mark color

A A red

A B Black

B A Black

B B blue

The crankcase and balance bearing are assembled in pairs according to the following table:

Front balance shaft bearing seat hole Front balance shaft journal Balance bearing

mark mark color

A 1 Red black

A 2 Blue

B 1 Black

B2

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13 Engine
13.6.1.2 Crankcase cleaning

WARNING Use eye protection to avoid eye damage.

Use a cleaning tool to clean the crankcase; Use

compressed air to dry the crankcase; Use

compressed air to blow out the oil passages.

Crankcase Inspection

Check the upper crankcase, lower crankcase, left cover, right cover, and oil pan

for cracks or other damage. If any, replace them.

Check the main bearing and balance bearing for scratches, severe wear, or other

damage. If so, replace them.

Rolling bearing/oil seal

inspection Check whether the 6204 rolling bearing 1 rotates flexibly and is damaged.

If so, replace it. Check whether the

14×24×6 oil seal 2 and HK1412 needle bearing 3 are damaged. If so, replace them.
1

4
Disassembly

Note
5
that if the bearing or oil seal is not damaged, the following corresponding

disassembly steps are not necessary. 4 2

3

Remove the M6×16 bolt 4 ; remove the

left bearing baffle 5 ; use a bearing

puller to pull out the 6204 rolling bearing 1 from the crankcase ; use a screwdriver

to pry off

the 14×24×6 oil seal 2 and discard it; use a bearing puller to pull out the

HK1412 needle bearing 3 from the crankcase ;

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CFMOTO
Bearing assembly diagram
Assemble in the reverse order of disassembly;
Assembly tools
When assembling the bearing, place a suitable support tool on the

bearing hole of the housing, as shown

in the figure on the right; Use a needle roller bearing punch Bearings

(0SQ0-011101-923-002) to install the HK1412 needle roller bearing 3

into the corresponding

hole of the crankcase until it is in place; Use an oil seal punch

(0SQ0-011101-923-001) to install the 14×24×6 oil seal 2 (with the marked

side facing outward) into the corresponding hole of the crankcase, and

apply a proper amount

Support tools
of grease to the lip of the oil seal after it is in place; Use a bearing press

(0SQ0-011101-921-002) to install the 6204 rolling bearing 1 (with the

marked side facing outward) into the

corresponding hole of the crankcase until it is in place; Use an M6×16

bolt 4 (with a proper amount of 243 Thread lock glue) fasten the left
. 6204 rolling bearing 1
bearing baffle 5 to the crankcase, and press the
1

4 2
3

Check the diameter of the crankshaft main bearing hole and the front balance

shaft bearing hole, and assemble the upper and lower crankcases; (install the main
1
bearing and balance bearing, and tighten the assembly bolts according to the specified

torque, refer to the "Engine Assembly - Crankcase Assembly" section)

Use a lever micrometer to measure the inner diameter of the crankshaft main bearing at

three locations vertical to the crankcase surface , and compare the crankshaft main 1
journal diameter at the corresponding location;

The inner diameter of the

Maintenance limit crankshaft main bearing is 34.055 mm

crankshaft main journal radial clearance

Standard 0.028 mm~0.060 mm 0.070 mm

maintenance limit

If the maintenance limit is exceeded, the main bearings and even the crankcase

need to be replaced;

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13 Engine
Use a lever micrometer to measure the inner diameter of the front balance shaft bearing

at two locations vertical to the crankcase sub-box surface , and compare the front balance

shaft journal diameter at the corresponding location; the

2

maintenance limit of the front balance

shaft bearing inner diameter is 26.050 mm

The standard radial clearance of the front

balance shaft journal is 0.040 mm~0.060 mm and the maintenance limit

is 0.070 mm. If it exceeds the maintenance limit, the balance

bearing and even the crankcase need to be replaced.

Notice

The upper crankcase and lower crankcase must be replaced as a set.

13.6.1.3 Right side cover

inspection

Check the right side cover 3 for cracks or damage. If so, replace it with a new one. Check

the oil

level sight glass 2 for damage or oil leakage. If so, replace it with a new one. Check the

12×20×5 oil seal 5 for

damage. If so, replace it with a new one.

Use the special tool

7
(0SQ0-013100-923-001) for assembling the new right side cover to install the oil level

sight glass 2 into the corresponding hole of the right side cover 3 ; Install the 6

wire retaining ring 1 into the retaining ring groove of the right side cover 3 , and the
5
retaining ring must be 4
completely inserted into the groove; Apply a proper amount of engine oil on the surface

of the HK1210 needle roller bearing 4 , and use the special tool (0SQ0-013000-923-003)
12
to install the needle roller bearing 4 (with the marked side facing outward) into the 3
corresponding hole of

the right side cover 3 ; Use the special tool (0SQ0-013000-923-002) to install the 12×20×5

oil seal 5 into the corresponding hole of the right side cover 3 , and apply a proper

amount of grease on the lip of the oil seal after installation; Install the

18×3.55 O-ring 6 onto the oil filler plug 7 ; Install the oil filler plug 7 onto the right side

cover 3 and tighten it.

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CFMOTO
13.6.2 Disassembly of the cylinder head cover
2

subassembly Remove the cylinder head cover sealing gasket 2 from the cylinder

head cover 1 ; Remove the air supply pin 3 from the cylinder head cover 1 ;

1 3

4
5
Note: If the labyrinth cover assembly 5 is not damaged, the following

disassembly steps are not necessary; 6

Remove the M6×12 bolt 4 ; remove

the labyrinth cover assembly 5 ;

remove and discard the labyrinth cover gasket 6 ;

{} The range is Euro 5 status Operation steps:

7
{Remove the M6×20 bolt 7 ; remove

the check valve cover assembly 8 ;

remove the reed valve .

assembly 9 }

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13 Engine
Check
2
whether the cylinder head cover gasket 2 is broken, hardened, or otherwise

damaged. If so, replace it with a new one;

Check whether the cylinder head cover 1 is cracked or otherwise damaged. If so,

replace it with a new one;

Check whether the labyrinth cover assembly 5 is broken or otherwise

damaged. If so, replace it with a new one;

Check whether the one-way valve cover assembly 8 is cracked or otherwise

1 3
damaged. If so, replace it with a new one;

Check whether the reed valve assembly 9 is damaged. If so, replace it with a
4
new one. 5

6
Assemble in the reverse order of disassembly. Note

that the

labyrinth cover gasket must not be reused and must be replaced with a new

one. Pay attention to the installation direction of the reed valve assembly.

Labyrinth cover bolt 4 torque

10N•m

Check valve cover bolt 7 torque

10N•m

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CFMOTO
13.6.3 Cylinder head sub-assembly valve

clearance inspection

Note that

valve clearance inspection and adjustment must be performed when the engine is cold.
1

Remove the timing inspection hole cover 1 ;

remove the filter cover 2 ;

•
1 cylinder valve clearance

Rotate the crankshaft 3 counterclockwise so that the piston of cylinder 1 is at the ignition top

dead center;

At this time, the "I" marked "T1 I" on the magneto rotor is aligned with the center of the notch

of the timing sight hole on the left cover;

Air Intake exhaust

At the same time, the engraved line on the intake timing sprocket is parallel to the plane on

the cylinder head, and the engraved line on the exhaust timing sprocket is parallel to the

plane on the cylinder head, as shown in the right figure;

Use a feeler gauge to measure the valve clearance of intake valve 4 and exhaust valve 5 of

cylinder 1 (magneto side) ;

Record the measured data and compare it with the "Valve Clearance (Cold Engine)" table.

If it does not meet the standard, replace the valve tappet with a suitable thickness. After

replacing
4
Feeler gauge
the valve tappet, re-measure the clearance until it meets the standard.

Valve clearance (cold

Valve
5
Intake valve engine) Clearance 0.10
Exhaust valve mm~0.15 mm 0.25 mm~0.31 mm

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13 Engine
• Valve clearance of cylinder 2

Rotate the crankshaft 3 270° counterclockwise so that the piston of cylinder 2 is at

ignition top dead center;

At this time, the "I" marked "T2 I" on the magneto rotor is aligned with the center of the

notch of the timing sight hole on the left cover;

3

Air Intake exhaust

At the same time, the engraved line on the intake timing sprocket forms a 45° angle

with the plane on the cylinder head, and the engraved line on the exhaust timing

sprocket forms a 45° angle with the plane on the cylinder head, as shown in the right figure;

Use a feeler gauge to measure the valve clearance of intake valve 4 and exhaust valve

5 of cylinder 2 (clutch side) ;

Record the measured data and compare it with the "Valve Clearance (Cold Engine)"

table. If it does not meet the standard, replace the valve tappet with a suitable thickness.
Feeler gauge

After
4
replacing the valve tappet, re-measure the clearance until it meets the standard.

Valve clearance (cold

Valve
5
Intake valve engine) Clearance 0.10
Exhaust valve mm~0.15 mm 0.25 mm~0.31 mm

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CFMOTO
The valve tappets are grouped according to thickness T as follows:

Valve tappet T size grouping table Group mark engraving position

Mark T (mm) Mark T (mm)
320 3.20 370 3.70
322 3.22 372 3.72
324 3.24 374 3.74
326 3.26 376 3.76
328 3.28 378 3.78
330 3.30 380 3.80
332 3.32 382 3.82
334 3.34 384 3.84
336 3.36 386 3.86
338 3.38 388 3.88
340 3.40 390 3.90
342 3.42 392 3.92
344 3.44 394 3.94
346 3.46 396 3.96
348 3.48 398 3.98
350 3.50 400 4.00
352 3.52 402 4.02
354 3.54 404 4.04
356 3.56 406 4.06
358 3.58 408 4.08
360 3.60 410 4.10
362 3.62 412 4.12
364 3.64 414 4.14
1
366 3.66 416 4.16
368 3.68 418 4.18

Cylinder head disassembly

Remove the valve tappet 1 ;

Notice
Note the position of the tappet so that you can quickly find it when reassembling it.

Quickly install it to its original position.

Install the valve spring compression clamp (0180-022006-

922-001); 2
Place the lower part of the valve spring compression clamp against the upper part of ,
the valve disc 2 and press it onto the valve spring upper seat 3 ;

Slowly rotate the lever on the top of the valve spring compression fixture to

The valve spring is compressed until the valve lock clip is fully exposed;

warn 3
Wearing goggles when compressing valve springs is not standard
Operation may cause the valve spring to be under strong preload
Under the action, parts may fly out and injure people.

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13 Engine
Use valve lock clamp tweezers to remove the valve lock clamp 4 ;

Be sure

to add an appropriate amount of butter to the valve lock clip tweezers to prevent the

valve lock clip from falling off the tweezers.

4

Slowly rotate the rotating rod at the top of the valve spring compression fixture to

restore the valve spring to a relaxed state;

Remove the valve spring upper seat 5 ; 5

remove the valve spring 6 ;
6
remove the valve 7 ;

Use pliers to gently grip the valve stem seal 8 and remove it;
8

Remove the valve spring lower seat 9 ; 9

the removal method of the remaining 7 valves is the same.

Note

that each time you remove a valve, you need to replace the valve stem seal. The

removed valves and related parts must be placed one by one so that they can be

quickly installed to the original position when reassembled.

Cylinder head
Exhaust camshaft seat
inspection Check whether there are cracks between the valve seats of the cylinder

head. If

so, replace them. Check whether there are bumps, severe wear or other damages on

the camshaft bearing holes on the cylinder head. If so, replace them.

Camshaft support surface

Check whether the surface of the camshaft seat supporting the camshaft has any

bumps, severe wear or other damage. If so, replace it.

Intake camshaft seat assembly

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Clean the cylinder head and camshaft seat; Assemble the

cylinder head and camshaft seat with the camshaft seat bolts (tighten diagonally in

three steps: 5N•m ÿ 8N•m ÿ 12N•m); Use a lever dial gauge to measure the diameter of

the camshaft bearing holes on 1

the intake and exhaust sides 1. If the hole diameter exceeds the maintenance limit,
1 1
replace the cylinder head and camshaft seat. Camshaft bearing hole diameter (intake
1 1
and exhaust) New part 24.000 mm~24.021

mm Maintenance limit 24.050 mm 1

Note

that the cylinder head, intake camshaft seat, and exhaust camshaft seat must be

replaced as a set.

Valve

Check the valve stem for abnormal wear and bending. If so, replace it. Use a

micrometer

to measure the valve stem diameter1 . If it exceeds the maintenance limit, replace it.

