RZ 650 MT

650MT
Service manual
CF650-3
CF650-3C
CF650-3F
WWW.CFMOTO.COM
All right reserved

ZHEJIANG CFMOTO POWER CO.,LTD.
FOREWORD
This manual introduces CF650-3/ Contents
CF650-3C/CF650-3F mainte-nance
information, disassembly procedure, check Maintenance Information 1
& adjustment methods, troubleshoot-ing Periodic Maintenance 2
and technical specifications. There are
illustrations, drawings to guide your EFI system(CF650-3) 3-1
operation. EFI system(CF650-3C/CF650-3F) 3-2
CFMOTO has final explanations to this
manual information.Without our prior written Cooling system 4
approval, Engine top 5
Any part in this manual is not allowed to
be copied and translated. approval, the Clutch 6
manual cannot be duplicated anddisclosed. Engine lubrication system 7
Do not use this manual to makethe video.
CFMOTO tried many ways and efforts to Engine removal and
8
make this manual perfect and accurate. But installation
this manual isn’t response for any different
Crankshaft and transmission 9
and missing.
CFMOTO reserves rights to make im- Wheels and tires 10
provements and modifications to the prod-
Drive chain and sprocket 11
ucts without prior notice. Overhaul and
maintenance should be done according to Breaking system 12
actual condition of vehicle.And isn’t re-
Suspension system 13
sponse for the product. This manual only for
reference. If any problems comes .Please Steering system 14
connect to your dealer to get the news for
Vehicle body 15
product.
The information in this manual refer to the Electric system 16
newest product when comes out. The
PDA 17
pictures, drawings and photos in this
manual doesn’tstand for the real model, Appendix
assy and parts.
This manual is compiled according to
standard. Contents can help you find out
GB/T9969-2008 and GB/ the topic you want and the chapter
T19678-2005. number. Use the page label to see
the chapter page. And find more
CFMOTO reserves rights to make accurate in contents each chapter.
improvements and modifications to
the products without prior notice.
Overhaul and maintenance should be CFMOTO CO.LTD
done according to actual condition of R&D department
vehicle. 1st brand

Units form
A Ampere lb Pounds
ABDC After bottom dead center m Meter
AC Alternating current min Minutes
ATDC After top dead center N Newton
BBDC Before bottom dead center Pa Pascal
BDC Bottom dead center PS Horsepower
BTDC Before top dead center psi Pound/Square inches
°C Celsius r Rounds
DC Direct current rpm Rounds per minutes
F Farad TDC Top dead center
°F Fahrenheit TIR Times indicator record
ft Feet V Volt
g Gram W Watt
h Hour Ω Ohm
L liter in Inches
US gal US gallon US qt US quart
oz Ounce HP Horse power
cm Hg Hg deepness in cm pint Pint
cu in Cubical inches mL mililiter
Introduction
This manual is designed primarily for use by well-trained mechanics in a properly
equipped workshop. So the operator should have basic and necessary mechanical
and electrical knowledge, as well as knowledge of proper use of tools. If you don’t have
enough experience, it is better to ask qualifi ed operator to work. In order to perform
the work efficiently and to avoid costly mistakes, it is important to read the manual
thoroughly.
For the warranty period, it is recommended to repair and maintain completely fol-
lowing this service manual. Any maintenance or repair procedure not performed in
accordance with this manual may void warranty.
To get the longest life out of your vehicle.
●Follow the maintenance schedule in this manual.
●Be alert for problems and non-scheduled maintenance.
●Use genuine CFMOTO parts and proper tools.
There are necessary information about genuine parts and special tools in our parts cata-
logue and special tools list.
●Follow the service manual procedures step by step. Do not take shortcuts.
●Remember to keep complete records of maintenance and repair with dates and any
new parts installed.
How to Use This Manual
This production seperate into several mainly systems in this manual. These systems
make up each chapters in this manual. The contents has shown all the system in this
production and can help you find out each chapters. Each chapter also has its own
contents.
Example:If you want to find out the ignition coil information.Find out electrical system
chapter in contents first. Then find the ignition in electrical system contents.
If you see the warning signal. Please pay more attention. And follow the safety handle
and service method.
Danger
This signal shows special indication. It may cause injury or death if the instruction
not followed.
Warning
This signal shows special indication. It may cause vehicle damaged if the
instruction not fallowed.
Note
This signal shows information about highly efficiency working way.
This manual has also 3 signals below（Except the warnings on top）. They will help you
see different level sign.
●Shows the job needs to be done
○Shows the job step or after step work. It maybe before the caution note.
★Shows the step’s solution. Depends on the step for testing or inspection result. For
most chapter after contents shows the exploded view. In the view, you can see the
tighten torque, lubrication oil, grease or glue.
1 General Information
Notice…………………………………1-1 Model Identification …………………1-8

Removal & Installation Attention ……1-3 General Specifications………………1-9
Unit Conversion Table ………………1-12
Notice
Safety Precautions
Exhaust contains toxic ingredients. Do not run When the engine just stops, the temperature
the engine in enclosed or poorly-ventilated of engine, muffler is still high; please do not
areas. touch them with bare hands, for avoiding burn.
Please wear uniform with long sleeves as well
as gloves when maintaining.
The liquor (dilute sulfuric acid) in Battery is The coolant is poisonous, please do not drink 1
strongly corrosive; it may burn the skin and it, do not let it contact the skin, eyes neither
blind the eyes when it contacts them. In case clothes. In case it contacts the skin or clothes,
of contact, please wash it with a great deal of please rinse it immediately. When it contacts
clear water immediately, and seek medical the eyes, please wash it thoroughly with a
treatment in hospital. Besides, please also great deal of clear water immediately, and
wash it by a great deal of clear water when it seek medical treatment in hospital. In case
contacts the clothes, for avoiding skin burn. the coolant is drunk by mistake, please try to
The Battery and Battery liquor must be stored throw it up, and seek medical treatment im-
strictly out of reach of children. mediately after gargling. The coolant must be
stored strictly out of reach of children.
1-1
CFMOTO
Uniform (pilot uniform etc), cap, safety boots No smoking or naked fire is allowed at the
suitable for the operation must be worn, and operation site, for the gasoline is
the safety articles such as dustproof goggles, combustible. Not only f ames, but electric
dust proof respirator and gloves shall be worn sparks shall be avoided. Besides, the
for protection when necessary. vapored gasoline is explosive, please
operate it in the place with nice ventilation.
The Battery may produce combustible and The personnel shall make them be aware of
explosive hydrogen when it is being charged. each other from time to time when
So it may explo-de if there is f ame or operating, for safety confirmation.
electric spark. So please charge it in the
place with nice ventilation.
Do not touch the turning or movable pieces

such as rear wheel, clutch, etc. Pay attention
not to get pinched when servicing.
1-2
Removal & Installation Attention
Before starting to perform an inspection service or carry out disassembly and installation
on a motorcycle, read the precautions given below. To facilitate acutal operations, notes,
illustrations, photograghs, cautions and descriptions have been included in each chapter
wherever necessary.This section explains the items that require particular attentions during
removal and reassembly.
Battery Connecting
Before completing any service on the
motorcycle, disconnect the battery cables
from the battery to prevent the engine from
accidentally turning over.
Disconnect the ground cable (-) first and
then the positive (+).When finishing the
service, first connect positive(+) cable to
the positive (+) terminal of the battery and
then the negative (-) cable to the negative (-
) terminal.
1
Edges of Parts
When service parts with edges, wearing
gloves to prevent injury.
Solvent
Use a high-flush point solvent when clean-
ing parts. High-flush point solvent should be
used according to directions of solvent
manufacturer.
Cleaning Vehicle Before Removal

Clean the vehicle completely before
disassembly.Dirt or other foreign materials
entering into sealed areas during vehicle
disassembly can cause excessive wear
and reduce vehicle performance.
1-3
CFMOTO
Arrangement and Cleaning of Removed
Parts
Disassembled parts are easy to confuse.
Arrange the parts according to the order of
parts disassembled and clean the parts in
order prior to installation.
Storage of Removed Parts

After all the parts including subassembly
parts have been cleaned, store the parts in
a clean area, put a clean cloth or plastic
sheet over the parts to protect from any
foreign materials that may collect before
reassembly.
Inspection
Reuse of worn or damaged parts may lead
to serious accidents.Visually inspect re-
moved parts for corrosion, discoloration or
other damage.Refer to the appropriate
sections of this manual for service limits on
individual parts. Replace the parts if any
damage has been found or if the part be-
yond the service limits.
Replacement of Parts
Replacement parts must be CFMOTO
genuine or recommended by CFMOTO.
Gaskets, O-rings, oil seals, grease seals,
circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the re-
verse of
disassembly.However,if assembly order is
provided in the Service Manual, follow the
procedures given.
1-4
Tightening Sequence
Generally, when installing a part with several
bolts, nuts or screws, start them all in their
holes and tighten them in snug fit. Then
tighten them according to specified se-
quence to prevent case warpage or deforma-
tion which can lead to malfunction.Conversely
when loosening the bolts, nuts or screws, first
loosen all of them by a quarter turn and then
remove them. If the specified sequences is
not indicated, tighten the fasteners alternat-
ing diagnoally.
Tightening Torque
Incorrect torque applied to a bolt, nut or
screw may lead to serious damage. Tighten
fasteners to the specified torque by using a
good quality torque wrench. Often, the tight-
ening sequence is followed twice initial
tightening and final tightening torque.
Porper Force
1
Use common sense during disassembly and
assembly.excessive force can cause expen-
sive or hard to repair damage.When
necessary, remove screws that have non-
permanent locking agent applied using an
impact driver. Use a plastic-faced mallet
whenever tapping is necessary.
Gasket and O-ring

Hardening, shrinkage, or damage of both
gaskets and O-ring after disassembly can
reduce sealing performance. Clean the
surface after remova. Use new gasket and o-
ring for replacement.
Liquid Gasket,Non-permanent Locking

Agent
For applications that require Liquid Gasket
1-5
CFMOTO
or a nonpermanent locking agent, clean the
surfaces so that no oil residue remains
before applying liquid gasket or non-perma-
nent locking agent. Do not apply them
excessively, excessive application can clog
oil passages and causes serious damage.
Bearing & oil seals

For items such as bearing or oil seals that
must bepressed into place, apply small
amount of oil on contact area. Be sure to
maintain proper alignment and use smooth
movements when installing.
Ball Bearing and Needle Bearing

Do not remove ball or needle unless re-
moval is absolutely necessary. Replace with
new ones whenever removed. Press bear-
ings with manufacturer and size marks
facing out. Press bearing into place by
putting pressure on the correct bearing
race as shown.
Oil seal & Grease Seal

Do not remove pressed oil or grease seals
unless removal is absolutely necessary.
Replace with new ones whenever removed.
Press new oil seals with manufacturer and
size marks facing out.Make sure the seal is
aligned properly when installing.
Apply specified grease to the lip of the seal

before installing the seal.
Circlips, Cotter Pins

Replace circlips or cotter pins that were
removed with new ones. Take care not to
open the clip excessively when installing to
prevent deformation.
1-6
Lubrication
It is important to lubricate rotating or sliding
parts during assembly to minimize wear
during initial operation. Lubrication points
are called out throughout this manual.Apply
specific oil or grease as specified.
Direction of Engine Rotation

When rotating crankshaft by hand, the free
play of amount of rotating direction will
affect adjustment. Rotate the crankshaft to
positive direction (Clockwise viewed from
output side).
Electrical Wires
1
When connecting electrical wires, first to
check color of wires and unless special
instruction, same color of wires should be
connected.
Instrument
Use a meter that has enough accuracy for
an accurate measurement. Read the
manufacturer’s instructions completely
before using the meter.Incorrect values may
lead to improper adjustments.
1-7
CFMOTO
Model Identification
1
3
2
① VIN ：
② Name Plate:
③ Engine Number：
1-8
General Specifcations
Item
Dimensions:
Overall length 2150mm(84.6in.)
Overall width 835mm(32.9in.)
Overall height 1332mm（52.4in.）
Road clearance Seat 170mm(6.7in.)
height 840mm
Dry mass 213kg(469.6lb)
Curb mass
distribution Front: 108kg(238.1lb)
Rear: 105kg(231.5lb)
Fuel tank capacity 18L(4.76USgal.)
Performance
Minimum turning radius 2.7m(8.9ft)
(LH or RH)
Engine
Type 2-cylinder, 4-strokes, DOHC
Cooling system liquid-cooled
Bore and stroke 83 mm× 60 mm (3.3in × 2.4 in.)
Displacement 649.3 cm³ (39.60 cu in.)
Compression ratio 11.3 : 1
Max. power 52 kW (70.6 PS) @8750 r/min (rpm) 1
Max. torque 62 N·m (6.3 kgf·m, 46 ft·lb) @7000 r/min (rpm)，
Carburetion system EFI
Starting system Electric starter
Ignition system ECU
Timing advance Electric starter(Digital ignitor)
Ignition timing From10° BTDC @1450r/min(rpm) to 35° BTDC
@4800r/min (rpm)
Spark plug CR8EI
Cylinder numbering left to right 1-2
methods
Firing order 1-2
Valve timing
Intake
Open 31° BTDC
Close 61° ABDC
Duration 272°
1-9
CFMOTO
Items
Exhaust valve:
Open 50°BBDC
Close 30°ATDC
Duration 260°
Lubrication system Forced lubrication(semi-dry sump)
Engine oil：
Type ELF 10W-40/SJ with JASOMA2
Viscosity SAE10W-40
Oil capacity 2.6L(2.7Usqt)
Drive train
Primary reduction system:
Type Gear
Reduction ratio 2.095(88/42)
Clutch type Wet, multi disc
Transmission::
Type 6-speed
Gear ratios:
1st 2.353(40/17)
2nd 1.714 (36/21)
3rd 1.333 (32/24)
4th 1.111 (30/27)
5th 0.966 (28/29)
6th 0.852 (23/27)
Main reduction system
Type Chain drive
Reduction ratio 3.067(46/15)
Overall drive ratio 5.474（ Top gear ）
Frame
Type Steel tube, steel plate welding
Caster angle（Rake angle） 24.5°
Trail 137mm(5.4in.)
Front tire
Type Tubeless
Size 120/70 ZR17M/C (58W)
Rim size 17×3.50
Rear tire
Type Tubeless
Size 160/60 ZR17M/C (69W)
Rim size 17×4.50
Front suspension
Type Telescopic fork
Wheel travel 127mm(5.0in.)
1-10
Items
Rear suspension：
Type Swing arm
Wheel travel 118 mm(4.6 in.)
Brake type：
Front Double disc
Rear Single disc
Electrical system
Battery 12V 10Ah
Headlight
Type partially closed type
Bulb High-beam：LED×2；low-beam：LED×1
Tail/Brake light High-beam：LED×2；low-beam：LED×1
Alternator
Type Three-phase AC
Rated output 24A/14V@5000r/min(rpm)
With the change of order status, the above parameters may differ from the real car.
This specification does not stand for all models.
1-11
CFMOTO
Conversion Table
Prefixes for units Units of Length
Prefix Symbol Power km × 0.6214 = mile
Mega M ×1000000 m × 3.281 = ft
Kilo k ×1000 mm × 0.03937 = in
Centi c ×0.01 Units of Torque
Milli m ×0.001 N·m × 0.1020 = kgf·m
Micro µ ×0.000001 N·m × 0.7376 = ft·lb
Units of Mass： N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kg × 2.205 = lb kgf·m × 7.233 = ft·lb
g × 0.03527 = oz kgf·m × 86.80 = in·lb
Units of Volume： Units of Pressure
L × 0.2642 = gal（US） kPa × 0.01020 = kgf/cm2
L × 0.2200 = gal（imp） kPa × 0.1450 = psi
L × 1.057 = qt(US) kPa × 0.7501 = cmHg
L × 0.8799 = qt(imp) kgf/cm2× 98.07 = kPa
L × 2.113 = pint( US ) kgf/cm2×14.22 = psi
L × 1.816 = pint(imp) cmHg × 1.333 = kPa
mL × 0.03381 = oz(US) Units of Speed：
mL × 0.02816 = oz ( imp )
mL × 0.06102 = cu in km/h × 0.6214 = mph
Units of Force Units of Power：
N × 0.1020 = kg kW × 1.360 = PS
N × 0.2248 = lb kW × 1.341 = HP
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP
Temperature Conversion Table
1-12
2 Periodic Maintenance
Table of Contents
Periodic Maintenance Chart……………………………………………………………………………………2-3
Torque Specifcations for tighten parts…………………………………………………………………………2-6

Standard Data & Service limit…………………………………………………………………………………2-11
Special Tools……………………………………………………………………………………………………2-13
Periodic Maintenance procedures……………………………………………………………………………2-14
Electronic Fuel Injection ……………………………………………………………………………………2-14
Air Filter Element Cleaning ……………………………………………………………………………2-14
Throttle Control System Inspection ……………………………………………………………………2-15
Idle Speed Inspection……………………………………………………………………………………2-16
Fuel Line Inspection (fuel leak, damage, installation condition)………………………………………2-17
Cooling System………………………………………………………………………………………………2-18
Coolant Level Inspection……………………………………………………………………………………2-18
Radiator Hose Damage and Installation Condition Inspection………………………………………2-18
Cylinder Head ………………………………………………………………………………………………2-19
Valve Clearance Inspection………………………………………………………………………………2-19
Valve Clearance Adjustment………………………………………………………………………………2-20
Clutch…………………………………………………………………………………………………………2-25
Clutch Operation Inspection………………………………………………………………………………2-25
2
Wheels/Tires…………………………………………………………………………………………………2-25
Air Pressure Inspection……………………………………………………………………………………2-25

Wheel/Tire Damage Inspection…………………………………………………………………………2-26
Tire Tread Wear, Abnormal Wear Inspection……………………………………………………………2-26
Wheel Bearing Damage Inspection………………………………………………………………………2-27
Drive Train………………………………………………………………………………………………………2-27
Drive Chain Lubrication Condition Inspection……………………………………………………………2-27
Drive Chain Slack Inspection………………………………………………………………………………2-28
Drive Chain Slack Adjustment……………………………………………………………………………2-28
Wheel Alignment Inspection…………………………………………………………………………………2-29
Drive Chain Wear Inspection…………………………………………………………………………………2-30
Chain Guide Inspection………………………………………………………………………………………2-30
Brake System…………………………………………………………………………………………………2-31
Brake Fluid Leak (Brake Hose and Pipe) Inspection……………………………………………………2-31
2-1
CFMOTO
Brake Hose and Pipe Damage and Installation Condition Inspection………………………………2-31

Brake Operation Inspection……………………………………………………………………………2-32
Brake Fluid Level Inspection……………………………………………………………………………2-32
Brake Pad Wear Inspection……………………………………………………………………………2-33
Brake Light Switch Operation Inspection……………………………………………………………2-33
Suspensions………………………………………………………………………………………………2-34
Front Forks/Rear Shock Absorber Operation Inspection……………………………………………2-34
Front Fork Oil Leak Inspection…………………………………………………………………………2-34
Rear Shock Absorber Oil Leak Inspection……………………………………………………………2-34
Steering System……………………………………………………………………………………………2-35
Steering Play Inspection…………………………………………………………………………………2-35
Steering Play Adjustment………………………………………………………………………………2-35
Steering Stem Bearing Lubrication……………………………………………………………………2-35
Electrical System…………………………………………………………………………………………2-36
Spark Plug Condition Inspection………………………………………………………………………2-36
Lights and Switches Operation Inspection…………………………………………………………2-37
Headlight Aiming Inspection…………………………………………………………………………2-39
Sidestand Switch Operation Inspection………………………………………………………………2-40
Engine Stop Switch Operation Inspection……………………………………………………………2-41
Others………………………………………………………………………………………………………2-42
Chassis Parts Lubrication…………………………………………………………………………………2-42
Bolts, Nuts and Fasteners Tightness Inspection………………………………………………………2-43
Replacement Parts…………………………………………………………………………………………2-44
Air Filter Element Replacement……………………………………………………………………………2-44
Fuel Line Replacement……………………………………………………………………………………2-44
Coolant Change………………………………………………………………………………………………2-45
Radiator Hose and O-ring Replacement…………………………………………………………………2-47
Engine Oil Change…………………………………………………………………………………………2-48
Oil Filter Replacement………………………………………………………………………………………2-48
Brake Hose and Pipe Replacement………………………………………………………………………2-48
Brake Fluid Change…………………………………………………………………………………………2-49
Master Cylinder Rubber Parts Replacement……………………………………………………………2-51
Caliper Rubber Parts Replacement………………………………………………………………………2-52
Spark Plug Replacement……………………………………………………………………………………2-54
2-2
Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motor-
cycle in good running condition.The initial maintenance is vitally important.
Maintenance Information
Cautions:
► = Severe Use Item. Reduce interval by 50% on vehicles subjected to severe use
■ = Have an authorized dealer perform repairs that involve this component or system
Maintenance Schedule
Maintenance before operation
Item
Hour Calendar km Remarks
Fuel system
Fuel hose - Daily - Inspect for aging
Electrical system
Switches - Daily -
Inspect
Lights and horns - Daily -
2-3
CFMOTO
Break-in Maintenance Schedule

Break-in Maintenance Interval
Item (Service whichever interval comes first)
Engine
■ Engine oil and oil filter - - 1000 Replace
Idle - - 1000
■ Coolant - - 1000 Inspect
Throttle system - - 1000
Electrical system
■ Functions of electrical parts - - 1000
Battery - - 1000 Inspect
Fuses or circuit breakers - - 1000
Brake system
Brake discs - - 1000
Brake pads - - 1000 Inspect
Brake fluid level - - 1000
Inspect for free
Brake lever - - 1000
play
Inspect for damage
■ Brake hoses - - 1000
and sealing
Wheels
Tire condition - - 1000
Inspect
Tire pressure - - 1000
Suspension system
Inspect for leaking
Rear shock absorber and front (maintain parts
■ - - 1000
forks according to the
requirement)
Cooling system
Coolant level - - 1000
■ Coolant - - 1000
Inspect
■ Radiator fan function - - 1000
Coolant hoses - - 1000
Steering system
■ Steering bearings - - 1000 Inspect
Other parts
■ Diagnosis connector - - 1000 Read with PDA
Lubricate; inspect
■ Mobile parts - - 1000
for flexibility
■ Bolts and nuts - - 1000 Inspect for fastness
Inspect for damage,
■ Cables and wires - - 1000
bending and routing
2-4
Periodic Maintenance Schedule

Periodic Maintenance Interval
Engine
Engine oil and oil filter - 6M 5000 Replace
■ Clutch - - 10000
Idle - - 10000 Inspect
- - 10000
■ Coolant
- 24M 30000 Replace
Throttle system - - 10000 Inspect
■ Throttle valve - - 5000 Clean
- - 10000 Inspect
► ■ Air filter element
- 24M -
Replace
■ Spark plug - - 10000
■ Valve clearance - 40000 Inspect
Electrical system
■ Functions of electrical parts - 12M 10000
Battery - 6M 5000 Inspect
Fuses or circuit breakers - 6M 5000
Inspect for damage,
■ Wires - 12M 10000
bending and routing
Brake system
- 12M 10000
2
Front and rear brake system
- 24M 20000
- 12M 10000
Brake discs
- 24M 20000
Inspect
- 12M 10000
► Brake pads
- 24M 20000
- 12M 10000
Brake fluid level
- - 20000
- 24M 20000 Inspect for free
Brake lever
- 12M 10000 play
- 24M 20000 Inspect for damage
■ Brake hoses
- 12M 10000 and sealing
■ Brake fluid 24M - Replace
Wheels
- 12M 10000
Tire condition
- 24M 20000
- 12M 10000
Tire pressure Inspect
- 24M 20000
- - 10000
■ Wheel bearings
- - 30000
2-5
Periodic Maintenance Interval
Suspension system
- - 5000
■ Suspension system - - 10000 Inspect
- - 15000
Inspect for leaking
- 12M 10000
Rear shock absorber and front (maintain parts
■
forks according to the
- 24M 20000
requirement)
- - 10000
■ Swing arms Inspect
- - 30000
Cooling system
- 12M 10000
Coolant level
- 24M 20000
- 12M 10000
■ Coolant
- 24M 20000
Inspect
- 12M 10000
■ Radiator fan function
- 24M 20000
- 12M 10000
■ Coolant hoses
- 48M 30000
Frame system
Frame - - 30000 Inspect
Steering system 2
- 12M 10000
■ Steering bearings Inspect
- 24M 20000
Chain
Chain, rear sprocket and - 12M 10000
► Inspect
engine sprocket - 24M 20000
Other parts
- 12M 10000
■ Diagnosis connector Read with PDA
- 24M 20000
- 12M 10000 Lubricate; inspect
■ Mobile parts
- 48M 30000 for flexibility
- 12M 10000
■ Bolts and nuts Inspect for fastness
- 48M 30000
- 12M 5000 Inspect for damage,
■ Cables and wires
- 24M 15000 bending and routing
Pipes, ducts, hoses and - 12M 10000 Inspect for cracks,
■
sleeves - 48M 30000 sealing and routing
Torque Specifcations for tighten parts

The following tables list the tightening torque for the major fasteners requiring use of a threadlocker.
Letters used in “remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque; EO: Apply engine oil;
2-5
CFMOTO
L: Apply a threadlocker to the threads;
Lh: Left-hand threads;
MO: Apply molibdenum disulfi de oil solution(mixture of engine oil and molybdenum disulfi
de grease in a
weight ratio 10:1);
R: Replacement Parts;
S: Follow the specifi ed tightening sequence;
Si: Apply silicone grease (ex.PBC grease);
SS: Apply silicone sealant
Torque
Fastener Remarks
N·m kgf·m ft·lb
Electronic Fuel Injection(EFI)
Water Temp. Sensor 12 1.2 106in·lb
Speed Sensor Bolt 8 0.80 69in·lb L
Fuel Pump Bolts 5 0.5 — L,S
Oxygen Sensor 60 6.60 44.3
Cooling System
Radiator Hose Clamp Bolts 2.5 0.25 —
Water Pump Impeller Bolt 10 1.0 87in·lb
Water Pump Cover Bolts 10 1.0 87in·lb
Water Pump Drain Bolt 7.0 0.70 62in·lb
Thermostat Housing Bolts 10 1.0 87in·lb
Engine Base Plate Bolts 6 0.60 52in·lb See text
Cylinder Head
Cylinder Cover Bolts 10 1.0 87in·lb
Camshaft Cap Bolts 12 1.2 106in·lb S
Cylinder Head Bolts (M10 New 54 5.5 40 MO,S
Bolts)
Cylinder Head Bolts (M10 Used 49 5.0 36 MO,S
Bolts)
Cylinder Bolt (M8) 27.5 2.8 20 MO,S
Cylinder Nut (M10) 49 5.0 36 MO,S
Cylinder Cover Bolts (M6) 12 1.2 106in·lb S
Cylinder Bolts (M6 12 1.2 106in·lb S
Bolts ,Air Intake Hose 12 1.2 106in·lb
Clamp, Air Intake Hose 2.0 0.2 1.5
Bolts, Tensioner 12 1.2 12
Nuts, Tensioner 20 1.2 20
Camshaft Sprocket Bolts 15 1.5 11 L
Spark Plug 15 1.5 11
Fixed Nuts, Exhaust Pipe 17 1.7 12
Front Mounting Bolts, Muffler 20 2.0 15
2-6
Torque
Fastener Remarks
N·m kgf·m ft·lb
Mounting Bolts ,Rear Muffler 20 2.0 15
Bolts, Anti Scald Plate 6 0.60 52in·lb See text
Clutch
Oil Filler Cover – – – tighten
Mounting Bolts, Clutch Cover 12 1.2 106in·lb
Spring Bolts, Clutch 10 1.0 87in·lb
Hub Nut, Clutch 132 13.5 98 R
Wheel bracket, clutch 10 1.0 87in·lb S
Cable bracket, clutch 10 1.0 87in·lb L
Tighten bolts, clutch 10 1.0 87in·lb
Engine Lubrication
Drain Bolt 30 3.0 22
Filler Plate Bolts 10 1.0 87in·lb L
Oil Filter 17 1.75 13 EO,R
Mounting bolts, oil filter 25 2.5 18 L
Oil Pan Bolts 12 1.2 106in·lb
Oil Pump Chain Guide Bolts 12 1.2 106in·lb L
Bolt, strainer 10 1.0 87in·lb L
Oil Pressure Warning Switch 15 1.5 11 SS
Bolt, oil pump cover 12 1.2 106in·lb L 2
Bolts ,Lower Fairing Bracket 12 1.2 106in·lb L
Bolt(Left), oil pump chain 12 1.2 106in·lb L,Lh
Oil Passage Plug 20 2.0 15 L
Engine Removal/Installation
Rear Mounting Nuts, Engine 45 4.6 32 S
Mounting Bracket Bolts, Engine 25 2.5 18 S
Front Mounting Nuts, Engine 45 4.6 32 S
Crankshaft/Transmission
Breather Plate Bolts 7 0.7 70in·lb L
Crankcase Bolts(M9,L=113mm) 44 4.5 32 MO,S
Crankcase Bolts (M9,L=83mm) 44 4.5 32 MO,S
Crankcase Bolts(M8,L=110mm) 27.5 2.8 20 S
Crankcase Bolts (M8,L=50mm) 27.5 2.8 20 S
Crankcase Bolts (M7) 20 2.0 15 S
Bolts, Upper Crankcase 27.5 2.8 20 S
2-7
CFMOTO
Torque
Fastener Re marks
N·m kgf·m ft·lb
Screw ,Shift Drum Bearing Holder 5 0.50 43in·lb L
Nuts ,C onnecting Rod B ig End see text ? ? MO
Timing Rotor Bolt 40 4.1 30
Relief Valve 15 1.5 11 SS
Gear Po sitioning Lever Bolt 12 1.2 106in·lb L
Shift Shaft R eturn Spring Pin 29 2.9 22 L
Shift Drum Cam Bolt 12 1.2 106in·lb L
Neutral Sensor 15 1.5 11
Bolt, G earshift Chamber Cover 20 2.0 15 L
Fixed Screw ,Neutral Switch 5 0.50 43in·lb L
Bolts ,Shift Shaft Cover 10 1.0 87in·lb L(2)
Screw, Transm issio n Cover 5 0.50 43in·lb L
W heels/Tires
Front Axle 10 8 11.0 80
Lock Bolt ,Front Axle 34 3.5 25
Nut ,Rear Axle 10 8 11.0 80
Final Drive
Engine Sprocket Nut 12 5 12.7 92 L
Nut ,Rear Axle 10 8 11.0 80
Nuts ,R ear Sprocket 59 6.0 44
Bolt ,Speed Sensor 8 0.80 69in·lb L
Bracket Bolts ,Speed Sensor 10 1.0 87in·lb
Brakes
Bleed Valve 7.8 0.80 69in·lb
Brake H ose Banjo Bolts 25 2.5 18
Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si
Brake Lever Pivot Bolt Lock nut 5.9 0.60 52in·lb
Bolt ,Brake Peda l 8.8 0.90 78in·lb
Nut, Brake Pipe 18 1.8 13
Mounting Bo lts ,Front Brake Disc 27 2.8 20 L
Screw ,Front Bra ke Light Switch 1.0 0.10 9in·lb
Screw, Front Bra ke Reservoir Cap 1.0 0.10 9in·lb
Mounting Bo lts , Front C aliper 34 3.5 25
Mounting Bo lts , Front B rake Ma ster Pump 8.8 0.90 78in·lb S
Mounting Bo lts ,Rear Brake Disc 27 2.8 20 L
Mounting Bo lts , Rear Caliper 25 2.5 18
Mounting Bo lts , Rear Brake Master Pump 25 2.5 18
Rear Master Cylinder Push Rod Locknut 18 1.8 13
Suspension
Front Axle Clamp Bolt 34 3.5 25
Allen Bo lts ,Front Fork Bottom 30 3.1 22 L
2-8
T orq ue
F as te ne r R e m a rk s
N·m kgf·m ft·lb
F ro n t Fo rk C lam p B o lts (L o w e r) 20 2.0 15 AL
F ro n t Fo rk C lam p B o lts (U p pe r) 20 2.0 15
F ro n t Fo rk Top P lu g s 25 2.5 18
B o lt ,R ear S ho ck A bs orb er 59 6.0 44
N ut ,R e a r S ho ck A bso rb er 59 6.0 44
N ut ,S w in g arm P ivo t S ha ft 1 80 — —
S teerin g
F ro n t Fo rk C lam p B o lts (L o w e r) 20 2.0 15 AL
F ro n t Fo rk C lam p B o lts (U p pe r) 20 2.0 15
H an dleba r H o lder B olts 25 2.5 18 S
L eft S w itch H o usin g S crew s 3 .5 0.3 6 31 in ·lb
R ig ht S w itch H o usin g S crew s 3 .5 0.3 6 31 in ·lb
S te ering S te m H ead B o lt 1 08 11 .0 80
S te ering S te m N ut 20 2.0 15
F ram e
F o otrest S tay B olts 34 3.5 25
F ro n t Fe nd er Bo lts 3 .9 0.4 0 35 in ·lb
F ro n t Fe nd er B racke t B olts 8 .8 0.9 0 78 in ·lb L
F ro n t Tu rn L ight M o un tin g S crew s 1 .2 0.1 2 11 in ·lb
G ra b R a il M ou nting B olts 25 2.5 18
L o w er F airin g M o u ntin g B olts 8 .8 0.9 0 78 in ·lb
S e a t Loc k M o untin g S crew s 1 .2 0.1 2 11 in ·lb
S ide stand B olt 44 4.5 32
S ide stand S w itc h B olt 8 .8 0.9 0 78 in ·lb L 2
E le ctrical S ystem
A lternato r C ov er B o lts 12 1.2 1 06 in·lb
A lternato r Lead H old ing P late Bo lt 10 1.0 87 in ·lb L
A lternato r R oto r B olt 1 55 15 .8 114 L
C rank sha ft P o sitio n S e nsor B olts 6 .0 0.6 0 53 in ·lb L
E n gine G roun d C a ble Te rm ina l B olt 9 .8 1.0 87 in ·lb
F ro n t B rake L igh t S w itch S crew 1 .2 0.1 2 11 in ·lb
F ro n t Tu rn L ight M o un tin g S crew s 1 .2 0.1 2 11 in ·lb
L eft S w itch H o usin g S crew s 3 .5 0.3 6 31 in ·lb
L ic e nse P late Light C over S cre w s 0 .90 0 .090 8 in·lb
L ic e nse P la te Light M ounting S cre w s 1 .2 0.1 2 11 in ·lb
N eu tra l S w itch 15 1.5 11
O il P re ssu re S w itch 15 1.5 11 SS
O x ygen S en sor 60 6.1 0 4 4.3
R eg ulato r/R ec tifie r B olts 8 .8 0.9 0 78 in ·lb
R ig ht S w itch H o usin g S crew s 3 .5 0.3 6 31 in ·lb
S ide stand S w itc h B olt 8 .8 0.9 0 78 in ·lb L
S p a rk P lug s 15 1.5 11
2-9
CFMOTO
Torque
Fastener Remarks
N·m kgf·m in·lb
Cable Terminal Nut ,Starter Motor 6.0 0.60 53
Mounting Bolts ,Starter Motor 12 1.2 106 SS
Bolts ,Stator Coil 12 1.2 106 L
Bolt ,Timing Rotor 40 4.1 362
Water Temp. Sensor 12.0 1.2 106
The table below, relating tightening torque to thread diameter, lists the basic torque
for the bolts and nuts. Use this table for only the bolts and nuts which do not require
a specific torque value.
Basic Torque for General Fasteners

Threads Torque
Diameter N·m kgf·m ft·lb
(mm)
5 4 .5 ～6 .0 0 .45～0.60 3.3～4 . 4
6 8 .0 ～1 2. 0 0 .80～1.20 6～8 . 8
8 18～25 1.8～2.5 13 .0～17.5
10 25～34 2.6～3.5 19.0～25
12 44～61 4.5～6.2 33～45
14 73～98 7.4～10.0 54～72
16 115～155 11.5～16.0 83～115
18 165～225 17.0～23.0 125～165
20 225～325 2 3.0～33.0 165～240
2-10
Standard Data & Service limit
Ite m Sta ndard Service limit
EFI
Throttle Grip Free Play 2mm~3mm (0.08in~0.12in.)
Idle Speed 1450r/min±145 r/m in(rpm)
Air F ilter Element Po lyurethane Foam
Cooling System
Co olant:
Type(recomme nded) Permanen t typ e of antifreeze
Color G reen
Mixed Ratio Soft water 50% , Coolant 50%
Fre ezing Po int –3 5°C(–31°F)
To ta l Amou nt 2.0L(2.1 USqt)
Cylinder Head
Valve C lea rance
Exha ust 0.20mm~0.26mm (0.0078in~0.0102in.)
Intake 0.08mm~0.13mm (0.0031in~0 .0051in.)
Clutch
C lu tch Leve r Free Pla y 2mm~3mm (0.08in~0.12in.)
Engine
Lubrication
System
2
Engine O il:: E L F 1 0W -4 0 /S J J A S O M A 2
Type 10W -40
Visco sity 2.0L(1.8USqt)( when filte r is not
replaced)
C apacity 2.2L(2.0USqt)( when filter is replaced)
2.6L (2.5 USqt)( total capa city)
Level Between upper and lower le ve l lin es
(after idling o r running)
Wheels/Tires
Tre ad Depth:
Front 4.5mm (0.18in.) 0 .8mm~1 .0m m
Rear 5.5mm (0.22in.) 0 .8mm~1 .0m m
Air Pre ssure (wh en C old):

Front 225kPa(1 or 2 person(s))
Rear 250kPa(1 person) 280kPab(2 persons)
2-11
CFMOTO
Item Standard Service Limit
Chain reduction system
Drive Chain Tightness 30mm~40mm (1.18in~1.575in.)
Drive Chain Wear 317.5mm~318.2mm
320mm
(20-link Length) (12.50in~12.53in.)
(12.6in.)
Standard Chain:
Make in Japan RK or DID 520×S01 or
Type 520 VP2-T
116 Links
Link
Brake
Brake Fluid:
Grade DOT4
Brake Pad Lining
Thickness
Front 4mm (0.15in.) 1mm (0.04in.)
Rear 5mm (0.196in.) 1mm (0.04in.)
Brake light timing On
Front
Rear About 10mm (0.39in.) after pedal
play
Electrical System
Spark Plug Gap 0.7mm~0.9mm (0.027in~0.035in.)
2-12
Special Tool
Caplier, inner circlip Extension tube
Wrench, lock nut of steering column Adjustor, screw
2
Wrench, oil filter
2-13
CFMOTO
Electronic Fuel Injection
Air Filter Element Cleaning
1. Screw
Attention
In dusty areas, the element should be
cleaned frequently than recommended
interval
After riding through rain or on muddily
road, element should be cleaned
immediately.
Attention
If dirt or dust is allowed to pass through
into the throttle assy, the throttle may
become stuck, possibly causing
accident.
Attention 2. Element Comp.