Valve stem diameter:

1
intake valve

new parts 4.475 mm ~ 4.490 mm, maintenance limit 4.465 mm exhaust

valve new parts 4.455 mm ~ 4.470 mm, maintenance limit

4.445 mm

Valve guide Check

the valve guide for severe wear or other damage. If so, replace the cylinder head.

Use a small inside diameter gauge to measure the valve guide hole diameter 1. If it exceeds

the maintenance limit, replace the cylinder head.

1

Note:

Clean the valve guide and remove carbon deposits before measuring.

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Valve guide bore (intake and exhaust)
New parts 4.500 mm~4.512 mm
Maintenance limit 4.540 mm

Valve stem and valve guide clearance

Check the clearance between the valve stem and the valve guide.
Repair limit, replace valve or cylinder head.

Valve stem and valve guide clearance

Intake valve

New 0.01 mm~0.037 mm

Parts Repair Limit 0.075 mm

Exhaust valve

New 0.03 mm~0.057 mm

Parts Repair Limit 0.095 mm

Valve cone and valve seat

Check the valve cone or valve seat for erosion or depression.
Yes, replace the valve or cylinder head.

Measure the valve seat contact surface width with a caliper 2 .

Valve seat contact width (intake and exhaust) 2

1
New parts 0.9 mm~1.1 mm
Repair limit 1.4 mm

If the measured value exceeds the service limit, replace the cylinder head.
1 Valve cone width 2 Valve seat contact surface width

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CFMOTO
Valve spring The

valve spring ensures the sealing between the valve and the valve seat. A reduction

in the spring force will lead to a reduction in engine power output and cause the

valve to produce large mechanical

noise; Measure the free length of the

spring 1 ; Free length of the valve

New spring 36.8 mm

Parts Repair Limit 35 mm

Use a spring force tester 2 to measure the spring force of the valve spring 3 when

it is compressed to a specified length;

refer to the "valve spring force value standard" and if the force value is not within

the specified range, replace the valve spring with a new one;
3
Valve spring force value: When

the standard valve spring is compressed to a length of 33mm, the spring force
2
value is 106N~124N; when the valve spring is compressed to a length of 25mm,

the spring force value is 423N~467N.

Thermostat

Check the thermostat of the thermostat , If the valve opens, replace it with a new one.

valve at room temperature.

To check the valve opening temperature, suspend the thermostat A in a water

container. The thermostat must be completely submerged in the water and must A B
not touch the sides or bottom of the container. At the same time, suspend a

standard thermometer B in the water , also making sure it does not touch the

container. Lock the thermostat and thermometer's thermal position C at the same

depth and heat the bottom of the container.

C

Thermostat opening temperature and full opening lift

Initial opening temperature 80ÿC~84ÿC Full opening

temperature 95ÿC Full opening lift ÿ8mm

If the measurement result is outside the specified range, replace the thermostat

with a new one.

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New cylinder head assembly

The cylinder head and camshaft seat must be used together. Check whether the codes

of the two are consistent. If you replace any one of them, you should replace them as a

set. Check

whether there are obvious aluminum chips, bumps, scratches, sand holes, etc. on each

surface of the cylinder head. If found, clean them up or replace them with new ones.

Use an air gun to blow air into the blow hole 1 to check whether the oil passage is 1
smooth; feel whether air is coming out from the outlet hole 2. If there is no air coming

out, replace the cylinder head;

Remove the M6×45 bolts 3 and M6×65 bolts 4 diagonally ; remove the intake camshaft
3
seat

assembly 5 ; remove the exhaust camshaft seat 6 ;

be careful not to drop the locating pins, 3

and the

removed camshaft seat and bolts must be placed as a set. 3 6

4

Apply an appropriate amount of 567 thread sealant to the threaded part of the main oil

channel cone plug 7 ;

Install the main oil channel cone plug

7 ; Main oil channel cone plug torque

20N•m

Install the valve spring lower seat 8 (with the large end surface facing downward);

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CFMOTO
Apply a proper amount of engine oil on the valve guide (the part where the valve

stem seal is installed); 9

Put the valve stem seal 9 on the valve stem seal hand punch.
A
A (0700-022400-923-002); Install the valve stem seal 9

onto the valve guide;

Turn over the cylinder

11
head; Apply a proper amount of engine oil to the ends of the intake

and exhaust valve stems; Insert the intake valve 10 into the intake valve guide, and

do not let it fall

into the valve seat; Insert the exhaust valve 11 into the exhaust valve guide, and do

not let it fall

into the valve seat; Use an air gun to blow and clean the joint surface between the

valve

and the cylinder head; Push the valve to make it fall into the valve seat, and turn over 10
the cylinder head;

Install valve spring 12;

Make

sure the end of the valve spring with the paint mark is facing up.

12

Install the valve spring upper seat 13;

13

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Install the valve spring compression clamp (0180-022006-922-001); Place the lower part of the

valve spring compression

14
clamp against the valve disc 14, and the upper part against the valve spring upper seat 15;

slowly rotate the rotating rod at the top of the valve spring

compression clamp to compress the valve spring until the locking groove on the valve is completely

exposed;

15

Warning:

Wear goggles when compressing the valve spring. Improper operation may cause the valve

spring to be under strong pre-pressure, causing parts to fly out and injure people.

Install the valve lock clip 16 onto the valve lock clip tweezers;

Be sure

to add an appropriate amount of butter to the valve lock clip tweezers to prevent the valve lock
16
clip from falling off the tweezers.

Install the valve lock clip 16 into the valve lock clip groove; slowly

rotate the rotating rod at the top of the valve spring compression fixture to restore the valve spring

to a relaxed state; install the remaining valve lock clips in

the same way; use a rubber rod and a rubber hammer to gently tap each valve

spring seat to make the valve-related parts fit in place; check the sealing of the cylinder head.

kerosene

kerosene

Cylinder head sealing inspection • Oil

inspection Use

dust-free paper to wipe the entire bottom of the cylinder head and the valve disc; Add a proper

amount of

kerosene or other cleaning solvent into the intake and exhaust passages; After standing for five 1
1
minutes, check whether kerosene flows out from the valve seat ring 1 .

• Optical inspection

When no suitable cleaning solvent is available, use optical inspection; Aim

the bottom of the cylinder head towards a light source;

Observe the valve seat ring from the intake and exhaust ports to see if there is light 1 shining

through.

If the cylinder head sealing fails the oil inspection or optical inspection, remove the valve and check

the corresponding valve and valve seat surface. If there is no problem, reclean the valve and valve
1
seat and reassemble them. If it still fails the oil inspection or optical inspection, replace it with a

new part.

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Install the valve tappet.

Apply a proper amount of a mixture of engine oil and MoS2 grease

(weight ratio 10:1) on the outer surface of the valve

tappet. Install the valve tappet 1 ;

Install studs Install

M8×42 studs 1 ; Cylinder head studs

torque 1 1
25N•m

Install the thermostat

Install the thermostat 1 (hole facing upwards);

1 hole facing up

Install the thermostat cover sealing ring 2 into the thermostat

cover 3 ; Use the M6×22 bolts 4 to install the thermostat cover onto the

cylinder head;

Thermostat cover bolt torque

10N•m
4
2 3

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Install the spark

plug Install the spark plug 1 ;

Spark plug torque 1

15N•m

Install the water temperature

sensor Install the water temperature

sensor 1 ; Water temperature sensor torque

1
15N•m

13.6.4 Cylinder Block

Inspection Check
the cylinder block for cracks, scratches, and wear steps on the upper
and lower ends. If any, replace it.

Cylinder Block Diameter

Cylinder block diameters are grouped according to the table below and the group mark positions are shown in

the figure on the right.

Cylinder block (new

Mark part) Cylinder
block diameter 72.000 mm~72.010 mm

ÿÿ 72.011 mm~72.019 mm

1 Cylinder group mark 2 Cylinder group marking

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CFMOTO
Because the degree of cylinder block wear is different in different directions, at the

position shown in the right figure, 10mm and 60mm away from the upper plane of the

cylinder block, measure the diameter 1 of the two cylinders along the direction of the

piston pin and perpendicular to the direction of the 10mm 1

1
piston pin respectively; if the cylinder block diameter 1 at any point exceeds the
60mm
maintenance limit, replace the cylinder block.

Cylinder diameter 1 1
maintenance limit 72.065 mm

Note:
Measured along the piston pin direction
When replacing the cylinder block, the piston ring must be replaced with a new one.

10mm 1

60mm

Measured perpendicular to the piston pin

13.6.5 Piston/Piston Ring/Piston Pin Piston

Inspection
Check the piston for scratches, cracks or other damage. If found,
replace the piston and piston ring.

Measure the piston skirt diameter 1 at a point perpendicular to

the piston pin hole and 10 mm from the bottom of the piston. If it
1
is less than the maintenance
10mm

limit, replace the

piston. Piston skirt diameter New part 71.960
mm~71.975 mm Maintenance limit 71.910 mm

Piston/cylinder clearance
Based on the above measurement results, calculate the clearance
between the piston and the cylinder. If the clearance is greater
than the maintenance limit, replace the

piston or cylinder, or both.

Standard Piston/cylinder clearance 0.033

maintenance limit mm~0.052 mm 0.10 mm

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Piston ring/piston ring groove clearance

Use a feeler gauge to measure the clearance between the piston ring and the ring groove at multiple locations;

If the clearance is greater than the maintenance limit, replace the piston and piston ring.

Piston ring/piston ring groove clearance

First gas ring/ring groove

Standard 0.02 mm~0.06 mm

maintenance limit 0.15 mm

Second gas ring/ring groove

Standard 0.02 mm~0.06 mm

maintenance limit 0.15 mm

Piston disassembly

Carefully open the opening of the first air ring 2 with your thumb and

Push the ring outward to remove the first gas ring;

Use the same method to remove the second gas ring 3 and the combined oil ring

4 . 2
3

Piston ring groove width

Use a vernier caliper to measure the first piston ring groove 5 , the second

The width of the gas ring groove 6 ;

5
If the groove width is greater than the service limit, replace the piston.

Piston ring groove width

First air ring groove 6

New 1.01 mm~1.03 mm

Parts Repair Limit 1.10 mm

Second air ring groove

New 1.01 mm~1.03 mm

Parts Repair Limit 1.10 mm

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Piston ring thickness

Use a micrometer to measure the thickness of the piston ring at multiple

locations7 ; If the measured value is less than the maintenance limit,

replace the piston

ring. Piston ring 7

New thickness First ring 0.97 mm~0.99

Parts Repair Limit mm 0.93 mm

7
Second ring 0.97

New mm~0.99 mm 0.93 mm

Parts Repair Limit

Gas ring mark:

First gas ring mark: ATG-V Second gas ring

mark: A

Gas ring mark

Gas ring opening

Piston ring opening clearance

8

Place the piston ring at the bottom of the cylinder bore of the cylinder block (i.e. the position

where the cylinder bore wear is minimal);

NOTE

To ensure that the piston ring is properly seated in the cylinder, push it in with the

piston.

Use a feeler gauge to measure the piston ring gap 8 ; if the gap

is greater than the maintenance limit, replace the piston ring. Piston ring

gap First ring 0.15 mm~0.30

mm 0.55 mm Second

New ring 0.10 mm~0.30 mm

Parts Repair Limit

New

Parts Repair Limit 0.55 mm

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Piston pin hole diameter

Measure the piston pin hole diameter 9. If the measured value is greater

than the maintenance

limit, replace the piston.

Piston pin hole diameter New part 17.002 mm~17.008 mm 9

Maintenance limit 17.035 mm

Piston pin diameter

Use a micrometer to measure the piston pin diameter at multiple locations

10
10. If the measured value is less than the

maintenance limit,
10
replace the piston pin. Piston pin diameter new part 16.992

mm ~ 16.997 mm Maintenance limit 16.980 mm

10

Piston Grouping

Piston skirt diameter 1 and weight grouping are shown in the table below and the marking positions

are shown in the figure on the right.

Piston (new) Skirt

Mark ÿ diameter 71.960

ÿ mm~71.967 mm
1
10mm

71.968 mm~71.975 mm

Piston (new) Weight

mark 152.3 g

O ~ 155.3 g 155.4 g ~ 158.3 g

No mark
Weight group marking

Note

that pistons of the same weight group must be assembled on the same

engine.

Exhaust side marking

Skirt diameter grouping mark

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Piston/Cylinder Assembly The piston

and cylinder must be assembled in pairs according to the requirements in the table

below. Cylinder Marking Piston Marking ÿ ÿ ÿ ÿ

When assembling
Piston pin retaining ring opening
the piston, use needle-nosed pliers to insert the piston pin retaining ring 11 from the piston

notch position;

stagger the piston pin retaining ring opening and the piston notch position. Note

that the

piston pin retaining ring cannot be used twice and must be replaced with a new one.

Piston gap
11

Install the combined oil ring, the second gas ring and the first gas ring into the First air ring opening

corresponding piston ring grooves in sequence as shown in the right figure.

Oil ring scraper ring opening Oil ring scraper ring opening
Note that
30° 30°

during assembly, the "ATG-V" mark on the first ring should face the top of the piston,

and the "A" mark on the second ring should face the top of the piston.

Oil ring liner and second gas ring opening

13.6.6 Camshaft Identification of Valve Train

Sub-Assembly There

is a distinguishing mark cast between the camshafts for cylinder 1 and cylinder 2. Intake

camshaft: IN

Exhaust camshaft: EX

Distinguishing the location of the logo

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Disassemble the intake camshaft

assembly and open the stopper to tighten part 1 ;

Remove the M6×19 bolt 2 , stopper 3 , centrifugal wheel 4 , and

intake timing sprocket 5 from the intake camshaft assembly 6 in
.
sequence.

5
4
3
2

1
Disassemble the exhaust camshaft

assembly and open the stopper to tighten part 1 ;

5
Remove the M6×12 bolt 2 , stopper 3 , exhaust timing sprocket
4 from the exhaust camshaft assembly 5 in sequence. . 4

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Camshaft journal
Measure the camshaft journal diameter 1. If the measured value exceeds the maintenance

Repair limit and replace new camshaft.

Camshaft journal diameter (intake and exhaust)

New parts 23.950 mm~23.972 mm
1 1 1
Maintenance limit 23.920 mm

1 1 1

Check the clearance between the camshaft journal and the camshaft bearing hole.

If the clearance exceeds the maintenance limit, replace the camshaft with a new one or

Cylinder head.

Clearance between camshaft journal and camshaft bearing hole

Standard 0.028 mm~0.071 mm

Repair limit 0.13 mm

Camshaft lobe height

Measure the cam height of the intake/exhaust camshaft respectively1 ;

If the measured value exceeds the service limit, replace the camshaft with a new one.

Cam height (intake)

New parts 32.298 mm ~ 32.408 mm
Maintenance limit 32.200 mm
1
Cam height (exhaust)
New parts 33.008 mm ~ 33.118 mm
Maintenance limit 32.910 mm

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Timing sprocket

Check the intake/exhaust timing sprocket for breakage, broken teeth or

other damage, or severe wear of the teeth. If so, replace with a new

timing sprocket.

Intake timing sprocket

Exhaust timing sprocket

"IN" mark hole and roller needle alignment

Assembly of intake camshaft assembly

Align the hole marked "IN" of intake timing sprocket 1 with the needle on

intake camshaft assembly 2 , and install the intake timing sprocket onto

the intake camshaft;

3 4

Put the M6×19 bolt 3 through the stopper 4 and the centrifugal wheel 5

in sequence and install them on the intake

camshaft; Intake timing sprocket bolt torque

10N•m
5

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CFMOTO
Flanged the stopper to prevent the bolt from loosening.

"EX" mark hole and roller needle alignment

Assembly of exhaust camshaft assembly

Align the hole marked "EX" on the exhaust timing sprocket 1 with the needle

on the exhaust camshaft assembly 2 , and install the exhaust timing

sprocket onto the exhaust camshaft;

3
Pass the M6×12 bolt 3 through the stopper 4 and install it on the exhaust

camshaft;

Exhaust timing sprocket bolt torque

10N•m

Flanged the stopper to prevent the bolt from loosening.

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Hydraulic tensioner assembly
3
4
Check whether the tensioner housing 1 and plunger 2 are damaged or severely worn. If so, 1
replace them with new ones. Check whether the

tensioner seal 3 and O-ring 4 are broken or hardened. If so, replace them with new ones.

Check whether the hydraulic tensioner compresses

and rebounds smoothly and powerfully. If it is stuck and weak, replace it with a new one.

13.6.7 Crankshaft and connecting rod

Connecting rod big end face clearance

AB
Measure the connecting rod big end face clearance: first place one side of the connecting rod

big end close to the crankshaft crank arm A , then use feeler gauge C to measure the
C
clearance between the other side of the connecting rod big end and the crankshaft

crank arm B ; use the same method to measure the other connecting rod big end face

clearance;

Standard maintenance limit of

connecting 0.15 mm~0.30 mm 0.50 mm

rod big end end clearance

If the clearance is greater than the maintenance limit, replace the connecting rod with a new

one and remeasure the clearance; if the clearance still exceeds the maintenance limit after

replacing the connecting rod, the crankshaft must be replaced.

Disassembly of crankshaft

connecting rod Remove connecting

4
rod bolt 1 ; remove connecting rod big head 4
cover 2 ; remove connecting rod
3
body 4 ; remove connecting rod bearing 3 from connecting rod big head cover 2 and
3
connecting rod body 4 ;

When
3
disassembling, make sure to mark the connecting rod cap, connecting rod body and 3
2
connecting rod bearing, and place them one by one so that they can be quickly installed in 2
the original position when reassembling. If the connecting rod bearing is not excessively
1
1
worn or damaged, do not remove it.

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Connecting rod grouping

The connecting rod big end hole diameter 1 and connecting rod weight grouping are shown in the table below.

The grouping marker positions are shown in the figure on the right.

Connecting rod big end hole (new)

Mark 1 diameter

2 38.000 mm~38.008 mm

38.009 mm~38.015 mm
Connecting rod big end hole diameter

Grouping Mark

Connecting rod weight G (new)

1
Pairing ID
Marking weight range (g)
294 293ÿG ÿ 295 Connecting rod weight marking

296 295ÿG ÿ 297

298 297ÿG ÿ 299

300 299ÿG ÿ 301

302 301ÿG ÿ 303

304 303ÿG ÿ 305

306 305ÿG ÿ 307

308 307ÿG ÿ 309

310 309ÿG ÿ 311

312 311ÿG ÿ 313

Notice

The same crankshaft must be equipped with the same weight group mark

of connecting rod.

Crankshaft connecting rod journal grouping Crankshaft: Status 1

The condition of the crankshaft is shown in the figure on the right.

Crankshaft: Status 2

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The crankshaft connecting rod journal diameter 1 group
1
is shown in the table below. Crankshaft

connecting rod journal (new part) Marking

1
diameter B 34.985 mm~34.992 mm A 34.993 mm~35.000

mm

Crankshaft: Status 1
The position of the crankshaft connecting rod journal grouping marks is shown in the right figure,

from left to right, they are the grouping marks of the connecting rod journals of cylinder 1 and

cylinder 2.

Connecting rod journal group marking

Crankshaft: Status 2

Connecting rod journal group marking

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Connecting rod
bearing grouping Connecting rod bearing

center wall thickness

et grouping see the table below. Connecting rod
bearing (new part) Color code Center wall thickness
et Red 1.482 mm~1.486 mm Black 1.487 mm~1.490
mm Blue 1.491 mm~1.494 mm
et

The radial clearance of the connecting

rod big end is the same as the initial state. Install the connecting rod bearing, install the

connecting rod bolt, and tighten it in two steps according to the table below, and then measure

the inner diameter of the .

connecting rod big end bearing 1 Step 1: Torque

20N•m±2N•m 1
Step 2: Corner
installation 100°±5°

Measure the crankshaft connecting rod journal diameter and compare it to the connecting rod big end

bearing inside diameter.

The connecting rod

journal diameter is 34.985 mm to 35.000 mm for new

parts and 34.955 mm for maintenance

The maintenance limit of the inner diameter

of the connecting rod big end bearing is 35.055 mm

Connecting rod big end radial clearance

Standard 0.04 mm~0.06 mm 0.07

maintenance limit mm

If the maintenance limit is exceeded, replace the crankshaft or connecting

rod bearings with new ones, or replace both.

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Crankshaft/connecting rod/connecting rod bearing assembly The

crankshaft, connecting rod and connecting rod bearing must be matched and assembled according to the requirements

in the

following table. Connecting rod Crankshaft connecting rod Connecting

big end hole journal marking rod

A bearing

mark 1 1 B mark

A red

twenty two B black black blue

The assembly of the crankshaft connecting rod is the opposite of the disassembly process, but pay

attention to the

following details: When the inner diameter of the connecting rod big end bearing exceeds the

maintenance limit, it is necessary to replace

the new connecting rod bearing; After the connecting rod bearing is placed in the connecting rod big

head cover and the connecting rod body, use compressed air to carefully clean

the connecting rod bearing and the connecting rod split surface; The connecting rod big head cover

and the connecting rod body must be assembled in pair according

to the marks on their sides, and the matching marks of the two must be the same; Before the

connecting rod is installed on the crankshaft,

apply a proper amount of engine oil to the inner surface of

the connecting rod bearing and the crankshaft connecting rod journal;

Tighten the connecting rod bolts as follows: Step 1: Torque, 20N•m±2N•m Step 2: Angle installation, 100° ±5°

13.6.8 Clutch Check

the inner buffer

spring 1 of the clutch cover for wear. If it is worn, there will be shaking
between the gear and the clutch housing, and abnormal noise will be
generated. If the shaking is large, the primary driven gear assembly 2
.
needs to be replaced.

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Friction plate and driven

plate Check the friction plate/driven plate one

by one; The friction material of the friction plate has no defects such as

falling off or loosening; The friction surface has no discoloration or uneven wear
1
caused

by overheating; Measure the thickness of each friction plate at

different points1 ; If any plate shows signs of damage or wear exceeds the

maintenance limit, replace it with a

new friction plate;

New Friction plate thickness 2.90

Parts Repair Limit mm~3.10 mm 2.80 mm

Place the friction plate or driven plate on the flat plate; Use

a feeler gauge to measure the gap between the friction plate or driven plate

and the flat plate from multiple directions. The gap is the flatness of the friction

plate or driven

plate. The flatness of the friction plate or driven

plate is ÿ0.15 mm for new parts and 0.3 mm for

maintenance

Clutch spring

Measure the free length of the clutch spring 1 ; if the measured value is less

than the maintenance limit, replace the

spring. Clutch spring free length New

part 42.5 mm~43.5 mm 41.5 mm

maintenance limit
1

Clutch sleeve Check

whether the clutch sleeve 1 is severely worn or damaged. If so, replace it with

a new one.

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Check whether the center sleeve 1 , butterfly spring seat 2 , disc spring 3 ,

tie rod 4 , rolling bearing 5 , and pressure plate 6 are seriously worn or

damaged. If so, replace them with new ones.

1 twenty three

4 5 6

Clutch grouping The

clutch is divided into group A and group B according to the primary driven gear

1. The grouping mark 2 is engraved on the primary driven gear. 2

The clutch and crankshaft combination are assembled in pairs according to the

following table: Clutch crankshaft combination grouping mark

Grouping mark

A B
B A

Please refer to Section 13.6.1.1 for the grouping of crankshaft combinations.

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13.6.9 Gear Shifting 13.6.9.1

Disassembly of the Spindle Assembly Circlip for

bearing sleeve shaft

20 Needle
Disassemble the spindle assembly as shown in the figure on the right; bearing washer 20.2×31×1.5
Elastic circlip for main
shaft second gear shaft 25
Check whether the tooth surface of each gear has pitting, bruises and excessive Spline washer 25×31×1 Main shaft
sixth gear
wear, check whether the needle bearing, bearing sleeve, spline sleeve and gasket

are worn or damaged, if any abnormality is found, replace with new parts. Spline

sleeve spline washer 25×31×1

shaft elastic ring 25

Spindle third and fourth gear gear

Elastic ring for shaft 25

Washer 25.2×30×1 Main shaft

fifth gear gear sleeve

25×28×11.8 Washer 25.2×30×1

Spindle

Spindle bearing 6205

Or: During assembly, the stamped rounded corner of the retaining ring should face the direction indicated by the arrow.
examine

gear

Note that

when replacing gears, they must be replaced in pairs; after the retaining ring is removed, it

must be replaced with a new one.