If dirt gets through into the engine,
excessive engine wear and possibly
engine damage will occur.
Removal:
Fuel tank(see Fuel Tank Removal in the
Fuel System Chapter);
Remove air filter element screw;
Remove air filter element comp.
3. Filter element
Remove:
Remove the holder.
Remove element
NOTE
○The wire screen is fastened with an adhe-
sive for the shaded portion.Do not remove the
wire screen
2-14
Warning
Clean the element in a well-ventilated area,
and make sure that there are no sparks or
flame anywhere nears the working area.
Because of the danger of highly flammable
liquids, do not use gasoline or flammable
solution to clean the element.
ŸClean the element element [A] in a bath of

non-flammable cleaning solution, and then dry
it .
ŸAfter cleaning, saturate a clean, lint-free towel
with SAE 15W/40 30 oil and apply the oil to
the element by tapping the element outside
with the towel.
ŸVisually check the element for tears or
breaks.
ŸIf the element has any tears or breaks, re-
place the element.
ŸInstall the element unit [A] with the foam ele-
ment outside (gray) facing down.
2
Throttle Control System Inspection
ŸCheck that the throttle grip moves smoothly
from full open to close [A], and the throttle
closes quickly and completely by the return
spring in all steering positions.
ŸIf the throttle grip doesn’t return properly,
check the throttle cable routing, grip free play,
and cable damage. Then lubricate the throttle
cable.
ŸCheck the throttle grip free play [A].

ŸIf the free play is incorrect, adjust the throttle
cable.
Throttle Grip Free Play
Standard:2mm～3mm(0.08in～0.12in)
2-15
CFMOTO
«If necessary, adjust the throttle cable as
follows.
ŸLoosen the locknut [1] at the upper end of 1
the throttle cable.

ŸTurn the adjuster [2] in completely so as to
give the throttle grip plenty of play.
2
ŸLoosen the locknut [3] at the middle of the 1. lock nut 2. Adjust nut
throttle cable.
ŸTurn the adjuster [4] until there is no play when
the throttle grip is completely closed. 3 4
ŸTighten the locknut.
ŸTurn the throttle cable adjuster until reach the
proper throttle grip free play.
ŸTighten the locknut.
(Fuel system chapter mainly introduces in-
put voltage check of throttle sensor ).
3. lock nut 4. Adjust nut
Idle Speed Inspection
ŸStart the engine and warm it up thoroughly.
ŸWith the engine idling, turn the handlebar to

both sides.
«If handlebar movement changes the idle
speed, the throttle cables may be improperly
adjusted or incorrectly routed or damaged. Be
sure to correct all of these conditions before
diding.(Refer to Appendix)
5. Handlebar turning direction
ŸCheck the idle speed.

«If the idle speed is out of the specified
range, check throttle body for air leaks and
calibration.
Idle Speed
Standard:1450r/min±145r/min(rpm)
2-16
Fuel Line Inspection (fuel leak, damage,
installation condition)
○The fuel hose is designed to be used
throughout the motorcycle’s life without any
maintenance. However, if the motorcycle is
not properly operated, the high pressure
inside the fuel line can cause fuel to leak [A]
or the line to burst. Remove the fuel tank
(refer to Fuel Tank Removal in the Fuel
System chapter) and check the fuel line.
«Replace the fuel line if any fraying, cracks

[B] or bulges [C] are noticed.
ŸCheck the line if it has been sharply bent or
kinked.
Hose Joints [A]
Fuel hose [B]
ŸCheck that the hose joints are securely con-

nected
○Push and pull [A] the hose hose [B] back
and forth more than two times, and make sure
2
it is locked.
«If it is not locked,reinstall the hose joint.
WARNING
WARNING
Make sure the hose joint is installed
correctly on the delivery pipe by sliding
the joint, or the fuel would leak.
2-17
CFMOTO
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold
(room or ambient temperature).
Ÿ Check the coolant level in the reserve tank
[A] with the motorcycle placed perpendicular
(Do not use the sidestand). A
«If the coolant level is lower than the “L”level
line[B], remove the right protection panel (see
Center Fairing Removal in the Frame
chapter) and unscrew the reserve tank cap,
and add coolant to the “F” level line [C].
“L”: low “F”: full
CAUTION C
For refilling, add the specified mixture of
coolant and soft water. Adding water alone
dilutes the coolant and degrades its
anticorrosion properties. The diluted
coolant can attack the aluminum engine B
parts. In an emergency, soft water alone
can be added. But the diluted coolant must
be returned to the correct mixture ratio
within a few days. If coolant must be added
often or the reservoir tank has run
completely dry, there is a probably leakage
in the cooling system. Check the system for
leaks. Coolant ruins painted surfaces.
Immediately wash away any coolant that
spills on the frame, engine, wheels or other
painted parts.
Radiator Hose Damage and Installation Con-

dition Inspection
○The high pressure inside the radiator hose
can cause coolant leak [A] or the hose burst
if the hose line is not properly maintained.
Ÿ Visually inspect the hoses for signs of
deterioration. Squeeze the hoses. Hoses
should not be neither hard and brittle,nor be
soft or swollen.
« Replace the hose if any fraying, cracks [B]
or bulges [C] are noticed.
« Check that the hoses are securely con-
nected and clamps are tightened correctly.
2-18
Cylinder Head
Valve Clearance Inspection
NOTE
Valve clearance must be checked and
adjusted when the engine is cold (room
temperature).
● Remove the cylinder head cover (see

Cylinder Head Cover Removal in the En-
gine Top End chapter)
● Unscrew the upper [A] and lower [B]

caps on the clutch cover.
● Check the valve clearance when the

pistons are at TDC.
● Using a wrench [A] to turn the crankshaft

clockwise until the “1/T” mark is aligned with
the notch [B].
2
“1/T” mark for #1 piston and “2/T”mark for
#2 piston.
1/T Mark [A]
2/T Mark [B]
Holeof Upper Cap [C]
Notch in Edge of Upper Hole[D]
● Using the feeler gauge [A], measure the

valve clearance between cam and valve lifter.
Valve Clearance Standard:

Exhaust: 0.20mm~0.26 mm
Intake: 0.08mm~0.13mm
○ Every piston has two intake and exhaust
valve.
2-19
CFMOTO
Cylinder #1, Valve Clearance Measuring Po-
sition
#1 Piston TDC at End of Compression Stroke
Intake valve clearances of #1 piston,and Ex-
haust valve clearances of #1 piston
NOTE
Check the valve clearance by using this
method only. Checking the clearance at any
other cam position may result in inaccurate
valve clearance.
Cylinder #2 Valve Clearance Measuring Po-
sition
#2 Piston TDC at End of Compression Stroke
Intake valve clearances of #2 piston, and Ex-
haust valve clearances of #2 piston
★ If the valve clearance is not within the

specified range,first record the clearance,and
adjust it.
● To change the valve clearance, remove the

cam shaft chain tensioner,camshafts and
valve lifters.
Replace the shim with one of a different
thickness.
NOTE
○ Mark and record the valve lifter and shim
location so they can be reinstalled in their origi-
nal positions
○ If there is no clearance,select a shim which
● Apply a thin coat of molybdenum disulfide
is normal sizes smaller and then measure the
grease to the valve lifters.
clearance.
● Install the camshafts. Be sure that cam
● To select a new proper shim in order to
have the valve clearance within specified shafts is installed properly (see Camshaft In-
range, refer to the Valve Clearance Adjust- stallation chapter).
ment Charts. ● Remeasure any valve clearance that was

adjusted. Readjust if necessary.
2-20
Valve Adjustment Chart(Intake Valve)
Valve Adjustment Chart(Intake Valve)
Present Shim Example
Mark 320 322 324 326 328 330 332 334 336 338 340 342 344 346 348 350 352 354 356 358 360 362 364 366
Thickness 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66
0～0.01 — — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56
0.02～0.03 — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58
0.04～0.05 — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6
0.06～0.07 — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62
0.08～0.13 Specifi ed Clearance/No Change Required
0.14～0.15 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68
0.16～0.17 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7
0.18～0.19 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72
0.20～0.21 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74
0.22～0.23 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76
E x a m p le
0.24～0.25 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78
0.26～0.27 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8
0.28～0.29 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82
0.30～0.31 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84
V a lve C le a ra n c e M e a s u r e m e n t
0.32～0.33 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86
0.34～0.35 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88
0.36～0.37 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9
0.38～0.39 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92
0.40～0.41 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94
0.42～0.43 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96
0.44～0.45 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98
0.46～0.47 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4
0.48～0.49 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02
0.50～0.51 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04
0.52～0.53 3.6 3.62 3.64 3.66 3.68
0.54～0.55 3.62 3.64 3.66 3.68 3.7
3.7 3.72
3.72 3.74
3.74 3.76 3.78
3.76 3.78 3.8
3.8 3.82
3.82 3.84
3.84 3.86 3.88
3.86 3.88 3.9
3.9 3.92
3.92 3.94
3.94 3.96 3.98
3.96 3.98 4
4 4.02 4.04
4.02 4.04 4.06
4.06
4.08 2
0.56～0.57 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1
0.58～0.59 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12
0.60～0.61 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14
0.62～0.63 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16
0.64～0.65 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.66～0.67 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.68～0.69 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.70～0.71 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.72～0.73 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.74～0.75 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.76～0.77 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.78～0.79 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.80～0.81 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.82～0.83 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.84～0.85 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.86～0.87 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.88～0.89 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.90～0.91 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.92～0.93 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.94～0.95 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.96～0.97 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.98～0.99 4.06 4.08 4.1 4.12 4.14 4.16 4.18
1.00～1.01 4.08 4.1 4.12 4.14 4.16 4.18
1.02～1.03 4.1 4.12 4.14 4.16 4.18
1.04～1.05 4.12 4.14 4.16 4.18
1.06～1.07 4.14 4.16 4.18
1.08～1.09 4.16 4.18
1.10～1.11 4.18
2-21
CFMOTO
Valve Clearance Adjustment Chart(Intake Valve)
Valve C lea rance Ad justmen t Chart(In ta ke Valve)
Presen t Shi m
Ma rk 368 370 372 374 376 378 380 382 384 386 388 390 392 394 396 398 400 402 404 406 408 410 412 414 416 418
Thickne ss 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0～0.01 3.58 3. 6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3. 82 3.84 3.86 3. 88 3. 9 3.92 3.94 3.96 3.98 4 4. 02 4.04 4.06 4. 08
0.02～0.03 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3. 84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4. 04 4.06 4.08 4.1
0.04～0.05 3.62 3.64 3.66 3.68 3. 7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3. 86 3.88 3.9 3. 92 3.94 3.96 3.98 4 4.02 4.04 4. 06 4.08 4.1 4. 12
0.06～0.07 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3. 88 3.9 3.92 3. 94 3.96 3.98 4 4.02 4.04 4.06 4. 08 4.1 4.12 4. 14
0.08～0.13 Spe cifie d Clearance/No Ch ang e Require d
0.14～0.15 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3. 94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4. 14 4.16 4.18
0.16～0.17 3.72 3.74 3.76 3.78 3. 8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3. 96 3.98 4 4. 02 4.04 4.06 4.08 4.1 4.12 4.14 4. 16 4.18
0.18～0.19 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3. 98 4 4.02 4. 04 4.06 4.08 4. 1 4.12 4.14 4.16 4. 18
0.20～0.21 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4. 06 4.08 4.1 4.12 4.14 4.16 4.18
0.22～0.23 3.78 3. 8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4. 02 4.04 4.06 4. 08 4. 1 4.12 4.14 4.16 4.18
0.24～0.25 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4. 04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.26～0.27 3.82 3.84 3.86 3.88 3. 9 3.92 3.94 3.96 3.98 4 4.02 4.04 4. 06 4.08 4.1 4. 12 4.14 4.16 4.18
0.28～0.29 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4. 08 4.1 4.12 4. 14 4.16 4.18
Cl earance Mea sure ment
0.30～0.31 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4. 16 4.18
0.32～0.33 3.88 3. 9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4. 12 4.14 4.16 4. 18
0.34～0.35 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4. 14 4.16 4.18
0.36～0.37 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4. 16 4.18
0.38～0.39 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4. 18
0.40～0.41 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.42～0.43 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.44～0.45 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.46～0.47 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4.16 4.18
0.48～0.49 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.50～0.51 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.52～0.53 4.08 4. 1 4.12 4.14 4.16 4.18
0.54～0.55 4.1 4.12 4.14 4.16 4.18
0.56～0.57 4.12 4.14 4.16 4.18
0.58～0.59 4.14 4.16 4.18
0.60～0.61 4.16 4.18
0.62～0.63 4.18
1.Measure the clearance (when engine is cold).

2.Check present shim size.
Example: Present shim is 3.50 mm.
Measured clearance is 0.25 mm.
Replace 3.50 mm shim with 3.62 mm shim.
Remeasure the valve clearance and readjust if necessary.
2-22
Valve Cle aran ce Adju stmen t(E xhaust Val ve)
Pre sent Shim Example
Mark 320 322 324 326 328 330 332 334 336 338 340 342 344 346 348 350 352 354 356 358 360 362 364 366 368 370
Thi ckne ss 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7
0～0.01 — — — — — — — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3. 4 3.42 3.44 3.46 3. 48 3.5
0.02～0.03 — — — — — — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3. 4 3.42 3.44 3.46 3.48 3.5 3.52
0.04～0.05 — — — — — — — — 3.2 3.22 3.24 3.26 3.28 3. 3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3. 52 3.54
0.06～0.07 — — — — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3. 5 3.52 3. 54 3.56
0.08～0.09 — — — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3. 4 3.42 3.44 3.46 3.48 3. 5 3.52 3.54 3. 56 3.58
0.10～0.11 — — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3. 5 3.52 3.54 3.56 3. 58 3.6
0.12～0.13 — — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3. 5 3.52 3.54 3.56 3.58 3.6 3.62
0.14～0.15 — — — 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3. 4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3. 62 3.64
0.16～0.17 3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3. 6 3.62 3. 64 3.66
0.18～0.19 — 3.2 3. 22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3. 5 3.52 3.54 3.56 3.58 3. 6 3.62 3.64 3. 66 3.68
0.20～0.26 Specified Clea rance /No Change Requ ired

0.27～0.28 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3. 7 3.72 3. 74 3.76
0.29～0.30 3.28 3.3 3. 32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3. 6 3.62 3.64 3.66 3.68 3. 7 3.72 3.74 3. 76 3.78
0.31～0.32 3.3 3.32 3. 34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3. 7 3.72 3.74 3.76 3. 78 3.8
0.33～0.34 3.32 3.34 3. 36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3. 7 3.72 3.74 3.76 3.78 3.8 3.82
0.35～0.36 3.34 3.36 3. 38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3. 6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3. 82 3.84
0.37～0.38 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3. 8 3.82 3. 84 3.86
0.39～0.40 3.38 3.4 3. 42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3. 7 3.72 3.74 3.76 3.78 3. 8 3.82 3.84 3. 86 3.88
0.41～0.42 3.4 3.42 3. 44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3. 8 3.82 3.84 3.86 3. 88 3.9
0.43～0.44 3.42 3.44 3. 46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3. 8 3.82 3.84 3.86 3.88 3.9 3.92
0.45～0.46 3.44 3.46 3. 48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3. 7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3. 92 3.94
0.47～0.48 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3. 9 3.92 3. 94 3.96
0.49～0.50 3.48 3.5 3. 52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3. 8 3.82 3.84 3.86 3.88 3. 9 3.92 3.94 3. 96 3.98
0.51～0.52 3.5 3.52 3. 54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3. 9 3.92 3.94 3.96 3. 98 4
Examp le
0.53～0.54 3.52 3.54 3. 56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3. 9 3.92 3.94 3.96 3.98 4 4.02
0.55～0.56 3.54 3.56 3. 58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3. 8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4. 02 4.04
0.57～0.58 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4. 04 4.06
2
0.59～0.60 3.58 3.6 3. 62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3. 9 3.92 3.94 3.96 3.98 4 4.02 4.04 4. 06 4.08
0.61～0.62 3.6 3.62 3. 64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4. 08 4.1
Cleara nce Mea sure me nt
0.63～0.64 3.62 3.64 3. 66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12
0.65～0.66 3.64 3.66 3. 68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3. 9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4. 12 4.14
0.67～0.68 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4. 1 4.12 4. 14 4.16
0.69～0.70 3.68 3.7 3. 72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4. 16 4.18
0.71～0.72 3.7 3.72 3. 74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4.16 4. 18
0.73～0.74 3.72 3.74 3. 76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4.16 4.18
0.75～0.76 3.74 3.76 3. 78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.77～0.78 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.79～0.80 3.78 3.8 3. 82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4.16 4.18
0.81～0.82 3.8 3.82 3. 84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.83～0.84 3.82 3.84 3. 86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.85～0.86 3.84 3.86 3. 88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4.16 4.18
0.87～0.88 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.89～0.90 3.88 3.9 3. 92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.91～0.92 3.9 3.92 3. 94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.93～0.94 3.92 3.94 3. 96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.95～0.96 3.94 3.96 3. 98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.97～0.98 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.99～1.00 3.98 4 4. 02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
1.01～1.02 4 4.02 4. 04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

1.03～1.04 4.02 4.04 4. 06 4.08 4.1 4.12 4.14 4.16 4.18
1.05～1.06 4.04 4.06 4. 08 4.1 4.12 4.14 4.16 4.18

1.07～1.08 4.06 4.08 4.1 4.12 4.14 4.16 4.18
1.09～1.10 4.08 4.1 4. 12 4.14 4.16 4.18
1.11～1.12 4.1 4.12 4. 14 4.16 4.18
1.13～1.14 4.12 4.14 4. 16 4.18
1.15～1.16 4.14 4.16 4. 18
1.17～1.18 4.16 4.18

1.19～1.20 4.18
2-23
CFMOTO
Valve Clearance Adjustment Exhaust Valve(Continued)
Present Shim
Mark 372 374 376 378 380 382 384 386 388 390 392 394 396 398 400 402 404 406 408 410 412 414 416 418
Thickness 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0～0.01 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98
0.02～0.03 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4
0.04～0.05 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02
0.06～0.07 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04
0.08～0.09 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06
0.10～0.11 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08
0.12～0.13 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1
0.14～0.15 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12
0.16～0.17 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14
0.18～0.19 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16
0.20～0.26 Specified Clearance/No Change Required
0.27～0.28 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.29～0.30 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.31～0.32 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
Clearance Measurement
0.33～0.34 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.35～0.36 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.37～0.38 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.39～0.40 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.41～0.42 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.43～0.44 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.45～0.46 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.47～0.48 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.49～0.50 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.51～0.52 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.53～0.54 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.55～0.56 4.06 4.08 4.1 4.12 4.14 4.16 4.18
0.57～0.58 4.08 4.1 4.12 4.14 4.16 4.18
0.59～0.60 4.1 4.12 4.14 4.16 4.18
0.61～0.62 4.12 4.14 4.16 4.18
0.63～0.64 4.14 4.16 4.18
0.65～0.66 4.16 4.18
0.67～0.68 4.18
1.Measure the clearance (when engine is cold).

2.Check present shim size.
Example: Present shim is 3.52 mm.
Measured clearance is 0.31 mm.
Replace 3.52 mm shim with 3.62 mm shim.
Remeasure the valve clearance and readjust if necessary.
2-24
Clutch
Clutch Operation Inspection
Ÿ Pull the clutch lever just enough to take up
the free play [A].
Ÿ Measure the gap between the lever and the
lever holder.
«If the gap is too wide,the clutch may not re-
lease fully. If the gap is too narrow, the clutch
may not engage fully. In either case, adjust it.
WARNING
To avoid a serious burn, never tough the
engine or exhaust pipe during clutch
adjustment.
Clutch Lever Free Play
Standard: 2mm~3mm(0.08in~0.12in.)
Ÿ Turn the adjuster [A] so that 5mm~6mm
(0.20in~0. 24 in.) [B] of threads are visible.
Ÿ Slide the dust cover [A] at the middle of the
clutch cable out of place.
Ÿ Loosen the locknut [B] at the middle of clutch
cable.
Ÿ Turn the adjustment nut [C] until the free play
is correct. 2
WARNING
Be sure that the outer cable end at the
clutch lever is fully seated in the adjuster at
the clutch lever, or it could slip into place
later, creating enough cable play to prevent
clutch disengagement.
After the adjustment, tighten the locknut and
start the engine. Check the clutch if it releases
properly.
Wheels/Tires
Air Pressure Inspection
Ÿ Remove the air valve cap.
Ÿ Measure the tire air pressure with an air
pressure gauge [A] when the tires are cold
(that is,when the motorcycle has not been
ridden more than a mile during the past 3
hours).
Ÿ Install the air valve cap.
2-25
CFMOTO
« Adjust the tire pressure according to the
specifications if necessary.
Air Pressure (when cold)
Front: 250kPa(2.25kgf/cm2,39.8psi)
Rear: 290kPa(2.50kgf/cm2,46.2psi)
Wheel/Tire Damage Inspection

Ÿ Remove any imbedded stones [A] or other
foreign particles [B] of tread.
Ÿ Visually inspect the tire for cracks and cuts,
and replace the tire if necessary. Swelling or
high spots indicate internal damage, requir-
ing tire replacement.
Ÿ Visually inspect the wheel for cracks, cuts
and dents damage.
« If any damage is found, replace the wheel
if necessary.
Tire Tread Wear, Abnormal Wear Inspec-
tion
When the tire tread is worn, the tire becomes
more susceptible to puncture and failure. An
accepted estimate is that 90% of all tire fail-
ures occur during the last 10% of tread life
(90% worn). So it is unsafe to use the tires
until they are bald.
Ÿ Measure the tread depth at the center of the
tread with a depth gauge [A]. Since the tire
may be worn unevenly,take measurement at
several places. WARNING
«If any measurement is less than the service To ensure safe handling and stability, use
only the recommended standard tires for
limit, replace the tire (see Tire Removal/Instal- replacement, inflated to the standard
lation in the Wheels/Tires chapter). pressure.
Tread Depth Standard: NOTE

Front: 4.5mm(0.18in.) ○Most countries may have their own regu-
Rear: 5.5mm(0.22in.) lations a minimum tire tread depth:be sure
Service Limit: to follow them.
Front: 0.8mm~1.0 mm
○Check and balance the wheel when a tire
Rear: 0.8mm~1.0 mm
is replaced with a new one.
2-26
Wheel Bearing Damage Inspection
Ÿ Raise the front wheel off the ground with
B
jack (see Front Wheel Removal in the
Wheels/Tires chapter).
Ÿ Turn the handlebar to the right or left.
Ÿ Inspect the roughness of the front wheel
bearing by pushing and pulling [A] the wheel.
Ÿ Spin [B] the front wheel lightly, and check
for smoothly turn, roughness, binding or noise. A
« If roughness, binding or noise is found, re-
move the front wheel and inspect the wheel
bearing (see Front Wheel Removal, Hub
Bearing Inspection in the Wheels/Tires
chapter).
Ÿ Raise the rear wheel off the ground with

side stand (see Rear Wheel Removal in the
Wheels/Tires chapter).
Ÿ Inspect the roughness of the rear wheel

bearing by pushing and pulling [A] the wheel. 2
Ÿ Spin [B] the rear wheel lightly, and check B
for smoothly turn, roughness,binding or noise.
« If roughness, binding or noise is found, re-
move the rear wheel and inspect the wheel
bearing (see Rear Wheel Removal, Hub
Bearing Inspection in the Wheels/Tire A
chapter) and coupling (see Coupling Bear-
ing Inspection in the Final Drive chapter).
Drive Train
CAUTION
Drive Chain Lubrication Condition Inspec- To avoid damage of the O-ring and loss of
tion lubricant, observe the following rules.
Use only kerosene or diesel oil for cleaning.
Ÿ Using special chain lubricant only when use Any other cleaning solution such as
gasoline or trichloroethylene will cause
chain for 500km to 800km. If the chain is es- deterioration and swelling of the O-ring.
pecially dirty, clean it before lubrication. Immediately blow the chain dry with
compressed air after cleaning. Complete
cleaning and drying the chain within 10
minutes.
2-27
CFMOTO
Ÿ Apply oil to the each sides of the rollers, oil
will penetrate to the rollers and bushings. Ap-
ply the oil to the O-rings.
Ÿ Wipe off any excess oil. Oil Applied Areas
[A] O-rings [B]
Drive Train Slack Inspection

NOTE
○Check the slack with the motorcycle set-
ting on its side stand.
○Clean the chain if it is dirty, and lubricate
it if it appears diry.
Ÿ Check the wheel alignment (see Wheel
Alignment Inspection).
Ÿ Rotate the rear wheel to find the position
where the chain is tightest.
Ÿ Measure the vertical movement (chain
slack) [A] midway between the sprockets. «
If the chain slack exceeds the standard, ad-
just it.
Chain Slack 5
Standard: 30mm~40mm(1.18in~1.57in.) 2
Drive Chain Slack Adjustment
Ÿ Remove the cotter pin [1], and loosen the 1
axle nut [2].
Ÿ Loosen the both chain adjuster locknuts [3].
« If the chain is too loose, turn in the left and 3
right chain adjuster bolts [4] evenly.
4
6
« If the chain is too tight, turn out the left and
right chain adjuster nuts evenly, and kick the
wheel forward.
ARNING
Ÿ Turn both chain adjuster nuts evenly until WARNING
the drive chain has the correct amount of Misalignment of the wheel will result in
abnormal wear and may result in an
slack. To keep the chain and wheel properly unsafe riding condition.
aligned, the value on the left wheel alignment
adjuster [5] should align with the same (left Ÿ Tighten both chain adjuster locknuts securely.
or right) edge [6] of inspection window on the Ÿ Tighten the rear axle nut.
swingarm that the right wheel alignment ad- Torque - Rear Axle Nut: 108N·m(11.
juster value aligns with. 0kgf·m,80ft·lb)
Bend cotter pin [A] on the nut[B].
2-28
Ÿ Turn the wheel, measure the chain slack
again the tightest position, and readjust if
necessary. Insert a new cotter pin [A].
NOTE
○ When inserting the cotter pin, if the slots
in the nut do not align with the cotter pin hole
in the axle,
tighten the nut clockwise [B] up to next
alignment.
○It should be within 30 degree .
○Loosen once and tighten again when
the slot goes past the nearest hole.
• Bend cotter pin[A] than nut [B]
W ARN ING
If th e re ar a xle n ut is not secu rely tig htene d
o r th e c otte r pin is in stalled incorrectly , a n
u ns afe rid ing co ndition m ay happe ns .
Wheel Alignment Inspection 2

•Check that the value on the left wheel align-
ment adjuster [1] aligns with the same (left or
right) edge [2] of inspection window on
swingarm that the right wheel alignment ad-
juster value aligns with.
« If they do not, adjust the chain slack and
align the wheel alignment (see Drive Chian
SlackAdjustment).
NOTE
○Wheel alignment can be also checked us-
ing the straightedge or string method.
W ARN ING 2 1
M is align m e nt o f th e w h ee l w ill re sult in
a bn orm al w ear, and m a y resu lt in a n u ns afe
ridin g c ond itio n.
2-29
CFMOTO
Drive Chain Wear Inspection
Ÿ Removal:
Chain Cover (see Swing arm Removal in
the Suspension chapter)
Ÿ Rotate the rear wheel to inspect the drive
chain for damaged rollers, and loose pins
and links.
« If there is any irregularity, replace
the drive chain. Lubricate the drive
chain if it appears dry.
« Stretch the chain taut by hanging a 98 N
(10 kg, 20 Ib) weight [A] on the chain. Mea-
sure the length of 20 links [B] on the straight
part[C] of the chain from the pin center of
the 1st pin to the pin center of the 21st pin.
Ÿ Since the chain may wear unevenly, take
measurements at several places.
« If any measurements exceed the service
limit, replace the claim. Also, replace the front
and rear sprockets when the drive chain is
replaced.
Drive Chain 20-link Length
Standard: 317.5mm~318.2mm(12.50in~
12.53in.)
Ÿ Service limit:320mm(12.6in.)
WARNING
If the drive train wear exceeds the service limit,
replace the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the
sprockets could snap on the engine sprocket or
lock the rear wheel, severely damaging the
motorcycle and causing it to go out of control. For
safety, use only the standard chain. It is an endless
type and should not be cut for installation.
Standard Chain Made by: RK,Japan

Type: 520xS01 or 520 VP2-T
Link: 116 links
Chain Guide Inspection A
Ÿ Removal:
Swing arm (see Swing arm Removal in the
Suspension chapter)
Ÿ Visually inspect the chain guide [A].
« Replace the chain guide if it shows any signs of abnormal wear or damage.
2-30
Brake System 1
Brake Fluid Leak (Brake Hose and Pipe) 2
Inspection
Ÿ Apply the brake lever or pedal and inspect
brake hoses [A],connector [B] for leakage.
« If the brake fluid leaked from any position,
inspect or replace the problem part.
Brake Hose and Pipe Damage and 1

Installation Condition Inspection
•Inspect the brake hoses, fittings and pipes
for deterioration, cracks and signs of leakage.
2
○The high pressure inside the brake line
can cause fluid to leak [A] or the hose to burst
« Bend and twist the rubber hose while 2
examing it. Replace the hose and pipe if any
crack [B], bulge [C] of leakage is noticed.
«Tighten any brake hose banjo bolts and
brake pipe joint nuts.
Torque-Brake Hose Banjo Bolts:
25N·m (2.5kgf·m, 18ft·lb)
Brake Pipe Joit Nuts(18N·m, 1.8kgf·m,
13ft·lb)
•Inspect the brake hose routing.
«If any brake hose routing is incorrect, re-
route the brake hose (refer to chapter 1)
2-31
CFMOTO
Brake Operation Inspection
Ÿ Inspect the operation of the front and rear
brake while running the vehicle on the dry
road.
«If the brake operation is insufficient, in-
spect the brake system.
C AU T IO N
I n s p e c t w h ile r u n n in g th e ve h ic le ,
p a y a tte n tio n to t h e s u rro u n d in g
t ra ff ic .
Brake Fluid Level Inspection

Ÿ Check that the brake fluid level in the front
brake reservoir [A] is above the lower level
line [B].
Caution
Caution
○Hold the reservoir horizontal by turning the
handlebar when checking brake fluid level.
« If the fluid level is lower than the lower level
A
line, fill to the upper level line [C] in the C
reservoir.
Ÿ Remove the seat (see Seat Removal in
the Frame Chapter).
Ÿ Check that the brake fluid level in the rear
B
brake reservoir [A] is above the lower level
line [B].
« If the fluid level is lower than the lower level
line, fill the reservoir to the upper level line
[C].
C AU T ION
I f th e ty p e a n d b ra n d o f th e b ra k e flu id in
t h e re se rv o ir a re u n id e n tif ie d , ch a n g e
t h e b ra k e flu id in th e b ra k e lin e
c o m p le te ly . A fte r c h a n g in g th e f lu id , u s e
t h e s a m e ty p e a n d b ra n d o f flu id
t h e re a fte r.
Recommended Brake Fluid

Grade:DOT4
2-32
Ÿ Follow the procedures to install the rear
2
brake fluid reservoir cap correctly.
○ With a cross-head screwdriver [1] to

tighten the cap [2] .
1
Brake Pad Wear Inspection
ŸCheck the lining thickness [A] of the pads
in each caliper.
«If the lining thickness of either pad is less
than the service limit [B], replace both pads
in the caliper as a set.
Pad Lining Thickness
Standard:
Front : 4.0mm(0.16in)
Rear: 5.0mm(0.20in)
Service Limit: 1mm(0.04in)
Brake Light Switch Operation Inspection

Ÿ Turn on the ignition switch
The brake light [A] should go on when the
A 2
brake lever is applied or after the brake pedal
is depressed about 10 mm (0.39 in.)
« If it does not, adjust the brake light switch.
Disconnect the connector [A].
« If it does not go on, inspect or replace the
following items.
Battery (see Charging Condition Inspection
in the Electrical System chapter)
Brake Light (see Tail/Brake Light Removal in
the Electrical System chapter)
Main Fuse 20 A and Taillight Fuse 10A (see
Switch Inspection in the Electrical System
chapter)
Front Brake Light Switch [A] (see Switch In-
spection in Electrical System chapter) Rear
Brake Light Switch (see Switch Inspec-tion in
the Electrical System chapter) Harness (see
Wiring Inspection in the Elec-trical System)
2-33
CFMOTO
Suspensions
Front Forks/Rear Shock Absorber Opera-
tion
Inspection
Ÿ Pump the forks down and up [A] 4 or 5 A
times, and inspect the smooth stroke. If the
forks do not work smoothly or noise is
found, inspect the fork oil level or fork
clamps (see Front Fork Oil Change in the
Suspension chapter).
Ÿ Pump the seat down and up [B] 4 or 5

times, and inspect the smooth stroke. B
Front Fork Oil Leak Inspection

Ÿ Visually inspect the front forks [A] for oil
leakage.
« Replace or repair any defective parts, if A
necessary.
Rear Shock Absorber Oil Leak Inspection

Ÿ Visually inspect the shock absorber [A]
for oil leakage.
« If the oil leakage is found, replace the
shock absorber with a new one.
2-34
Steering System
Steering Play Inspection
Ÿ Raise the front wheel off the ground with jack
(see Front Wheel Removal in the Wheels/Tires
chapter).
Ÿ With the front wheel pointing straight ahead,
alternately tap each end of the handlebar.
Handlebar should be turned flexibly.
« If the wheel binds or catches before the stop,
the steering is too tight.
Feel for steering looseness by pushing and pull-
ing the forks.
« If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect 3 4 5
on the motion of the fork which must be taken 1
into account.
○ Be sure the wires and cables are properly
routed.
○The bearings must be in good condition and
properly lubricated in order for any test to be valid 2
Steering Play Adjustment 2
Ÿ Removal:
Headlight Assy (see Headlight Removal/
Installation in the Electrical System chapter)
Handlebar cover (see Handlebar Removal in
the Steering chapter)
Remove bolt (2), take off LH handlebar assy. [1]
Lock bolt]3] of front fork
Rotate bolt r[4]
Loosen connector of ignition switch lock.
Remove upper board assy.[5]
Bend the claws [A] of the claw washer straighten.
Remove the steering stem locknut [B] and claw
washer [C].
Adjust the steering
Special Tool - Steering Stem Nut Wrench [A]
«If the steering is too tight, loosen the stem nut
[B] a fraction of a turn.
«If the steering is too loose, ltight the stem nut
[B] a fraction of a turn.
2-35
CFMOTO
NOTE
○Turning steering stem nut 1/8 at most.
Install the claw washer [A] so that its bent side
[B] faces upward, and engage the bent claws
with the grooves of stem locknut [C].
Ÿ Tighten the stem locknut by hand until it
touches the claw washer.
Ÿ Tighten the stem locknut clockwise until the
claws are aligned with the grooves (ranging
from 2nd to 4th) of stem nut [D], and bend the 2
claws downward [E].
Ÿ Install the steering stem board.
Ÿ Install the washer, and tighten the stem head
bolt.
Ÿ Tighten:
Torque - Steering Stem Head Bolt:
108N·m (11.0kgf·m, 80ft·lb)
Front Fork Clamp Bolts(upper):
20N ·m (2.0kgf ·m, 15ft·lb)
Ÿ Check the steering again.
« If the steering is still too tight or too loose,
repeat the adjustment.
Install the removed parts
Steering Stem Bearing Lubrication
Ÿ Remove the steering stem (see Stem, Stem
Bearing Removal in the Steering chapter).
Ÿ Using a high-flash point solvent, wash the
upper and lower ball bearings in the cages, and
wipe the upper and lower outer races, which
are press-fitted into the frame head pipe, clean
off grease and dirt.
« Visually check the outer races and the ball
bearings. Replace the bearing assemblies if
they show wear or damage.
Ÿ Pack the upper and lower ball bearings [A] in the cages with grease, and apply a light coat
of grease to the upper and lower outer races.
Ÿ Install the steering stem (see Stem, Stem Bearing Installation in the Steering chapter).
Ÿ Adjust the steering (see Steering Play Adjustment).
Electrical System
Spark Plug Condition Inspection
Ÿ Remove the spark plugs (see Spark Plug Replacement).
2-36
Ÿ Visually inspect the spark plugs.
« If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged,
or if the insulator [C] is cracked, replace the plug.
« If the spark plug is dirtied or the carbon is accumulated, replace the spark plug.
Ÿ Measure the gap [D] with a thickness gauge.
« If the gap is incorrect, replace the spark plug
Spark plug clearance: 0.7mm~ 0.9mm (0.028in~0.035in)
Ÿ Use the standard spark plug or its uivalent.
Spark plug: CR8EI
A
Lights and Switches Operation Inspection
First step
Ÿ Turn the ignition switch on
Ÿ The following light should be on according to
below table.
Position light [A] on
Taillight[B] on
Rear license light [C] on
Dashboard LCD[F] on
Neutral indicator（LED）[E] on
on
MIL（LED）[D]
for about 5s 2
« If the light does not on. Inspect or replace the
following item.
B
Battery(See electrical system chapter charg-
ing inspection)
Applicable bulb(LED) (See wiring diagram on C
electrical chapter)
LCD dashboard (Refers to dashboard inspec-
tion in electrical system chapter)
Neutral indicator light(LED)(See dashboard
inspection on electrical system chapter)
EFI indicator (LED)(See dashboard inspec- D
tion on electrical system chapter)
ECU(See ECU inspection on EFI system
chapter)
Main fuse 20A and taillight fuse 10A (See fuse
inspection on electrical system chapter)
Ignition switch (See switch inspection in elec-
trical chapter) F
F
2-37
CFMOTO
Neutral switch(See switch inspection in electrical chapter)
Wire(See wiring inspection on electrical system chapter).
Ÿ Ignition switch off
Ÿ All the indicators should be off
« Replace the ignition switch if not off.
Second step
ŸTurn the ignition switch[A]on and turn the posi-
tion light [B] on. A
ŸThe position light, tail light and licence light
should be on.
«If the light does not on. Inspect or replace
B
the item below.
Ignition switch or right handlebar switches or
inspect the wire (See switch inspection in
electrical system chapter)
Third step
ŸTurn the steering indicating light on[D](LH or
RH).
ŸAccorading to the switch position. Steering
indicator [E] should be blinking.
ŸThe indicator in the dashboard [F] should be
blinking.
«If the light doesn’t blinking. Inspect or replace E
the item below.
Steering indicator light bulb(See steering in-
dicator light bult on electrical system chapter)
Steering indicator(LED)(See dashboard in-
spection in electrical system chapter)
Flasher fuse 15A(See fuse inspection on
Steering indicator switch(See switch inspec-
tion in electrical system chapter) F
Flash ( See inspection on electrical system
chapter)
Cable (See cable inspection on electrical sys-
tem chapter)
Ÿ Press steering indicator switch.
ŸSteering indicator and indicating light should
be off.
2-38
«If the light does not off. Inspect or replace the item below.
Steering signal switch(See switch inspection in electrical system chapter)
Flash (See flash relay inspection on electrical system chapter)
Fourth step
ŸTurn the dimmer switch to low beam
ŸStart the engine.
ŸLow beam headlight should be on.
«If low beam is not on. Inspect or replace the item below.
Low beam bulb of headlight.(See headlight bulb replacement in electrical system chapter)
Headlight relay fuse 10A (See fuse inspection in electrical system chapter)
Dimmer switch (See switch inspection in electrical system chapter)
Headlight relay(See headlight relay inspection in electrical system chapter).
Wire(See electrical system chapter).
Ÿ Turn dimmer switch to highbeam.
Ÿ Low beam [A] and high beam [B] headlight

should be on.
Ÿ Highbeam indicator(LED)[C] should be on. A
« If highbeam head light and/or indicator is not
on. Inspect or replace the item below.
Highbeam bulb of headlight (See headlight B
bulb replacement in electrical system chapter)
Dimmer switch(See switch inspection in
2
Ÿ Turn the engine stop switch off
Ÿ Low beam and high beam headlight should
be on.
« If high beam and low beam indicator goes
C
off. Inspect or replace the item below.
Headlight relay (See high beam and low
beam relay inspection in electrical system
chapter)
Ÿ Turn the ignition switch off.
Ÿ High beam indicator(LED)should be off.
Headlight axis inspection

Ÿ Inspect the ray axis.
« If the axis point to one side insdead of
straight ahead.
Adjust the horizontal axis
2-39
CFMOTO
Headlight axis horizontal adjustment
Ÿ Use screwdriver to turn the horizontal adjuster on
headlight [A] Until the axis straight ahead. If the head-
light too low or too high. Adjust the vertical adjuster.
Headlight axix vertical adjustment
Ÿ Use screw driver to turn the vercital adjuster [A]
To adjust the headlight.
NOTE:
○ For high beam headlight, when driver on
the seat, the axis of headlight should be a
little lower then horizontal point.
Adjust headlight angel according to the lo-
cal law.
Side stand switch inspection

•Inspect the side stand switch[A] accord-
ing to the form below.
Side stand operation
Side Gear Clutch Engine Engine
stand start running
Up Neutral Release Start run
Up run
Neutral Tight Start
Up Not
Release Cannot Stop
neutral start
Up Not run
Tight Start
neutral
Down Neutral Release Start run
Down Neutral Tight Start run

A
Not Cannot
Down Release Stop
neutral start
Not Cannot
Down Tight Stop
neutral start
2-40
«If sidestand is normal but the engine still
cannot work. Inspect or replace the item
below.
Battery (See charging inspection in electri-
cal system chapter)
Main fuse 20A (See fuse inspection in elec-
trical system chapter)
Fuel pump relay fuse 15A (See fuse inspec-
tion in electrical system chapter)
Ignition switch (See switch inspection in
Side stand switch (See switch inspection
in electrical system chapter)
Engine stop switch (See switch inspection
Start button (See switch inspection in elec-
trical system chapter)
Neutral switch (See switch inspection in A
Starting relay (See start system inspection
2
Relay box (See relay inspection in electri-
cal system chapter)
Auxilary relay (See start system inspection
Wire (See wire inspection in electrical sys-
tem chapter)
« If all the parts are OK. Replace the ECU.
(See ECU replace ment on EFI chapter)
Engine stop switch inspection

First step
ŸTurn on the ignition switch.
Ÿ Set the vehicle on N gear.
Ÿ Set the engine stop switch to start position
Ÿ Press the start button and run the engine
Ÿ Set the engine stop switch to stop position
Ÿ Stop engine immediately.
« If the engine is still running. Inspect or re-
place the item below.
2-41
CFMOTO
Engine stop switch. (See switch inspection in electrical system chapter)
« If the switch is OK, Replace the ECU (See ECU replace ment on EFI chapter)
Others
Chassis lubrication
Ÿ Before lubricate the parts. Use the clean-
ing solution to clean up the rustese, grease,
oil, dust and dirt.
Ÿ Use named lubricant to lubricate the points
below.
Note
○ Use normal lubricant whenever the humit,
rainy or washed.
Points: Lubricate with Grease

Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand
Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends
[A]
Throttle Inner Cable Upper and Lower Ends
Cables: Lubricate with Rust Inhibitor.

Clutch Cable
Throttle Cables
Ÿ Lubricate the cables by seeping the oil
between the cable and housing
○ The cable may be lubricated by using a
commercially available pressure cable lubri-
cator with an aerosol cable lubricant. With
the cable disconnected at both ends, the in-
ner cable should move freely [A] within the
cable housing.
« If cable movement is not free after
lubricating, if the cable is frayed [B], or if the
cable housing is kinked [C], replace the cable.
2-42
Bolts, Nuts and Fasteners Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin
is in place and in good condition.
NOTE
○ For the engine fasteners, check the tightness of them when the engine is cold (at room
temperature).
« If there are loose fasteners, retighten them to the specified torque following the specified
tightening sequence. Refer to the appropriate chapter for torque specifications. If torque speci-
fications are not in the appropriate chapter, see the Standard Torque Table. For each fastener,
first loosen it by 1/2 turn, then tighten it.
« If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Nut
Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting
Bolts
Wheels:
Front Axle
Front Axle Clamp Bolt
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes: 2
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolt and Nut
Swingarm Pivot Shaft Nut
Steering:
Steering Stem Head Bolt
Handlebar Holder Bolts
Others:
Footpeg Stay Bolts
Front Fender Bolts
Sidestand Bolt
2-43
CFMOTO
Parts Replacement
Air Filter Element Replacement
Ÿ Refer to the Air Cleaner Element Cleaning
Fuel hose Replacement
WARNING
When removing and installing the fuel line
joint, do not apply strong force to the outlet
pipe on the fuel pump and delivery pipe on
the throttle body assy. The pipes made from
resin could be damaged.
Ÿ Remove the fuel tank (see Fuel Tank Re-

moval in the Fuel System (EFI) chapter).
Ÿ Pull the fuel pipe joint[A] out from the pump
[B].
WARNING
Be prepared for fuel spillage; any spilled fuel
must be completely wiped up immediately.
When the fuel line is disconnected, fuel spills
out from the line and the pipe. Cover the line
connection with a clean shop towel to
prevent fuel spillage.
Install the new fuel hose

Ÿ Insert [A] the fuel hose joint [B] straight onto
the delivery pipe until the hose joint clicks.
Ÿ Push and pull the fuel hose joint back and
forth more than two times and make sure it
is locked and doesn’t come off.
«If it comes off, reinstall the hose joint.
Ÿ Run the fuel line correctly.(See the wires ,
cables and pipe goes in attached chapter)
Ÿ Install the removed parts (see appropriat
chapters).
Ÿ Start the engine and check the fuel hose for
leaks.
WARNING
Make sure the fuel hose joint is installed
correctly on the delivery pipe or the fuel
could leak.
2-44
Coolant Change
WARNING
To avoid burns, do not remove the
radiator cap or try to change the coolant
when the engine is still hot. Wait until it
cools down. Coolant on tires will make
them slippery and can cause an accident
and injury. Immediately wipe up or wash
away any coolant that spills on the frame, B
engine, or other painted parts. Since
coolant is harmful to the human body, do
not use for drinking.
A
Ÿ Removal:
Right Center Fairing (see Center Fairing
Removal in the Frame chapter)
Lower Fairing (see Lower Fairing Removal
in the Frame chapter)
Reserve Tank Bolts [A]
Reserve Tank [B]
Put a tank under the leaking bolt [C]. Then

2
remove the leaking bolt.
2-45
CFMOTO
Ÿ Remove the rediator cap [A] by 2 steps. First
turn the cap counterclockwise to the first stop.
Then push and turn it further in the same di-
rection and remove the cap.
ŸThe coolant will drain from the radiator
and engine. A
ŸTurn over [A] the reservoir tank, remove the
cap, and pour the coolant into a suitable
container.
Ÿ Place the reserve tank on the right side of
frame.
ŸTighten the drain bolt with the gasket.
○Replace the drain bolt gasket with a new
one.
Torque - Water Pump Drain Bolt:
7.0N·m (0.70kgf·m, 62in·lb)
Ÿ When filling the coolant, choose a suit-
B
able mixture ratio by referring to the cool-
ant manufacturer’s directions.
CAUTION
Soft or distilled water must be used with the
antifreeze in the cooling system.
If hard water is used in the system, it causes
scales accumulation in the water passages,
and considerably reduces the efficiency of
the cooling system.
Water and Coolant Mixture Ratio
(Recommended)
Soft Water: 50%
Coolant: 50%
Freezing Point: –35°C (–31°F)
Total Amount: 1.7L (1.8USqt)
Ÿ Fill the radiator up to the filler neck [A] with
coolant.
NOTE
○ Pour in the coolant slowly so that it can
expel the air from the engine and radiator.
Ÿ Check the cooling system for leaks.
Ÿ Tap the radiator hoses to force any air
bubbles caught inside.
Ÿ Fill the radiator up to the filler neck with
coolant.
2-46
ŸTemporarily install the reserve tank to the
frame with two bolts.
ŸFill the reserve tank up to the “F” (full) level
B
line [A] with coolant and install the cap [B].
ŸStart the engine, warm it up thoroughly until
the radiator fan turns on and then stop the
engine.
A
ŸCheck the coolant level in the reserve tank
after the engine cools down.
«If the coolant level is lower than the “L” level
line, add coolant to the “F” level line.
CAUTION
Do not add more coolant above the
Do not add more coolant above the "F"
Level line.
Radiator Hose and O-ring Replacement

ŸDrain the coolant (see Coolant Change).
ŸRemoval:
Thermostat Housing [A] (see Water Pump
Removal in the Cooling System chapter)
Water Pump Cover [B] (see Water Pump
Removal in the Cooling System chapter)
2
Hoses [C]
O-rings [D]
ŸApply grease to the new O-rings and install
them.
Installation
ŸInstall the new hoses and tighten the clamps
securely.
ŸFill the coolant (see Coolant Change).
ŸCheck the cooling system for leaks.
2-47
CFMOTO
Engine Oil Replacement
Ÿ Place the motorcycle vertically after warm-
ing up the engine.
Ÿ Unscrew the oil filler plug [A].
A
Ÿ Place on oil pan beneath the engine.
Ÿ Remove the engine oil drain bolt [B] to drain
the oil.
○The oil in the oil filter can be drained by
r em ov in g th e filte r (s ee Oil Filte r
Replacement).
Replace the drain bolt gasket with a new
one.
Ÿ Tighten the drain bolt.
Torque - Engine Oil Drain Bolt:

30N·m (3.0kgf·m, 22ft·lb) B
ŸPour in the specified type and amount of
oil.
Recommended Engine Oil

Type: ELF,10W-40/SJ level JASO MA2
Capacity: 2.2 L (2.3 US qt) (when filter is
removed)
2.6 L (2.7 US qt) (when engine is com-
pletely dry)
NOTE
○ Although SAE15W-40 engine oil is the
recommended oil for most conditions, the oil
viscosity may need to be changed to accom-
modate atmospheric conditions in your riding
area.
Ÿ Check the oil level (see Oil Level Inspec-
tion in the Engine Lubrication System
chapter).
Oil Filter Replacement

Ÿ Drain the engine oil (see Engine Oil
Change).
ŸRemove the oil filter [A] with the oil filter
wrenc [B].
Special Tool - Oil Filter Wrench
2-48
Ÿ Replace the filter with a new one.
Ÿ Apply engine oil to the gasket [A] before A
installation.
Ÿ Tighten the filter with the oil filter wrench.
Torque - Oil Filter: 17N·m (1.75kgf·m,
13ft·lb)
NOTE
○ Oil filter can not be tightend by hand since
it does not reach to specified tightening
torque.
Ÿ Pour in the specified type and amount of
oil (see Engine Oil Change).
B
Brake Hose and Pipe Replacement
CAUTION C
Brake fluid quickly ruins painted plastic
surfaces; any spilled fluid should be
completely washed away immediately.
B
Ÿ When removing the brake hose, take care
not to spill the brake fluid on the painted or
plastic parts.
Ÿ When removing the brake hoses [C].tem-
2
porarily secure the end of the brake hose to
C
some high place to keep fluid loss to a
minimum.
Ÿ Immediately wash away any brake fluid that
spills.
Brake Fluid Replacement
NOTE
D
○ The procedure to change the front brake
fluid is as follows. Changing the rear brake E
fluid is the same as for the front brake.
Ÿ Level the brake fluid reservoir. B
Ÿ Remove the reservoir cap and diaphragm.
Ÿ Remove the rubber cap from the bleed valve
[D] on the caliper.
Ÿ Attach a clear plastic hose [E] to the bleed
valve.and run the other end of the hose into a
container.
Ÿ Fill the reservoir with fresh specified brake
fluid.
2-49
CFMOTO
ŸChange the brake fluid.
○Repeat this operation until fresh brake fluid
comes out from the plastic hose or the color
of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
NOTE
○The fluid level must be checked often dur-
ing the changing operation and replenished
with fresh brake fluid. If the fluid in the reser-
voir runs out any time during the changing
operation, the brakes will need to be bled
since air will have en tered the brake line.
○Front Brake: Repeat the above steps for
the other caliper.
ŸRemove the clear plastic hose.
ŸInstall the diaphragm and reservoir cap.
ŸTighten
Torque - Front Brake Reservoir Cap
Screws
1.0N·m (0.10kgf·m, 9in·lb)
ŸFollow the procedure below to install the
rear brake fluid reservoir cap correctly.
○ Use criss cross screw driver [C] to tight
the screw [D].
Torque - Bleed Valve: 7.8N·m
(0.80kgf·m, 69in·lb)
ŸAfter changing the fluid, check the brake for
good braking power, no brake drag, and no
fluid leakage.
«Bleed the air from the lines is a must.
Ÿ Replace Master Cylinder Rubber Parts
Front Master Cylinder Disassembly
ŸRemove the front master cylinder (see Front
Master Cylinder Removal in the Brakes
chapter).
ŸRemove the reservoir cap and diaphragm,
and pour the brake fluid into a container.
2-50
ŸUnscrew the locknut and pivot bolt, and remove the brake lever.
ŸPull the dust cover [A] out of place, and remove the circlip [B].
Special Tool - Inside Circlip Pliers
ŸPull out the piston [C], secondary cup [D], primary cup [E], and return spring [F].
Rear Master Cylinder Disassembly

NOTE
○Do not remove the push rod clevis for mas-
ter cylinder disassembly since removal
reguires brake position adjustment.
Remove rear master cylinder
Remove dust cover and circlip.
Pull out the push rod with the piston stop.
ŸTake off the piston [A], secondary cup [B],
primary cup [C] and return spring [D].
CAUTION
Do not remove the secondary cup from the
piston since removal will damage it.
Master Cylinder Assembly
Ÿ Before assembly, clean all parts including
the master cylinder with brake fluid or alcohol. 2
CAUTION
Except for the disc pads and disc, use only
disc brake fluid, isopropyl alcohol, or ethyl
alcohol for cleaning brake parts. Do not use
any other fluid for cleaning these parts.
Gasoline, engine oil, or any other petroleum
distillate will cause deterioration of the rubber
parts. Oil spilled on any part will be difficult to
wash off completely, and will eventually
deteriorate the rubber used in the disc brake.
Ÿ Apply brake fluid to the new parts and to the

inner wall of the cylinder.
Ÿ Take care not to scratch the piston or the
inner wall of the cylinder.
Ÿ Tighten the brake lever pivot bolt and locknut.
Ÿ Apply silicone grease.
Ÿ Brake Lever Pivot Bolt
Ÿ Tighten:
Torque - Brake Lever Pivot Bolt:
1.0N·m (0.10kgf·m, 9in·lb)
Brake Lever Pivot Bolt Locknut:
6.0N·m 90.60kgf·m, 52in·lb)
2-51
CFMOTO
Caliper Rubber Parts Replacement
Front Caliper Disassembly
Ÿ Removal:
Front Caliper (see Front Caliper Removal in
the Brakes chapter)
Brake Padal (see Front Brake Pad Re-
moval in the Brakes chapter)
Ÿ Using compressed air, remove the pistons.
○ Cover the piston area with a clean, thick
cloth [A].
○Blow compressed air [B] into the hole for
the banjo bolt to remove the piston.
WARNING
To avoid serious injury, never place your
fingers or palm in front of the piston. If you
apply compressed air into the caliper, the
piston may crush your hand or fingers.
○Pull out the pistons by hand.
Ÿ Remove the dust seals [A] and fluid seals
[B].
Ÿ Remove the bleed valve [C] and rubber cap
[D].
NOTE
○ If compressed air is not available, with the
brakehose still attached, apply the brake le-
ver toremove the piston. The remaining pro-
cess is asdescribed above.
Front Caliper Assembly
Ÿ Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol.
Ÿ Install the bleed valve and rubber cap.
Ÿ Torque - Bleed Valve:
7.8N·m (0.80kgf·m, 69in·lb)
Replace the fluid seals [A] with new ones.
○ Apply brake fluid to the fluid seals, and

install them into the cylinders by hand.
ŸReplace the dust seals [B] with new ones
if they are damaged.
Ÿ Apply brake fluid to the dust seals, and
install them into the cylinders by hand.
2-52
ŸApply brake fluid to the outside of the pistons,
and push them into each cylinder by hand.
ŸCheck the shaft rubber friction boot [A] and
the dust cover [B] replace them with new ones
if they are damaged.
Ÿ Apply a thin coat of PBC (Poly Butyl
Cuprysil) grease to the caliper holder shafts
[C] and holder holes [D] (PBC is a special
high-temperature, water-resistance grease).
ŸInstall the anti-rattle spring [A].
ŸInstall the pads (see Front Brake Pad Instal-
lation in the Brakes chapter).
ŸWipe up any spilled brake fluid on the cali-
per with wet cloth.
Rear Caliper Disassembly

ŸRemove the rear caliper (see Rear Caliper
Re moval in the Brakes chapter).
ŸRemove the pads and anti-rattle spring (see
Rear Brake Pad Removal in the Brakes
chapter).
ŸUsing compressed air, remove the piston. 2
○Cover the piston area with a clean, thick
cloth [B].
○Blow compressed air [A] into the hole for
the banjo bolt to remove the piston.
ŸRemove the dust seal and fluid seal.
ŸRemove the bleed valve and rubber cap.
NOTE
○If compressed air is not available, with the
brake hose still attached, apply the brake
pedal to remove the piston. The remaining
process is as described above.
Rear Caliper Assembly
ŸClean the caliper parts except for the pads.
ŸInstall the bleed valve and rubber cap.
ŸTorque - Bleed Valve ：7.8N·m（0.

80kgf·m，69in·lb）
ŸReplace the fluid seal [A] with a new one.
○Apply brake fluid to the fluid seal, and install
2-53
CFMOTO
it into the cylinder by hand.
ŸReplace the dust seal [B] with a new one if
it is damaged.
○Apply brake fluid to the dust seal, and in-
stall it into the cylinder by hand.
ŸApply brake fluid to the outside of the piston,
and push it into the cylinder by hand.
ŸReplace the shaft rubber friction boot [A]
and dust cover [B] if they are damaged.
Ÿ Apply a thin coat of PBC (Poly Butyl
Cuprysil) grease to the caliper holder shafts
[C] and holder
holes [D] (PBC is a special high temperature,
water-resistance grease).
ŸInstall the anti-rattle spring [A] in the caliper
as shown.
ŸInstall the pads (see Rear Brake Pad Instal-
lation in the Brakes chapter).
ŸWipe up any spilled brake fluid on the cali-
per with wet cloth.
Spark Plug Replacement

ŸRemoval:
Ignition Coils (see Ignition Coil (Ignition Coil
together with Spark Plug Cap) Removal in
ŸRemove the spark plugs using the 16 mm
plug wrench [A].

Owner’s Tool - Spark Plug Wrench 16mm
ŸInsert the spark plug vertically into the plug
hole with the spark plug installed in the plug
wrench [A].
Owner’s Tool - Spark Plug Wrench, 16 mm
ŸTighten:
Torque - Spark Plugs: 15N·m(1.5kgf·m,
11ft·lb)
ŸInstallation
Ignition Coils (see Ignition Coil (Ignition Coil
together with Spark Plug Cap) Installation in
2-54
3-1 EFI System
3-1 EFI SYSTEM(64 pin ECU for CF650-3)

EFI System …………………………………………………………………………………3-2
ECU Pin Function …………………………………………………………………………3-4
EFI Specification……………………………………………………………………………3-6
Service Tool…………………………………………………………………………………3-8
EFI Service Precautions……………………………………………………………………3-10
EFI Trouble Shooting………………………………………………………………………3-11
Overview………………………………………………………………………………3-11
Outline ………………………………………………………………………………3-15
Self-diagnosis Outline ………………………………………………………………3-16
EFI System Trouble Shooting Guide…………………………………………………3-17
EFI System Self-diagnosing ………………………………………………………………3-26
Self-diagnosing Overview……………………………………………………………3-26
Trouble Code …………………………………………………………………………3-29
Trouble Shooting………………………………………………………………………3-31
EFI Parts Service ……………………………………………………………………………3-32
Throttle Body …………………………………………………………………………3-32
T- MAP Sensor…………………………………………………………………………3-36
Water Tempreture Sensor ………………………………………………………… 3-39
Trigger…………………………………………………………………………………3-41 3
Speed Sensor…………………………………………………………………………3-42
Roll-over Sensor ………………………………………………………………………3-44
Oxygen Sensor ………………………………………………………………………3-46
Ignition Coil ……………………………………………………………………………3-49
Trouble Indicator Light…………………………………………………………………3-51
ECU ……………………………………………………………………………………3-53
High Pressure Fuel Pipe………………………………………………………………3-56
Fuel Pump ……………………………………………………………………………3-58
Fuel Injector……………………………………………………………………………3-64
Throttle Cable and Throttle Lever……………………………………………………3-69
Throttle Body Assy……………………………………………………………………3-70
3-1
CFMOTO
△FUEL SYSTEM (EFI) Composition of EFI
3-2
3-1 EFI System
1. Ignition Switch
2. Engine Stop Switch
3. Starter Relay
4. Tachometer
5. MIL(LED)
6. Spark Plug
7. Trigger(Crankshaft Position Sensor)
8. Fuel Injector
9. Throttle Position Sensor
10. Fuel Rail
11. Throttle Body Valve
12. Fuel Pump
13. Pressure Regulator
14. Fuel Tank
15. Air Filter Element
16. Inlet Air Temperature Sensor
17. Air Filter Housing
18. Neutral Switch
19. Speed Sensor
20. Roll-over Sensor
3
21. Oxygen Sensor
22. Battery
23. ECU
24. Inlet Airf low Direction
25. Pressurized Fuel Direction
26. Coolant Temperature Sensor
3-3
CFMOTO
ECU Pin and Function
ECU pin and function

1(Q1) Null 26(L2) Throttle position sensor
2(P1) Oxygen sensor 1 heating 27(K2) Clutch switch
3(Q2) Ignition Coil 1 28(J2) Null
4(P2) Oxygen sensor 2 heating 29(H2) Oxygen Sensor 2
5(Q3) Ignition ground wire 30(G2) Null
6(P3) Null 31(F2) Null
7(Q4) Ignition coil 2 32(E2) Main Relay
8(P4) Uncontinuous power 33(D2) Null
9(O1) Engine RPM output 34(C2) Null
10(N1) Null 35(B2) Stepper motor phase C
11(M1) Roll-Over switch 36(A2) Stepper motor phase D
12(L1) Null 37(O3) Carbon solenoid valve
13(K1) Confort/Sport mode switch 38(N3) Null
14(J1) Neutral Switch 39(M3) Ground to sensors1
15(H1) Cable K diagnosis 40(L3) Ground to sensors2
16(G1) Continuous power 41(K3) Coolant temperature sensor
17(F1) Ignition switch 42(J3) Side stand switch
18(E1) 5V Power 2 43(H3) Ground to electric
19(D1) 5V Power 1 44(G3) Null
20(C1) MIL Light 45(F3) Oxygen Senor 1
21(B1) Stepper motor phase B 46(E3) Engine phase sensor B
22(A1) Stepper motor phase A 47(D3) Engine phase sensor A
23(O2) Null 48(C3) Power to ground
24(N2) Null 49(B3) Injector 2
25(M2) Air inlet temperature signal 50(A3) Injector 1
3-4
3-1 EFI System
ECU pin and function
51(O4) Uncontinuous power

52(N4) Auxiliary Relay
53(M4) Null
54(L4) Ground to Sensors 3
55(K4) Null
56(J4) Null
57(H4) Null
58(G4) Null
59(F4) Air intake pressure sensor
60(E4) Oil pump sensor
61(D4) Null
62(C4) Fan Relay
63(B4) Unused
64(A4) Unused
3-5
CFMOTO
EFI Specifications
Item Standard
EFI
Idle Speed 1 450 r/min ±145 r/min (rpm)
Throttle Body Assy:
Type Two barrel type
Bore Ф38 mm
ECU:
Make UAES
Type Digital memory type, with IC igniter,
sealed with resin
Available Engine Speed 100 r/min~11 000 r/m in (rpm)
Fuel Pressure (High Pressure