1
Check whether each gear is damaged. If so, replace it with a new one. Measure the inner

diameter of the sixth gear of the main shaft . If it is larger than the maintenance limit, replace it with

a new one. The inner

diameter of the sixth gear of the main shaft is

the 28 mm~28.021 mm 28.027 mm

maintenance limit of the new part.

Measure the inner diameter of the fifth gear of the main shaft 2. If it is larger than the maintenance limit, replace

it with a new one. The inner

diameter of the fifth gear of the main shaft is the

2
maintenance 28 mm~28.021 mm 28.027 mm

limit of the new one.

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Measure the width of the third and fourth gear shift fork slots of the main shaft 3. If it is greater

than the maintenance limit, replace it with a new one. The

3

width of the third and fourth gear shift fork slots of the main

shaft is 5.10 mm~5.17 mm for new parts and the maintenance limit is

5.27 mm

Bearing sleeve

Check whether the bearing sleeve is seriously worn or otherwise damaged. If so, replace it

with a new one.

Measure the inner diameter of the bearing sleeve 1. If it is larger than the maintenance limit,

replace it with a new one.

The inner diameter of

1
the bearing sleeve is 26.007 mm~26.020 mm for new parts and the

maintenance limit is 26.027 mm

Spline sleeve

Check whether the spline sleeve is severely worn or otherwise damaged. If so, replace it with

a new one. Measure

the outer diameter of the spline sleeve 1. If it is less than the maintenance limit, replace it with

a new one.
1
The outer diameter of

the spline sleeve is 27.959 mm to 27.980 mm for new parts and 27.952 mm

for maintenance

Check

whether the sleeve is severely worn or otherwise damaged. If so, replace it with a new one.

Measure the inner

diameter 1 and outer diameter 2 of the sleeve . If they exceed the maintenance limit, replace

them with a new one.

Shaft sleeve inner

diameter 1 New part 25.000 mm ~ 25.021 mm Maintenance limit 25.027 mm

Shaft sleeve outer diameter 2 New part 27.959 mm ~ 27.980 mm 1 2

Maintenance limit

27.952 mm

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CFMOTO
Spindle and spindle bearings

Check whether the spindle is damaged; Spindle bearings

Check whether the splines on the spindle have pitting, bruises and excessive wear. If there

are any abnormalities, replace them with new ones; Check

whether the spindle bearings are flexible and whether there is any jamming or abnormal

noise. If there are any, replace them with new ones;

Measure the spindle outer diameter 1 and outer diameter 2. If they are less than the

maintenance limit, replace them

with new ones. Spindle 2 1

2

outer diameter 1 new part 19.987 mm~20.000 mm Maintenance limit 19.980

mm

Spindle outer diameter

2 new part 24.967 mm ~ 24.980 mm maintenance limit 24.960 mm

Note that

when the spindle or spindle bearing needs to be replaced, the spindle and the spindle

bearing must be replaced together.

Assemble
Assembly diagram of retaining ring in circumferential direction
in the reverse order of disassembly, but pay attention to the following details: Before

assembly, apply

a proper amount of engine oil on the corresponding mating surfaces of the main shaft,

sleeve, main shaft fifth gear, spline sleeve, and main shaft sixth gear; The main shaft third

and fourth

gears should be able to slide smoothly under their own weight after installation; The removed

shaft
Retaining Ring

elastic ring cannot be reused and must be replaced with a new one; The shaft elastic ring is

not allowed to be
Wrong assembly Correct assembly
installed in reverse, and the direction of the ring is detailed in the "Disassembly" section of

Chapter 13.6.9.1; The circumferential assembly of the shaft

elastic ring should be as shown in the right figure; Make sure that the shaft elastic ring is

completely inserted into the groove.

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13 Engine
13.6.9.2 Disassembly of the countershaft
Bearing
assembly
sleeve shaft retaining
Disassemble the countershaft assembly as shown in the figure on the right; ring 20 Needle

roller bearing washer 20.2×31×1.5

Countershaft first gear assembly

Check whether the tooth surface of each gear has pitting, bruises and excessive

wear, check whether the needle bearing, bushing, spline sleeve and washer are Washer 20.2×31×1.5

worn or damaged, if any abnormality is found, replace with new parts. Countershaft fifth gear

Elastic ring for shaft 28 spline

washer

countershaft third gear

Countershaft 4th gear

Spline

sleeve spline

washer shaft circlip 28

Countershaft 6th gear

Elastic ring for shaft 28

Washer 28.2×36×1 Countershaft

second gear gear sleeve

28×10.5

Countershaft

Countershaft bearing 62-28

O-ring 25×2 Countershaft sleeve

Or: During assembly, the stamped rounded corner of the retaining ring should face the direction indicated by the arrow.

examine

gear

Note that

when replacing gears, they must be replaced in pairs; after the retaining ring is removed, it

must be replaced with a new one.

Check whether the gears are damaged. If so, replace them with new ones.

Measure the inner diameter of the countershaft second gear gear 1. If it is larger

than the maintenance

limit, replace it with a new one. 1

New parts 31.000 mm~31.025 mm

Maintenance limit 31.032 mm

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CFMOTO
Measure the inner diameter of the countershaft fourth gear gear 2. If it is larger
Number of teeth: 28
than the maintenance

limit, replace it with a new one.

New parts 31.000 mm~31.025 mm Maintenance limit 31.032 mm

Measure the inner diameter of the countershaft third gear gear 3. If it is larger Number of teeth: 30

than the maintenance

limit, replace it with a new one.

New parts 31.000 mm~31.025 mm Maintenance limit 31.032 mm

Measure the inner diameter of the countershaft first gear assembly 4. If it is

larger than the maintenance limit,

replace it with a new one. The inner

diameter of the countershaft first gear assembly is 20.020

mm~20.041 mm. The maintenance limit is 20.048 mm. 4

5 Number of teeth: 28

Measure the width of the sixth gear shift fork slot of the countershaft 5. If it is greater than the

maintenance limit, replace it with a new part. The

width of the sixth gear shift fork slot of the

5.10 mm~5.17 mm 5.27 mm

countershaft New part maintenance limit

Note

the marking groove A on the countershaft sixth gear to distinguish it from the

countershaft fifth gear.

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13 Engine
Measure the width of the fifth gear shift fork slot of the countershaft 6. If it is larger than the
Number of teeth: 30

maintenance limit, replace it with a new one. The 6

width of the fifth gear shift fork slot of the

5.10 mm~5.17 mm 5.27 mm

countershaft is the maintenance limit of the new one.

Bearing sleeve

Check whether the bearing sleeve is seriously worn or otherwise damaged. If so, replace it

with a new one.

Measure the inner diameter of the bearing sleeve 1. If it is larger than the maintenance limit,

replace it with a new one.

The inner diameter of

1
the bearing sleeve is 26.007 mm~26.020 mm for new parts and the

maintenance limit is 26.027 mm

Spline sleeve

Check whether the spline sleeve is severely worn or otherwise damaged. If so, replace it

with a new one.

Measure the outer diameter of the spline sleeve 1. If it is less than the maintenance limit,

replace it with a new one.

The outer diameter of 1

the spline sleeve is 30.950 mm to 30.975 mm for new parts and 30.943 mm

for maintenance

Sleeve 28×10.5 Check

whether the sleeve is severely worn or otherwise damaged. If so, replace it with a new

one. Measure the

inner diameter 1 and outer diameter 2 of the sleeve. If they exceed the maintenance limit,

replace it with a new one.

Shaft sleeve inner

diameter 1 New part 28.000 mm~28.021 mm Maintenance limit 28.027 mm 1 2

Shaft sleeve outer diameter 2 New part 30.950 mm~30.975 mm

Maintenance limit

30.943 mm

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CFMOTO
Countershaft sleeve

Check whether the countershaft sleeve is severely worn or otherwise damaged. If so, replace it with a

new one. Measure the outer

diameter of the countershaft sleeve 1. If it is less than the maintenance limit, replace it with a new

one.

The outer diameter of the 1

countershaft sleeve is 39.975 mm~40.000 mm for new parts and 39.965 mm for

maintenance

Sub-shaft and Sub-shaft Bearing

Check if the sub-shaft is damaged; Check if Countershaft bearing

the spline on the sub-shaft has pitting, bruises and excessive wear. If any abnormality is found, replace

with a new part; Check if the sub-shaft bearing rotates flexibly and

if there is any jamming or abnormal noise. If so, replace with a new part; Measure the sub-shaft outer

diameter 1 and outer diameter 2. If they are less than the

maintenance limit, replace with a new part. Sub-shaft outer diameter 1 new part 19.987 mm~20.000 mm

Maintenance limit 19.980 mm Sub-shaft

1
outer diameter 2 new 2

part 27.967 mm~27.980 mm Maintenance limit 27.960 mm

Note that

when the countershaft or countershaft bearing needs to be replaced, the countershaft and countershaft

bearing must be replaced together.

Assemble

in the reverse order of disassembly, but pay attention to the following details: Before assembly, apply a

proper amount of

engine oil on the countershaft, sleeve, spline sleeve and the corresponding mating surfaces of each

gear; The countershaft sixth gear and fifth gear should be able to slide

smoothly under their own weight after installation; The O-ring must be replaced with a new one; The
Assembly diagram of retaining ring in circumferential direction

removed shaft elastic ring

cannot be reused and must be replaced with a new one; The

shaft elastic ring is not allowed to be installed in reverse, and the direction of the ring is detailed in the

"Disassembly" section

of Chapter 13.6.9.2; The circumferential assembly of the shaft elastic ring should be as shown in the right

figure; Make sure that the shaft elastic ring is completely inserted into

the groove.
Retaining Ring

Wrong assembly Correct assembly

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13 Engine
Shift fork
Shift fork (left, right) Shift fork (middle)
identification

The fork body has identification marks;

Shift fork (left, right): CF R/L Shift fork (center): CF C

Check the fork

2
guide pin 1 and fork claw 2 for excessive wear or damage. Check whether the

fork claw 2 is

bent. A bent shift fork may cause difficulty in shifting or abnormal gear meshing.

If there is any abnormality, replace it with a new one.

The shift fork claw thickness of the shift fork (left and right) and the shift fork 3
(center) is the same. Measure the thickness of the shift fork claw 3. If it is less

than the maintenance limit, replace it with a

new one. The

New thickness of the shift fork claw is

Parts Repair Limit 4.93 mm~5.00 mm 4.83 mm

The shift fork guide pin diameters of the shift forks (left and right) and the shift

fork (center) are the same. Measure the fork guide pin diameter 4. If it is less

than the maintenance limit, replace it with a new one. Shift fork

guide pin diameter 6.942

New mm~7.000 mm 6.850 mm

Parts Repair Limit

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CFMOTO
Check the

fork shaft for deformation, scratches, wear and tear, and replace with a new

one if necessary. Put the fork

on the fork shaft, move the fork forward and backward, and turn the fork left

and right to check if the movement is smooth. If not, replace with a new one.

Speed Shift

Hub Check the speed shift hub for excessive wear or damage, if so, replace

with a new one;

Measure the width of the speed hub groove 1. If it is less than the maintenance limit, replace 1
1
1
it with a new one.

Shift hub groove

New width 5.45 mm~5.55 mm 5.35 mm

Parts Repair Limit

Shift lever assembly

Check whether the shift lever welding assembly 1 is damaged, bent, or severely

worn. If so, replace it with a new one. Check

whether the shift lever return torsion spring 2 is damaged or severely

deformed. If so, replace it with a new one.

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13.6.10 Lubrication system

13.6.10.1 Lubrication oil circuit diagram

1
1

1
2

3 6

9 10
5

1. Camshaft bearing 2. 6. Connecting rod

Hydraulic tensioner assembly 3. bearing 7. Oil pressure switch

Balance bearing 4. Oil 8. Filter 9. Oil

filter 5. Main bearing pump 10. Oil

pressure limiting valve

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CFMOTO
13.6.10.2 Oil pump Check the

friction and wear of the oil pump; Check the friction and

wear between the outer rotor of the oil pump and the oil pump cavity on the crankcase; If

the parts are severely worn or

damaged, they must be replaced with new ones;

Needle Roller

Oil pump shaft

Oil pump chamber Outer rotor

Inner rotor

Check the friction and wear of the needle roller groove on the inner rotor. If it is severely

worn or damaged, replace it with a new one.

Check the wear of the concave surface 1 on the inner rotor . If it is severely worn or

damaged, replace it with a new one.