Line):
After Ignition Switch is ON 323 kPa (3.3 kgf/cm2, 47 psi) with fuel
pump running.
After 3 Seconds from Ignition Switch 265 kPa (2.7 kgf/cm2, 38 psi) with fuel
is ON pump stopped
With Engine Idling 333 kPa (3.4 kgf/cm2, 48 psi) with fuel
pump running
Fuel Pump:
Type In-tank friction pump
Leakage 60 mL or more in every 3 seconds
Fuel Injectors:
Type F01R00M139
Nozzle Type One spray with 4 holes
Resistance About 12 Ω at 20°C (68°F)
Throttle Position Sensor Non-adjustable and non-movable
Input Voltage 4.75V~5.25V DC between Lg/Y and Gr /R
Output Voltage at Idle Throttle 0.34V~ 0.64V DC between Lg /Y and Br/R
Opening
Output Voltage at Full Throttle More than or equal to 4V DC between Lg
Opening /Y and Br/R
Inlet Air Temperature Sensor:

Resistance See text in Inlet Air Temperature Sensor
Section
Output Voltage at ECU About 2.5 V ~3.50 V at 20°C
Coolant Temperature Sensor:
Resistance See Electrical System chapter
Speed Sensor:
Input Voltage at Sensor About 9V~11V DC at Ignition Switch is ON
Output Voltage at Sensor About 0.05V~1V DC at Ignition Switch is
ON and speed at 0 km/h
Roll-Over Sensor：
Detection Method Resistance detection method
Detection Angle More than 55 °~75 ° for each bank
3-6
3-1 EFI System
EFI Specifications
Item Standard
Oxygen Sensor:
Output Voltage (high) 0.7V or higher
Output Voltage (low) 0.2V or lower
Throttle Grip and Cables
2mm~3mm (0.08 in~0.12 in.)
3-7
CFMOTO
Maintanence Tool
Oil Pressure Gauge Needle Adaptor Set
Throttle Sensor Setting Harness Hand Tester
T-joint Fuel Hose
Peak Voltage Adapter
3-8
3-1 EFI System
EFI Servicing Precautions
There are some important precautions that
should be followed when service the EFI
system.
● This EFI system is designed to be used
with a 12 V sealed battery as its power source.
Do not use any other battery except for a 12
V sealed battery as a power source.
● Do no t r everse t he bat te ry cab le
connections. This will damage the ECU.
● To prevent damage to the EFI parts, do
not disconnect the battery cables or any other
electrical connections when the ignition
switch is on or while the engine is running.
● Take care not to short the leads that are
directly connected to the battery positive (+)
terminal to the chassis ground.
● When charging, remove the battery from
the motorcycle. This is to prevent ECU dam-
age by excessive voltage.
● Do not turn the ignition switch ON while 3
any of the EFI electrical connectors are
disconnected. The ECU memorizes service
codes.
● Do not spray water on the electrical parts,
EFI parts, connectors, leads, and wiring
● Whenever the EFI electrical connections
are to be disconnected, first turn off the igni-
tion switch, and disconnect the battery (-)
terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the EFI
electrical connections are firmly reconnected
before starting the engine.
● Connect these connectors until they click
[A].
●If a transceiver is installed on the vehicle,
makesure that EFI system operation is not
influenced by electric wave radiated from the
antenna. Check operation of the system with
the engine at idle. Locate the antenna as far
as possible away from the ECU.
3-9
CFMOTO
● When any fuel hose is disconnected, fuel
may spout out by residual pressure in the
fuel line. Cover the hose joint with a piece
of clean cloth to prevent fuel spillage.
● When any fuel hose is disconnected, do
not turn on the ignition switch. Otherwise,
the fuel pump will operate and fuel will
spout from the fuel hose.
● Do not operate the fuel pump if the pump
is completely dry.
●Before removing the fuel system parts,
blow the outer surfaces of these parts
clean with compressed air.
●To prevent corrosion and deposits in the
fuel system, do not add to fuel any fuel an
tifreeze chemicals.
To maintain the correct fuel/air mixture (F/

A), there must be no inlet air leaks in the EFI
system. Be sure to install the oil filler plug [A]
and Clutch Cover [B] properly after filling the
engine oil.
3-10
3-1 EFI System
EFI Malfunction Excluded
Outline
When an abnormality in the system occurs, the
MIL (LED) goes on to alert the rider on
the meter panel. In addition, the condition of the
problem is stored in the memory of the ECU
(electronic control unit). With the engine stopped
and turned in the self diagnosis mode, the ser-
vice code [A] is indicated by the number of times
the FI indicator light (LED) blinks.
When due to a malfunction, the MIL (LED) re-
mains lit, ask the rider about the conditions
[B] under which the problem occurred and try to
determine the cause [C].
First, conduct a self-diagnosis inspection and
then a non-self-diagnosis inspection. The non-
self-diagnosis items are not indicated by the MIL
(LED). Don’t rely solely on the EFI
self-diagnosis function, use common sense.
Even when the EFI system is operating normally,
the FI indicator light (LED) [A] may light up un- 3
der strong electrical interference. No repair
needed. Turn the ignition switch OFF to stop the
indicator light.
When the MIL (LED) goes on and the motorcycle
is brought in for repair, check the service codes. 650MT
When the repair has been done, the light (LED)

doesn’t go on. But the service codes stored in
memory are not erased to preserve the prob-
lem history, and the light (LED) can display the
codes in the self-diagnosis mode. The problem A
history is referred when solving unstable
problems.
When the motorcycle is down, the vehicle-down
sensor is turned OFF and the ECU shuts off the
fuel injectors and ignition system. The MIL(LED)
blinks but the service code cannot be displayed.
The ignition switch is left ON. If the starter button
is pushed, the electric starter turns but the en-
gine doesn’t start.
3-11
CFMOTO
To start the engine again, raise the motorcycle,
turn the ignition switch OFF, and then ON. The
vehicledown sensor is turned ON and the light
(LED) goes OFF.
●The DFI part connectors [A] have seals [B],
including the ECU.
●Join the connector and insert the needle
adapters[C] inside the seals [B] from behind
the connector until the adapter reaches the
terminal.
CAUTION
Insert the needle adapter straight
along the terminal in the connector to
prevent short-circuit between
terminals.
●Make sure that measuring points are cor-
rect in the connector, noting the position of
the lock [D] and the lead color before
measurement. Do not reverse connections of
the hand tester or a digital meter.
●Be careful not to short-circuit the leads of
the EFI or electrical system parts by contact
between adapters.
●Turn the ignition switch ON and measure
the voltage with the connector joined.
CAUTION
Incorrect, reverse connection or short

circuit by needle adapters could dam-
age the DFI or electrical system parts.
● After measurement, remove the needle
adapters and apply silicone sealant to the
s e a l s [ A] o f t h e co n n e ct o r [ B ] f o r
waterproofing.
● Always check battery condition before
replacing the EFI parts. A fully charged bat-
tery is a must for conducting accurate tests of
the EFI system.
●Trouble may involve one or in some cases
all items. Never replace a defective part with
3-12
3-1 EFI System
out determining what CAUSED the problem. If
the problem was caused by some other item or
items, they too must be repaired or replaced, or
the new replacement part will soon fail again.
● Measure the electrical resistance of the
coil after the EFI parts cool down.
●Make sure the electric connection clean
and tight.And check the wire if it got burned,
abrasion,too short and etc.Damaged cable
and bad connection can cause the trouble
comes out again and again and make the EFI
system running unstable.
●If the cable is damaged or aging. Please
replace the cable.
●Disconnect each connectors[A]And check
if there is any corrosion, dust or damaged.
●If connectors getting corrosions or dusted.
Please clean up carefully.If the connectors get-
ting damaged.Plase replace the connectors.
Connectors should be well connected.
●Check the wiring continuity. Use the wir- 3
ing diagram to find the trouble wire termination.
● Connect the AVO meter on wire
termination.
●Set the AVO meter on X1Ω mode. And
read out the data showing on AVO meter.
● If the data is not 0 Ω. Means the prob-
lem on cable.Replace the maincable or sec-
ondary cable.
●If the cable[A] is far. Use a Cable[D]Con-
nect [C] o the ground[B] and check another
connector[E] and[F] to make sure it is OK.
That can check the connection of the long
cable. If connection is poor, replace the cable.
●When check the cable[A] shortcut or not,
Open[B] side and check the connection from
another side [C] to [D]. If OK, the cable has
shortcut and needs repairing.
●Check the ECU connection again and again,
To make the trouble easier point out.
3-13
CFMOTO
●If the wire and connector has no trouble, then
EFI parts may be next point. Use input and out
put voltage checking way. But it cannot check
the ECU itself.
●If you find trouble, replace the trouble parts.
If the wire, connector and EFI parts has no
trouble. Replace the ECU
● Lead Color Codes:
B: Black L: Blue Gr: Grey
Br: Brown G: Green Lg: Light Green
Sb: Sky Blue O: Orange R: Red
P: Purple W: White Y: Yellow

There are two ways to inspect the EFI system.
One is voltage Check Method and the other
is Resistance Check Method.
(Voltage Check Method)
●This method is conducted by measuring
the input voltage [B] to a sensor [A] first and
then the output voltage [C] from the sensor.
●Sometimes this method can detect a fault
of the ECU.
●Refer to each sensor inspection section
for detail in this chapter.
●Use a fully charged battery and a digital
meter [D] which can be read two decimal
places voltage or resistance.
(Resistance Check Method)
●This method is simple. No need for a fully
charged battery and the needle adapter.
Just do the follow ing especially when a sen
sor [A] is suspect.
●Turn the ignition switch OFF and discon-
nect the connectors.
● Inspect the sensor resistance, using a «If the sensor, the wiring and connections
digital meter (see each sensor inspection). are good, inspect the ECU for its ground and
●Inspect the wiring and connectors [B] for power supply (see ECU Power Supply
continuity, using the hand tester [C] (analog Inspection). If the ground and power supply
tester) rather than a digital meter. are good, the ECU is suspect. Replace the
ECU.
3-14
3-1 EFI System
EFI Diagnosis Process Chart
Problem occurs.
Confirm problems.
Gather information from rider
The ignition switch is turned on, and the state of FI

indicator light (LED) is seen.
Unlit Lit
Conduct self-diagnosis inspection

Conduct non-self-diagnosis
Conduct general fuel

system inspection
3
(Fuel system includes:

Throttle body assy.、air
filter、fuel pump ect.) End
Inquiries to Rider
●Each rider reacts to problems in different ways, so it is important to confirm what kind of
symptoms the rider has encountered.
●Try to find out exactly what problem occurred under exactly what conditions by asking
the rider; knowing this information may help you reproduce the problem.
●The following sample diagnosis sheet will help prevent you from overlooking any areas,
and will help you decide if it is an EFI system problem, or a general engine problem.
3-15
CFMOTO
Sample Diagnosis Sheet：

Rider name: Registration No. (License plate No.):
Year of initial registration: Model:
Engine No.: Frame No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather fine, cloudy, rain, snow, always, other:
Temperature hot, warm, cold, very cold, always
Problem frequency chronic, often, once
Road street, highway, mountain road (uphill, downhill), bumpy,
Altitude normal, high (about 1000 m), higher(more than 2000m)
Motorcycle conditions when problem occurred.
FI indicator light up immediately after ignition switch ON, and goes off after 5s
light (LED) lights blinks 10s after ignition switch ON, and stays on (EFI problem)
light up 5s after ignition switch on，then blink 15 times and stay on
（indicate mantainence）
Non-lights (light (LED), ECU, speedometer or its wiring fault)
sometimes lights up (probably wiring fault)
Starting starter motor not rotating
difficulty starter motor rotating but engine doesn’t turn over
starter motor and engine don’t turn over
no fuel flow (no fuel in tank, no fuel pump sound)
engine flooded (do not crank engine with throttle opened, which
promotes engine flooding)
no spark
other
Engine stops after starting
when opening throttle grip
when closing throttle grip
when moving off
when stopping the motorcycle
when cruising
others
Bad operation very low idle speed, very high idle speed, rough idle speed
at low speed battery voltage is low (charge the battery)
spark plug loose (tighten it)
spark plug dirty, broken, or gap maladjusted (remedy it)
back firing
after firing
hesitation when acceleration
engine oil viscosity too high
brake dragging
3-16
3-1 EFI System
q clutch slipping
q others
q Poor runningq spark plug loose (tighten it)
or no power atq spark plug dirty, broke, or gap maladjusted (remedy it)
high speed q spark plug incorrect(replace it)
q knocking (fuel poor quality or incorrect，use high-octane gasoline)
q brake dragging
q clutch slipping
q engine overheated
q engine level too high
q engine oil viscosity too high
q others

NOTE
●This is not an exhaustive list, giving every possible cause for each problem listed. It is
meant simply as a rough guide to assist the troubleshooting for some of the more common
diffi culties.
●The ECU may be involved in the EFI electrical and ignition system troubles. If these parts
andcircuits are checked out good, be sure to check the ECU for ground and power supply. If
the ground and power supply are checked good, replace the ECU.
Engine Doesn’t Start, Starting Diffculty
3-17
CFMOTO
Symptoms or possible C auses Actions (chapter)

Starter motor doesn’t rotate:
Ignition and engine stop switches not ON Turn both switches ON .
Clutch switch or neutral switch trouble Inspect (see chapter 16).
Starter motor trouble Inspect (see chapter 16 ).
Low battery voltage Inspect and charge (see chapter 16)
Starter or auxiliary relays not contacting or
Inspect the starter relay (see chapter 16
operating
Starter button not contacting Inspect and replace (see chapter 16).
Starter system wiring o pen or shorted Inspect the wiring (see chapter 16).
Ignition switch trouble Inspect and replace (see chapter 16)
Engine stop switch trouble Inspect and repair or replace (see chapter 16).
Main 20A or ECU ignition fuse blown Inspect and replace (see chapter 16).
Starter motor rotating but engine
doesn’t turn:
Starter clutch trouble Inspect (see chapter 16).
Starter idle gear trouble Inspect (see chapter 16).
engine doesn’t turn:
Valve seizure Inspect and replace (see chapter 5).
Cylinder, piston seizu re Inspect and replace (see chapter 5).
Camshaft seizure Inspect and replace (see chapter 5).
Connecting rod small e nd seizure Inspect and replace (see chapter 9).
Connecting rod big end seizure Inspect and replace (see chapter 9).
Crankshaft seizure Inspect and replace (see chapter 9).
Transmission gear or b earing seizure Inspect and replace (see chapter 9).
Balancer bearing seizu re Inspect and replace (see chapter 9).
No fuel:
No or little fuel in tank Supply fuel (see Owner’s Manual).
Fuel pump not rotatin g Inspect (see chapter 3).
Fuel injector trouble Inspect and replace (see chapter 3).
Fuel filter or pump scre en clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator clogged Inspect and replace fuel pump (see chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Engine overflow:
Spark plug dirty, broken or gap maladjusted Replace (see chapter 2).
Starting technique fau lty W hen flooded, don’t crank engine with throttle
fully opened.
No spark or spark wea k:
Ignition and engine stop switches not ON Turn both switches ON
3-18
3-1 EFI System
Symptoms or possible Causes Actions (chapter)
Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral
whether side stand up or not
Though clutch lever pulled in, side stand up and Side stand down and clutch lever pulled in
gear not in neutral whether gear in neutral or not
Vehicle-down-sensor coming off Reinstall (see chapter 3).
Vehicle-down-sensor trouble Inspect (see chapter 3).
ECU ground or power supply trouble Inspect (see chapter 3).
low battery voltage Inspect and charge (see chapter 16).
Ignition coil trouble Inspect ignition coil (see chapter 16).
Stick coil shorted or not in good contact Reinstall or inspect stick coil (see chapter 16).
Spark plug incorrect Replace it with the correct plug (see chapter 16).
IC igniter in ECU trouble Inspect (see chapter 16).
Neutral, starter lockout or side stand switch Inspect each switch (see chapter 16).
trouble
Crankshaft sensor trouble Inspect (see chapter 16).
Ignition switch shorted Inspect and replace (see chapter 16).
Engine stop switch shorted Inspect and repair or replace (see chapter 2).
Starter system wiring shorted or open Inspect and repair or replace (see chapter 16).
Main 20A or fuse (15V) of fuel pump relay blown Inspect and replace (see chapter 16).
Fuel/air mixture is incorrect: 3
Air cleaner clogged, poorly sealed or missing Clean or reinstall (see chapter 3).
Leak from oil filler cap, crankcase breather hose Inspect and repair or replace (see chapter 3).
or air cleaner drain hose
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Fuel pressure may be low Inspect (see chapter 3).
Fuel pump trouble Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).
Cylinder pressure is low:
Spark plug loose Reinstall (see chapter 16).
Cylinder head not sufficiently tightened down Tighten (see chapter 5).
Cylinder, piston worn Inspect and replace (see chapter 5).
Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).
Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
Cylinder head gasket damaged Replace (see chapter 5).
3-19
CFMOTO
Symptoms or Possible Causes Actions (chapter)
Cylinder head warped Inspect and replace (see chapter 5).
No valve clearance Adjust (see chapter 2).
Valve guide worn Inspect and replace (see chapter 5).
Valve spring broken or weak Inspect and replace (see chapter 5).
Valve not seating properly (valve bent, worn Inspect and repair or replace (see chapter 5).
or carbon accumulating on seating surface)
Poor running at low speed
Spark weak:
Stick coil trouble Inspect the stick coil (see chapter 16).
Replace it with the correct plug (see chapter
Spark plug incorrect
16).
Crankshaft position sensor trouble Inspect (see chapter 16).
Fuel/air mixture is incorrect:
Little fuel in tank Supply fuel (see Owner’s Manual).
Air cleaner clogged, poorly sealed, or Clean element or inspect sealing (see chapter
missing (2,3)
Air cleaner duct loose Reinstall (see chapter 3).
Throttle body assy loose Reinstall (see chapter 3).
Throttle body sensor not calibrated or
Recalibrate (see diagnosis).
calibration is incorrect
Air inlet pipe damage Replace (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator clogged Inspect fuel pressure and replace fuel pump
(see chapter 3)
Thermostat trouble Inspect and replace (see chapter 4).
Unstable (rough) idling:
Throttle valves not synchronizing Inspect (see chapter 3).
Inlet air temperature sensor trouble Inspect (see chapter 3).
Coolant temperature sensor trouble Inspect (see chapter 3).
Fuel pressure too low or too high Inspect (see chapter 3).
3-20
3-1 EFI System
Incorrect idle speed:
Throttle body sensor not calibrated or calibration
is incorrect
Engine stalls easily:
see diagnosis
is incorrect
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump
(see chapter 3).
Stick coil trouble Inspect (see chapter 16).
Compression Low:
Cylinder head not sufficiently tightened down Tighten (see chapter 5). 3
Piston ring bad (worn, weak, broken or sticking ) Inspect and replace (see chapter 5).
Valve guide worn or stem seal damaged Inspect and replace (see chapter 5).
Valve not seating properly (valve bent, worn or Inspect and repair or replace (see chapter 5).
carbon accumulating on seating surface)
Camshaft cam worn Inspect and replace (see chapter 5).
Work with hesitation:
fuel pressure too low Inspect (see chapter 3
fuel line clogged Inspect and repair (see chapter 3).
Fuel pump trouble Inspect (see chapter 3
Fuel injector trouble Inspect (see chapter 3
Inlet air temperature sensor trouble Inspect (see chapter 3
Main throttle sensor trouble Inspect (see chapter 3
Coolant temperature sensor trouble Inspect (see chapter 3
injector connectors loose Remedy (see chapter 3).
Crankshaft position sensor trouble Inspect and repair or replace (see chapter 16).
Stick coil trouble Inspect and repair or replace (see chapter 16).
Loose terminal of battery (–) cable or engine Inspect and repair (see chapter 16).
3-21
CFMOTO
Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see
chapter 16).
Poor acceleration:
Fuel pressure too low Inspect (see chapter 3).
Water or other matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Stick coil trouble Inspect and replace (see chapter 16).
Engine oil level to high Repair (see chapter 7).
Spark plug dirty, broken or gap
Replace (see chapter 2).
maladjusted
Stumble:
Main throttle sensor malfunction Inspect (see chapter 3).
Surge:
Unstable fuel pressure Fuel pressure regulator trouble (Inspect and replace
fuel pump) or kinked fuel line (Inspect and repair fuel
line) (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 3).。
Backfiring when deceleration:
Spark plug dirty, broken or gap
maladjusted
After fire:
Spark plug burned or gap
maladjusted
3-22
3-1 EFI System

Loose terminal of battery (–) cable or ECU Inspect and repair (see chapter 16).
ground lead
Carbon accumulating on valve seating
Repair (see chapter 5).
surface
Engine overheating (see Overheating of Troubleshooting Guide, see
chapter 17)
Other:
Engine oil viscosity too high Change (see chapter 2).
Drive train trouble Inspect drive chain (see chapter 2) and sprocket
(See chapter 11).
Brake dragging Inspect caliper fluid seal damage or clogging of
master cylinder relief and supply ports (see chapter
12)
Clutch slipping Inspect friction plates for wear (see chapter 6).
chapter 17)
Intermittent any EFI fault and its recovery Check that EFI connectors are clean and tight, and
examine wires for signs of burning or fraying (see
chapter 3).
3
Poor Running or No Power at High Speed：
Firing incorrect:
Spark plug dirty, broken or maladjusted Replace (see chapter 2).
Stick coil trouble Inspect stick coil (see chapter 16).
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or
Clean element or inspect sealing (see chapter 3).
missing
Air cleaner O-ring damaged Replace (see chapter 3).
chapter 3).
Throttle body assy O-ring damaged Replace (see chapter 3).
Fuel pump operates intermittently and Pump bearings may wear. Replace the pump
often EFI fuse (15V)blows. (see chapter 3).
3-23
CFMOTO
Symptoms or Possible Causes

Actions (chapter)
tightened down
Fuel injector clogged Visually inspect and replace (see chapter 3).
Compression low:
Cylinder head not sufficiently Tighten (see chapter 5).
Piston ring bad (worn, weak, broken or
Inspect and replace (see chapter 5).
sticking)
Cylinder head gasket damaged Replace (see chapter 5) .
Valve not seating properly (valve bent , Inspect and repair or replace (see chapter 5).
worn
Knocking:
Carbon built up in combustion chamber Repair (see chapter 5).
Fuel poor quality or incorrect (Use the Change fuel (see chapter 3).
gasoline (See Owner’s Manual)
Others：
Throttle valves won’t fully open Inspect throttle cable and lever linkage (see
chapter 3).
12).
Engine overheating - Water temperature (See Overheating of Troubleshooting Guide in
sensor chapter 17).
Engine oil level too high Repair (see chapter 7)
Drive train trouble Inspect drive chain (see chapter 2) and sprockets
(see chapter 11).
3-24
3-1 EFI System
Symptoms or Possible Causes tightened down Actions (chapter)

Exhaust Smokes Excessively:
(White smokes)
Piston oil ring worn Inspect and replace (see chapter 5).
Cylinder worn Inspect and replace (see chapter 5).
Valve oil seal damaged Replace (see chapter 5)
Valve guide worn Replace the guide (see chapter 5).
Engine oil level too high Repair (see chapter 7).
Water into fuel

Symptom s or Possible
Cau ses Actions (chapter)
(B lack smoke)
Air cleaner cl ogged C lean (see chapter 3).
Too high fuel pressure Inspect (see chapter 3).
Injector s tuck open Inspect (see chapter 3).
Coolant temperature sensor trouble Inspect and replace (see chapter 3).
Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
3
3-25
CFMOTO
Self-diagnosis
Self-diagnosis Outline
ECU constantly monitor sensors, actuators
and circuits, MIL and battery voltage, etc, even
ECU itself and inspect the sensor output
signal, actuator drive signal and internal sig-
nal ( such as close loop control, coolant
temperature, idle speed control and battery
voltage control, etc.) for reliablity. If any pro-
cess or signal is suspect, ECU records the
trouble code in the RAM memory.
Faulty information is recorded in the form of
trouble code, and in the sequence of which
trouble comes first.
When servicing, using PDA and MIL, the de-
fective parts can be promptly foud to improve
the service efficiency and quality.
Self-diagnosis Procedures
When a problem occurs with the EFI system
and ignition system, the MIL (LED) [A] goes
on.
650MT
Note
Use a fully charged battery when conducting
self-diagnosis. Otherwise, the light (LED)
blinks very slowly or doesn’t blink.
A
MIL Flashing Conditions
IF: Turn on the ignition switch and the en-

gine does not work. No trouble code
appears:
●MIL keeps on for 4 seconds and then turns
off. Or start engine before MIL off.
gine dose not work. Trouble code appears:
●Diagnosing light keep on for 4s and off for
1s. Then blinking for 2Hz.
IF: Turn on the ignition switch and the engine
works. Trouble code appear:
●Diagnosing light blinking in 2Hz.
3-26
3-1 EFI System
Indicator light blinking control

Flashing code needs special function to become true. Before the engine start.(Speed is 0
and engine RPM is 0) Turn the throttle into full opened (Or throttle valve opened over 65.1)
And keep the throttle full opened. Then turn the ignition on. If the EMS hasn’t diagnose the
trouble out. The indicator light will be off after shining 4s. If the EMS diagnosed the trouble.
Indicator light will blinking the code. Trouble light will stop blinking for 1s between 2 numbers.
If EMS diagnosed two troubles at the same time. Indicator light will blinking from the
sequence of troubles. Between two trouble codes. Indicator light will be off for 4s. After
blinking all trouble codes. The light turns off automatically.
During the running of engine, MIL is on when system diagnoses fault parts, and flash fre-
quency is 2Hz. Restart ignition switch after engine flameout. If the system detected that the
fault is repaired, FI light will be on constantly until start engine. If the system still detected
fault, then FI light will be on for 4s and off for 1s, flashing frequency is 2Hz, until start engine.
Error Code Instruction

Fault codes based on five code. For example P0560. MIL through left side to right side at 1
Hz frequency showing fault. If one code is 0, MIL will flash 10 times. For example, error code
P0560 flash way is : light on for 4s and off for 1s- flash for 10 times-stop- flash for 5 times-
stop-flash for 6 times-stop-flash for 10 times. Error codeP0112,P0122 flash way: light on for
4s and off for 1s-flash for 10times-stop-flash for 1 time-stop-flash for 1 time-stop-flash for 2
times-off for 4s-flash for 10 times-stop-flash for 1 time-stop-flash for 2 times-stop-flash for 2
time-off.
3-27
CFMOTO
How to Erase Error Codes
●Even if ignition switch is turned off, the battery or the ECU is disconnected or the prob-
lem is solved, all trouble codes remain in ECU.
● For the current fault code, if a fault does exist, then the current fault code cannot be
eliminated; Restart the vehicle after troubleshooting eliminated, and advance the throttle
above 2500upm, fault light is off when failover.But previously fault still can be read by PDA
that had been stored in the system information, this information can be cleared directly
through PDA, or automatically cleared after five warm up cycle.(Warm up cycle means a
loop that water temperature is less than 51 degrees after engine start , and water tempera-
ture is higher than 71 degrees after warming )
●Refer to the eliminated parts of PDA error code to eliminated error code.
Diagnose error by PDA
PDA has many functions which is more intuitive, more accurately and more quickly than FI
light. We recommend you to use PDA for the following functions:
●PDA can read ”Error code” directly and eliminate them.
●PDA has the function of ”Read data stream” which can reflect vehicle operating situation,
and also judge EFI error.
●PDA with an "actuator test" function, you can use this feature to check the continuity of the
cable and whether the electronic fuel injection parts is good.
«PDA usage refer to chapter ”PDA Use”
3-28
3-1 EFI System
Trouble Code Chart
NO. Pcode Decription(UAES)

1 P0030 O2 Sensor 1 Heater Contr. Circ. Open
2 P0031 O2 Sensor 1 Heater Contr. Circ. Low
3 P0032 O2 Sensor 1 Heater Contr. Circ. High
Manifold Abs.Pressure or Bar.Pressure Low
7 P0107
Input
Manifold Abs.Pressure or Bar.Pressure High
8 P0108
Input
9 P0112 Intake Air Temp.Circ. Low Input
10 P0113 Intake Air Temp.Circ. High Input
11 P0117 Engine Coolant Temp.Circ. Low Input
12 P0118 Engine Coolant Temp.Circ. High Input
13 P0122 Throttle Pos.Sensor Circ. Low Input
14 P0123 Throttle Pos.Sensor Circ. High Input
15 P0130 O2 Sensor Circ.,Bank1-Sensor1 Malfunction
16 P0131 O2 Sensor Circ.,Bank1-Sensor1 low Voltage
17 P0132 O2 Sensor Circ.,Bank1-Sensor1 High Voltage
O2 Sensor Circ.,Bank1-Sensor1 No Activity
18 P0134
Detected
O2 Sensor Circ.,Bank1-Sensor2 No Activity 3
22 P0154
Detected
23 P0201 Cylinder 1- Injector Circuit
24 P0261 Cylinder 1- Injector Circuit Low
25 P0262 Cylinder 1- Injector Circuit High
29 P0322 Ign./Distributor Eng.Speed Inp.Circ. No Signal
30 P0480 cooling fan control Circuit Open
31 P0511 Idle Air Control Circui
32 P0560 System Voltage Malfunction
33 P0562 System Voltage Low Voltage
34 P0563 System Voltage High Voltage
35 P0627 Fuel Pump “A” Control Circuit /Open
36 P0629 Fuel Pump “A” Control Circuit High
37 P0650 Malfunction Indicator Lamp Control Circ.
38 P0691 cooling fan control Circuit Low
39 P0692 cooling fan control Circuit High
40 P0501 Vehicle Speed No Sensor
41 P1116 Engine Coolant Temp High
42 P0602 Control Module Programming Error
Engine Coolant Temp Sensor Circuit Range/
43 P0116
Performance
44 P1098 ROLL Sensor Malfunction
3-29
CFMOTO
Note:
●If all the parts and circuits checked out good, be sure to check the ECU for ground and
power supply. If the ground and power supply are checked good, replace the ECU.
●If theere is no trouble code is displayed, then the electrical parts of the EFI system has
no fault, but the mechanical parts of the EFI system and the engine are suspect.
3-30
3-1 EFI System
Solutions
The ECU takes the following measures to prevent engine damage when the EFI or the
ignition system parts have troubles.
Trouble Output Signal Unstable

Codes Parts Range or Criteria Backups by ECU
Inlet Air If the inlet air tem sensor fails(the signal

P0112 Temp is out of the usable range, wiring short
Inlet Air Temp
or
Sensor Ta=－40°C~+130°C or open), the ECU sets temperature at
P0113
40°C or 130°C ；
Coolant If the water temp sensor system fails(the
P0117 Temp signal is out of the usable range, wiring
Water Temp Sensor
or Sensor Tw=－40°C~+129°C short or open), the ECU sets Temp. at
P0118 -40°C or 129°C
The oxygen sensor is If the oxygen sensor is not activated or

P0130,
Oxygen active and sensor must correct, the ECU stops oxygen sensor
P0131, feedback mode.
Sensor send signals (output
P0132&
#1 voltage) continuously to
P0134
the ECU.
The oxygen sensor is
P0136,
Oxygen active and sensor must If the oxygen sensor is not activated or
3
P0137,
Sensor send signals (output correct, the ECU stops oxygen sensor
P0138&
#2 voltage) continuously to feedback mode.
P0140
the ECU.
3-31
CFMOTO
EFI System Service
Throttle Position Sensor Service
Throttle Position Sensor Removal/Adjust-
ment
CAUTION
Do not remove or adjust the throttle po-

sition sensor [A] since it has been ad-
justed and set with precision at the
factory.
Never drop the throttle body assy, espe-
cially on a hard surface. Such a shock to A
the sensor can damage it.
Throttle Position Sensor Input Voltage

Inspection
NOTE
●Be sure the battery is fully charged.
●Turn the ignition switch OFF.
● Disconnect the throttle position sensor
connector and connect the harness adapter
[A] between these connectors.
● Connect a digital meter to the harness
adapter lead.
●Measure the sensor input voltage with the
engine stopped and with the connector joined.
●Turn the ignition switch ON.
Connections to Adapter
Meter(+)→ Gr/R(C)
Meter(-)→ Lg/Y(D)
Standard： 4.75V～5.25V DC
（c o n n e c t o r o f f ）
Standard：4.0V～4.5V DC
（connector on）
«If the input voltage is normal, check the sen-
sor output voltage.
«If the input voltage is less than the standard,
remove the ECU and check the wiring be-
tween these connectors.
3-32
3-1 EFI System
● Disconnect ECU connector and throttle
position sensor connector.
●Using multimeter to test the continuity of
the 2 lead wires
ECU Connector[A]←→ Throttle Body
Connector[B]
Throttle Body ConnectorGr/R ←→ ECU
terminal 18
Throttle Body ConnectorLg/Y ←→ ECU
terminal 39
Standard：0 Ω
«If the wiring is good, check the ECU for its
ground and power supply (see ECU Power
Supply Inspection).
Main Throttle Sensor Output Voltage

Inspection
Measure the output voltage at the main
throttle sensor in the same way as input 3
voltage inspection, Note the following:
●Disconnect the main throttle sensor con-
nector and connect the harness adapter [A]
between these connectors.
●Start the engine and warm it up thoroughly.
（Ab o v e 8 0 ℃）。
● Check idle speed to ensure the throttle
opening is correct and adjust screw is ok.
Idle Speed Standard:
1450r/min ± 145r/min
range, adjust it (Inspect throttle cable and EFI
system). A
●Measure the output voltage of the sensor
with the engine stopped, and with the con-
nector joined.
3-33
CFMOTO
Throttle Service
Throttle Position Sensor Output Voltage
Meter(+)→ Br/R(sensor output) lead
Meter(+)→ Lg/Y((sensor ground)lead
Standard:
Idle throttle opening: 0.34V～0.64V DC
Full throttle opening：≥ 4V DC
«If the output voltage is out of the standard,

i n sp e c t t h e ma i n t hr o t t le se nso r
resistance.
«If the output voltage is normal, check the
wiring for continuity.
Wiring Connection
●Test the continuity of the 2 lead wires.

Connector[B]
Throttle Body Connector Br/R ←→ ECU
terminal 26
Throttle Body Connector Lg/Y ←→ ECU
terminal 39
Standard：0 Ω
Supply Inspection).
3-34
3-1 EFI System
Throttle Service
Throttle Position Sensor input Voltage
●Disconnect throttle position sensor con
nector
●Connect a hand tester [A] to the throttle
position sensor connector [B].
●Measure the throttle position sensor
resistance.
Main Throttle Sensor Resistance
Connections: Gr/R lead[C]←→ Br/R
lead[D]
Standard: 1 . 1 k Ω～1 . 4 k Ω（2 0 ℃）
«If the reading is out of the range, replace
the throttle body assy.
«If the reading is within the range, but the
problem still exists, replace the ECU (see
ECU Removal/ Installation).
1. ECU 2. TPS
3-35
CFMOTO
T-MAP Sensor Service
CAUTION
Never drop the sensor, especially on a
hard surface. Such a shock to the part
can damage
T-MAP sensor output voltage
inspection.
● Make sure the battery get fully charged
●The output voltage changement follows
the intake
tempchanging.
●Remove the ECU(See ECUremoval).Do
not disconnect theECUconnector.
● Use adapter to connecter and ECU.
● Stop the engine and meter connected.
Measure
the out put voltege.
● Turn the ignition switch on.
Intake temp sensor output voltage.
(Active line)
Meter(+) → W/Br( ECUpin 25)
Meter(-)→ L/G( ECUpin 40)
Standard: Output voltage when intake
temp 20℃
About 2.5V ~3.5V
Intakepressuresensor output voltage
(Dottedline)
Meter(+) → L/R(ECUpin 19)
Meter(-) → R/B(ECUpin 59)
Standard:Output voltagein normal
atmosphere.
About 4V~ 4.7V
Turnoff the ignitionswitch
theECU groundwireandpowerline
«f theoutput voltageisnot in standard.
(SeeECUpower inspection).
Remove the
«If the wires are OK. Inspect the intake
fuel tank and check the wire. If the output
temp sensor resistance.
voltage is
●Remove the adapter and use the sili-
5V.ECUis normal.
con glue to seal the connector avoid
«If theoutput voltage isin standard. Inspect
water.
3-36
3-1 EFI System
Inlet Air Temperature Sensor Service
Inlet Air Temperature Sensor Resistance
Inspection
● Remove the inlet air temperature sen-

sor
●Suspend the sensor [A] in a container of
machine oil so that the heat-sensitive por-
tion is submerged.
● Suspend a thermometer [B] with the
heatsensitive portion [C] located in almost
the same depth with the sensor.
NOTE
● The sensor and thermometer must not

touch the container side or bottom.
●Place the container over a source of heat
and gradually raise the temperature of the
M ax Re si st an ce
Tem p.（°C）Mi n Re si st an ce St an da rd
oil while stirring the oil gently for even

3
（ OH M） R es ist an ce OH M）（ O HM ）
-40±1 42661 48153 542 24

-35 ±1 31810 3 5763 40 118
temperature. -30±1 23970 268 85 30015
-25 ±1 18258 2037 6 22 695
●Using a hand tester, measure the inter- -20 ±1 14 039 15614 17333
1089 5 12078 13 365
nal resistance of the sensor across the termi- -15 ±1
-10 ±1 8529.5 9428.0 103 99
8161.4
nals at the temperatures shown in the table. -5±1 673 3.5
5358.1
7419.0
6457 .8
0 ±1 588 6.7
5±1 4295.9 4706. 9 514 9.8
10±1 3469 .2 3791 .1 4137. 3
15±1 2820.9 3074. 9 3347.5
Inlet Air Temperature Sensor Resis- 20±1 2308.8 2510.6 2726.8
25±1 190 4.0 2062.9 2235. 6
tance 30±1 1586.1 1715.4 185 3.1
35±1 13 26.3 1 431.8 1544 .1
40±1 11 13.0 1 199.6 1291.5
45±1 9 37.41 10 08.6 1081. 2
Standard：2 4 1 6 Ω～2 5 8 3 Ω（2 0 ℃） 50±1 792.27 851.10 913 .15
55±1 671.90 720.65 77 2.28
60±1 571.72 612.27 655 .16
273.2 Ω～285.8 Ω（85℃） 65±1 488 .07 521. 91 557.67
70±1 41 7.98 446.3 3 476.24
75±1 359.08 382 .89 407.9 9
If the measurement is out of the range, re- 80±1 3 09.41 32 9.48 350.61
267.40 284 .06 302 .22
place the sensor. If in ,replace the ECU. 85±1
90±1 231.76 246.15 261. 27
95±1 201.44 213.6 8 2 26.53
100± 1 175 .52 186.00 196.9 5
105± 1 15 3.18 16 2.35 171.88
110± 1 134.0 1 142 .08 150.43
115± 1 117.5 9 124.66 132.0 0
120± 1 1 03.12 109.65 116.12
125± 1 91.80 96.68 102.39
130± 1 3 0.58 85.4 5 90 .51
3-37
CFMOTO

T-MAP Sensor Circuit
1. ECU 2. Inlet Temperature & Pressure Sensor
3-38
3-1 EFI System
Water Temperature Sensor Service
Water Temperature Sensor Removal/Installation
Note
Never drop the sensor, especially on a hard

surface. Such a shock to the part can dam-
age it.
●Drain the coolant (see Coolant Change
in the Periodic Maintenance chapter).
●Disconnect the sensor connector [A], and
unscrew the water temperature sensor [B].
Torque : 12N ˙ m
●Apply grease to new O-ring on the water
temperature sensor.
●Fill the engine with coolant and bleed the A
B
air from the cooling system (see Coolant
Change in the Periodic Maintenance
chapter).
Water Temperature Sensor Output Voltage

3
Inspection
●Remove the ECU (see ECU Removal).
Do not disconnect the connectors.
● Connect a hand tester [A] to the ECU
connector [B] with the needle adapter set.
●Measure the sensor output voltage with
the engine stopped and the connector
joined.
Meter (+)→ Gr/Wlead(ECU terminal 41)

Meter (-)→ L/G lead (ECU terminal40)
Standard: 2 .5 V ～3 . 5 V （20 ℃）
3-39
CFMOTO
Coolant Temperature Sensor Service
NOTE
●Coolant temperature sensor output voltage varies with the coolant temperature change.
●Turn the ignition switch off.
«If the output voltage is within the standard, check the ECU for its ground, and power supply
(see ECU Power Supply Inspection).
«If the output voltage is out of the standard, check the wiring. And if the output voltage is 4.
8 V, the ECU is normal.
«If the wiring is good, check the water temperature sensor resistance.
●Remove the needle adapter set, and apply silicone sealant to the seals of the connector
for waterproofing.
Water Temperature Sensor Circuit
1. ECU 2. Coolant Temperature Sensor 3. Dashboard
Coolant Temperature Sensor Resistance Inspection

● Remove coolant temperature sensor (refer to
Co o la nt Te m p e r a t ur e Se n so r Rem o va l/
Installation).
●Refer to Coolant Temperature Sensor Inspection.
3-40
3-1 EFI System
Crankshaft Position Sensor Service
Crankshaft Position Sensor Removal/Installation
●Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter.
Crankshaft Position Sensor Inspection

●The crankshaft sensor has no power source, and when the engine stops, the crankshaft
sensor generates no signals.
●Crank the engine and measure the peak voltage of the crankshaft position sensor (see
Crankshaft Sensor Inspection in the Electrical System) in order to check the sensor.
●Check the wiring for continuity, using the following diagram.
Crankshaf Position Sensor Circuit
1. ECU 2. Crankshaft Position Sensor
3-41
CFMOTO
Speed Sensor Service
Speed Sensor Removal/Installation
●Refer to the Speed Sensor Removal/Instal-
lation in the Electrical System chapter.
Speed Sensor Inspection
●Refer to the Speed Sensor Inspection in
the Electrical System chapter.
Speed Sensor Input Voltage Inspection
NOTE
● Disconnect the speed sensor connector
A
and connect the harness adapter [A] between
the harness connector and speed sensor
connector.
● Connect a hand tester to the harness
adapter leads.
engine stopped, and with the connector
joined.
Speed Sensor Input Voltage
Meter(+)→ W/G(sensor)lead[C]
Meter(-)→ G/B (sensor)lead[D]
Standard: About 9V~13VDC at Ignition
Switch ON
«If the reading is out of the range, check the
wiring (see wiring diagram in this section)
«If the reading is good, check the output
voltage.
Speed Sensor Output Voltage

● Before this inspection, inspect the input
voltage (see Speed Sensor Input Voltage
Inspection).
NOTE
●Disconnect the speed sensor connector A
3-42
3-1 EFI System
and con nect the harness adapter [A] be-
tween the harness connector and speed sen-
sor connector.
adapter leads.
●Measure the sensor output voltage with the
joined.
Speed Sensor Output Voltage at Sen-

sor Connections to Adapter
Meter(+)→ P(sensor) lead [C]
Meter(-)→ G/B(sensor) lead [D]
Standard: About 0.05V~1.0VDC
Speed Sensor Circuit
1. Speed Sensor 2. Dashboard
3-43
CFMOTO
Roll-over Sensor Service
Roll-over Sensor installation/ Removal
CAUTION

can damage it.
Removal：
●Disconnect connector [B] and roll-over
sensor [A].
Installation：
●Roll-over sensor should be installed as il-
lustrated
WARNING
Incorrect installation of the vehicle-down

sensor could cause sudden loss of en-
gine power.The rider could lose balance
during certain riding situations like lean-
ing over in a turn with the potential for an
accident resulting in injury or death. En-
sure that the down sensor is held in place
by the sensor brackets.
Roll-over Sensor Output Voltage In-

spection (No tilt)
NOTE
●Connect a hand tester [A] to the connec-

tor [B] of the roll-over sensor [C] with the
needle adapter set [D].
the engine stopped, and with the connector
joined.
Roll-over Sensor Output Voltage
Meter(+)→ Gr/B lead[E]
Meter(-)→ L/G lead[F]
3-44
3-1 EFI System
●Turn the ignition switch on and measure
roll-over sensor power source voltage.
Roll-over Sensor Output Voltage(No tilt):
Standard: 12V DC (battery voltage)
«If the reading of input voltage is less than the
standard, check the ECU for its ground, power
supply and wiring shorted.
«If the wiring is normal, check roll-over sensor
resistance.
● Remove the whole set of needle adapter and
with silicone sealant applied to the connector.
spection (when tilted)
●Remove the sensor [G] (see Roll-over Sen-
sor Removal).
tor [B] with needle adapter set [D].
3
Meter(+)→Gr/B lead[E]
Meter(-)→L/G lead[F]
●Hold the sensor vertically.
●Turn the ignition switch ON, and measure
the output voltage with the connector joined.
●Tilt the sensor 55°~75° degrees or more
[C] right or left, then and measure the
output voltage.
Sensor Output Voltage
Standard: 0V~0.5V
NOTE
●If you need to test again, turn the ignition
switch OFF, and then ON.
●Remove the needle adapter set, and ap- «If the wiring is good, check the ECU for its
ply silicone sealant to the seals of the con- ground and power supply (see ECU Power
nector for waterproofing. Supply Inspection).
«If the output voltage is normal, the wiring «If the output voltage is out of the specified,
is suspect. Check the wiring. replace the roll-over sensor.
3-45
CFMOTO
Oxygen Sensor Service

Oxygen Sensor Removal / Installation
WARNING
Never drop the sensor [B], especially on

a hard surface. Such a shock to the part
can damage it. Do not touch the portion
[A] of the sensor, otherwise, the oil resi-
due on your hand may contaminate the
sensor and cause performance
degeneration.
Oxygen Removal
Disconnect connector[A] and remove

oxygen sensor [B].
Oxygen Sensor Installation
Connect oxygen sensor [B] and connector

[A].
Torque: 6 0 N ·m ± 2 N ·m
3-46
3-1 EFI System
Oxygen Sensor Output Signal Inspection
●Disconnect the oxygen sensor connec
tor [A] of one cylinder.
●Place the transmission in neutral
●Start the engine and throughly warm it
up, then have the engine run at more than
8000rpm.
●Measure oxygen sensor output volatage
using meter[B].
Oxygen Sensor Output Voltage

Cylinder 1:
Meter(+)→3 terminal[C]
Meter(-)→4 terminal[D]
Cylinder 2:
Meter(-)→4 termina[D]
3
Oxygen Sensor Output Voltage:
Standard：About 0.8V

●Place the transmission in neutral.
●Start the engine and let it idle.
3-47
CFMOTO
●Remove the hose [B].
●Measure oxygen sensor output voltage

with hand tester [B].
Cylinder 1:
Meter(-)→4terminal[D]
Cylinder 2:
Meter(+)→3terminal[C]

Standard: about 0.1V
●Use the meter [B] to measure the sen-

sors resistance.
Sensor heat up resistance
Cylinder 1
Meter(+) →Pin 2 [C]
Meter(-) →Pin 1 [D]
Cylinder 2
Standard: About 1 Ohm.
3-48
3-1 EFI System
Ignition Coil Service
Ignition Coil Removal/Installation
WARNING

can damage it.
Ignition Coil Input Voltage Inspection

NOTE
●Remove the fuel tank.
●Remove the air filter
●Remove the ignition switch connector [A].
●Connect a hand tester [B] as shown.
●Measure the input voltage to each pri-
mary winding of the ignition coils with the
engine stopped, and with the connectors
joined.
●Turn the ignition switch ON. Measure the 3
ignition coil input voltage during fuel pump
working time.
Ignition Coil Input Voltage:
Ignition coil 1#：

Meter(+)→ W/Blead[C]
Meter(-)→ Ground
Standard: About 12VDC
Ignition coil 2#：

Meter(+)→ Ground
Standard: About12VDC
3-49
CFMOTO
Ignition Coil
Ignition Coil Circuit
1. Main Fuse 2. Battery

3. ECU 4. Ignition Switch
5. Fuse Box 6. Engine Stop Switch
7. Main Relay 8. Ignition Coil 2#
9. Ignition Coil 1#
3-50
3-1 EFI System
MIL Service
Flowing diagram of MIL
Re pa ir or r ep lace th e
Tu rn th e ig niti on
me ter o r wiri ng .
Switch o n.
Malfunction
Off
D oe s the li gh t (L ED) Check FI light and
g o o n? cables
On
Normal
Yes
If the FI light is off FI light and EFI is
after it is on for 4s normal
3
No
If the FI light is on Yes EFI system detected

after it is on for 4s repaired fault
No
Turn ignition switch off，
If the FI light is on end inspection，turn to
for 4s and stop for repaired fault clean up
1s, flash at 2Hz
frequency.
No
Ask the rid er if the pr ob lem
Turn ignition switch EFI is normal
EFI is no rm al. occu rs a ga in .
off, end inspection，
turn to fault
diagnosis. Yes
Replace ECU
3-51
CFMOTO
MIL Service
MIL check
●Disassemble the dashboard (See dashboard replacement on chapter 16).
●Use four auxilary connect the dashboard to the battery for MIL.
The battery voltage should be 12V

Positive pole(+)→ Dashboard pin 1 and pin 2
Negative pole(-)→ Dashboard pin 3 and pin 13
MIL should be on after connected.
●If the trouble indicator light doesnot on. Replace the dashboard.
MIL Circuit
1. Main Fuse 2.Battery

7. Main relay 8. Dashboard
3-52
3-1 EFI System
ECU Service
ECU assembly/ disassembly
Attention A
Do not drop the ECU, especially hard

cover. Or the shock from the impact will
damage the ECU.
ECU disassembly
●Disassemble the seat.
●Take out the ECU[A] and wires.
● Disconnect the ECU connector[B]。
ECU Assembly
● Assemble the ECU and connect the
connector. B
ECU power and ground wire checking

●Eye check the ECU connector.
«If the connector is jammed by the dust or 3
mud. Use the compressed air clean up.
«If the cable connector has cracks, bent or
damage.Replace the maincable.
«If the ECU connector has cracks,bent or
damaged.Replaced the ECU.
●With the ECU connector[A]connected. Off
the ignition switch. Use the AVO meter To
check the ground wire connection below.
Battery[B]
AVO meter[C]
ECU ground wire check

Connector pin 5, pin 48←→Battery(-):0 ohm
Engine ground wire ←→ Battery(-):0 ohm
«If the ground wire is not connected.Check

the connector,engine ground wire or main cable.
Replace or repair if nacessary.
3-53
CFMOTO
●Check the ECU power voltage with a hand
tester [A].
●Use the drawings in this chapter to see the
16
ECU connector [B] numbers and position the 8
1
2
A B C D E F G H J K L M N O P Q
3
pins.
4
Battery [C]
Meter Connections: 51
Pin 16 ←→ Battery (-) between pins
Pin 8 ←→ Battery (-) between pins A
When ignition Switch is OFF: C
Pin 16 and battery(-): Battery voltage
(12.8V or higher)
When ignition Switch is ON and Engine Stop
Switch is ON:
Pin 8,51 and Battery(-): 0V
«If the meter does not read as specified,

check the following.
●Main Fuse 20A(see Fuse Inspection in the
Electrical System chapter)
●ECU fuse 7.5A(see Fuse Inspection in the
Power SourceWiring (see wiring diagram
below)
«If the inspection checks good, the ECU is
damaged. Replace the ECU (see ECU
Removal/Installation). The ECU itself cannot
be checked or serviced.
3-54
3-1 EFI System
E C U Service
ECU wiring diagram
3 1
2
3
+
5
-
4
L /R
R /G
1
20A
6
7 . 5A
15A
15A
7 3
1. Fuse 2.Battery
3. ECU 4. Ignition switch
5. Main fuse 6. Engine stop switch
7.Main relay
3-55
CFMOTO
High pressure fuel pipe service
Fuel pressure check
Attention
● Pressure check can tell you where the
problem comes from. Including EFI system
problem, mechanical problem or electrical
problem.
●If the vehicle got problem on running. The
fuel pressure test can be easier to find the
reason.
● Make sure that battery is fully charged.
Fuel pressure test
●Disassemble the fuel tank.
● Make sure the fure pipe connector has
been wrap around by a cloth to avoid the fuel
leaking.
●Pressure the lock [A].
●Disconnect the connector [B].
●Disassemble the fuel pipe[C].
Warning
Avoid the fuel leaking. Leaked fuel must
be cleaned up immediately.
Fuel will flow from hose and pipe when
fuel hose is disconnected. Use a clean
cloth to cover hose connection part.
● Assemble the fuel pressure adapter[A]be-
tween the fuel outlet pipe[B]and the fuel rail[C].
Warning
Do not start the engine with thefuel pipe
disconnected.
Fuel tank[E], Pressure meter[D],Connector[F]

● Connect the connector tightly, make sure
there is no leak.
●Turn the ignition switch on. Let the fuel pump
running 3 second,then stop.
Warning
Do not start the fuel pump when the tank
is empty .
3-56
3-1 EFI System
Fuel pressure check
●Stop the engine to test the fuel pressure.
Fuel pressure
When ignition switch is on and fuel pump is

running:
Standard: 330kPa(0.33MPa)
After the ignition switch is on for 3s and fuel pump
stoped.
The pressure should be kept for 30s
The pressure meter[A] tip[B] will wave when
testing. Get the average pressure between the
Max and min.
«If the fuel pressure is normal. The fuel circu-
lation system(Fuel pump, Pressure adjuster,
Fuel pipes)is OK.Check the EFI system
(Injector, Each sensor,ECU).
« If the pressure is lower than mormal
3
standard. Check the item below.
●Fuel pipe leaking.
● Fuel pump running( Check the fuel pipe
sound).
●Fuel pump flow( See the fuel pump flowing
inspection).
« If the pressure is higher than normal
standard. Inspect the item below：
●Fuel pipe jammed.
●Injector jammed.
●Adjuster of the fuel pump damaged.
3-57
CFMOTO
Fuel pump service
Fuel pump flowing check
Attention
●Make sure the pattery fully charged.
Warning
Gasoline is extremely flammable and can
be explosive under certain conditions.
Make sure the area is well-ventilated and
free from any source of flame or sparks;
this includes any appliance with a pilot
light. Do not smoke. Turn the ignition
switch OFF. Be prepared for fuel spillage;
any spilled fuel must be completely wiped
up immediately.
● Turn the ignition switch and engine stop
switch off.
●Waiting for engine cool down.
●Prepare a plastic hose of the inside diam-
eter 7.5mm (0.30 in.) and a measuring
cylinder.
●Disassemble the fuel tank bolt.
●Open the fuel tank cap[A] To release the
pressure.
Warning
Be prepared for fuel spillage; any spilled
fuel must be completely wiped up
immediately. When the fuel hose is
disconnected, fuel spills out from the
hose and the pipe because of residual
pressure. Cover the hose connection
with a piece of clean cloth to prevent fuel
spillage.
● Connect the plastic hose [A] to the fuel

pump outlet pipe.
●Secure the plastic hose with a clamp [B].
●Insert the plastic pipe into measuring cylin-
der [C]
3-58
3-1 EFI System
Fuel pump service
Warning
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder
vertical.
●Assemble the fuel tank.

●Ignition on with the engine stop.Running the
fuel pump for 3s.Then stop. Repeat several
times until the pipe full of fuel.
Warning
Do not drive the fuel pump without the
fuel inthe fuel tank.
●Measure the discharge for 3 seconds with
the plastichose filled with fuel.
●Repeat this operation several times.
Amount of Fuel Flow
Standard: 60 mL or more for 3 seconds 3

« If the fuel flow is much less than the
specified, check the battery condition (see
Charging Condition In spection in the Electri-
cal System chapter). If the battery is good,
replace the fuel pump (see Fuel Pump Re-
moval/Installation).
●After inspection, install the fuel tank (see
Fuel Tank Installation).
● Start the engine and check for fuel
leakage.
3-59
CFMOTO
Fuel Pump
Fuel Pump Removal
Warning
Never drop the fuel pump, especially on
a hard surface. Such a shock to the
pump can damage it.
Warning
switch OFF. Disconnect the battery (-)
terminal.To make fuel spillage minimum,
draw the fuel out from the fuel tank when
the engine is cold. Be prepared for fuel
spillage; any spilled fuel must be com-
pletely wiped up immediately.
●Draw the fuel out from the fuel tank.

● Remove the fuel tank (see Fuel Tank
Removal).
●Be careful of fuel spillage from the fuel
tank since fuel still remains in the fuel tank
and fuel pump. Plug the fuel pipe of the fuel
tank.
●Turn the fuel tank upside down.
«Remove:
●Fuel Pump Bolts [A].
●Fuel Pump [B].
●Replace fuel pump gasket [C] if dam-
aged
Warning
Do not pull the lead of the fuel pump. If
they are pulled, the lead terminals may
be damaged.
3-60
3-1 EFI System
Fuel Pump
Fuel Pump Installation
●Clean dirt or dust from the fuel pump [B] by
lightly using compressed air.
● Replace the fuel pump gasket [C] with a
new one if damaged.
●Tighten the fuel pump bolts to a snug fit,
tighten them in a crisscross pattern.
Torque - Fuel Pump Bolts: 5 N·m
●Tighten the pump bolts again in a criss-
cross pattern to check the tightness.
Fuel Pump Operation Inspection

NOTE
● Just listen to the pump sound in the fuel
tank to confirm pump operation.
●Turn the ignition switch ON and make sure
that the fuel pump operates (make light
sounds) for 3 seconds, and then stops.
●Turn the ignition switch OFF
3
«If the pump does not work as described
above, inspect the operating voltage.
Fuel Pump Operating Voltage Inspection

NOTE
●Turn the ignition switch OFF and disas
semble the tank.
●Disconnect fuel pump connector[A]
●Measure the voltage when engine stops.
●The tester needle should indicate battery
voltage for 3 seconds, and then 0 V.
Tester Connections:
Tester(+) → terminal 1(lead B/Y)
Tester(-) → terminal 2(lead G)
With the ignition switch on:
Standard: Battery Voltage keeps for 3
seconds, and then goes to 0 V.
3-61
CFMOTO
Fuel Pump
«If the reading stays on battery voltage, and
never shows 0 V. Check the ECU and fuel
pump relay.
«If the voltage is normal but fuel pump does
not work, replace the fue pump.
«If thereis no battery voltage, check the fuel
pump relay.
Pressure Regulator Removal

●The pressure regulator [A] is built into the
fuel pump [B] and cannot be removed.
● If the pressure regulator is suspected of
clogging or being damaged, replace the fuel
pump as a set.
Pump Screen, Fuel Filter Cleaning

●The fuel filter [A] is built into the pump and
cannot be cleaned or checked.
●If the fuel filter is suspected of clogging or
being damaged, replace ithe fuel pump as a
set.
3-62
3-1 EFI System
Fuel pump
Fuel pump wiring diagram
3
1. Fuse 2. Battery
7. Main relay 8. Relay, fuel pump
9. Fuel pump1
3-63
CFMOTO
Fuel Injector Service

Fuel Pump Removal/Installation
●Refer to the Throttle Body Assy Disassem-
bly/Assembly.
Audible Inspection
●Start the engine.

●Apply the tip of a screwdriver [A] to the in-
jector [B]. Put the grip end onto your ear, and
listen where the injector is clicking or not.(A
sound scope [C] can also be used.
●Do the same for the other injectors
«If all the injectors click at a regular intervals,

the injectors are good. The trouble may be
related to the fuel line, requiring fuel pres-
sure inspection.
●The click interval becomes shorter as the
engine speed rises.
●If any injector(s) doesn’t click, the EFI cir-
cuit or the injector is suspect. Perform fuel In-
jector Power Source Voltage Inspection”, first.
Fuel Injector Power Source Voltage Inspec-

tion
●Turn the ignition coil OFF
●Remove the air filter.
●Connect the fuel injector connector [A].
●Connect a hand tester [B] to the fuel injec-
tor connector.
Fuel Injector Output Voltage:
Cylinder 1:
Meter (+)→ lead [C]
Meter (-) →Battery (-)
Cylinder 2:
Meter (+) → lead [C]
3-64
3-1 EFI System
Fuel Injector
●Turn the ignition switch ON
Fuel fump input voltage is the battery volt-
age in first 3 seconds, then 0 V.
«If the output voltage is normal, perform in-
jector Signal Test
check the following :
●Main Fuse 20 A fuel pump relay fuse 15A
(see Fuse Inspection in the Electrical System
chapter)
●Fuel Pump Relay (see Relay Circuit In-
spection in the Electrical System chapter)
● Power Source Wiring (see wiring dia-
gram below)
Fuel Injector Wiring Inspection

●Connect a hand tester [A] to check the con-
tinuity between ECU connector [B] and fuel B
injector connector [C]. Break-line part is cyl- 1
A
3
2
3
inder 2.
Cylinder 1:
ECU terminal 50 ----- lead [D]
Standard: continuity
E D
Cylinder 2:
ECU terminal 49 -------lead [E]
C
«If the wiring is good, inspect the resistance

of the injectors (see Injector Resistance
Inspection).
3-65
CFMOTO
Fuel Injector
Injector Signal Test
●Prepare two test light sets with male ter-
minals as shown.
●Rating of Bulb [A]: 12 V ×(3 ~ 3.4) W
Terminal Width [B]: 1.8 mm (0.071 in.)
Terminal Thickness [C]: 0.8 mm (0.031
in.)
CAUTION
Do not use larger terminals than speci-
fied above. A larger terminal could dam-
age the injector main harness connector
(female), leading to harness repair or
replacement. Be sure to connect bulbs
in series. The bulb works as a current lim-
iter to protect the solenoid in the injector
from excessive current.
Test Lights Wiring
●Remove the fuel tank(see Fuel Tank
●Disconnect the connector of fuel injector
[A].
● Connect each test light set [B] to the in-
jector sub harness connector [C].
●While cranking the engine with the starter
motor, watch the test lights.
«If the test lights flicker at regular intervals,
the injector circuit in the ECU, and the wiring
are good. Perform the "Injector Resistance
Inspection". Injector Signal Test : Prepare two
test light sets with male terminals as shown.
Rating of Bulb [A]: 12 V x3 ~ 3.4 W Terminal
Width [B]: 1.8
«If the test light doesn’t flicker (or the tester
needle doesn’t oscillates), check the wiring
and connectors.
If the wiring is good, check the injector voltage.
If the wiring is good, inspect the ECU for its
Supply Inspection).
3-66
3-1 EFI System
Fuel Injector
Fuel Injector Resistance Inspection
● Remove the fuel tank(see Fuel Tank
Removal).
●Remove the air filter housing(see Air Fil-
ter Housing Removal).
●Disconnect the connector from the con-
nector [A].
●Measure the injector resistance with the
hand tester [B].
Injector Resistance:
Standard: 1 2 . 1 Ω± 1 Ω（20 ℃）
«If the reading is out of the range, perform

the “Injector Unit Test”.
Injector Unit Test

●Use two leads [A] and the same test light
set [B] as in “Injector Signal Test”.
Rating of Bulb [C]: 12 V×(3 ~ 3.4) W 3
12 V Battery [D]
CAUTION
Be sure to connect the bulb in series.
The bulb works as a current limiter to
protect the solenoid
●Connect the test light set to the injector [E]

as shown.
●Open and connect [F] the end of the lead
to the battery (-) terminal repeatedly. The in-
jector should click.
«If the injector does not click, replace the
injector.
«If the injector clicks, check the wiring again.
If the wiring is good, replace the injector (may
be clogged) or ECU.
3-67
CFMOTO
Fuel Injector
Fuel Injector Wiring Diagram
1. Fuse 2. Battery
7. Main relay 8. Fuel Injector 2
9. Fuel Injector 1
3-68
3-1 EFI System
Throttle Grip and Cables Service
Throttle Grip Free Play Inspection

●Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter.
Throttle Grip Free Play Adjustment
Throttle Cable Installation

●Install the throttle cables in accordance with Cable, Wire, and Hose Routing section in
the Appendix chapter.
●Install the lower ends of the throttle cables in the cable bracket on the throttle body assy
after installing the upper ends of the throttle cables in the grip.
●After installation, adjust each cable properly.
Warning
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding
condition.
Throttle Cable Lubrication

●Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. 3
3-69
CFMOTO
Throttle Body Assy
●Refer to the Idle Speed Inspection in the
Periodic Maintenance chapter.
Engine Vacuum Synchronization Inspection/
Adjustment
●Refer to the Engine Vacuum Synchroni-
zation Inspection in the Periodic Maintenance
chapter.
Throttle Body Assy Removal
WARNING
Turn the ignition switch OFF. Disconnect
the battery (-) cable terminal. Do not
smoke. Make sure the area is well-venti-
lated and free from any source of flame
or sparks; this includes any appliance
with a pilot light. Be prepared for fuel
spillage: any spilled fuel must be com-
●Remove fuel tank (see Fuel Tank Removal)
● Air filter housing (see Air Filter Housing
Removal)
●Disconnect throttle Body Sensor Connec-
tor [A]
●Disconnect fuel Hose Lower End [B]
●Disconnect evaporative emission control
hose [C] of cylinder 1
●Loosen Clamp [D] of cylinder 1
●Disconnect Fuel injector connector [E] of
cylinder 1
● Disconnect Air intake tempreature and
pressure sensor[F].
●Disconnect the throttle cable[A].
●Loosen: Clamp [B]
● Disconnect fuel injector connector [C] of
clinder 2
hose [D] of cylinder 2
3-70
3-1 EFI System
Throttle Body Assy
●After removed the throttle body assy, put
clean cloth into the throttle body holders.
WARNING
If dirt gets into the engine, it will cause
engine excessive wear and damage .
Throttle Body Assy Installation

●Install the throttle body on the intake mani-
fold [A].
●Install the clamp bolts [B] in the direction
shown, facing outwards.
●Install the fuel injector connector, evapora-
tive emission control hose, throttle cable, high
pressure fuel line joint.
Warning
Operation with an incorrectly routed
cable could result in an unsafe riding
condition. 3
CAUTION
Do not remove, disassemble or adjust
the throttle position sensor [A], because
it is adjusted or set by the manufacturer.
Adjustment of these parts could result in
poor performance, or replacement of the
throttle body assy.
CAUTION
Do not remove, disassemble or adjust the

idle adjusting screw [A], [B], because they
are adjusted or set by the manufacturer.
throttle body assy.
3-71
3-2 EFI System
3-2 EFI SYSTEM(48 pin ECU for CF650-3C\CF650-3F)

EFI System …………………………………………………………………………………3-73
ECU Pin Function …………………………………………………………………………3-75
EFI Specification……………………………………………………………………………3-76
Service Tool…………………………………………………………………………………3-78
EFI Service Precautions……………………………………………………………………3-80
EFI Trouble Shooting………………………………………………………………………3-81
Overview………………………………………………………………………………3-81
Outline ………………………………………………………………………………3-85
Self-diagnosis Outline ………………………………………………………………3-86
EFI System Trouble Shooting Guide…………………………………………………3-88
EFI System Self-diagnosing ………………………………………………………………3-96
Self-diagnosing Overview……………………………………………………………3-96
Trouble Code …………………………………………………………………………3-99
Trouble Shooting………………………………………………………………………3-101
EFI Parts Service ……………………………………………………………………………3-102
Throttle Body …………………………………………………………………………3-102
T-MAP Sensor…………………………………………………………………………3-106
Water Temperature Sensor …………………………………………………………3-109
Trigger…………………………………………………………………………………3-111 3
Speed Sensor…………………………………………………………………………3-112
Roll-over Sensor ………………………………………………………………………3-114
Oxygen Sensor ………………………………………………………………………3-116
Ignition Coil ……………………………………………………………………………3-119
Trouble Indicator Light…………………………………………………………………3-121
ECU ……………………………………………………………………………………3-123
High Pressure Fuel Pipe………………………………………………………………3-126
Fuel Pump ……………………………………………………………………………3-128
Fuel Injector……………………………………………………………………………3-134
Throttle Cable and Throttle Lever……………………………………………………3-139
Throttle Body Assy……………………………………………………………………03-140
3-72
CFMOTO
△FUEL SYSTEM (EFI) Composition of EFI
3-73
3-2 EFI System
1. Ignition Switch
2. Engine Stop Switch
3. Starter Relay
4. Tachometer
5. MIL(LED)
6. Spark Plug
7. Trigger(Crankshaft Position Sensor)
8. Fuel Injector
9. Throttle Position Sensor
10. Fuel Rail
11. Throttle Body Valve
12. Fuel Pump
13. Pressure Regulator
14. Fuel Tank
15. Air Filter Element
16. Inlet Air Temperature Sensor
17. Air Filter Housing
18. Neutral Switch
19. Speed Sensor
20. Roll-over Sensor
3
21. Oxygen Sensor
22. Battery
23. ECU
24. Inlet Airf low Direction
25. Pressurized Fuel Direction
26. Coolant Temperature Sensor
3-74
CFMOTO
ECU Pin and Function
ECU pin and function:

1(M1) Oxygen sensor 2 heating 25(D2) Null
2(L1) Oxygen sensor 1 heating
26(C2) Auxiliary Relay
3(M2) Ignition Coil 1
27(B2)Stepper motor phase A
4(L2) Null
28(A2) Stepper motor phase B
5(M3) Ignition ground wire
29(K3) MIL Light
6(L3) Null
30(J3) 5V Power 1
7(M4) Ignition coil 2
31(H3) Null
8(L4) Uncontinuous power
32(G3) Ignition switch
9(K1) Air intake pressure sensor 33(F3) Continuous power
10(J1) Ground to sensors1 34(E3) Cable K diagnosis
11(H1) Air intake temperature sensor 35(D3) Neutral Switch
12(G1) Throttle position sensor 36(C3) Ignition Coil 1
13(F1) Coolant temperature sensor 37(B3) Clutch switch
14(E1) Main relay 38(A3) Roll-Over switch
15(D1) CAN low 39(K4) Confort/Sport mode switch
16(C1) CAN high 40(J4) Engine RPM output
17(B1) Stepper motor phase D 41(H4) Speed sensor
18(A1) Stepper motor phase C 42(G4)Engine phase sensor B
19(K2) Oxygen Senor 1 43(F4) Engine phase sensor A
20(J2) Oxygen Senor 2 44(E4) Headlamp relay
21(H2) Ignition coil 2 45(D4) Fan Relay
22(G2) Null 46(C4)Oil pump sensor
23(F2) Side stand switch 47(B4) Injector 2
24(E2) Null 48(A4)Injector 1
3-75
3-2 EFI System
EFI Specifications
Item Standard
EFI
Idle Speed 1 450 r/min ±145 r/min (rpm)
Throttle Body Assy:
Type Two barrel type
Bore Ф38 mm
ECU:
Make UAES
Type Digital memory type, with IC igniter, sealed with resin
Available Engine Speed 100 r/min ~11 000 r/min (rpm)
Fuel Pressure (High Pressure
Line):
After Ignition Switch is ON 323 kPa (3.3 kgf/cm2, 47 psi) with fuel pump running.
After 3 Seconds from Ignition 265 kPa (2.7 kgf/cm2, 38 psi) with fuel pump stopped
Switch is ON
With Engine Idling 333 kPa (3.4 kgf/cm2, 48 psi) with fuel pump running
Fuel Pump:
Type In-tank friction pump
Leakage 60 mL or more in every 3 seconds
Fuel Injectors:
Type F01R00M140
Nozzle Type One spray with 6 holes
Resistance About 12 Ω at 20°C (68°F)
Throttle Position Sensor Non-adjustable and non-movable 3
Input Voltage 4.75V~ 5.25 V DC between Lg/Y and Gr /R
Output Voltage at Idle Throttle 0.4V~ 0.8V DC between Lg /Y and Br/R
Opening
Output Voltage at Full Throttle More than or equal to 3.9 V DC between Lg /Y and
Opening Br/R
Inlet Air Temperature Sensor:

Resistance See text in Inlet Air Temperature Sensor Section
Coolant Temperature Sensor:
Resistance See Electrical System chapter
Speed Sensor:
Input Voltage at Sensor About 9 V~11 V DC at Ignition Switch is ON
Output Voltage at Sensor About 0.05 V~1 V DC at Ignition Switch is ON and
speed at 0 km/h
Roll-Over Sensor：
Detection Method Resistance detection method
Detection Angle More than 55 °~75 ° for each bank
3-76
CFMOTO
EFI Specifications
Item Standard
Oxygen Sensor:
Output Voltage (high) 0.7V or higher
Output Voltage (low) 0.2Vor lower
Throttle Grip and Cables
2 mm ~3mm (0.08 in ~0.12in.)
3-77
3-2 EFI System
Maintanence Tool
Oil Pressure Gauge Needle Adaptor Set
Throttle Sensor Setting Harness Hand Tester
T-joint Fuel Hose
Peak Voltage Adapter
3-78
CFMOTO
There are some important precautions that
should be followed when service the EFI
system.
● This EFI system is designed to be used
with a 12 V sealed battery as its power source.
Do not use any other battery except for a 12
V sealed battery as a power source.
● Do no t r everse t he bat te ry cab le
connections. This will damage the ECU.
● To prevent damage to the EFI parts, do
not disconnect the battery cables or any other
electrical connections when the ignition
switch is on or while the engine is running.
● Take care not to short the leads that are
directly connected to the battery positive (+)
terminal to the chassis ground.
● When charging, remove the battery from
the motorcycle. This is to prevent ECU dam-
age by excessive voltage.
● Do not turn the ignition switch ON while
any of the EFI electrical connectors are
disconnected. The ECU memorizes service
codes.
● Do not spray water on the electrical parts,
EFI parts, connectors, leads, and wiring
● Whenever the EFI electrical connections
are to be disconnected, first turn off the igni-
tion switch, and disconnect the battery (-)
terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the EFI
electrical connections are firmly reconnected
before starting the engine.
● Connect these connectors until they click
[A].
●If a transceiver is installed on the vehicle,
makesure that EFI system operation is not
influenced by electric wave radiated from the
antenna. Check operation of the system with
the engine at idle. Locate the antenna as far
as possible away from the ECU.
3-79
3-2 EFI System
● When any fuel hose is disconnected, fuel
may spout out by residual pressure in the
fuel line. Cover the hose joint with a piece
of clean cloth to prevent fuel spillage.
● When any fuel hose is disconnected, do
not turn on the ignition switch. Otherwise,
the fuel pump will operate and fuel will
spout from the fuel hose.
● Do not operate the fuel pump if the pump
is completely dry.
●Before removing the fuel system parts,
blow the outer surfaces of these parts
●To prevent corrosion and deposits in the
fuel system, do not add to fuel any fuel an
tifreeze chemicals.
To maintain the correct fuel/air mixture (F/

A), there must be no inlet air leaks in the EFI
system. Be sure to install the oil filler plug [A] 3
and Clutch Cover [B] properly after filling the
engine oil.
3-80
CFMOTO
Outline
When an abnormality in the system occurs, the
MIL (LED) goes on to alert the rider on
the meter panel. In addition, the condition of the
problem is stored in the memory of the ECU
(electronic control unit). With the engine stopped
and turned in the self diagnosis mode, the ser-
vice code [A] is indicated by the number of times
the FI indicator light (LED) blinks.
When due to a malfunction, the MIL (LED) re-
mains lit, ask the rider about the conditions
[B] under which the problem occurred and try to
determine the cause [C].
First, conduct a self-diagnosis inspection and
then a non-self-diagnosis inspection. The non-
self-diagnosis items are not indicated by the MIL
(LED). Don’t rely solely on the EFI
self-diagnosis function, use common sense.
Even when the EFI system is operating normally,
the FI indicator light (LED) [A] may light up un-
der strong electrical interference. No repair
needed. Turn the ignition switch OFF to stop the
indicator light.
When the MIL (LED) goes on and the motorcycle
is brought in for repair, check the service codes. 650MT
When the repair has been done, the light (LED)

doesn’t go on. But the service codes stored in
memory are not erased to preserve the prob-
lem history, and the light (LED) can display the
codes in the self-diagnosis mode. The problem A
history is referred when solving unstable
problems.
When the motorcycle is down, the vehicle-down
sensor is turned OFF and the ECU shuts off the
fuel injectors and ignition system. The MIL(LED)
blinks but the service code cannot be displayed.
The ignition switch is left ON. If the starter button
is pushed, the electric starter turns but the en-
gine doesn’t start.
3-81
3-2 EFI System
To start the engine again, raise the motorcycle,
turn the ignition switch OFF, and then ON. The
vehicledown sensor is turned ON and the light
(LED) goes OFF.
●The DFI part connectors [A] have seals [B],
including the ECU.
●Join the connector and insert the needle
adapters[C] inside the seals [B] from behind
the connector until the adapter reaches the
terminal.
CAUTION
Insert the needle adapter straight along
the terminal in the connector to prevent
short-circuit between terminals.
●Make sure that measuring points are cor-

rect in the connector, noting the position of
the lock [D] and the lead color before
measurement. Do not reverse connections of
the hand tester or a digital meter.
●Be careful not to short-circuit the leads of 3
the EFI or electrical system parts by contact
between adapters.
●Turn the ignition switch ON and measure
the voltage with the connector joined.
CAUTION
Incorrect, reverse connection or short

circuit by needle adapters could dam-
age the DFI or electrical system parts.
● After measurement, remove the needle
adapters and apply silicone sealant to the
s e a l s [ A] o f t h e co n n e ct o r [ B ] f o r
waterproofing.
● Always check battery condition before
replacing the EFI parts. A fully charged bat-
tery is a must for conducting accurate tests of
the EFI system.
●Trouble may involve one or in some cases
all items. Never replace a defective part with
3-82
CFMOTO
out determining what CAUSED the problem. If
the problem was caused by some other item or
items, they too must be repaired or replaced, or
the new replacement part will soon fail again.
● Measure the electrical resistance of the
coil after the EFI parts cool down.
●Make sure the electric connection clean
and tight.And check the wire if it got burned,
abrasion,too short and etc.Damaged cable
and bad connection can cause the trouble
comes out again and again and make the EFI
system running unstable.
●If the cable is damaged or aging. Please
replace the cable.
●Disconnect each connectors[A]And check
if there is any corrosion, dust or damaged.
●If connectors getting corrosions or dusted.
Please clean up carefully.If the connectors get-
ting damaged.Plase replace the connectors.
Connectors should be well connected.
●Check the wiring continuity. Use the wir-
ing diagram to find the trouble wire termination.
● Connect the AVO meter on wire
termination.
●Set the AVO meter on X1Ω mode. And
read out the data showing on AVO meter.
● If the data is not 0 Ω. Means the prob-
lem on cable.Replace the maincable or sec-
ondary cable.
●If the cable[A] is far. Use a Cable[D]Con-
nect [C] o the ground[B] and check another
connector[E] and[F] to make sure it is OK.
That can check the connection of the long
cable. If connection is poor, replace the cable.
●When check the cable[A] shortcut or not,
Open[B] side and check the connection from
another side [C] to [D]. If OK, the cable has
shortcut and needs repairing.
●Check the ECU connection again and again,
To make the trouble easier point out.
3-83
3-2 EFI System
●If the wire and connector has no trouble, then
EFI parts may be next point. Use input and out
put voltage checking way. But it cannot check
the ECU itself.
●If you find trouble, replace the trouble parts.
If the wire, connector and EFI parts has no
trouble. Replace the ECU
● Lead Color Codes:
B: Black L: Blue Gr: Grey
Br: Brown G: Green Lg: Light Green
Sb: Sky Blue O: Orange R: Red
P: Purple W: White Y: Yellow

There are two ways to inspect the EFI system.
One is voltage Check Method and the other
is Resistance Check Method.
(Voltage Check Method)
●This method is conducted by measuring
the input voltage [B] to a sensor [A] first and
then the output voltage [C] from the sensor.
3
●Sometimes this method can detect a fault
of the ECU.
●Refer to each sensor inspection section
for detail in this chapter.
●Use a fully charged battery and a digital
meter [D] which can be read two decimal
places voltage or resistance.
(Resistance Check Method)
●This method is simple. No need for a fully
charged battery and the needle adapter.
Just do the follow ing especially when a sen
sor [A] is suspect.
●Turn the ignition switch OFF and discon-
nect the connectors.
● Inspect the sensor resistance, using a «If the sensor, the wiring and connections
digital meter (see each sensor inspection). are good, inspect the ECU for its ground and
●Inspect the wiring and connectors [B] for power supply (see ECU Power Supply
continuity, using the hand tester [C] (analog Inspection). If the ground and power supply
tester) rather than a digital meter. are good, the ECU is suspect. Replace the
ECU.
3-84
CFMOTO
EFI Diagnosis Process Chart
Problem occurs.
Confirm problems.
Gather information from rider
The ignition switch is turned on, and the state of FI

indicator light (LED) is seen.
Unlit Lit
Conduct self-diagnosis inspection

Conduct non-self-diagnosis
Conduct general fuel

system inspection
(Fuel system includes:

Throttle body assy.、air
filter、fuel pump ect.) End
Inquiries to Rider
●Each rider reacts to problems in different ways, so it is important to confirm what kind of
symptoms the rider has encountered.
●Try to find out exactly what problem occurred under exactly what conditions by asking
the rider; knowing this information may help you reproduce the problem.
●The following sample diagnosis sheet will help prevent you from overlooking any areas,
and will help you decide if it is an EFI system problem, or a general engine problem.
3-85
3-2 EFI System
Sample Diagnosis Sheet：
Rider name: Registration No. (License plate No.):
Year of initial registration: Model:
Engine No.: Frame No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather fine, cloudy, rain, snow, always, other:
Temperature hot, warm, cold, very cold, always
Problem frequency chronic, often, once
Road street, highway, mountain road (uphill, downhill), bumpy,
Altitude normal, high (about 1000 m), higher(more than 2000m)
Motorcycle conditions when problem occurred.
FI indicator light up immediately after ignition switch ON, and goes off after 5s
light (LED) (normal)
lights blinks 10s after ignition switch ON, and stays on (EFI problem)
light up 5s after ignition switch on，then blink 15 times and stay on
（indicate maintenance）
Non-lights (light (LED), ECU, speedometer or its wiring fault)
sometimes lights up (probably wiring fault)
Starting starter motor not rotating
difficulty starter motor rotating but engine doesn’t turn over
starter motor and engine don’t turn over 3
no fuel flow (no fuel in tank, no fuel pump sound)
engine flooded (do not crank engine with throttle opened, which
promotes engine flooding)
no spark
other
Engine stops after starting
when opening throttle grip
when closing throttle grip
when moving off
when stopping the motorcycle
when cruising
others
Bad very low idle speed, very high idle speed, rough idle speed
operation at battery voltage is low (charge the battery)
low speed spark plug loose (tighten it)
spark plug dirty, broken, or gap maladjusted (remedy it)
back firing
after firing
hesitation when acceleration
engine oil viscosity too high
brake dragging
3-86
CFMOTO
q clutch slipping
q others
q Poor q spark plug loose (tighten it)
running or no q spark plug dirty, broke, or gap maladjusted (remedy it)
power at high q spark plug incorrect(replace it)
speed q knocking (fuel poor quality or incorrect， use high-octane
gasoline)
q brake dragging
q clutch slipping
q engine overheated
q engine level too high
q engine oil viscosity too high
q others
3-87
3-2 EFI System
NOTE
●This is not an exhaustive list, giving every possible cause for each problem listed. It is
meant simply as a rough guide to assist the troubleshooting for some of the more common
diffi culties.
●The ECU may be involved in the EFI electrical and ignition system troubles. If these parts
andcircuits are checked out good, be sure to check the ECU for ground and power supply. If
the ground and power supply are checked good, replace the ECU.
Symptoms or possible C auses Actions (chapter)
Starter motor doesn’t rotate:
Ignition and engine stop switches not ON Turn both switches ON .
Clutch switch or neutral switch trouble Inspect (see chapter 16).
Starter motor trouble Inspect (see chapter 16 ).
Low battery voltage Inspect and charge (see chapter 16)
Starter or auxiliary relays not contacting or
Inspect the starter relay (see chapter 16
operating
Starter button not contacting Inspect and replace (see chapter 16).
Starter system wiring o pen or shorted Inspect the wiring (see chapter 16).
Ignition switch trouble Inspect and replace (see chapter 16)
Main 20A or ECU ignition fuse blown Inspect and replace (see chapter 16).
Starter motor rotating but engine
doesn’t turn:
Starter clutch trouble Inspect (see chapter 16).
3
Starter idle gear trouble Inspect (see chapter 16).
engine doesn’t turn:
Valve seizure Inspect and replace (see chapter 5).
Cylinder, piston seizu re Inspect and replace (see chapter 5).
Camshaft seizure Inspect and replace (see chapter 5).
Connecting rod small e nd seizure Inspect and replace (see chapter 9).
Connecting rod big end seizure Inspect and replace (see chapter 9).
Crankshaft seizure Inspect and replace (see chapter 9).
Transmission gear or b earing seizure Inspect and replace (see chapter 9).
Balancer bearing seizu re Inspect and replace (see chapter 9).
No fuel:
No or little fuel in tank Supply fuel (see Owner’s Manual).
Fuel pump not rotatin g Inspect (see chapter 3).
Fuel injector trouble Inspect and replace (see chapter 3).
Fuel filter or pump scre en clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator clogged Inspect and replace fuel pump (see chapter 3).
Engine overflow:
Starting technique fau lty W hen flooded, don’t crank engine with throttle
fully opened.
No spark or spark wea k:
Ignition and engine stop switches not ON Turn both switches ON
3-88
CFMOTO
Symptoms or possible Causes Actions (chapter)
Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral
whether side stand up or not
Though clutch lever pulled in, side stand up and Side stand down and clutch lever pulled in
gear not in neutral whether gear in neutral or not
Vehicle-down-sensor coming off Reinstall (see chapter 3).
Vehicle-down-sensor trouble Inspect (see chapter 3).
ECU ground or power supply trouble Inspect (see chapter 3).
Ignition coil trouble Inspect ignition coil (see chapter 16).
Replace it with the correct plug (see chapter
16).
Neutral, starter lockout or side stand switch trouble Inspect each switch (see chapter 16).
Ignition switch shorted Inspect and replace (see chapter 16).
Engine stop switch shorted Inspect and repair or replace (see chapter 2).
Inspect and repair or replace (see chapter
Starter system wiring shorted or open
16).
Main 20A or fuse (15V) of fuel pump relay blown Inspect and replace (see chapter 16).
Air cleaner clogged, poorly sealed or missing Clean or reinstall (see chapter 3).
Leak from oil filler cap, crankcase breather hose or Inspect and repair or replace (see chapter 3).
air cleaner drain hose
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system
(see chapter 3).
(see chapter 3)
Fuel pressure may be low Inspect (see chapter 3).
Cylinder pressure is low:
Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).
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3-2 EFI System
Valve guide worn Inspect and replace (see chapter 5).
Valve not seating properly (valve bent, worn Inspect and repair or replace (see
or carbon accumulating on seating surface) chapter 5).
Poor running at low speed
Spark weak:
Stick coil trouble Inspect the stick coil (see chapter 16).
Reinstall or inspect stick coil (see chapter
Stick coil shorted or not in good contact
16).
Replace it with the correct plug (see
chapter 16).
Little fuel in tank Supply fuel (see Owner’s Manual).
Air cleaner clogged, poorly sealed, or Clean element or inspect sealing (see
3
missing chapter (2,3)
Throttle body sensor not calibrated or
calibration is incorrect
Air inlet pipe damage Replace (see chapter 3).
Inspect and replace fuel pump (see
Fuel filter or pump screen clogged
chapter 3).
Fuel pressure regulator clogged Inspect fuel pressure and replace fuel
pump (see chapter 3)
Thermostat trouble Inspect and replace (see chapter 4).
Unstable (rough) idling:
Throttle valves not synchronizing Inspect (see chapter 3).
3-90
CFMOTO

Incorrect idle speed:
is incorrect
Engine stalls easily:
see diagnosis
is incorrect
(see chapter 3).
Compression Low:
Piston ring bad (worn, weak, broken or sticking ) Inspect and replace (see chapter 5).
Valve guide worn or stem seal damaged Inspect and replace (see chapter 5).
Valve not seating properly (valve bent, worn or Inspect and repair or replace (see chapter 5).
carbon accumulating on seating surface)
Work with hesitation:
Fuel pressure too low Inspect (see chapter 3
Fuel pump trouble Inspect (see chapter 3
Fuel injector trouble Inspect (see chapter 3
Inlet air temperature sensor trouble Inspect (see chapter 3
Main throttle sensor trouble Inspect (see chapter 3
Coolant temperature sensor trouble Inspect (see chapter 3
Injector connectors loose Remedy (see chapter 3).
Crankshaft position sensor trouble Inspect and repair or replace (see chapter 16).
Stick coil trouble Inspect and repair or replace (see chapter 16).
Loose terminal of battery (–) cable or engine Inspect and repair (see chapter 16).
3-91
3-2 EFI System

Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see
chapter 16).
Poor acceleration:
Water or other matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Stick coil trouble Inspect and replace (see chapter 16).
Engine oil level to high Repair (see chapter 7).
Spark plug dirty, broken or gap maladjustedReplace (see chapter 2).
Stumble:
Main throttle sensor malfunction Inspect (see chapter 3).
Surge:
3
Unstable fuel pressure Fuel pressure regulator trouble (Inspect and replace
fuel pump) or kinked fuel line (Inspect and repair fuel
line) (see chapter 3).
Backfiring when deceleration:
Spark plug dirty, broken or gap maladjustedReplace (see chapter 2).
After fire:
Spark plug burned or gap maladjusted Replace (see chapter 2).
Engine can’t be stopped:
Ignition switch trouble Inspect and replace (see chapter 16).
3-92
CFMOTO

Loose terminal of battery (–) cable or ECU Inspect and repair (see chapter 16).
ground lead
Carbon accumulating on valve seating Repair (see chapter 5).
chapter 17)
Other:
Drive train trouble Inspect drive chain (see chapter 2) and sprocket
(See chapter 11).
12)
chapter 17)
Intermittent any EFI fault and its recovery Check that EFI connectors are clean and tight, and
examine wires for signs of burning or fraying (see
chapter 3).
Poor Running or No Power at High Speed：

Firing incorrect:
Spark plug dirty, broken or maladjusted Replace (see chapter 2).
Stick coil trouble Inspect stick coil (see chapter 16).
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or
Clean element or inspect sealing (see chapter 3).
missing
Air cleaner O-ring damaged Replace (see chapter 3).
chapter 3).
Throttle body assy O-ring damaged Replace (see chapter 3).
Fuel pump operates intermittently and Pump bearings may wear. Replace the pump
often EFI fuse (15V)blows. (see chapter 3).
3-93
3-2 EFI System
Symptoms or Possible Causes

Actions (chapter)
tightened down
Fuel injector clogged Visually inspect and replace (see chapter 3).
Compression low:
Cylinder head not sufficiently Tighten (see chapter 5).
Piston ring bad (worn, weak, broken or
Inspect and replace (see chapter 5).
sticking)
Cylinder head gasket damaged Replace (see chapter 5) .
Valve not seating properly (valve bent , Inspect and repair or replace (see chapter 5).
worn
Knocking:
Carbon built up in combustion chamber Repair (see chapter 5). 3
Fuel poor quality or incorrect (Use the Change fuel (see chapter 3).
gasoline (See Owner’s Manual)
Others：
Throttle valves won’t fully open Inspect throttle cable and lever linkage (see
chapter 3).
12).
Engine overheating - Water temperature (See Overheating of Troubleshooting Guide in
sensor chapter 17).
Engine oil level too high Repair (see chapter 7)
Drive train trouble Inspect drive chain (see chapter 2) and sprockets
(see chapter 11).
3-94
CFMOTO
Symptoms or Possible Causes tightened

Actions (chapter)
down
Exhaust Smokes Excessively:
(White smokes)
Piston oil ring worn Inspect and replace (see chapter 5).
Cylinder worn Inspect and replace (see chapter 5).
Valve oil seal damaged Replace (see chapter 5)
Valve guide worn Replace the guide (see chapter 5).
Engine oil level too high Repair (see chapter 7).
Water into fuel
Symptom s or Possible
Cau ses Actions (chapter)
(B lack smoke)
Air cleaner cl ogged C lean (see chapter 3).
Too high fuel pressure Inspect (see chapter 3).
Injector s tuc k open Inspect (see chapter 3).
Coolant temperature sensor trouble Inspect and replace (see chapter 3).
Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
3-95
3-2 EFI System
Self-diagnosis
Self-diagnosis Outline
ECU constantly monitor sensors, actuators
and circuits, MIL and battery voltage, etc, even
ECU itself and inspect the sensor output
signal, actuator drive signal and internal sig-
nal ( such as close loop control, coolant
temperature, idle speed control and battery
voltage control, etc.) for reliablity. If any pro-
cess or signal is suspect, ECU records the
trouble code in the RAM memory.
Faulty information is recorded in the form of
trouble code, and in the sequence of which
trouble comes first.
When servicing, using PDA and MIL, the de-
fective parts can be promptly foud to improve
the service efficiency and quality.
When a problem occurs with the EFI system
and ignition system, the MIL (LED) [A] goes
3
on.
650MT
Note
Use a fully charged battery when conducting
self-diagnosis. Otherwise, the light (LED)
blinks very slowly or doesn’t blink.
A
MIL Flashing Conditions

gine does not work. No trouble code
appears:
●MIL keeps on for 4 seconds and then turns
off. Or start engine before MIL off.
gine dose not work. Trouble code appears:
●Diagnosing light keep on for 4s and off for
1s. Then blinking for 2Hz.
IF: Turn on the ignition switch and the engine
works. Trouble code appear:
●Diagnosing light blinking in 2Hz.
3-96
CFMOTO
Indicator light blinking control
Flashing code needs special function to become true. Beore the engine start
(Speed is 0 and engine RPM is 0),turn the throttle into full opened(Or throttle
valve opened over 65.1),and keep the throttle full open;then turn the ignition on,if
the EMS diagnosed the trouble out,the indicator light will be off after shining 4s,
then flash frequency is 2Hz.If the EMS diagnosed the trouble,indicator light will
blinking the code,trouble light will stop blinking for 1s between 2 numbers. If
EMS diagnosed two trouble at the same time,indicator light will blinking from
the sequence of troubles. Between two trouble codes,indicator light will be off for
4s,after blinkong all trouble codes,the light turns off aeronautically.
During the running engine,MIL is on when system diagnoses fault parts. Restart
ignition switch after engine flame out,if the system detected that the fault is
repaired,fault light will be on constantly until start engine. If the system still de-
tected fault,the fault light will be on,after the engine starts,the fault light will be on
constantly.
Error Code Instruction

Fault codes based on five code. For example P0560. MIL through left side to right side at 1
Hz frequency showing fault. If one code is 0, MIL will flash 10 times. For example, error code
P0560 flash way is : light on for 4s and off for 1s- flash for 10 times-stop- flash for 5 times-
stop-flash for 6 times-stop-flash for 10 times. Error codeP0112,P0122 flash way: light on for
4s and off for 1s-flash for 10times-stop-flash for 1 time-stop-flash for 1 time-stop-flash for 2
times-off for 4s-flash for 10 times-stop-flash for 1 time-stop-flash for 2 times-stop-flash for 2
time-off.
3-97
3-2 EFI System
How to Erase Error Codes
●Even if ignition switch is turned off, the battery or the ECU is disconnected or the prob-
lem is solved, all trouble codes remain in ECU.
● For the current fault code, if a fault does exist, then the current fault code cannot be
eliminated; Restart the vehicle after troubleshooting eliminated, and advance the throttle
above 2500upm, fault light is off when failover.But previously fault still can be read by PDA
that had been stored in the system information, this information can be cleared directly
through PDA, or automatically cleared after five warm up cycle.(Warm up cycle means a
loop that water temperature is less than 51 degrees after engine start , and water tempera-
ture is higher than 71 degrees after warming )
●Refer to the eliminated parts of PDA error code to eliminated error code.
Diagnose error by PDA
PDA has many functions which is more intuitive, more accurately and more quickly than FI
light. We recommend you to use PDA for the following functions:
●PDA can read ”Error code” directly and eliminate them.
●PDA has the function of ”Read data stream” which can reflect vehicle operating situation,
and also judge EFI error.
●PDA with an "actuator test" function, you can use this feature to check the continuity of the 3
cable and whether the electronic fuel injection parts is good.
«PDA usage refer to chapter ”PDA Use”
3-98
CFMOTO
Trouble Code Chart
NO. Pcode Decription(UAES)

Manifold Abs.Pressure or Bar.Pressure Low
7 P0107
Input
Manifold Abs.Pressure or Bar.Pressure High
8 P0108
Input
9 P0112 Intake Air Temp.Circ. Low Input
10 P0113 Intake Air Temp.Circ. High Input
11 P0117 Engine Coolant Temp.Circ. Low Input
12 P0118 Engine Coolant Temp.Circ. High Input
13 P0122 Throttle Pos.Sensor Circ. Low Input
14 P0123 Throttle Pos.Sensor Circ. High Input
18 P0134
Detected
22 P0154
Detected
29 P0322 Ign./Distributor Eng.Speed Inp.Circ. No Signal
30 P0480 cooling fan control Circuit Open
31 P0511 Idle Air Control Circui
32 P0560 System Voltage Malfunction
33 P0562 System Voltage Low Voltage
34 P0563 System Voltage High Voltage
35 P0627 Fuel Pump “A” Control Circuit /Open
36 P0629 Fuel Pump “A” Control Circuit High
37 P0650 Malfunction Indicator Lamp Control Circ.
38 P0691 cooling fan control Circuit Low
39 P0692 cooling fan control Circuit High
40 P0501 Vehicle Speed No Sensor
41 P1116 Engine Coolant Temp High
42 P0602 Control Module Programming Error
Engine Coolant Temp Sensor Circuit Range/
43 P0116
Performance
44 P1098 ROLL Sensor Malfunction
3-99
3-2 EFI System
Note:
●If all the parts and circuits checked out good, be sure to check the ECU for ground and
power supply. If the ground and power supply are checked good, replace the ECU.
●If theere is no trouble code is displayed, then the electrical parts of the EFI system has
no fault, but the mechanical parts of the EFI system and the engine are suspect.
3-100
CFMOTO
Solutions
The ECU takes the following measures to prevent engine damage when the EFI or the
ignition system parts have troubles.
Trouble Output Signal Unstable

Parts Backups by ECU
Codes Range or Criteria
Inlet Air If the inlet air tem sensor fails(the signal is
P0112 or Temp Inlet Air Temp out of the usable range, wiring short
P0113 Sensor Ta=－40°C~+130°C or open), the ECU sets temperature at
40°C or 130°C ；
Coolant If the water temp sensor system fails(the
P0117 or Temp Water Temp Sensor signal is out of the usable range, wiring
P0118 Sensor Tw=－40°C~+129°C short or open), the ECU sets Temp. at
-40°C or 129°C
The oxygen sensor is If the oxygen sensor is not activated or

P0130,
active and sensor must correct, the ECU stops oxygen sensor
P0131, Oxygen feedback mode.
send signals (output
P0132& Sensor #1
voltage) continuously to
P0134
the ECU.
The oxygen sensor is
P0150,
active and sensor must If the oxygen sensor is not activated or
P0151, Oxygen
send signals (output correct, the ECU stops oxygen sensor
P0152& Sensor #2
voltage) continuously to feedback mode.
P0154
the ECU.
3-101
3-2 EFI System
EFI System Service
Throttle Position Sensor Service
Throttle Position Sensor Removal/Adjust-
ment
CAUTION
Do not remove or adjust the throttle po-

sition sensor [A] since it has been ad-
justed and set with precision at the
factory.
Never drop the throttle body assy, espe- A
cially on a hard surface. Such a shock to
the sensor can damage it.

Inspection
NOTE
● Disconnect the throttle position sensor
connector and connect the harness adapter 3
[A] between these connectors.
● Connect a digital meter to the harness
adapter lead. A
engine stopped and with the connector joined.
Meter(+)→ Gr/R(C)
Meter(-)→ Lg/Y(D)
Standard： 4.75V～5.25V DC
（c o n n e c t o r o f f ）

«If the input voltage is normal, check the sen-
sor output voltage.
«If the input voltage is less than the standard,
remove the ECU and check the wiring be-
tween these connectors.
3-102
CFMOTO
●Using multimeter to test the continuity of
the 2 lead wires
Connector[B]
Throttle Body ConnectorGr/R ←→ ECU
terminal 30
Throttle Body ConnectorLg/Y ←→ ECU
terminal 10
Standard：0 Ω
Supply Inspection).
Main Throttle Sensor Output Voltage

Inspection
Measure the output voltage at the main
throttle sensor in the same way as input
voltage inspection, Note the following:
●Disconnect the main throttle sensor con-
nector and connect the harness adapter [A]
between these connectors.
●Start the engine and warm it up thoroughly.
（A b o v e 8 0 ℃）。
● Check idle speed to ensure the throttle
opening is correct and adjust screw is ok.
Idle Speed Standard: 1450r/min ±
145r/min
range, adjust it (Inspect throttle cable and EFI A
system).
●Measure the output voltage of the sensor
with the engine stopped, and with the con-
nector joined.
3-103
3-2 EFI System
Throttle Service
Throttle Position Sensor Output Voltage
Meter(+)→ Br/R(sensor output) lead
Meter(+)→ Lg/Y((sensor ground)lead
Standard:
Idle throttle opening: 0.4V～0.8V DC
Full throttle opening：≥ 3.9V DC
«If the output voltage is out of the standard,

i n sp e c t t h e ma i n t hr o t t le se nso r
resistance.
«If the output voltage is normal, check the
wiring for continuity.
3
Wiring Connection
●Test the continuity of the 2 lead wires.