Use a feeler gauge to measure the top clearance A (gap between the inner and outer

rotors) and the side clearance B (gap between the outer rotor and the oil pump cavity). If

it exceeds the maintenance limit, the inner and outer rotors must be replaced at the same

time. The maintenance

limit of the clearance A between the inner and

outer rotors is 0.25 mm

A
The clearance B between the outer rotor and the oil pump cavity has

a maintenance limit of 0.25 mm

13.6.10.3 Oil pump cover/oil pressure limiting valve Check whether

1
the oil pump cover 1 is severely worn or damaged. If so, replace it with a new one;

The oil pressure limiting valve 2 is installed on the oil pump cover;

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13 Engine
In the direction indicated by the arrow in the right figure, use a suitable tool

to press the gasket 3 of the oil pressure limiting valve to feel whether the

spring moves smoothly. If it is stuck, disassemble the oil pressure

limiting valve and carefully check each part.

Removal of the oil

pressure

limiting valve Use a suitable tool to push the gasket 3 to the notch position of the oil

pump cover, and remove the gasket 3 from the notch ;

3

gap

Remove the spring 4 ;

remove the plunger 5 .

Check

whether the gasket, spring and plunger are severely worn or damaged. If

so, replace them with new ones;

Measure the free length of the spring. If it is less than the maintenance limit,

replace the spring with a

new one. The nominal value

of the free length of the new spring is 39.4 mm. Maintenance

limit 38.5 mm

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CFMOTO
3
Assembly Assemble the oil pressure limiting valve in the reverse order

of disassembly; Apply a proper amount of oil to the outer surface of plunger 5 , 4

and place plunger 5 into the

corresponding hole on the oil pump cover; Apply a proper amount of oil to the
5
surface of spring

4 , and place spring 4 into plunger 5 ; Use a suitable tool to compress spring 4 ,

install gasket 3 from the notch of the oil pump cover , and ensure that gasket 3

falls completely into the step hole gap

of the oil pump cover; Press gasket 3 with a suitable tool , and the movement of

spring 4 should be smooth without jamming.

13.6.10.4 Oil channel cover assembly

Check whether the oil cooler sealing ring 1 is damaged or hardened. If so,

replace it with a new one;

Check whether the oil channel cover assembly 2 is damaged. If so, replace it

with a new one.

13.6.11 Water pump assembly

Check whether the O-ring 34×2.5 1 and O-ring 22×2.3 2 are aged, damaged

or severely deformed. If so, replace them with new ones. 2

Check the water pump

subassembly to see if the water pump cover 3 and water pump body 4 are cracked or

damaged. If so, replace them with 3

new ones. Check if the water pump shaft 5 rotates flexibly. If the bearing is stuck, replace

it with a new one. Check if there is

coolant leakage at the joint surface of the water pump cover and the water pump body. If

so, it means that there is a problem with the water pump cover seal, or the water pump

cover or water pump body is seriously deformed and needs to be replaced with a new

one. Check if there is liquid flowing out of the leakage hole 6 on the water pump body .
4
If coolant flows out, it means that there is a problem with the water seal. If there is oil

flowing out, it means that there is a problem with the oil seal and needs to be replaced

with a new one.

6 5

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13 Engine
Water pump cover

removal Remove the M6×22 bolts 7 and washers, and take off the water pump cover;

Check whether the water pump cover sealing ring 8 is aged, damaged, or

severely deformed. If so, replace it with a

new one; Check whether the water pump impeller 9 is cracked or damaged. If 9
so, replace it. 8

Note that

the water pump sub-assembly is a component that requires extremely high sealing performance.

During maintenance, except for the water pump cover and water pump cover sealing ring which

can be replaced separately, the rest should be replaced as a whole; it is recommended to replace

the entire water pump sub-assembly.

Water pump cover

assembly Assemble the water pump cover in the reverse order of disassembly, and

the torque of the M6×22 bolts is 10N•m.

13.6.12 Electric start

1
2
4 3
Disassembly of overrunning

clutch
2

assembly Remove the starting gear

assembly 1 ; Remove the M6×12 hexagon socket head screw 2 ;

Remove the overrunning clutch seat 3 ; 2

Remove the overrunning clutch 4 .

NOTE

If the overrunning clutch is not faulty, it does not need to be disassembled.

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CFMOTO
Check

the function of the overrunning clutch and rotate the starting gear

assembly in the overrunning clutch;

A
Check the overrunning clutch and overrunning clutch seat for wear and

other damage.

Note

that when the starter gear assembly is rotated clockwise, the overrunning

clutch must be locked. If the overrunning clutch, overrunning clutch seat

and starter gear assembly are damaged, they must be replaced at the

same time. A ÿLock direction

Overrunning clutch function test

Assembly: Install the overrunning clutch 4 onto the overrunning clutch 1

2
seat 3 ; Install the overrunning clutch seat 3 onto the magneto 4 3

rotor; Install the M6×12 hexagon socket head screw 2 (apply a proper 2
amount of 243 thread locking glue on the thread), screw torque:

10N•m;

Apply a proper amount of engine oil to the inner ring of the

overrunning clutch 4 ; Screw the starting gear assembly 1 into the overrunning clutch 4 .
2

Check the starting gear assembly, duplex gears, and duplex gear

shafts

Check the starting gear assembly, especially the wear and other damage

of the tooth surface 1 and the clutch cylindrical surface 2 ; if necessary,

replace the starting gear assembly;

Measure the inner diameter 3 and outer diameter 4 of the starting gear
4
assembly . If they exceed the maintenance limit,
3
replace with new parts. The inner

diameter of the starting gear assembly is 32.025 mm to

32.050 mm. The maintenance limit is 32.075 mm.

The outer diameter of the starting

gear assembly is 45.660 mm to 45.673 mm. The maintenance

limit is 45.635 mm.

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13 Engine
Check whether the double gear 5 and double gear shaft 6 are seriously

worn or damaged. If so, replace them with new ones.

6

13.6.13 Disassembly of

magneto stator Remove the 4

M6×30 bolt 1 ; Remove the 2
M5×16 bolt 2 ; Remove the stator 3
. the magneto stator 4
wire pressure plate 3 ; Remove

1
2

Check
whether the stator is damaged, if so, replace it with a new one;

Check the metal coil for breakage, deterioration or other

damage. If so, replace it.

Assembly: Install the magneto stator 4 onto the left

cover; Install the M6×30 bolt 1 (apply an appropriate amount of 243
4
thread lock glue to the threaded part);

Magneto stator bolt torque

2
3
12N•m

Arrange the magneto stator wiring harness, install the stator wire
clamp 3 to hold
the wiring harness; Install the

M5×16 bolt 2 ; Wire clamp bolt torque

6N•m 1
2

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CFMOTO
13.6.14 Rear balance shaft assembly

Check the rear balance shaft assembly for severe wear or damage. If so,

replace with new parts.

1 1
Use a micrometer to measure the rear balance shaft journal diameter 1.

If it is less than the maintenance limit,

replace it with a new one. Rear

balance shaft journal diameter New part 19.980 mm ~ 19.993

mm Maintenance limit 19.960 mm

Check and confirm that the balance shaft marking point is located accurately, as shown in the figure on

the right.

Center line of tooth

Marking Points

One cylinder balance weight center

The rear balance shaft assembly is divided into two groups, A and B, according to the
2

balance shaft driven gear 1. The grouping mark 2 is engraved on the balance shaft

driven gear.

The rear balance shaft assembly and crankshaft assembly are assembled in pairs according to the

following table: Rear balance shaft Crankshaft

assembly grouping mark assembly grouping marking

A B

B A

Please refer to Section 13.6.1.1 for the grouping of crankshaft combinations.

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13 Engine
13.7 Engine Assembly 13.7.1 Installing

the Rear Balance Shaft Assembly Note : The rear

balance

shaft assembly and crankshaft assembly must be assembled in pair according to the

requirements in the following table.

Rear balance shaft Crankshaft

assembly group marking grouping marking

A B

B A

For the grouping of rear balance shaft assemblies, please refer to Section 13.6.14;

For the grouping of crankshaft assemblies, please refer to Section 13.6.1.1;

Apply a proper amount of engine oil evenly on the surface of the upper crankcase bearing

mounting hole and the inner rings of the two rolling bearings;

A : Tilt the clutch side of the rear balance shaft assembly 1 , and then insert A
it into the bearing mounting hole of the upper crankcase;
B
B : Install the gear-side journal of the rear balance shaft assembly 1 into the C
rolling bearing on the magneto side;

C : Install 6204 rolling bearing 2 (with the marked side of the bearing facing outward)

into the corresponding hole of the upper crankcase from the clutch side, and pass the

inner ring of the bearing through the journal of the balance shaft;
2
1

Apply an appropriate amount of 243 thread locker evenly on the threaded

3
part of the M6×16 bolt 3 ;

Fasten the right bearing baffle 4 to the upper crankcase with M6×16 bolts 3 .

Right bearing guard bolt torque

10N•m

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CFMOTO
13.7.2 Install the speed hub, positioning star wheel and positioning

rocker arm. Apply a proper amount of engine oil evenly on the support 2
journals

on both sides of the speed hub 1. Install the 16005 rolling bearing 2 (the

marked side of the bearing faces the clutch side) on the

A
journal of the speed hub 1. A : Assemble the speed hub 1 and the 16005

rolling bearing 2 to the upper crankcase from the clutch side.

Install 6.3×16.3×1.2 washer 3 and M6×16 bolt 4 , and tighten 16005

rolling bearing 2 ; M6×16 bolt torque 10N•m

Apply an appropriate amount of 243 thread lock glue evenly on the

threaded part of the shift
positioning torsion spring pin 5 ; Install the shift positioning

torsion spring pin 5 on the upper crankcase; 5

20N•m

Install the P3×9.8 needle roller 6 into the corresponding hole of the speed 7
hub; Install the speed hub bushing 7 onto the speed hub;

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13 Engine
Align the pin hole of the positioning star wheel 7 with the P3×9.8 needle roller 6 ,

and assemble the positioning star wheel 7 onto the speed hub, and ensure that the

neutral position A of the positioning star wheel is close to the neutral stop groove B of

the speed hub ;

Apply an appropriate amount of 243 thread locker evenly on the

threaded part of the M6×16 9
bolt 9 ; Use the M6×16 bolt 9 to fix the positioning star wheel to the
speed hub;

Positioning star wheel bolt torque

10N•m

Assemble the shift positioning rocker arm

components. Assemble the shift positioning rocker arm torsion spring 10,

6.3×16.3×1.2 washer 11 , shift positioning rocker arm sub-component 12, shift

12
positioning rocker arm shaft sleeve 13, and M6×16 hexagon socket head screw 14
11
together as shown in the right figure; the end of the

shift positioning rocker arm torsion spring should be stuck into the groove of the shift
10
14
positioning rocker arm sub-

component; the shift rocker arm sub-component should rotate flexibly on the shift

positioning rocker arm shaft sleeve; 13

Note

that the smooth surface of the washer 6.3×16.3×1.2 faces the shift

positioning rocker arm subassembly.

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CFMOTO
Turn the shift hub to the position shown in the right figure;

fix the shift positioning component 15 to the upper crankcase, and make the positioning

wheel of the shift rocker arm sub-component snap into the neutral position of the

positioning star wheel; 14

M6×16 Hexagon socket head screw 14 torque
10N•m 15

13.7.3 Install the countershaft assembly

2
Install the 62-28 bearing retaining ring 1 into the groove of the upper crankcase, ensuring

that it is fully inserted into the groove;

Install the P4×7.8 needle roller 2 into the corresponding hole of the upper crankcase;
1

Apply a proper amount of engine oil evenly on the inner surface of the bearing 3 5
sleeve 3 ; Install the bearing sleeve 3 onto the needle roller bearing of the

countershaft assembly 4 ; Align the bearing thrust groove 5 of the countershaft

assembly 4 with the 62-28 bearing retaining ring 1 , and align the limiting hole of the

bearing sleeve 3 with the P4×7.8 needle roller 2 , and install the countershaft assembly

4 onto the upper crankcase;

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13 Engine
13.7.4 Install the shift fork shaft assembly and the shift fork Apply

a proper amount of engine oil evenly on the outer surface of the shift fork 6
5
shaft assembly; Pass the shift fork shaft assembly 1 (the end with the bowl-shaped

plug facing the magneto side) through the installation

hole of the upper crankcase; Insert the shift fork (left and right) 2 into the shift fork

groove of the countershaft sixth gear 3 , and push the shift fork shaft assembly 1 3
1
through the shift fork hole; Install the shift fork (middle) 4 onto the shift fork shaft 2
assembly 1 ; Insert the shift fork (left and right) 2 into the shift fork groove of the
4

countershaft fifth gear 5 , and push the shift fork shaft assembly 1 through the shift
2
fork

hole; Rotate the shift fork shaft assembly 1 so that the rolling pin on it is aligned with

the groove on the upper crankcase, and push the shift fork shaft assembly 1 axially

into place (at this time, the positioning hole at the other end of the shift fork shaft

assembly 1 is aligned with the hole on

the upper crankcase); Insert the 6×16.2 positioning pin 6 into the positioning hole of

the shift fork shaft assembly 1 to fix the position of the shift fork shaft assembly 1 ;

Note

that the marking "CF R/L" on the shift fork (left and right) faces the magneto side,

the marking "CF C" on the shift fork (center) faces the clutch side, and the fork

guide pin is correctly inserted into the shift hub groove.