Connector[B]
Throttle Body Connector Br/R ←→ ECU
terminal 12
Throttle Body Connector Lg/Y ←→ ECU
terminal 10
Standard：0 Ω
Supply Inspection).
3-104
CFMOTO
T-MAP Sensor Service
CAUTION
can damage it.
T-MAP sensor output voltage

inspection.
● Make sure the battery get fully charged
●The output voltage changement follows
the intake
tempchanging.
●Remove the ECU(See ECUremoval).Do
not disconnect theECUconnector.
● Use adapter to connecter and ECU.
● Stop the engine and meter connected.
Measure
the out put voltege.
● Turn the ignition switch on.
Intake temp sensor output voltage.
(Active line)
Meter(+) → W/Br( ECUpin 11)
Meter(-)→ L/G( ECUpin 10)
Standard: Output voltage when intake
temp 20℃
About 2.0V ~3.5V
Intakepressuresensor output voltage
(Dottedline)
Meter(+) → L/R(ECUpin 30)
Meter(-) → R/B(ECUpin 9)
Standard:Output voltagein normal
atmosphere.
About 3.5V~ 4.5V
Turnoff the ignitionswitch theECU groundwireandpowerline
«f theoutput voltageisnot in standard. (SeeECUpower inspection).
Remove the «If the wires are OK. Inspect the intake
fuel tank and check the wire. If the output temp sensor resistance.
voltage is ●Remove the adapter and use the sili-
5V.ECUis normal. con glue to seal the connector avoid
«If theoutput voltage isin standard. Inspect water.
3-105
3-2 EFI System
Inlet Air Temperature Sensor Resistance
Inspection
● Remove the inlet air temperature sen-

sor
machine oil so that the heat-sensitive por-
tion is submerged.
● Suspend a thermometer [B] with the
heatsensitive portion [C] located in almost
the same depth with the sensor.
NOTE
● The sensor and thermometer must not

touch the container side or bottom.
oil while stirring the oil gently for even
3
temperature.
●Using a hand tester, measure the inter-
nal resistance of the sensor across the termi-
nals at the temperatures shown in the table.
Inlet Air Temperature Sensor Resis-

tance
Standard：2 4 1 6 Ω～2 5 8 3 Ω（2 0 ℃）
273.2 Ω～285.8 Ω（85℃）
«If the measurement is out of the range, re-

place the sensor. If in ,replace the ECU.
3-106
CFMOTO
Intake temp and pressure sensor
Wiring diagram
1. ECU 2. Inlet Temperature & Pressure Sensor
3-107
3-2 EFI System
Water Temperature Sensor Service
Water Temperature Sensor Removal/Installation
Note
Never drop the sensor, especially on a hard

surface. Such a shock to the part can dam-
age it.
●Drain the coolant (see Coolant Change
●Disconnect the sensor connector [A], and
unscrew the water temperature sensor [B].
Torque : 12N·m
●Apply grease to new O-ring on the water
temperature sensor.
●Fill the engine with coolant and bleed the A
B
air from the cooling system (see Coolant
chapter).

3
Inspection
●Remove the ECU (see ECU Removal).
Do not disconnect the connectors.
● Connect a hand tester [A] to the ECU
connector [B] with the needle adapter set.
the engine stopped and the connector
joined.
Meter (+)→ Gr/Wlead(ECU terminal 13)

Meter (-)→ L/G lead (ECU terminal
10)
Standard: 2 .0 V ～3 . 5 V （20 ℃）
3-108
CFMOTO
Coolant Temperature Sensor Service
NOTE
●Coolant temperature sensor output voltage varies with the coolant temperature change.
●Turn the ignition switch off.
«If the output voltage is within the standard, check the ECU for its ground, and power supply
(see ECU Power Supply Inspection).
«If the output voltage is out of the standard, check the wiring. And if the output voltage is 4.
8 V, the ECU is normal.
«If the wiring is good, check the water temperature sensor resistance.
●Remove the needle adapter set, and apply silicone sealant to the seals of the connector
for waterproofing.
Water Temperature Sensor Circuit
1. ECU 2. Coolant Temperature Sensor
Coolant Temperature Sensor Resistance Inspection

● Remove coolant temperature sensor (refer to
Co o la nt Te m p e r a t ur e Se n so r Rem o va l/
Installation).
●Refer to Coolant Temperature Sensor Inspection.
3-109
3-2 EFI System
Crankshaft Position Sensor Service
Crankshaft Position Sensor Removal/Installation
●Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter.
Crankshaft Position Sensor Inspection

●The crankshaft sensor has no power source, and when the engine stops, the crankshaft
sensor generates no signals.
●Crank the engine and measure the peak voltage of the crankshaft position sensor (see
Crankshaft Sensor Inspection in the Electrical System) in order to check the sensor.
●Check the wiring for continuity, using the following diagram.
Crankshaf Position Sensor Circuit
1. ECU 2. Crankshaft Position Sensor
3-110
CFMOTO
Speed Sensor Service
Speed Sensor Removal/Installation
●Refer to the Speed Sensor Removal/Instal-
lation in the Electrical System chapter.
●Refer to the Speed Sensor Inspection in
the Electrical System chapter.
Speed Sensor Input Voltage Inspection
NOTE
● Disconnect the speed sensor connector
and connect the harness adapter [A] between
the harness connector and speed sensor A
connector.
adapter leads.
joined.
Speed Sensor Input Voltage
Meter(+)→ W/G(sensor)lead[C]
Meter(-)→ G/B (sensor)lead[D]
Standard: About 9~13VDC at Ignition
Switch ON
«If the reading is out of the range, check the
wiring (see wiring diagram in this section)
«If the reading is good, check the output
voltage.
Speed Sensor Output Voltage

● Before this inspection, inspect the input
voltage (see Speed Sensor Input Voltage
Inspection).
NOTE
●Disconnect the speed sensor connector A
3-111
3-2 EFI System
and con nect the harness adapter [A] be-
tween the harness connector and speed sen-
sor connector.
adapter leads.
●Measure the sensor output voltage with the
joined.
Speed Sensor Output Voltage at Sensor

Meter(+)→ P(sensor) lead [C]
Meter(-)→ G/B(sensor) lead [D]
Standard: About 0.05~1.0VDC
Speed Sensor Circuit
1. Speed Sensor 2. Dashboard
3-112
CFMOTO
Roll-over Sensor installation/ Removal
CAUTION

can damage it.
Removal：
●Disconnect connector [B] and roll-over
sensor [A].
Installation：
●Roll-over sensor should be installed as il-
lustrated
WARNING
Incorrect installation of the vehicle-down

sensor could cause sudden loss of en-
gine power.The rider could lose balance
during certain riding situations like lean-
ing over in a turn with the potential for an
accident resulting in injury or death. En-
sure that the down sensor is held in place
by the sensor brackets.

spection (No tilt)
NOTE

tor [B] of the roll-over sensor [C] with the
needle adapter set [D].
the engine stopped, and with the connector
joined.
Meter(+)→ Gr/B lead[E]
Meter(-)→ L/G lead[F]
3-113
3-2 EFI System
●Turn the ignition switch on and measure
roll-over sensor power source voltage.
Roll-over Sensor Output Voltage(No tilt):
Standard: 12V DC (battery voltage)
«If the reading of input voltage is less than the
standard, check the ECU for its ground, power
supply and wiring shorted.
«If the wiring is normal, check roll-over sensor
resistance.
● Remove the whole set of needle adapter and
with silicone sealant applied to the connector.
spection (when tilted)
●Remove the sensor [G] (see Roll-over Sen-
sor Removal).
tor [B] with needle adapter set [D].
3
Meter(+)→Gr/B lead[E]
Meter(-)→L/G lead[F]
●Hold the sensor vertically.
●Turn the ignition switch ON, and measure
the output voltage with the connector joined.
●Tilt the sensor 55°~75 °degrees or more
[C] right or left, then and measure the
output voltage.
Sensor Output Voltage
Standard: 0V~0.5V
NOTE
●If you need to test again, turn the ignition
switch OFF, and then ON.
●Remove the needle adapter set, and ap- «If the wiring is good, check the ECU for its
ply silicone sealant to the seals of the con- ground and power supply (see ECU Power
nector for waterproofing. Supply Inspection).
«If the output voltage is normal, the wiring «If the output voltage is out of the specified,
is suspect. Check the wiring. replace the roll-over sensor.
3-114
CFMOTO

Oxygen Sensor Removal/Installation
WARNING
Never drop the sensor [B], especially on

a hard surface. Such a shock to the part
can damage it. Do not touch the portion
[A] of the sensor, otherwise, the oil resi-
due on your hand may contaminate the
sensor and cause performance
degeneration.
Oxygen Removal
Disconnect connector[A] and remove

oxygen sensor [B].
Oxygen Sensor Installation
Connect oxygen sensor [B] and connector

[A].
Torque: 6 0 N ·m ± 2 N ·m
3-115
3-2 EFI System
Oxygen Sensor Output Signal Inspection
●Place the transmission in neutral
●Start the engine and throughly warm it
up, then have the engine run at more than
8000rpm.
●Measure oxygen sensor output volatage
using meter[B].
Oxygen Sensor Output Voltage

Cylinder 1:
Meter(-)→4 terminal[D]
Cylinder 2:
Meter(-)→4 termina[D]
3
Standard：About 0.8V

●Place the transmission in neutral.
●Start the engine and let it idle.
3-116
CFMOTO
●Remove the hose [B].
●Measure oxygen sensor output voltage

with hand tester [B].
Cylinder 1:
Cylinder 2:
Meter(+)→3terminal[C]

Standard: about 0.1V
●Use the meter [B] to measure the sen-

sors resistance.
Sensor heat up resistance
Cylinder 1
Cylinder 2
Standard: About 1 Ohm.
3-117
3-2 EFI System
Ignition Coil Service
Ignition Coil Removal/Installation
WARNING

can damage it.
Ignition Coil Input Voltage Inspection

NOTE
●Remove the ignition switch connector [A].
●Connect a hand tester [B] as shown.
●Measure the input voltage to each pri-
mary winding of the ignition coils with the
engine stopped, and with the connectors
joined.
●Turn the ignition switch ON. Measure the 3
ignition coil input voltage during fuel pump
working time.
Ignition Coil Input Voltage:
Ignition coil 1#：

Meter(-)→ Ground
Standard: About 12VDC
Ignition coil 2#：

Meter(+)→ Ground
Standard: About12VDC
3-118
CFMOTO
Ignition Coil
Ignition Coil Circuit
1. Main Fuse 2. Battery

7. Main Relay 8. Ignition Coil 2#
9. Ignition resistor 2# 10. Ignition Coil 1#
11.Ignition resistor 1#
3-119
3-2 EFI System
MIL Service
Flowing diagram of MIL
Replace the
Ignition on dashboard or cable
Trouble
No See the indicator

Trouble indicator and cable
Light up
Normal
Then indicator light Indicator and EFI

after engine run are normal
No
3
Yes
No
Ignition off then EFI tested
on ,Indicator light historical trouble
still on after 4s
Yes
Off the ignition
EFI tested Current switch turn to clear
trouble . up the code
No
Ask the driver if the
Off the ignition EFI OK
trouble comes out
switch turn to
again
clearing of the fault
Yes
Replace
3-120
CFMOTO
MIL Service
MIL check
●Disassemble the dashboard (See dashboard replacement on chapter 16).
●Use four auxilary connect the dashboard to the battery for MIL.
The battery voltage should be 12V

Positive pole(+)→ Dashboard pin 1 and pin 2
Negative pole(-)→ Dashboard pin 3 and pin 13
MIL should be on after connected.
●If the trouble indicator light doesnot on. Replace the dashboard.
MIL Circuit
1. Main Fuse 2.Battery

7. Main relay 8. Dashboard
3-121
3-2 EFI System
ECU Service
ECU assembly/ disassembly
Attention A
Do not drop the ECU, especially hard

cover. Or the shock from the impact will
damage the ECU.
ECU disassembly
●Disassemble the seat.
●Take out the ECU[A] and wires.
● Disconnect the ECU connector[B]。
ECU Assembly
● Assemble the ECU and connect the
connector. B
ECU power and ground wire checking

●Eye check the ECU connector.
«If the connector is jammed by the dust or 3
mud. Use the compressed air clean up.
«If the cable connector has cracks, bent or
damage.Replace the maincable.
«If the ECU connector has cracks,bent or
damaged.Replaced the ECU.
●With the ECU connector[A]connected. Off
the ignition switch. Use the AVO meter To
check the ground wire connection below.
Battery[B]
AVO meter[C]
ECU ground wire check

Connector pin 5, pin 48←→Battery(-):0 ohm
Engine ground wire ←→ Battery(-):0 ohm
«If the ground wire is not connected.Check

the connector,engine ground wire or main cable.
Replace or repair if nacessary.
3-122
CFMOTO
●Check the ECU power voltage with a hand
tester [A].
●Use the drawings in this chapter to see the
ECU connector [B] numbers and position the
pins.
Battery [C]
Meter Connections:
When ignition Switch is OFF:
Pin 33 and battery(-): Battery voltage
(12.8V or higher)
Pin 8 and battery(-):0V
When ignition Switch is ON and Engine Stop
Switch is ON:
Pin 8 and Battery(-): Battery voltage
(12.8V or higher)

check the following.
●Main Fuse 20A(see Fuse Inspection in the
●ECU fuse 7.5A(see Fuse Inspection in the
Power SourceWiring (see wiring diagram
below)
«If the inspection checks good, the ECU is
damaged. Replace the ECU (see ECU
Removal/Installation). The ECU itself cannot
be checked or serviced.
3-123
3-2 EFI System
E C U Service
ECU wiring diagram
1. Fuse 2.Battery
3. ECU 4. Ignition switch
5. Main fuse 6. Engine stop switch
7.Main relay
3-124
CFMOTO
Fuel pressure check
Attention
● Pressure check can tell you where the
problem comes from. Including EFI system
problem, mechanical problem or electrical
problem.
●If the vehicle got problem on running. The
fuel pressure test can be easier to find the
reason.
● Make sure that battery is fully charged.
Fuel pressure test
●Disassemble the fuel tank.
● Make sure the fure pipe connector has
been wrap around by a cloth to avoid the fuel
leaking.
●Pressure the lock [A].
●Disassemble the fuel pipe[C].
Warning
Avoid the fuel leaking. Leaked fuel must
be cleaned up immediately.
Fuel will flow from hose and pipe when
fuel hose is disconnected. Use a clean
cloth to cover hose connection part.
● Assemble the fuel pressure adapter[A]be-
tween the fuel outlet pipe[B]and the fuel rail[C].
Warning
Do not start the engine with thefuel pipe
disconnected.
Fuel tank[E], Pressure meter[D],Connector[F]

● Connect the connector tightly, make sure
there is no leak.
●Turn the ignition switch on. Let the fuel pump
running 3 second,then stop.
Warning
Do not start the fuel pump when the tank
is empty .
3-125
3-2 EFI System
Fuel pressure check
●Stop the engine to test the fuel pressure.
Fuel pressure
When ignition switch is on and fuel pump is

running:
After the ignition switch is on for 3s and fuel pump
stoped.
The pressure should be kept for 30s
The pressure meter[A] tip[B] will wave when
testing. Get the average pressure between the
Max and min.
«If the fuel pressure is normal. The fuel circu-
lation system(Fuel pump, Pressure adjuster,
Fuel pipes)is OK.Check the EFI system
(Injector, Each sensor,ECU).
« If the pressure is lower than mormal
3
standard. Check the item below.
●Fuel pipe leaking.
● Fuel pump running( Check the fuel pipe
sound).
●Fuel pump flow( See the fuel pump flowing
inspection).
« If the pressure is higher than normal
standard. Inspect the item below：
●Fuel pipe jammed.
●Injector jammed.
●Adjuster of the fuel pump damaged.
3-126
CFMOTO
Fuel pump service
Attention
●Make sure the pattery fully charged.
Warning
switch OFF. Be prepared for fuel spillage;
any spilled fuel must be completely wiped
up immediately.
● Turn the ignition switch and engine stop
switch off.
●Waiting for engine cool down.
●Prepare a plastic hose of the inside diam-
eter 7.5mm (0.30 in.) and a measuring
cylinder.
●Disassemble the fuel tank bolt.
●Open the fuel tank cap[A] To release the
pressure.
Warning
Be prepared for fuel spillage; any spilled
fuel must be completely wiped up
immediately. When the fuel hose is
disconnected, fuel spills out from the
hose and the pipe because of residual
pressure. Cover the hose connection
with a piece of clean cloth to prevent fuel
spillage.
● Connect the plastic hose [A] to the fuel

pump outlet pipe.
●Secure the plastic hose with a clamp [B].
●Insert the plastic pipe into measuring cylin-
der [C]
3-127
3-2 EFI System
Fuel pump service
Warning
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder
vertical.
●Assemble the fuel tank.

●Ignition on with the engine stop.Running the
fuel pump for 3s.Then stop. Repeat several
times until the pipe full of fuel.
Warning
Do not drive the fuel pump without the
fuel inthe fuel tank.
●Measure the discharge for 3 seconds with
the plastichose filled with fuel.
●Repeat this operation several times.
Amount of Fuel Flow
Standard: 60 mL or more for 3 seconds 3

« If the fuel flow is much less than the
specified, check the battery condition (see
Charging Condition In spection in the Electri-
cal System chapter). If the battery is good,
replace the fuel pump (see Fuel Pump Re-
moval/Installation).
●After inspection, install the fuel tank (see
Fuel Tank Installation).
● Start the engine and check for fuel
leakage.
3-128
CFMOTO
Fuel Pump
Fuel Pump Removal
Warning
Never drop the fuel pump, especially on
a hard surface. Such a shock to the
pump can damage it.
Warning
switch OFF. Disconnect the battery (-)
terminal.To make fuel spillage minimum,
draw the fuel out from the fuel tank when
the engine is cold. Be prepared for fuel
spillage; any spilled fuel must be com-
●Draw the fuel out from the fuel tank.

● Remove the fuel tank (see Fuel Tank
Removal).
●Be careful of fuel spillage from the fuel
tank since fuel still remains in the fuel tank
and fuel pump. Plug the fuel pipe of the fuel
tank.
●Turn the fuel tank upside down.
«Remove:
●Fuel Pump Bolts [A].
●Fuel Pump [B].
●Replace fuel pump gasket [C] if dam-
aged
Warning
Do not pull the lead of the fuel pump. If
they are pulled, the lead terminals may
be damaged.
3-129
3-2 EFI System
Fuel Pump
Fuel Pump Installation
●Clean dirt or dust from the fuel pump [B] by
lightly using compressed air.
● Replace the fuel pump gasket [C] with a
new one if damaged.
●Tighten the fuel pump bolts to a snug fit,
tighten them in a crisscross pattern.
Torque - Fuel Pump Bolts: 5 N·m
●Tighten the pump bolts again in a criss-
cross pattern to check the tightness.
Fuel Pump Operation Inspection

NOTE
● Just listen to the pump sound in the fuel
tank to confirm pump operation.
●Turn the ignition switch ON and make sure
that the fuel pump operates (make light
sounds) for 3 seconds, and then stops.
●Turn the ignition switch OFF
3
«If the pump does not work as described
above, inspect the operating voltage.
Fuel Pump Operating Voltage Inspection

NOTE
●Turn the ignition switch OFF and disas
semble the tank.
●Disconnect fuel pump connector[A]
●Measure the voltage when engine stops.
●The tester needle should indicate battery
voltage for 3 seconds, and then 0 V.
Tester Connections:
Tester(+) → terminal 1(lead B/Y)
Tester(-) → terminal 2(lead G)
With the ignition switch on:
Standard: Battery Voltage keeps for 3
seconds, and then goes to 0 V.
3-130
CFMOTO
Fuel Pump
«If the reading stays on battery voltage, and
never shows 0 V. Check the ECU and fuel
pump relay.
«If the voltage is normal but fuel pump does
not work, replace the fue pump.
«If thereis no battery voltage, check the fuel
pump relay.
Pressure Regulator Removal

●The pressure regulator [A] is built into the
fuel pump [B] and cannot be removed.
● If the pressure regulator is suspected of
clogging or being damaged, replace the fuel
pump as a set.
Pump Screen, Fuel Filter Cleaning

●The fuel filter [A] is built into the pump and
cannot be cleaned or checked.
●If the fuel filter is suspected of clogging or
being damaged, replace ithe fuel pump as a
set.
3-131
3-2 EFI System
Fuel pump
Fuel pump wiring diagram
3
1. Fuse 2. Battery
7. Main relay 8. Relay, fuel pump
9. Fuel pump1
3-132
CFMOTO
Fuel Injector Service

Fuel Pump Removal/Installation
●Refer to the Throttle Body Assy Disassem-
bly/Assembly.
Audible Inspection
●Start the engine.

●Apply the tip of a screwdriver [A] to the in-
jector [B]. Put the grip end onto your ear, and
listen where the injector is clicking or not.(A
sound scope [C] can also be used.
●Do the same for the other injectors
«If all the injectors click at a regular intervals,

the injectors are good. The trouble may be
related to the fuel line, requiring fuel pres-
sure inspection.
●The click interval becomes shorter as the
engine speed rises.
●If any injector(s) doesn’t click, the EFI cir-
cuit or the injector is suspect. Perform fuel In-
jector Power Source Voltage Inspection”, first.
Fuel Injector Power Source Voltage Inspec-

tion
●Turn the ignition coil OFF
●Remove the air filter.
●Connect the fuel injector connector [A].
●Connect a hand tester [B] to the fuel injec-
tor connector.
Fuel Injector Output Voltage:
Cylinder 1:
Meter (+)→ lead [C]
Cylinder 2:
Meter (+) → lead [C]
3-133
3-2 EFI System
Fuel Injector
●Turn the ignition switch ON
Fuel fump input voltage is the battery volt-
age in first 3 seconds, then 0 V.
«If the output voltage is normal, perform in-
jector Signal Test
check the following :
●Main Fuse 20 A fuel pump relay fuse 15A
(see Fuse Inspection in the Electrical System
chapter)
●Fuel Pump Relay (see Relay Circuit In-
spection in the Electrical System chapter)
● Power Source Wiring (see wiring dia-
gram below)
Fuel Injector Wiring Inspection

●Connect a hand tester [A] to check the con-
tinuity between ECU connector [B] and fuel
injector connector [C]. Break-line part is cyl-
inder 2.
B 3
A
Cylinder 1:
ECU terminal 48 ----- lead [D]
Cylinder 2:
ECU terminal 47-------lead [D]
D
«If the wiring is good, inspect the resistance C

of the injectors (see Injector Resistance
Inspection).
3-134
CFMOTO
Fuel Injector
Injector Signal Test
●Prepare two test light sets with male ter-
minals as shown.
●Rating of Bulb [A]: 12 V ×3 ~ 3.4 W
Terminal Width [B]: 1.8 mm (0.071 in.)
Terminal Thickness [C]: 0.8 mm (0.031
in.)
CAUTION
Do not use larger terminals than speci-
fied above. A larger terminal could dam-
age the injector main harness connector
(female), leading to harness repair or
replacement. Be sure to connect bulbs
in series. The bulb works as a current lim-
iter to protect the solenoid in the injector
from excessive current.
Test Lights Wiring
●Remove the fuel tank(see Fuel Tank
●Disconnect the connector of fuel injector
[A].
● Connect each test light set [B] to the in-
jector sub harness connector [C].
●While cranking the engine with the starter
motor, watch the test lights.
«If the test lights flicker at regular intervals,
the injector circuit in the ECU, and the wiring
are good. Perform the "Injector Resistance
Inspection". Injector Signal Test : Prepare two
test light sets with male terminals as shown.
Rating of Bulb [A]: 12 V ×3 ~ 3.4 W Termi-
nal Width [B]: 1.8
«If the test light doesn’t flicker (or the tester
needle doesn’t oscillates), check the wiring
and connectors.
If the wiring is good, check the injector voltage.
If the wiring is good, inspect the ECU for its
Supply Inspection).
3-135
3-2 EFI System
Fuel Injector
Fuel Injector Resistance Inspection
● Remove the fuel tank(see Fuel Tank
Removal).
●Remove the air filter housing(see Air Fil-
ter Housing Removal).
●Disconnect the connector from the con-
nector [A].
●Measure the injector resistance with the
hand tester [B].
Injector Resistance:
Standard: 12.1 Ω± 1 Ω（2 0 ℃）
«If the reading is out of the range, perform

the “Injector Unit Test”.
Injector Unit Test

●Use two leads [A] and the same test light
set [B] as in “Injector Signal Test”.
Rating of Bulb [C]: 12 V× (3 ~ 3.4) W 3
12 V Battery [D]
CAUTION
Be sure to connect the bulb in series.
The bulb works as a current limiter to
protect the solenoid
●Connect the test light set to the injector [E]

as shown.
●Open and connect [F] the end of the lead
to the battery (-) terminal repeatedly. The in-
jector should click.
«If the injector does not click, replace the
injector.
«If the injector clicks, check the wiring again.
If the wiring is good, replace the injector (may
be clogged) or ECU.
3-136
CFMOTO
Fuel Injector
Fuel Injector Wiring Diagram
1. Fuse 2. Battery
7. Main relay 8. Fuel Injector 2
9. Fuel Injector 1
3-137
3-2 EFI System
Throttle Grip and Cables Service
Throttle Grip Free Play Inspection

Throttle Grip Free Play Adjustment
Throttle Cable Installation

●Install the throttle cables in accordance with Cable, Wire, and Hose Routing section in
the Appendix chapter.
●Install the lower ends of the throttle cables in the cable bracket on the throttle body assy
after installing the upper ends of the throttle cables in the grip.
●After installation, adjust each cable properly.
Warning
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding
condition.
Throttle Cable Lubrication

●Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter. 3
3-138
CFMOTO
Throttle Body Assy
●Refer to the Idle Speed Inspection in the
Engine Vacuum Synchronization Inspection/
Adjustment
●Refer to the Engine Vacuum Synchroni-
zation Inspection in the Periodic Maintenance
chapter.
Throttle Body Assy Removal
WARNING
Turn the ignition switch OFF. Disconnect
the battery (-) cable terminal. Do not
smoke. Make sure the area is well-venti-
lated and free from any source of flame
or sparks; this includes any appliance
with a pilot light. Be prepared for fuel
spillage: any spilled fuel must be com-
●Remove fuel tank (see Fuel Tank Removal)
● Air filter housing (see Air Filter Housing
Removal)
●Disconnect throttle Body Sensor Connec-
tor [A]
●Disconnect fuel Hose Lower End [B]
hose [C] of cylinder 1
●Loosen Clamp [D] of cylinder 1
●Disconnect Fuel injector connector [E] of
cylinder 1
● Disconnect Air intake tempreature and
pressure sensor[F].
●Disconnect the throttle cable[A].
●Loosen: Clamp [B]
● Disconnect fuel injector connector [C] of
clinder 2
hose [D] of cylinder 2
3-139
3-2 EFI System
Throttle Body Assy
●After removed the throttle body assy, put
clean cloth into the throttle body holders.
WARNING
If dirt gets into the engine, it will cause
engine excessive wear and damage .
Throttle Body Assy Installation

●Install the throttle body on the intake mani-
fold [A].
●Install the clamp bolts [B] in the direction
shown, facing outwards.
●Install the fuel injector connector, evapora-
tive emission control hose, throttle cable, high
pressure fuel line joint.
Warning
Operation with an incorrectly routed
cable could result in an unsafe riding
condition. 3
CAUTION
Do not remove, disassemble or adjust
the throttle position sensor [A], because
it is adjusted or set by the manufacturer.
throttle body assy.
CAUTION
Do not remove, disassemble or adjust the

idle adjusting screw [A], [B], because they
are adjusted or set by the manufacturer.
throttle body assy.
3-140
4 Cooling System
Exploded View…………………………………………………………………………… 4-2

Coolant Flow Chart……………………………………………………………………… 4-4
Specifications………………………………………………………………………………4-6
Special Tools………………………………………………………………………………4-7
Coolant………………………………………………………………………………………4-8
Coolant Deterioration Inspection…………………………………………………4-8
Coolant Level Inspection……………………………………………………………4-8
Coolant Draining………………………………………………………………………4-8
Coolant Filling…………………………………………………………………………4-8
Pressure Testing……………………………………………………………………4-8
Cooling System Flushing……………………………………………………………4-9
Coolant Reserve Tank Removal/Installation………………………………………4-9
Water Pump…………………………………………………………………………………4-10
Water Pump Removal…………………………………………………………………4-10
Water Pump Installation………………………………………………………………4-10
Mechanical Seal Inspection…………………………………………………………4-11
Water Pump Housing Disassembly…………………………………………………4-11
Water Pump Housing Assembly…………………………………………………4-11
Impeller Assembly…………………………………………………………………4-12
Pump Impeller Inspection…………………………………………………………4-12 4
Radiator……………………………………………………………………………………4-13
Radiator and Radiator Fan Removal……………………………………………4-13
Radiator and Radiator Fan Installation……………………………………………4-14
Radiator Inspection…………………………………………………………………4-14
Radiator Cap Inspection……………………………………………………………4-14
Radiator Filler Neck Inspection……………………………………………………4-15
Thermostat…………………………………………………………………………………4-16
Thermostat Removal …………………………………………………………………4-16
Thermostat Installation………………………………………………………………4-16
Thermostat Inspection………………………………………………………………4-16
Hose and Pipes……………………………………………………………………………4-18
Hose Installation………………………………………………………………………4-18
Hose Inspection………………………………………………………………………4-18
Coolant Temperature Sensor……………………………………………………………4-19
Coolant Temperature Sensor Removal/Installation………………………………4-19
Coolant Temperature Sensor Inspection…………………………………………4-19
4-1
CFMOTO
Exploded View
4-2
4 Cooling System
Torque
No. Fastener Remark
N·m kgf·m ft·lb
2 Bolt, water pump impeller 10 1.0 87in·lb
3 Bolt, water pump cover 10 1.0 87in·lb
4 Bolt, water pump exhaust 7.0 0.70 62in·lb
5 Bolt, thermostat housing 10 1.0 87in·lb
6 Water temp. sensor 12 1.2 106in·lb
18 Bolt, reservoir tank 5.9 0.60 52in·lb
1. Clam p B30
7. W ate r o utlet pipe, reservoir tank
8. Clam p B12.5
9. Clamp B7
10 . Vacuum pipe , canister
11 . Guide pipe, reservoir ta nk
12. R eser voir tank
13. Cylinder head cover
14. Thermostat
15. Impeller, water pump
16. Seal
17. C ap, reservoir tank
19. RubberⅡ
20. Cap, water filler
21. GB/T5789 bolt M6×12
22. GB/T93 washer 6 4
23. GB/T96 washer 6
24. Nut M6
25. Fan assy.
26. Radiator assy.
27. W ater inlet pipe, radiator
28. Rubber Ⅱ bushing
29. GB/T5789 bolt M8×30
30. Radiator comp.
31. W ater outlet pipe, radiator
G：Grease
HG：High temperature grease
L：Locker
R：Replace part
4-3
CFMOTO
Coolant Flow Chart
Hot Coolant
Cold Coolant
1. Cylinder head sleeve 2. Thermostat 3.Cynlinder sleeve 4. Overflow pipe

5. Reservoir tank 6. Raditor 7. Cooling fan 8. Raditor cap 9. Cooling pipe
10.Water pump
4-4
4 Cooling System
Antifreeze is added into coolant to protect the cooling system from rust and corrosion.
When the engine starts, the water pump turns and impels the coolant circulate.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes.
The thermostat continuously changes its valve opening to keep the coolant temperature at
the proper level. When coolant temperature is below 70°C~74°C(158°F~165°F),
thermo-stat closes so that the coolant fl ow is restricted and engine will warm up more
quickly. When coolant temperature is more than 70°C~74°C, thermostat opens and the
coolant flows. When the coolant temperature goes up beyond 83°C~93°C(181°F~199°
F), the radiator fan relay conducts to operate the radiator fan. The radiator fan draws air
through the radiator core when there is not sufficient air flow such as at low speeds. This
increases up the cooling action of the radiator.
When the temperature is below 81°C(178°F), the fan relay disconnetcts and the radiator fan
stops. In this way, this system controls the engine temperature within narrow limits where the
engine operates most efficiently even if the engine load varies. The system is pressurized by
the radiator cap to suppress boiling and the resultant air bubbles which can cause engine
overheating. As the engine warms up, the coolant in the radiator and the water jacket expands.
The excess coolant flows through the radiator cap and hose to the reserve tank to be stored
there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the
water jacket contracts, and the stored coolant flows back to the radiator from the reserve
tank. The radiator cap has two valves. One is a pressure valve which holds the pressure in the
system when the engine is running. When the pressure exceeds 112.3 kPa~ 141.7 kPa (1.15
kgf/cm²~ 1.45 kgf/cm², 16.3 psi~ 20.5 psi), the pressure valve opens and releases the pres- 4
sure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the
pressure at 112.3 kPa~ 141.7 kPa (1.15kgf/cm² ~ 1.45 kgf/cm², 16.3 psi~ 20.5 psi). When
the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and
allows the coolant from the reserve tank to enter the radiator.
4-5
CFMOTO
Item Standard
Coolant
Model（Recommend） Permanent type of antifreeze (soft water and
ethylene glycol plus corrosion and rust inhibitor
chemicals for aluminum engines and radiators)
Color Green
Mix ratio Water 50%，Coolant 50%
Freezing point -35℃(-31°F)
Capacity 1.8L (Reservoir F level，Including radiator and the
Engine)
Radiator cap
Release pressure 112.3 kPa～141.7kPa(1.15 kgf/cm2 ～
1.45kgf/cm 2,16.3 psi～20.5psi)
Thermostat
Valve open temp 70℃～74℃(158℉～165℉)
Full open clearance 85℃(185℉),8mm(0.31in)
4-6
4 Cooling System
Special tool
Tools kit, bearing installation Tool, oil seal installation
4-7
CFMOTO
Coolant Deterioration Inspection
ŸRemove the right center fairing (see Center
Fairing Removal in the Frame chapter).
ŸVisually inspect the coolant [A] in the reserve A
tank.
«If whitish cotton-like wafts are observed,
aluminum parts in the cooling system are
corroded. If the coolant is brown, iron or steel
parts are rusting. In either case, flush the cool-
ing system.
«If the coolant gives off an abnormal smell,
check for a cooling system leak. It may be
caused by exhaust gas leaking into the cool-
ing system.
Coolant Level Inspection
ŸRefer to the Coolant Level in the Periodic
Maintenance chapter
Coolant Draining
ŸRefer to the Coolant Change in the Periodic
Maintenance chapter.
Coolant Filling
ŸRefer to the Coolant Change in the Periodic
Maintenance chapter.
Pressure Testing
ŸRemove the reserve tank (see Coolant
chapter).
ŸRemove the radiator cap, and install a cool-
ing system pressure tester [A] on the fi ller
neck [B].
NOTE
○ Wet the cap sealing surfaces with water
orcoolant to prevent pressure leaks.
ŸBuild up pressure in the system carefully
until the pressure reaches 141.7kPa(1.
45kgf/cm2, 0.5psi).
WARNING
Do not beyond design pre ssure during
pressure test procedures. The ma ximum
pressure is: 141.7kPa(1.45kgf/cm 2 ,20.5psi)
4-8
4 Cooling System
ŸWatch the gauge for at least 6 seconds.
«If the pressure holds steady, the system is allright.
«If the pressure drops and no external source is found, check for internal leaks. Droplets in
the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump.
Check inside leaking
If the oil appeard for means leaking out. Check cylinder head gasket and waterpump.
ŸRemove the pressure tester, replenish the coolant, and install the radiator cap
Cooling System Flushing