Apply a proper amount of engine oil evenly on the surface of the 15×1.9 O-ring 7

and place it into the corresponding hole of the

upper crankcase; Install the fork shaft cover 8 on the upper

crankcase. Torque of the

fork shaft cover 5N•m

7
8

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CFMOTO
13.7.5 Install the spindle assembly. Install

the 6205 bearing retaining ring 1 into the groove of the upper crankcase, ensuring that it is 1
completely inserted into the

groove; Install the P4×7.8 needle roller 2 into the corresponding hole of the upper crankcase;

2 3

Apply a proper amount of engine oil evenly on the inner surface of the bearing

sleeve 4 ; Install the bearing sleeve 4 onto the needle bearing of the main shaft assembly 5
7
5 ; Insert the shift fork (middle) 3 into the fork groove of the third and fourth gear gears 6 of

the main shaft; Align the

bearing thrust groove 7 of the main shaft assembly 4 with the 6205 bearing retaining ring 1 ,

and align the limit hole of the bearing sleeve 4 with the P4×7.8 needle roller 2 , and install

the main shaft assembly 5 on the upper crankcase; The gears of the main and counter

shafts

should mesh normally; Apply a proper amount of engine oil

on the tooth surface of each gear; Rotate the main shaft

assembly 5 , it should be flexible and without sticking.

4 6

13.7.6 Install the shift lever assembly. Apply a

proper amount of engine oil evenly on the mating surface of the shift lever. Align the

shift lever with the mounting hole on the case body, and clamp the shift positioning torsion

spring pin 3 with the shift lever return torsion spring 2. Install the shift lever assembly 1 on
2

the upper crankcase. Note that before

3
assembly,
4
check whether the shaft elastic retaining ring 14 4 on the shift lever is completely located

in the retaining ring groove, and whether the washers 14×21×1 on both sides of the

retaining ring are missing.

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13.7.7 Installing the crankshaft connecting rod assembly and front balance shaft assembly

Before assembly, recheck the main shaft on the upper crankcase according to the table below.

Bearing 1 and balance bearing 2 are assembled correctly;

Crankcase/crankshaft/main bearing assembly

Crankshaft main bearing seat hole Crankshaft main journal Main bearing
1 2
mark mark color
A A red
A B Black
B A Black
B B Blue

Crankcase/front balance shaft/balance bearing assembly

Front balance shaft bearing seat hole Front balance shaft journal Balance bearing

mark mark color

A 1 Red black
A 2 Blue
B 1 Black
B2

Use dust-free paper to clean the surface of the main bearing and balance bearing;

Apply an appropriate amount of machine evenly on the inner surface of the main bearing and balance bearing.

Oil;

Turn the rear balance shaft so that the engraved mark on it is aligned with the crankshaft.

The pit markings on the box are aligned vertically;

Logo Alignment

At this time, the dot mark on the driven gear of the balance shaft is aligned with the crankshaft.

The pit markings on the box are also aligned vertically;

Logo Alignment

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CFMOTO
Use the rear balance shaft positioning and anti-rotation tool A
3
(0SQ0-000000-922-005) to fix the rear balance shaft in the above
position;
4

Use dust-free paper to clean the crankshaft main

journal; Hold the conical part on the left side of the crankshaft and the timing

sprocket on the right side with both hands, and slowly put the crankshaft

connecting rod assembly 3 into place at 45 degrees from right to left. At

this time, the mark 4 on the balance shaft driving gear is flush with the

assembly surface;

Note that A
the crankshaft assembly and rear balance shaft assembly should be assembled in pairs according to the

table below.

Crankshaft Rear balance shaft

grouping marking assembly group marking

A B

B A

Please refer to Section 13.6.1.1 for the grouping of crankshaft assemblies;

Please refer to Section 13.6.14 for the grouping of rear balance shaft assemblies;

Use dust-free paper to clean the journal of the front balance shaft
4
assembly 5 ; Align the mark 6 on the balance shaft driven gear with the

mark 4 on the balance shaft driving gear , and slowly put the front balance

shaft assembly 5 into place; 6

5

Note that

the crankshaft assembly and the front balance shaft assembly should be assembled in pairs as shown in the

table below.

Crankshaft Front balance shaft

grouping marking assembly group marking

A B

B A

For the grouping of the front balance shaft components, please refer to Section 13.6.1.1;

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13 Engine
Apply a proper amount of engine oil evenly on the exposed crankshaft main journal and front

balance shaft journal surfaces;

Remove the rear balance shaft positioning and anti-rotation

tooling; Rotate the crankshaft, it should be flexible and without sticking;

Apply an appropriate amount of 243 thread locker evenly on the

threaded part of the M6×16
bolt 7 ; Use the M6×16 bolt 7 to fix the left bearing baffle 8 to the upper
crankcase and tighten the bearing;

Torque of the left bearing baffle bolt

7
10N•m

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13.7.8 Crankcase assembly According

to the matching assembly table in the section "Engine Assembly - Installing the Crankshaft

Connecting Rod Assembly and Front Balance Shaft Assembly", confirm again that the main

bearing 1 and balance bearing 2 on the lower crankcase are assembled correctly; Use

dust-free paper to clean the surface of the main bearing and balance bearing; Apply

a proper amount of engine oil evenly on the inner surface of the main bearing and balance

bearing;
1 2

Wipe the upper and lower crankcase joint surfaces with dust-free paper to ensure that the

joint surfaces are clean and dry;

Apply KB598 flat sealant on the joint surface of the lower crankcase. The diameter of the

glue line is (1.5±0.5) mm. The glue line should be continuous and even. The glue application

track is shown in the black area on the right.

Flat sealant

Install the throttle plug 3 (with the small hole facing downward) into the corresponding hole in the
4
upper crankcase;

Check whether the ÿ10×14 positioning pins 4 at various locations on the upper crankcase

are missing;

3
4
4

Align the positioning hole of the lower crankcase 5 with the ÿ10×14 positioning pin 4 on the 5
upper crankcase , and assemble the lower crankcase onto the upper crankcase;

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13 Engine
Pre-tighten the box bolts to the bolt heads according to the sequence shown in the figure.

Just fit the box surface (torque is not higher than 4N•m);
twenty one 20

11
8 10

twenty two
7 9

3 1 5

4 2 6

12
13

14
15

17
16
18 19

Bolt number Part Name

Tighten the closing bolts in the same order and following steps;
1~6 Combination bolt M9×108
Tightening steps Bolt No. Torque (N•m)
7 , 9 , 13 combination bolts M8×105
First step 1 ~ 19 Second 8
14 Combination bolt M8×55
step 1 ~ 19 Third step 1 ~ 6 20
12, 15 Combination bolt M8×45
Fourth step 7 ~ 19 Fifth step 35
11, 18, 19 Bolt M8×45
20 ~ 22 27
8 , 10, 16, 17 bolts M8×55
10
20, 21, 22 Bolt M6×30

Use dust-free paper to wipe clean the squeezed out parts of the box surface.

Flat sealant;
Turn the crankshaft, main shaft and counter shaft, they should be smooth and without any jamming.

The bolts for inspection should be loosened.

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CFMOTO
Note

that the time from applying glue to tightening the bolts must be controlled within 5

minutes; before assembling the bolts, evenly apply a proper amount of a mixture

of engine oil and MoS2 grease (weight ratio of 10:1) on the bolt head bearing

surface and threaded part of bolts 1 to 6 , and evenly apply a proper amount of a

mixture of engine oil and MoS2 grease (weight ratio of 10:1) on the threaded part

of bolts 7 to 19 .

13.7.9 Installing the oil pump subassembly and oil pressure switch

Install the P4×7.8 needle roller 1 into the corresponding hole of the lower

crankcase; Install the oil pump outer rotor 2 into the corresponding hole of the 3
1
lower crankcase; Insert the P4×15.8 needle roller 3 into the hole of the oil pump
5
shaft 4 , and make the length of both ends of the needle roller exposed
2
from the hole roughly the same; Make the needle roller groove of the oil pump inner

rotor 5 face inward and align with the P4×15.8 needle roller 3 , and install the oil

pump inner rotor 4

on the oil pump shaft; Install the oil pump shaft and the oil pump inner rotor together
1
on the lower crankcase;

Note :

Before assembly, evenly apply a proper amount of engine oil on the surface of the oil

pump mounting hole of the lower crankcase and the surface of the oil pump shaft.

Pass the oil pump cover assembly 6 through the oil pump shaft 4 and align it with

the P4×7.8 needle roller, and install it on the lower crankcase;

6 7

Install and tighten the M6×22 bolts diagonally and crosswise 7 ;

Oil pump cover bolt torque

4
10N•m

7 7

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13 Engine
Install the washer 11×20×18 onto the oil pump shaft; insert the

P4×21.8 needle roller 9 into the hole of the oil pump shaft 4 , and make sure
9
4 8 11
that the lengths of both ends of the needle roller exposed from the

hole are roughly the same; make the needle roller groove of the oil pump

gear 10 face inward and align it with the P4×21.8 needle roller 9 , and install

the oil pump 8

gear onto the oil pump shaft; then install the washer 11×20×18 and the ÿ11

shaft circlip 11 onto the oil pump shaft in

10
turn ;

note that the shaft circlip must not be used a second time and must be

replaced with a new one; the circlip must completely fall into the groove of the oil pump shaft.

Apply an appropriate amount of 567 thread sealant evenly to the threaded part

of the oil pressure switch 12 and install it on the lower

crankcase. Torque of the oil

pressure switch is 20N•m

12

13.7.10 Installing the water pump assembly

Check and confirm that the O-ring 34×2.5 1 and O-ring 2

22×2.3 2 are not damaged or lost;

Turn the water pump shaft 3 to align the square part on the shaft with the square
1 3
groove on the front balance

shaft; Insert the water pump shaft 3 into the square groove of the front balance shaft;

Use M6×42 bolts 4 (one of which passes through the wire clamp assembly 5 )

to fix the water pump assembly 6 to the crankcase, and tighten the bolts
4
diagonally and
6
crosswise; Water pump assembly bolt torque

10N•m 4

Tighten the M6×22 bolt 7 .

M6×22 bolt torque
10N•m 5 7

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13.7.11 Installing the oil pan

Check and confirm that the oil suction plate seal ring 1 is not damaged
3
or lost; Align the positioning column 2 of the filter 3 with the positioning hole
5 2 1
on the crankcase, and insert the filter 3 into the corresponding hole of

the lower crankcase; Press the filter 3 so that its end face 4 contacts the

lower crankcase and

install it in place; Install the ÿ8×12 positioning pin 5 ; 4

Wipe the joint surface of the crankcase and oil pan with dust-free paper to ensure

that the joint surface is clean and dry;

Apply KB598 flat sealant on the joint surface of the oil pan. The diameter of the
Flat sealant
glue line is (1.5±0.5) mm. The glue line should be continuous and even. The

glue application track is shown in the black area on the right.

Align the positioning hole of the oil pan 6 with the ÿ8×12 positioning 6
pin on the lower crankcase, and install the oil pan onto the lower

M I E
crankcase; Install and tighten the M6×25 bolts in the order H
L
of A to M; Oil pan bolt torque
10N•m A

C
Note that
D
the time from starting to apply glue to completing the tightening of the bolts should be controlled
B
within 5 minutes.
K G F J

Put the M12×1.5 magnetic oil drain bolt 3 on the washer 4 and 4
3
install it on the oil pan;

Magnetic drain bolt torque

35N•m

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13 Engine
13.7.12 Install the oil channel cover assembly

Turn over the assembled components and place them stably

and reliably; Install the oil cooler seal ring 1 to the lower crankcase, ensuring

that the seal ring is fully 2

seated in the groove; Use M6×18 bolts 2 to fasten the oil channel cover

assembly 3 to the lower crankcase, and tighten the bolts

diagonally. Oil channel cover

bolt torque 10N•m 1

3
2

13.7.13 Installing the oil filter

Install the oil filter mounting bolt 1 to the lower crankcase; Torque

of the oil filter mounting bolt

25N•m

Apply a proper amount of oil evenly on the sealing ring of the oil filter 2 ;

Install the oil filter 2 on the lower crankcase. Oil filter

torque 17N•m

13.7.14 Install the cylinder block and piston

components. Put the M14×1.25×12 bolt 1 on the gasket 14 2 and install it

1
on the upper crankcase. The

torque of the M14×1.25×12 bolt is 25N•m.

3 2

Check and confirm that the water inlet sealing ring 3 is not

damaged; Install the water inlet sealing ring 3 (with the chamfered side facing upward)

onto the upper crankcase;

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CFMOTO
Check to make sure that the ÿ8×12 locating pin 4 is not missing; Install the cylinder

block gasket 5 onto the upper crankcase; Note that the cylinder block gasket
5
must not

be used a second time and must be replaced with a new one.

Rotate the crankshaft and adjust one of the connecting rod ends to the highest point; A
7

6
Apply a proper amount of engine oil evenly on the surface of the piston pin hole and the outer surface 8
of the piston pin;

Pass the piston pin 7 through the piston pin hole and the small end hole of the connecting rod, and

install the piston component 6 onto the connecting rod;

Use needle-nosed pliers to assemble the piston pin retaining ring 8 on the other side. The retaining ring must be

completely inserted into the groove, and the notch of the retaining ring and the notch of the piston should be staggered;

Assemble the other piston part in the same way;

Note that

during assembly, the pit A on the top of the piston must face the exhaust side; the piston pin

retaining ring must not be reused and must be replaced with a new one.

To facilitate the installation of the piston into the cylinder block 9 , evenly apply a proper amount of

engine oil within the range of 20mm at the bottom of the cylinder hole; Press

the piston ring of one of the pistons by hand and install the piston ring completely into the cylinder
9
block 9 ; Rotate the crankshaft until the

piston of the other cylinder is easy to assemble; Use the same method to install the other piston

component into the cylinder block 9 ; Align the positioning hole of the cylinder block 9 with the ÿ8×12

positioning

pin, and install the cylinder block 9 on the upper crankcase; Press the cylinder block and rotate

the crankshaft flexibly; Use dust-free paper to remove the engine

oil on the top of the piston;

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13 Engine
During assembly, pay attention to the following details:

The piston and cylinder body must be assembled in pairs according to the requirements in

the table below; Cylinder body mark Piston mark ÿ ÿ ÿ ÿ

The same engine must be equipped with pistons of the same weight group. For

details on piston weight groups, see the “Piston Grouping” section in Chapter 7.4.5.

13.7.15 Install the timing chain assembly. Place

1
the timing chain assembly 1 into the chain cavity of the cylinder block and hang

it on the crankshaft sprocket;

Pass the limiting hole on the timing chain support plate 2 through the limiting post

on the lower crankcase;

Install the M6×12 bolt 3 to fix the timing chain support plate 2 to the lower

crankcase; Timing chain

support plate bolt torque

10N•m 3 2

Install the threaded pin 4 and fix the tension plate 5 to the upper crankcase;

5
6
Torque of threaded pin of tensioning plate

20N•m

Install the chain guide 6 in place. 4

13.7.16 Install the cylinder head assembly.

Clean the upper surface of the cylinder block with dust-

free paper. Check to make sure that the ÿ8×12 positioning pin 1 is not
1
missing. Install the cylinder head gasket assembly 2 onto the cylinder block.

Note 2
that the cylinder head gasket assembly must not be used again and must be replaced

with a new one.

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Clean the lower surface of the cylinder head assembly with dust-

free paper; Align the positioning hole of the cylinder head assembly 3 with the ÿ8×12

positioning pin, and install the cylinder head assembly 3 onto the cylinder body;
3

4
Apply a proper amount of a mixture of engine oil and MoS2
5 4
grease (weight ratio 10:1) evenly on the threaded part of the 4
M10×150 cylinder 5
5
head bolt 4 ; insert the M10×150 cylinder head bolt 4 through the
10.5×19×2.3 washer 5 and into the cylinder head mounting hole;
5
4

Tighten in two steps in the order of A to F.

M10×150 cylinder head bolt 4 , torque see the table below;

M10×150 Cylinder head bolt torque 1st

D E
time 20N•m 2nd time 54N•m
New bolts
1st time 20N•m 2nd time 49N•m

Old bolts A B

F C

Install M6×90 bolt 6 ;

M6×90 Cylinder head bolt torque

10N•m

Pass the cylinder head shock-absorbing bolt 7 through the cylinder head cover bolt

sealing ring 8 (with the sealing band facing inward) and the timing chain assembly,
8
and install it on the cylinder head; 7

Cylinder head damping bolt torque

10N•m

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13 Engine
13.7.17 Install the magneto rotor assembly. Apply an

appropriate amount of 567 thread sealant evenly on the threaded portion of the main

oil passage cone plug 1. Install

the main oil passage cone plug 1 onto the lower crankcase.
2
Main oil channel cone plugging torque

20N•m

Clean the conical hole of the magneto rotor and the conical surface of the crankshaft

with dust-free

paper; align the keyway of the magneto rotor with the semicircular key on the

crankshaft, and install the magneto rotor assembly 2 onto the crankshaft;
1

A
Use the magneto rotor stop fixture A (0SQ0- 031000-922-001) to fix the

magneto rotor;

Install the 12.5×33×5 washer 3 (the side with the larger chamfer of the hole faces

the bolt flange surface) and the M12×1.25×40 bolt 4 to fix the magneto rotor to the

crankshaft; The torque of the magneto rotor bolt is 155N•m

4 3

Tilt the double gear 5 into the crankcase and make the gear teeth of the double gear

mesh with the gear teeth of the starting gear;

6

Apply a proper amount of engine oil evenly on the outer surface of the intermediate gear
5
shaft 6 ;

Insert the intermediate gear shaft 6 into the holes of the double gear 5 and the

crankcase.

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13.7.18 Install the left cover assembly and

check to make sure that the ÿ8×12 positioning pin 1 is not missing;
1

Wipe the crankcase and the left cover's joint surface with dust-free paper to ensure Rubber block inside

that the joint surface is clean and dry;

Apply an appropriate amount of rubber to the rubber block groove inside the magneto stator.

KB598 flat sealant, snap the rubber block onto the left cover;

Apply KB598 flat sealant on the box-joining surface of the left cover. The diameter of

the glue line is (1.5±0.5) mm. The glue line should be continuous and even. The glue

application track is shown in the black area in the right figure.

Flat sealant

Align the positioning hole on the left cover with the ÿ8×12 positioning pin on the
K
crankcase, and install the left cover assembly 2 onto the crankcase; Install and A
tighten the J
G
M6×30 bolts in the order of A to L to secure the left cover;
D H

Left cover bolt torque

I C
10N•m
2

Note that B F
the time from starting to apply glue to completing the tightening of the bolts should be controlled L
within 5 minutes.

13.7.19 Install the intake and exhaust camshaft assemblies.

Rotate the crankshaft 1 counterclockwise to align the assembly mark "I" on the

magneto rotor with the center of the notch of the timing observation hole on the

left cover;

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13 Engine
Apply a proper amount of engine oil evenly on the support journals of the intake

camshaft assembly 2 and the exhaust camshaft assembly 3 ;

hang the timing sprockets of the intake camshaft assembly 2 and the exhaust camshaft

assembly 3 on the chain and install them on the cylinder head; note that

during

assembly, the "IN" mark on the intake timing sprocket is parallel to the plane on the

cylinder head, and the "EX" mark on the exhaust timing sprocket is parallel to the

plane on the cylinder head, as shown in the right figure. 3 2

Check and confirm that the ÿ8×14 positioning pin 4 is not missing;

Install the intake camshaft seat assembly 5 and the exhaust camshaft seat 6 onto the
7
cylinder head;
9
Note 5
8
that the intake and exhaust camshaft seats and cylinder heads must be assembled

in pairs and have the same coding marks.

7
7

Install M6×45 bolt 7 , M6×65 bolt 8 and chain guide block 9 ; 6 7

7
Note: Tighten the camshaft seat bolts three times in sequence from A to L. The torque

is shown in the table below. The camshaft seat bolt

torque is the first tightening torque.

5N•m
F
Tighten for the second time 8N•m C

Tighten for the third time 12N•m

I D

Adjust the valve clearance when the engine is cold (for adjustment methods, refer to the L A
G
"Valve clearance inspection" section in Chapter 7.4.3); Valve clearance (cold B
engine) 0.10 mm~0.15 mm 0.25
J
E
Intake valve mm~0.31 mm
K
Exhaust valve
H

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13.7.20 Install the timing sprocket stopper A

(0SQ0-000000-922-004) for the hydraulic tensioner assembly. Clamp the

exhaust timing sprocket at the ignition top dead center position of cylinder 1;

Apply a proper
A
amount of engine oil evenly on the surface of the tensioner seal ring 1 , the

tensioner mounting hole, and the part where the tensioner assembly 2 3 2
contacts the 2

tensioner plate; Install the tensioner seal ring 1 into the seal groove of the

tensioner

assembly 2 ; Fix the tensioner assembly 2 to the cylinder head with the 1
1
M6×20 bolt 3 ; 3

Tensioner bolt torque

10N•m

Turn the crankshaft clockwise (viewed from the left side of the engine) (torque

should not exceed 10N•m) to check whether the tensioner has tensioned the

chain; after the

tensioner plunger pops out and tensions the chain, remove the timing sprocket

anti-rotation fixture. 1

2
13.7.21 Install the cylinder head cover
3
assembly. Apply a proper amount of engine oil evenly on the surface where

the transition joint assembly 1

and the end face oil seal 2 meet. Install the end face oil seal 2 on the joint

assembly 1 , with the oil

seal lip facing the camshaft. Apply a proper amount of engine oil evenly on

the surface where

the intake camshaft and the end face oil seal contact. Use M6×20 bolts 3 4 6

(torque 10N•m) to fix the transition joint assembly 1 to the cylinder head. The
6

lip of the end face oil seal 2 should fit well with the end face of the camshaft.

Install the cylinder head cover assembly 4 onto the cylinder head; 5
5

Install the cylinder head cover bolt seal 5 (with the sealing strip facing

downward) and the cylinder head cover bolt 6 (tighten diagonally and

crosswise); Cylinder head cover bolt torque

10N•m

Insert the ignition coil 7 (the direction and position of the plug connector are shown in the

right figure) into the corresponding position of the cylinder head cover and press it into place;
9 8

Use M6×12 bolts 9 to fix the pressure plate 8 to the cylinder head cover and

press the ignition coil 7 ; Ignition coil

pressure plate bolt torque

10N•m 7

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13 Engine
13.7.22 Install the starter motor Apply

a proper amount of engine oil evenly on the sealing ring of the starter

motor 1 and the corresponding mounting

hole of the crankcase; Mesh the gear of the starter motor 1 with the double

gear and install the starter motor 1 on

. 2
the crankcase; Install the M6×25 bolt

Starting motor bolt torque

10N•m

1 2

13.7.23 Install the clutch Note: The

clutch and

crankshaft combination must be assembled in pair according to the requirements in

the following table.

Clutch Crankshaft
group marking grouping marking
A B
B A

Please refer to Section 13.6.8 for the grouping of clutches;

Please refer to Section 13.6.1.1 for the grouping of crankshaft assemblies;

1
Install 25.2×46×5.8 washer 1 (large end facing outward) and clutch

sleeve 2 (apply appropriate amount of engine oil evenly to the inner ring);

3
Install the oil pump driving gear 3 (with the lettering facing outward)
onto the primary driven gear assembly 4 ;

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Apply a proper amount of engine oil evenly on the bushing surface of the primary

driven gear

assembly 4 ; Install the primary driven gear assembly 4 onto the main shaft;

Install the 25.2×39×2 washer 5 and the center sleeve 6 onto the main shaft

in sequence;

Use clutch master and slave hub anti-rotation tool A (0SQ0- 050000-922-001) A
to fix the center sleeve;

Install the elastic washer 20 7 (the small end of the cone faces the M20×1.5

nut 8 ); Install the M20×1.5 nut 8

to fix the primary driven gear assembly;

A

Clutch nut torque

7
125N•m

Remove the clutch master and slave hub anti-rotation tooling A ; 8

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Install disc spring seat 9 -- disc spring 10 -- friction plate assembly II 11 -- driven
11 13 11
plate II 12 -- friction plate assembly I 13 -- driven plate II 12 -- friction plate

assembly I 13 -- driven plate II 12 -- friction plate assembly I 13 -- driven plate II

12 -- friction plate assembly II 11 in sequence into the center sleeve;

Note

that the small end of the conical surface of the disc spring is assembled inward

(magneto side); friction plate assembly I is wider than friction plate assembly II;

driven plate II is wider than driven plate I.

9 10 12 14

15
Install the friction plate assembly II 11 and the driven plate I 14 onto the pressure
11
plate 15 in
14
sequence; install the 6001 rolling bearing 16 into the bearing hole on the pressure

plate 15 , with the marked side of the bearing facing outward (magneto

side); install the tie rod 17 into the 6001 rolling bearing 16;
16
17

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Install the pressure plate assembly 18 into the center
Friction plate assembly II offset assembly
sleeve;

note that the outermost friction plate assembly II should be assembled in an offset manner.

18

Install the clutch spring 19;

19

19

20

Install the M6×35 bolts 21 to secure the clutch spring pressure

plate 20.

Clutch spring pressure plate bolt torque

10N•m
twenty one

twenty one

1
13.7.24 Install the right side cover assembly

and check to make sure that the ÿ8×12 positioning pin 1 is not missing;

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13 Engine
Wipe the crankcase and the right side cover's joint surface with dust-free paper to ensure

that the joint surface is clean and dry;

Apply KB598 flat sealant on the right cover’s box-joining surface. The diameter of the

glue line is (1.5±0.5) mm. The glue line should be continuous and even. The glue

application track is shown in the black area in the right figure.

Flat sealant

Align the positioning hole on the right side cover with the ÿ8×12 positioning pin on the
Bolt with 5×2 O-ring
crankcase, and install the right side cover assembly 2 onto the crankcase; Install and
D
A
tighten the
F
M6×25 bolts in the order of A to K to secure the right side cover;

H
K
Right side cover bolt torque

10N•m 2
I
J
Note that
E G
the time from starting to apply glue to completing the tightening of the bolts should be controlled

within 5 minutes. B C

5
Install the clutch lever return torsion spring 3 onto the clutch control shaft, and insert the

end of the torsion spring into the notch of the clutch operating arm 4 ; Install the
4
12.5×18.5×0.6 washer 5 onto the clutch control shaft;

6
Install the clutch control shaft assembly 6 onto the right side cover, and hang the other

end of the clutch lever return torsion spring 3 on the right side cover; rotate the clutch

control

shaft assembly 6 clockwise , and you can feel it cooperate with the clutch lever.

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13.7.25 Install the gear position sensor assembly. Install

the contact spring 1 and the spherical contact 2 into the corresponding holes of the

gear hub in

sequence; Apply a proper amount of engine oil to the 31.5×2.5 O-ring 3 and install it
3
into the corresponding hole of the upper crankcase;

Install the gear position sensor assembly 4 (apply a proper amount of engine oil

to the matching cylindrical surface and end surface)

on the upper crankcase; Install the M6×25 bolt 5 (apply a proper amount of 243

thread lock glue to the threaded part) to fix the gear position sensor
4
assembly 4 ; Gear position sensor bolt torque

10N•m

Install the 14×28×1 washer 6 and the ÿ14 shaft circlip 7 onto the shift shaft in

sequence; note that the ÿ14 shaft circlip

must

not be reused and must be replaced with a new one, and the circlip must be

completely inserted into the groove; 6

Check and confirm that the 13×2 O-ring 8 and 35×3.5 O-ring 9 are not damaged;

Apply a proper amount of engine

oil to the 13×2 O-ring 8 and install it into the corresponding hole on the left side
8
cover; Install the timing observation 10
hole cover 10 on the left side cover; The torque of the timing

observation hole cover is 4N•m

Apply a proper amount of engine oil to the 35×3.5 O-ring 9 and install it on the

filter cover 11; install the

filter cover 11 on the left cover. Torque of filter

cover 10N•m 9

11

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13.7.26 Install the throttle body assembly and the fuel distribution pipe

2
assembly. Install the 46.2×2 O-ring 1 into the sealing groove of the throttle

body connecting pipe assembly 2 ;

2
3
Use M6×18 bolt 3 to fix the throttle body connecting pipe assembly 2 to 3
3
the cylinder head; The

throttle body connecting pipe bolt torque

10N•m

Put the clamp 62 4 (direction as shown in the figure, do not tighten) on the

throttle body connecting pipe assembly 2 ;

Install the throttle body assembly 5 onto the throttle body connecting pipe

assembly; tighten the clamp 62 4 ;

Install the fuel distribution pipe assembly 6 onto the throttle body assembly;

Install M6×16 bolt 7 to fix the fuel distribution pipe assembly 6. .

Torque of the fuel distribution pipe bolt
10N•m

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13.7.27 Install the countershaft oil seal punch

(0SQ0-010001-923-001) for the output sprocket assembly. Install the 40×58×8

countershaft oil seal 1 (apply a proper amount of grease to the lip) into the

crankcase hole; install the output sprocket

assembly 2 and the anti-loosening washer 3 onto the countershaft in sequence;

use the

output sprocket stop wrench (0MQ0-062030-922-001) to fix the output sprocket

assembly 2 ; install the M20×1.5 nut 4 ; the

output sprocket nut torque is 125N•m

4 3 2

Use a flat-blade screwdriver and a hammer to flange the anti-loosening washer

3 to prevent the M20×1.5 nut 4 from loosening.

13.7.28 Filling the engine oil, checking the oil level, and testing the oil

pressure. To fill

the engine oil, unscrew the filler plug 1 , inject the engine oil, and then tighten the filler plug;
1

Oil fill: Replace oil and

oil filter: 2.5L Total oil (dry crankcase): 2.7L

Oil level check:

Put the engine in a horizontal position;

2
Start the engine and let it run at idle for a few minutes; Turn off the engine and 3
wait for

a few minutes until all the oil flows back to the oil pan; Observe the oil level

through the

oil level sight glass, the oil level should be between the upper mark 2 and the

lower mark 3 ; If the oil level

is lower than the lower mark 3 , add oil appropriately until the oil level is

appropriate; Note that you must strictly

follow

the above steps, otherwise the wrong oil level will be displayed; The engine

must be in a horizontal position.

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13 Engine
Oil pressure

detection : Remove the oil pressure switch on the

engine; Install the box oil hole joint (0SQ0-000000-922-014) and the oil

pressure gauge; Start the

engine and check the engine oil pressure; the oil

temperature is 90ÿ. If the

0.08~0.12MPa
engine idle oil

pressure does not meet the requirements, please check whether the oil

circuit is blocked and whether

the oil pump is worn; Note: The temperature of the engine will be very high

after running for a period of time. Please take protective measures to avoid burns.

Warning:

Operation should be carried out in a well-ventilated area.

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14 Handlebar, upper and lower connecting plate assembly

14.1 Handlebar Assembly.................................................................. 14-2 14.1.1 Handlebar

Switches........................................................................... 14-3
14.1.1.1 Left Handlebar Switch Assembly.................................................. 14-3
14.1.1.2 Right Handlebar Switch Assembly...................................................... 14-4
14.2 Throttle Handle.................................................................................. 14-4 14.3
Handlebar Inspection........................................................................... 14-5
14.3.1 Checking the Clutch Handle Play.................................................. 14-5 14.3.2
Adjusting the Clutch Cable Free Travel.................................................. 14-5
14.3.3 Checking Direction Interference.................................................. 14-5 14.4
Assembling Upper and Lower Connecting Plates.................................. 14-6
14.4.1 Upper connecting plate assembly.................................................................. 14-7
14.4.2 Front fork tube and lower connecting plate assembly.................................. 14-7

14-1
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CFMOTO
14.1 Handlebar Assembly

2
3

9 10

8 11

12

1 Left handle switch assembly 2 Right handle switch assembly 3 Hexagon socket bolt 4-way handle upper cover

5. Handlebar 6 Handlebar mounting bracket 7 Bolt 8 Zipper hook

9 Bolts 10 Upper connecting plate fastening screw 11 Hexagon socket head screw 12 Upper connecting plate assembly

14-2
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14 Handlebar, upper and lower connecting plate assembly

14.1.1 Handlebar switch

14.1.1.1 Disassembly of left-hand handlebar

2
switch

assembly Remove

screw 1 ; Remove switch 2 ;

Remove the hexagon socket bolt

4
3 ; remove the clutch handle 4 ;

Remove the left handlebar balance block

5 ; remove the throttle grip 6 .

5 6

Installation Installation should be carried out in the

reverse

order of disassembly. Note: When installing the switch to the steering handlebar, there is a

positioning structure inside the switch. Connect the device A to the steering handle fixing
A
point B before tightening the bolts.

14-3
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CFMOTO
14.1.1.2 Remove the bolt 1 from the right-hand
2
handle

switch assembly ;

separate the lower cover of the right-hand handle switch 2 ;

Remove bolt 3 ;
Remove right handlebar switch 4 ;

Installation Install in the reverse order of disassembly.

3 4

14.2 Remove the bolt 1

from the throttle

2
handle ; Separate the throttle seat cover 2 ;
1

Remove the right-hand handlebar balance

block 3 ; separate the throttle cable and

throttle seat 4 ; remove the throttle seat

lower cover 5 ; remove the throttle .grip 6

5 6 3

14-4
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14 Handlebar, upper and lower connecting plate assembly

14.3 Handlebar Inspection

14.3.1 Check the clutch handle

clearance Check whether the clutch handle 1

returns smoothly; Check the clutch handle

free travel 1 ; Free travel: 2mm is appropriate.

14.3.2 When fine-tuning the free travel

of the clutch cable, loosen the locking nut 2 , rotate the
adjusting nut 3 to adjust, and tighten the locking nut 2 ;

twenty three

When adjusting the engine end: loosen the locking nut 5 , rotate
the adjusting nut 4 to adjust, and tighten the locking nut .5

14.3.3 Check the interference of the steering handle.

Swing the steering handle left and right to check whether the various wires interfere with the front wheel;

when

the steering handle is turned to the maximum, check whether it interferes with the fuel tank.

14-5
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CFMOTO
14.4 Upper and lower connecting plate combination

4
5

9 9
10

1 Upper connecting plate fastening screw 2 Washer 25x35x0.5 3 Upper connecting plate 4 Dust cover

5 Dust ring assembly 6 Steering bearing assembly 7 Front fork tube 8 Lower connecting plate

9 Hexagon socket head screw 10 Front fork tube plug

14-6
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14 Handlebar, upper and lower connecting plate assembly

14.4.1 Disassembly of the upper

1
connecting plate assembly Remove the
3
hexagon socket bolt 1 ; Remove the

handlebar gland 2 ; Remove the handlebar tube 3 ;

Remove the bolts 4 connecting the upper connecting plate and the mounting
5
seat ; remove the direction handlebar mounting seat

.
5 ; remove the upper connecting plate shock-absorbing fixing bolts 6

6 6
4

14.4.2 Disassembly of the front fork tube and

lower

connecting plate

Remove nut 1 ; Remove bolt 2 ;

Remove the dust cover and dust ring assembly 3 ;

14-7
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CFMOTO
Remove the hexagon socket bolts 4 ; remove

the left and right front shock absorbers 5 ; the

.
6
lower connecting plate and front fork tube assembly 6
4

5
5

Check

whether the upper and lower steering bearing assembly 1 is complete or

worn, if so, replace it in

time. Check whether the bearing steel bowl has cracks or abnormal wear, if

so, replace it in time.

1

Installation: Installation should be carried out in the

reverse order of disassembly. Steering column locking nut torque

value: 25 N·m Upper connecting plate fastening screw torque value: 20 N·m

Note: When installing or replacing, apply sufficient grease to

the bearing steel bowl.

14-8