Over a period of time, the cooling system accumulates rust, scale, and lime in the water
jacket and radiator. When this accumulation is suspected or observed, fl ush the cooling
system. If this accumulation is not removed, it will clog up the water passage and consider-
able reduce the efficiency of the cooling system. Drain the cooling system (see Coolant Change
ŸFill the cooling system with fresh water mixed with a flushing compound.
WARNING
Do not use chemical liquid which can
cause aluminum corrosion.
Follow the owner’s manual from suppliers.
ŸWarm up the engine, and run it at normal operating temperature for about ten minutes
ŸStop the engine, and drain the cooling system. 4
ŸFill the system with fresh water.
ŸWarm up the engine and drain the system.
ŸRepeat the previous two steps once more.
ŸFill the system with a permanent type coolant and bleed the air from the system (see Cool-
ant Change in the Periodic Maintenance chapter).
Coolant Reserve Tank Removal/Installation
ŸThe coolant reserve tank is removed and installed during coolant change (see Coolant
Change in the Periodic Maintenance chapter).
4-9
CFMOTO
Water Pump Removal
ŸDrain the coolant (see Coolant Change
ŸLoosen the clamp and remove the radia-
tor hose [A] from the water pump cover [B].
ŸRemove the water pump cover bolts [C].
ŸShift the transmission into 1st gear

ŸWhile applying the rear brake, remove the
water pump impeller bolt [A].
ŸRemoval:
Impeller [B]
Water Pump Housing [C]
Water Pump Installation

ŸWhen installing the water pump impeller
bolt,shift the transmission into 1st gear and
apply therear brake.
ŸReplace the O-rings [A] on the water
pumphousing with new ones and apply
grease them.
ŸApply high-temperature grease to the lips of
the water pump housing oil seal [B].
ŸBe sure that the dowel pin [A] is in position

ŸInstall the water pump housing.
ŸTighten:
Torque - Water Pump Impeller Bolt:
10N·m(1.0kgf·m,87in·lb)
ŸReplace the O-ring [A] on the water pump

cover with a new one and grease it.
4-10
4 Cooling System
ŸInstall the water pump cover, being careful
of the two dowel pins [A].
Torque - Water Pump Cover Bolts:

10N·m(1.0kgf·m,87in·lb)
Mechanical Seal Inspection

ŸVisually inspect the mechanical seal.
«If any one of the parts is damaged, replace
the mechanical seal as a unit.
○The sealing seat and rubber seal may be
removed easily by hand.
Impeller Sealing Seat Surface [A]
Rubber Seal [B]
Mechanical Seal Diaphragm [C]
Water Pump Housing Disassembly

Note
Do not damaged the sealant surface.
4
ŸTake the oil seal [A] out of the housing [B]
with a hook [C].
ŸPress the mechanical seal [A] out of the

housing with a bearing driver [B].
Special Tool - Bearing Driver Set
Water PumpHousingAssembly
● Apply high-temperature grease [A] to the
newoil seal [B].
● Press the oil seal into the housing with a
bearing driver so that the seal surface isfl
ush [C] withtheend of the hole.
● Press the newmechanical seal into the
housing with the oil seal driver [D] until its fl
ange [E] touches the surface [F] of the
housing.
Special Tool - Oil Seal Driver
4-11
CFMOTO
Impeller Assembly
ŸClean the sliding surface of the mechani-
cal seal with a high-fl ash point solvent, and
apply a little coolant to the sliding surface
to give the mechanical seal initial
lubrication.
ŸApply coolant to the surfaces of the rub-
ber seal [A] and sealing seat [B], and in-
stall the rubber seal and sealing seat into
the impeller by pressing them by hand until
the seat stops at the bottom of the hole.
Pump Impeller Inspection
ŸVisually check the impeller [A].
If the surface is corroded, or if the blades are
damaged,replace the impeller (see Water
Pump Removal).
4-12
4 Cooling System
Radiator and Radiator Fan Removal
ŸDrain the coolant (see Coolant Change in E
the Periodic Maintenance chapter).
Ÿ Removal：
Center Fairings (see Center Fairing in the
Frame chapter)
Reserve Tank (see Coolant Change in the
Periodic Maintenance chapter)
Radiator Fan Motor Connector [A]
(Disconnect)
Radiator Hose Clamp Screw [B] (Loosen)
ŸLoosen: Radiator Hose Clamp Screw [A]
ŸRemove: Radiator Bolt [B]
A G D F C B
ŸPull [A] the radiator [B] toward the left, not-
ing the baffl e plate [C] on the cylinder head
cover.
WARNING
Do not touch the cooling fin. It will
cause the fin damaged and finally
cause the cooling bad.
ŸIf necessary, remove:

Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
4-13
CFMOTO
Radiator and Radiator Fan Installation
ŸInstall the grommets [A] so that its large side
faces the front.
ŸInstall the radiator [B] to the frame.
ŸAlign [C] the projection on the frame with
the hole on the radiator.
ŸTighten the radiator bolt [D].
ŸNote the baffl e plate on the cylinder head
cover when installing the radiator.
ŸPosition the radiator hose clamp screws [E]
as shown.
Radiator Inspection
ŸCheck the radiator core.
ŸIf there are obstructions to air fl ow, remove
them.
ŸIf the corrugated fi ns [A] are deformed, care-
fully straighten them.
ŸIf the air passages of the radiator core are
blocked more than 20% by unremovable ob-
structions or irreparably deformed fi ns, re-
place the radiator with a new one.
CAUTION
When cleaning the radiator with steam
cleaner, be careful of the following to
prevent radiator damage: Keep the
steam gun [A] away more than 0.5m
(1.6 ft) [B] from the radiator core.
Hold the steam gun perpendicular [C]
(not oblique [D]) to the core surface.
Run the steam gun, following the coref
n direction.
Radiator Cap Inspection

ŸRemoval:
Reserve Tank (see Coolant Change in the
Radiator Cap
ŸCheck the condition of the bottom [A] and
top [B] valve seals and valve spring [C].
«If any one of them shows visible damage,
replace
4-14
4 Cooling System
Install the cap [A] on a cooling system pres-
sure tester [B].
NOTE
○Wet the cap sealing surfaces with water
or coolant to prevent pressure leaks.
ŸWatching the pressure gauge, pump the
pressure tester to build up the pressure until
the relief valve opens: the gauge needle fl
icks downward. Stop pumping and measure
leak time at once. The relief valve must open
within the specifi ed range in the table below
and the gauge hand must remain within the
same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard:
112.3kPa～141.7kPa
(1.15kgf/cm2～1.45kgf/cm2,16.3psi～20.
5psi)
«If the cap can not hold the specifi ed pres-
sure or if it holds too much pressure, replace
it with a new one.
4
Radiator Filler Neck Inspection
ŸRemove the reserve tank (see Coolant
chapter).
ŸRemove the radiator cap.
ŸCheck the radiator fi ller neck for signs of
damage.
ŸCheck the condition of the top and bottom
sealing seats [A] in the fi ller neck. They must
be smooth and clean for the radiator cap to
function properly.
4-15
CFMOTO
Thermostat Removal
Ÿ Drain the coolant (see Coolant Change
Ÿ Remove:
Left Center Fairing (see Center Fairing
Thermostat Hosing Bolts [A]
Thermostat Hosing [B]
ŸPull the thermostat [A] out of the cylinder

head.
Thermostat Installation
ŸInstall the thermostat [A] in the cylinder head
so that the air bleeder hole [B] is on top.
ŸInstall a new O-ring into the housing and ap
ply grease it.
ŸTighten:
Torque - Thermostat Hosing Bolts:
10N·m(1.0kgf·m，87in·lb)
ŸFill the radiator with coolant (see Coolant
chapter).
Thermostat Inspection
Ÿ Remove the thermostat, and inspect the
thermostat valve [A] at room temperature.
If the valve is open, replace the thermostat
with a new one
4-16
4 Cooling System
• To check valve opening temperature, sus
pend the thermostat [A] in a container of
water and raise the temperature of the
water.
○The thermostat must be completely sub-
merged and must not touch the container
sides or bottom. Suspend an accurate
thermometer [B] in the water so that the
heat sensitive portions [C] are located in
almost the same depth. It must not touch
the container, either.
«If the measurement is out of the specifi ed
range, replace the thermostat with a new one.
Thermostat Valve Opening Temperature

70°C～74°C(158°F～165°F)
4-17
CFMOTO
Hose Installation
ŸInstall the hoses and pipes, being careful
to follow bending direction. Avoid sharp
bending, kinking, fl attening or twisting.
ŸRun the hoses (see Cable, Wire, and
Hose Routing section in the Appendix
chapter).
ŸInstall the clamp [A] as near as possible
to the hose end to clear the raised rib of
the fiting. This will prevent the hoses from
working loose.
○The clamp screws should be positioned
correctly to prevent the clamps from con-
tacting the other parts.
Torque - Radiator Hose Clamp Screws:
2.5N·m(0.25kgf·m,17in·lb)
Hose Inspection
Refer to the Radiator Hose Damage and
Installation Condition Inspection in the Peri-
odic Maintenance chapter.
4-18
4 Cooling System
C AUTION
The coolant temperature sensor should

never be allowed to fall on a hard surface.
Such a shock to the water tem perature
sen sor can dam ag e coolant temperature
sen sor .
Coolant Temperature Sensor Removal/

Installation
ŸRefer to the Water Temperature Sensor
A
Removal/ Installation in the Fuel System
(EFI) chapter. Coolant Temperature Sensor
[A]
Coolant Temperature Sensor Inspection

ŸRefer to the Water Temperature Sensor In-
spection in the Electrical System chapter.
4-19
5 Engine Top End
Exploded view…………………………………………………………………………………………5-2
Specifications………………………………………………………………………………………… 5-7
Special tool sand sealant …………………………………………………………………………5-9
Cylinder headcover.………………………………………………………………………………… 5-11
Cylinder head cover removal …………………………………………………………………5-11
Cylinder head cover installation………………………………………………………………5-11
Timing chain tensioner………………………………………………………………………………5-13
Timing chain tensioner removal ………………………………………………………………5-13
Timing chain tensioner installation……………………………………………………………5-13
Camshaft/Timing chain…………………………………………………………………………… 5-15
Camshaft removal………………………………………………………………………………… 5-15
Camshaft installation ……………………………………………………………………………5-16
Camshaft and sprocket assembly……………………………………………………………5-18
Camshaft/Camshaft cap wear…………………………………………………………………5-19
Camshaft run-out ………………………………………………………………………………… 5-19
Cam wear…………………………………………………………………………………………… 5-20
Timing chain removal……………………………………………………………………………5-20
Cylinder head……………………………………………………………………………………………5-21
Cylinder compression measurement…………………………………………………………5-21
Cylinder head removal……………………………………………………………………………5-22 5
Cylinder head installation…………………………………………………………………………5-23
Cylinder head wear…………………………………………………………………………………5-24
Valves…………………………………………………………………………………………………………-5- 25
Valve clearance inspection……………………………………………………… ……………5-25
Valve clearance adjustment……………………………………………………………………… 5-25
Valve removal…………………………………………………………………………………………5-25
Valve installation………………………………………………………………………………………5-25
Valve guide removal………………………………………………………………………………. 5-26
Valve guide installation…………………………………………………………………………….5-26
Valve-to-guide clearance measurement (Wobble Method)……………………………….5-27
Valve seat inspection……………………………………………………………………………….5-28
Valve seat repair……………………………………………………………………………………. 5-28
Cylinder/Piston…………………………………………………………………………………………… 5-29
Cylinder removal………………………………………………………………………………………5-29
Cylinder installation………………………………………………………………………………… 5-29
5-1
CFMOTO
Piston removal……………………………………………………………………………………………5-30
Piston installation…………………………………………………………………………………………5-31
Cylinder wear………………………………………………………………………………………………5-32
Piston ring/Piston ring groove wear……………………………………………………………5-32
Piston ring groove width…………………………………………………………………………… 5-33
Piston ring thickness………………………………………………………………………………5-34
Piston ring cut clearance………………………………………………………………………… 5-35
Intake manifold……………………………………………………………………………………………5-36
Intake manifold installation…………………………………………………………………………5-36
5-2
5 Engine Top End
Exploded View
5-3
CFMOTO
NO Fastener Torque Remark

N·m kgf·m ft·lb
1 Bolt, clamp 10 1.0 87 in·lb
2 Bolt, cylinder head cover 10 1.0 87 in·lb
3 Bolt, camshaft cover 12 1.2 106 in·lb S
4 Bolt, cylinder head (M10 new bolt) 54 55 40 MO,S
Bolt, cylinder head (M10 old bolt) 49 50 36 MO,S
5 Bolt, cylinder head (M6) 12 1.2 106 in·lb S
6 Bolt, air inlet pipe 12 1.2 106 in·lb
7 Bolt, tension plate 20 2.0 15 L
8 Bolt, tensioner 10 1.0 87 in·lb
9 Plug, tensioner 28 2.9 21
10 Bolt, spring seat 20 2.0 15
11 Spark plug 15 1.5 11
12 Bolt, camshaft sprocket 15 1.5 11 L
13 Bolt, top plate 6 0.60 52 in·lb L
14 Bolt, top plate 6 0.60 52 in·lb
L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfi de grease.
MO: Apply molybdenum disulfide oil solution.(mixture of the engine oil and molybdenum
disulfide grease in a weight ratio of 10 : 1)
R: Replacement Parts
S: Follow the specifi ed tightening sequence.
SS:Apply silicone sealant.
5-4
5 Engine Top End
Exploded View
5-5
CFMOTO
Exploded View
Torque
No. Fastener Remark
N·m kgf·m ft·lb
1 Bolt, cylinder body (M8) 27.5 2.8 20 MO,S
2 Nut, cylinder body (M10) 49 5.0 36 MO,S
3 Bolt, cylinder head (M6) 12 1.2 106in·lb S
4 Fixed nut, exhaust pipe 17 1.7 12
5 Mount bolt, muffler(front) 20 2.0 15
6 Mount bolt, muffler(rear) 20 2.0 15
7: “A”marked side faces up.

8: “A”marked side faces up
9: Hollow mark faces forward.
MO: Apply molybdenum disulfi de oil solution.
(mixture of the engine oil and molybdenum disulfi de grease in a weight ratio of 10 : 1)
5-6
5 Engine Top End
Specifications
Ite m S ta n d a r d S e r v ic e li m it
C am shaft
C a m h e ig h t
3 5 . 8 4 3 m m ～ 3 5 .9 5 7 m m
E xha ust 3 5 . 7 4 m m (1 . 4 0 7 1 in . )
(1 . 4 11 1 i n ～ 1 .4 1 5 6 in . )
3 6 . 5 4 3 m m ～ 3 6 .6 5 7 m m
In t a k e 3 6 . 4 4 m m (1 . 4 3 4 6 in . )
(1 .4 3 8 7 in ～ 1 .4 4 3 2 in .)
C a m s h a f t jo u rn a l a n d 0 .0 2 8 m m ～ 0 .0 7 1 m m
0 .1 6 m m (0 .0 0 6 3 in .)
c a m s h a ft c o v e r ( 0 . 0 0 1 1 in ～ 0 . 0 0 2 8 i n . )
2 3 . 9 5 0 m m ～ 2 3 .9 7 2 m m
C a m s h a f t d i a m e te r 2 3 .9 2 m m (0 .9 4 2 in .)
( 0 .9 4 2 9 in ～ 0 .9 4 3 8 in .)
C am shaft cover h o le 2 4 . 0 0 0 m m ～ 2 4 . 0 2 1 m m
2 4 .0 8 m m (0 .9 4 8 in .)
d ia m e te r (0 .9 4 4 9 in ～ 0 .9 4 5 7 in .)
C a m s h a f t w e a rin g 0 .0 2 m m (0 . 0 0 0 8 in . ) 0 .1 m m (0 .0 0 4 in .)
C y lin d e r h e a d
C y lin d e r co m p re s s io n 9 6 1 k P a ～ 1 4 7 1 k P a (9 . 8 k g f / c m 2
–– –
p re s s u re ～ 1 5 . 0 k g f /c m 2) a t4 0 0 r / m i n ( r p m )
C y lin d e r h e a d fla tn e s s –– – 0 . 0 5 m m (0 . 0 0 2 in .)
V a lv e
V a lv e c l e a r a n c e ：
E xha ust 0 . 2 0 m m ～ 0 . 2 6 m m ( 0 . 0 0 7 8 in ～ 0 . 0 1 0 2 i n . ) –– –
In t a k e 0 . 0 8 m m ～ 0 . 1 3 m m ( 0 . 0 0 3 1 in ～ 0 . 0 0 5 1 i n . ) –– –
V a lv e r o d s tra ig h tn e s s 0 .0 1 m m (0 .0 0 0 4 in .) 0 . 0 5 m m (0 . 0 0 2 in .)
V a lv e r o d d ia m e t e r：
4 .4 5 5 m m ～ 4 .4 7 0 m m
E xha ust 4 . 4 4 m m (0 . 1 7 5 in .)
( 0 .1 7 5 4 in～ 0 .1 7 6 in .)
In t a k e
4 .4 7 5 m m ～ 4 .4 9 0 m m
4 . 4 6 m m (0 . 1 7 6 in .) 5
( 0 . 1 7 6 2 in ～ 0 . 1 7 6 8 i n . )
V a lv e c o n d u c tin g p ip e in n e r d ia m e te r ：
4 .5 0 0 m m ～ 4 . 5 1 2 m m
E xha ust 4 . 5 8 m m (0 . 1 8 0 in .)
(0 . 1 7 7 2 in ～ 0 .1 7 7 6 in .)
4 .5 0 0 m m ～ 4 . 5 1 2 m m
In t a k e 4 . 5 8 m m (0 . 1 8 0 in .)
(0 . 1 7 7 2 in ～ 0 .1 7 7 6 in .)
V a lv e /v a lv e c o n d u c t in g p ip e
0 .0 7 m m ～ 0 .1 4 m m
E xha ust 0 .2 7 m m (0 .0 1 0 6 in .)
( 0 . 0 0 2 8 in ～ 0 . 0 0 5 5 i n . )
In t a k e 0 . 0 2 m m ～ 0 . 0 8 m m ( 0 . 0 0 0 8 in ～ 0 . 0 0 3 2 i n . ) 0 .2 2 m m (0 .0 0 8 7 in .)
V a lv e s e a t s e a l a n t
W id th ：
E xha ust 0 .5 m m ～ 1 .0 m m ( 0 .0 2 in ～ 0 .0 3 9 i n .) –– –
In ta k e 0 .5 m m ～ 1 .0 m m ( 0 .0 2 in ～ 0 .0 3 9 i n .) –– –
O u t d ia m e te r ：
E xha ust 2 6 . 6 m m ～ 2 6 .7 m m ( 1 .0 8 7 in ～ 1 .0 9 4 in .) –– –
In ta k e 3 1 . 2 m m ～ 3 2 .3 m m ( 1 .2 8 3 in ～ 1 .2 9 1 in .) –– –
5-7
CFMOTO
Specifications
Item Standard Service limit

Valve spring free length
Exhaust 41.6mm (1.638in.) 40mm (1.575in.)
Intake 41.6mm (1.638in.) 40mm (1.575in.)
Cylinder , Piston
Cylinder inner diameter 82.98 mm～83mm(3.2669 in～3.2677in.) 83.1mm (3.2717in.)
Piston skirt diameter 82.975 mm～82.995mm(3.2667in～3.2675in.) 82.82mm (3.2606in.)
Piston and cylinder
0.002 mm～0.030mm(0.0004 in -0.0015in.) –––
clearance
Piston ring /groove clearance:
1st air ring 0.04mm～0.075mm(0.00157in～0.00295in.) 0.17mm (0.0067in.)
2nd air ring 0.02 mm～0.06mm(0.0008 in～0.0024in.) 0.16mm (0.0063in.)
Piston groove width:
1st air ring 0.92 mm～0.94mm(0.0362 in～0.0370in.) 1.02mm (0.040in.)
Piston ring thickness:
1st air ring 0.865mm～0.88mm(0.0341in～0.03465in.) 0.80mm (0.031in.)
Piston ring close clearance:
1st air ring 0.15 mm～0.30mm(0.0059 in～0.0118in.) 0.7mm (0.028in.)
5-8
5 Engine Top End
Special tools and sealing glue
Pressure gauge Valve seat knife tool
Valve spring fixture tool Valve seat knife locking axle
Valve seat knife tool Valve seat knife tool
Valve seat knife tool Valve seat knife tool
Valve seat knife tool Spring compression adpator
5-9
CFMOTO
Special tools and sealing glue
Piston pin puller
Pressure gauge
adaptor
Valve seat
knife bracket Puller seat
Guide axle Sealing glue
Valve conducting
pipe knife
5-10
5 Engine Top End
Cylinder Head Cover
Cylinder Head Ccover Removal

●Remove:
1. Fuel Tank (see Fuel Tank Removal in the
Fuel System (EFI) chapter)
2. Housing of air fi lter (see Air fi lter Housing
Removal in the Fuel System (EFI) chapter)
3. Ignition coil[C]
4. Baffle plate[D]
5. Throttle cables[E]
6. Clutch Cable Holder [F] with Bolt [G]
7. Cylinder Head Cover Bolts [H]
8. Cylinder Head Cover [I]
9. Spring valve[J]（CF650-3F)
Cylinder Head Cover Installation

● Replace the head cover gasket [A] with a
new one.
● Apply silicone sealant [B] to the cylinder 5
head as shown.
● Install gaskets of spark plug hole [C].
● Install:
Washers [A]
Cylinder Head Cover Bolts [B]
Spring valve[J]（CF650-3F)
o Install the washers with metal side [C] faces

upward.
●Tighten bolt of cylinder head over.
（CF650-3F)
Torque - Cylinder Head Cover Bolts
10 N·ｍ
5-11
CFMOTO
Cylinder Head Cover
● Install the baffle plate [A].
o Put the insulators [B] under the baffle

plate and the washers [C] .
o Apply a non-permanent locking agent to

the baffle plate bolts and tighten them.
Torque - Baffl e Plate Bolts: 6 N·ｍ
5-12
5 Engine Top End
Timing Chain Tensioner
Timing Chain Tensioner Removal
● Remove:
Plug [A]
Washer[B]
Tensioner[C]
Timing Chain Tensioner Installation
● Install tensioner[C]. There should be no

any stuck after installation.
● Install plug[A] and washer[B].
● Tighten plug.
Torque: Plug 28N·m
●Turn the crankshaft for 2~3 rounds clockwisely
to let the tensioner tight the chain up and check
the timing again.
5
Timing Chain Tensioner Removal
Caution
This is a non-return type camshaft chain
tensioner. The push rod does not return
to its original position once it moves out
to take up camshaft chain slack. Observe
all the rules listed below:
When removing the tensioner, do not take
out the mounting bolts only halfway. Re-
tightening the mounting bolts from this
position could damage the tensioner and
the camshaft chain. Once the bolts are
loosened, the tensioner must be removed
and reset as described in “Camshaft Chain
Tensioner Installation”. Do not turn over the
crankshaft while the tensioner is removed.
This could upset the camshaft chain timing,
and damage the valves.
5-13
CFMOTO
Timing Chain Tensioner
● Remove:
Bolt [A]
Washer[B]
Spring [C]
● Remove the mounting bolts [D] and take off
the timing chain tensioner.
Timing Chain Tensioner Installation

● Release the stopper [A] and push the push
rod [B] into the tensioner [C].
● Install the tensioner so that the stopper

faces upward.
● Tighten the tensioner mounting bolts [A].
Torque: Tensioner Mounting Bolts :

1 2 N ·m
● Install the spring and washer
● Tighten the cap bolt [B].
Torque: Spring seat bolt 20N·m

● Turn the crankshaft clockwise for 2 rounds
to let the tensioner getting tight.And check the
camtiming again.
5-14
5 Engine Top End
Camshaft/Timing Chain
Warning
The crankshaft maybe tured while the
crankshafts are removed.Aways pull the
chain taut while turning the crankshaft.
This avoids kinking the chain on the
lower(crankshaft) sprocket. A kinked
chain could damage both the chain and
the sprocket.
Camshaft Removal
●Remove:
Cylinder Head Cover (see Cylinder Head
Cover Removal)
●Position the crankshaft as follows
oRemove the upper [A] and lower [B] caps

on the clutch cover(right side cover).
5
o Using a wrench on the crankshaft rotation
bolt, turn the crankshaft clockwise until the 2/
T mark line [A] on the timing rotor is aligned
with the notch [B] in the edge of the upper hole
[C] in the clutch cover.
● Remove:
Camshaft Chain Tensioner (see Camshaft

Chain Ten-sioner Removal)
Camshaft Cap Bolts [A]
Camshaft Caps [B]
Camshafts [C]
5-15
CFMOTO
Camshaft Installation
● Be sure to install the Plug Hole Gaskets
[A]
● Apply molybdenum disulfide oil solution to

all cams [A] journals [B] and thrust blocks [C]
with ×marks.
★If a new camshaft is to be used, apply a
thin coat of molyb-denum disulfide grease to
the cam surfaces.
NOTE
The exhaust camshaft has a EX mark [D]
and the inlet camshaft has a IN mark [E].
Be careful not to mix up two shafts.
5-16
5 Engine Top End
● Pull the tension side (exhaust side) of the

chain taut to install the chain.
● Engage the camshaft chain with the cam-
shaft sprockets so that the timing marks on the
sprockets are positioned as shown.
oUsing a wrench on the crankshaft rotation

bolt, turn thecrankshaft clockwise until the 2/T
mark line [A] on the timing rotor is aligned with
the notch [B] in the edge of the upper hole [C]
in the clutch cover.
● If the clutch cover is removed, perform the
next procedure.
o Using a wrench on the crankshaft rotation

bolt, turn the crankshaft clockwise until the 1/T
mark line [A] on the timing rotor is aligned with
the wating surface [B] of the crankcase halves.
The timing marks must be aligned with

the cylinder head upper surface [C]. 5
#1 Pin [F]
EXMark [D] (between #1 pin and #2 pin)
INMark [E] (between #31 pin and #32 pin) #2 Pin [G]
#31 Pin [H]
#32 Pin [J]
5-17
CFMOTO
NOTE
The exhaust cap has a “EX” mark [A] and
the inlet cap has a “IN” mark [B]. Be care-
ful not to mix up these caps.
● Assemble the bolts of the camshaft
o First tighten all the camshaft cap bolts evenly

to seat the camshaft in place, then tighten all
bolts following the specified tightening
sequence.
Torque-Camshaft Cap Bolts (1 < 12)
1 2 N ·ｍ
●Installation:
Camshaft Chain Tensioner (see Timing Chain
Tensioner Installation)
Cover Installation)
Camshaft and Sprocket Assembly
oThe inlet and exhaust sprockets are identical.

●Install the sprockets so that the marked (“IN”
and “EX”) side faces to the right side.
● Apply a non-permanent locking agent to

the camshaft sprockets bolts and tighten them.
Torque-Camshaft Shaft Sprockets
Bolt s ：1 5 N ·ｍ
5-18
5 Engine Top End
Camshaft/Timing chain
Camshaft, Camshaft Cap Wear ● Measure camshaft journal diameter.
● Remove Camshaft Caps and camshaft
Diameter of Camshaft Journal Stan-
(see Camshaft Removal)
dard : 23.950mm~23.972mm
● Retighten camshaft cap and measure hole Service Limit : 23.920mm
diameter of camshaft cap <A>,<B>,<C>.
Torque: Camshaft cap bolt 12N.m
★ If the camshaft journal diameter is less
Hole diameter of camshaft cap than the service limit, replace the cam-
Standard : 24.00mm~24.021mm shaft with a new one and measure the
Service Limit: 24.05mm clearance again. If the clearance still
remains out of the limit, replace the
cylinder head unit.
★If out of service limit, replace new cylinder
head.
Camshaft Journal, Camshaft Cap Clear
ance
Standard: 0.028mm~0.071mm
Service Limit : 0.13mm
Camshaft run-out
●Remove the camshaft (see Camshaft
Removal).
★If the runout exceeds the service limit,
replace the shaft.
5-19
CFMOTO
● Set the camshaft in a camshaft alignment

jig or on V blocks.
● Measure runout with a dial gauge at the

specifi ed place as shown.
Camshaft Runout
Standard: Less than 0.02mm
Service limit: 0.04mm
Camshaft wear
● Remove the camshaft (see Camshaft
Removal).
● Measure the height [A] of each cam with
a micrometer.
★ If the cams are worn down past the ser-
vice limit, replace the camshaft.
Cam Height
EX: 35.843mm~35.957mm
IN : 36.543mm~36.657mm
Service Limit
EX :35.74mm
IN:36.44mm
Camshaft Chain Removal

● Split the crankcase (see Crankcase Split-
ting in the Crankshaft/Transmission chapter).
● Disassemble the timing chain ont the
crankshaft [A].
5-20
5 Engine Top End
Cylinder head
Cylinder Compression Measurement
NOTE:Use the battery which is fully
charged.
● Warm up the engine thoroughly.
● Stop the engine.
● Remove
Fuel Tank (see Fuel Tank Removal in the Fuel
System (EFI) chapter)
Air Cleaner Housing (see Air Cleaner Hous-
ing Removal in the Fuel System (EFI)
chapter)
Ignition Coils (see Ignition Coil together with
Spark Plug Cap Removal in the Electrical
System chapter)
Spark Plugs (see Spark Plug Replacement
in the Periodic Maintenance chapter)
Owner’s Tool - Spark Plug Wrench 16mm
● Attach the compression gauge [A] and

adapter [B] firmly into the spark plug hole. 5
Using the starter motor, turn the engine over
with the throttle fully open until the compres-
sion gauge stops rising; the compression is
the highest reading obtainable.
Special tools: Compression Gauge,
20kgf/cm 2
Pressure meter adjuster M10x1.0
Cylinder pressure standard:
9 6 1 k P a ～1 4 7 1 k P a ( 9 . 8 k g f / c m 2 ～1 5 .
0kgf/cm 2 ） at400r/min(rpm)
● Use same way to test the other cylinder.

● Assemble the spark plug. Spark plug
torque: 1 5N ·m
● If the pressure is not in standard please
follow form below .
5-21
CFMOTO
Cylinder head
Question Diagnose Solution

Cy linder Pres sure Too much carbon on piston and Clean the c arbon and replace the
is beyond Combustion room damaged pars
specified range
Gasket thickness is wrong Replace the gasket into standard
Replace the gas ket and check the
Gasket leaking
flatnes s
Cy linder Valve seat leaking Repair the valv e s eat
pressure is less Valve clearance not right Adjust the valve c learance
than specified Piston and cy linder clearance too much Replace the piston and cylinder body
range
Check the cylinder. Replace the c ylinder
Piston jammed
or piston if needs
Piston ring or groov e wearing Replace the piston or piston ring
Cylinder Head Removal

● Remove:
Exhaust Pipes (see Exhaust Pipe Removal)
Cover Removal)
Camshafts (see Camshaft Removal)
Throttle Body Assy (see Throttle Body Assy
Intake manifold
Water Hose
Water Temperature Sensor Connector
Chain Guide Plate
●Firstly remove the 4 pcs of M6 cylinder
head bolts and M6 cylinder bolts [A].
●Secondly, remove the M8 bolts [B].
●Thirdly, remove the M10 nut [C].
●Finally, remove the M10 bolts [D].
5-22
5 Engine Top End
Cylinder head
Cylinder head installation
NOTE
The camshaft cap is machined with the cyl-
inder head,so if a new cylinder head is
installed, replace camshaft at the same time.
Number of the two should be same.
● Install a new cylinder head gasket [A] and

dowel pins [B]
● Apply molybdenum disulfide oil solution [A]

to both sides of washers and the threads of
bolts and nut Torque - Cylinder head bolt (M10):
M10 Cylinder Head Bolts [B] First: 25N·m
M10 Cylinder Nut [C] Final:
M8 Cylinder Bolt [D] Used Cylinder Head Bolts: 49 N·m
New Cylinder Head Bolts: 54 N·m
● Follow the order to tight up the bolts and
Cylinder Nut(M10): 49 N·m
nuts[1-8]
5
5-23
CFMOTO
Cylinder head
● Tighten the M6 cylinder head bolts and

M6 cylinder bolts [A].
Torque - Cylinder Head Bolts (M6):
12 N·m(1.2 kgf·m, 106 in·Ib)
Cylinder Bolts (M6):
12 N·m (1.2 kgf·m, 106 in·Ib)
● Install the front camshaft chain guide [A].
o Insert the end [B] of front camshaft chain

guide into the hollow on the lower crankcase
half.
● Install the removed parts ( see appropri-
ate chapters).
Cylinder Head Warp

● Clean the cylinder head.
● Lay a straightedge across the lower sur-
face of the cylinder head at several positions.
● Use a thickness gauge [A] to measure the
space between the straightedge [B] and the
head.
Cylinder Head Warp Standard: Service
Limit: 0.05mm
★ If the cylinder head is warped more than
the service limit, replace it.
★ If the cylinder head is warped less than the
service limit, repair the head by rubbing the
lower surface on emery paper secured to a
surface plate (fi rst No. 200, then No.400).
5-24
5 Engine Top End
Valves
Valve Clearance Inspection
● Refer to the Valve Clearance Inspection in
the Periodic Maintenance chapter.
Valve Clearance Adjustment

● Refer to the Valve Clearance Adjustment
in the Periodic Maintenance chapter.
Valve Removal
● Remove cylinder head (see Cylinder Head
Removal).
● Remove the valve lifter and shim Mark and
record the valve lifter and shim locations so
they can be installed in their original positions.
● Using the valve spring compressor
assembly, remove the valve.
Special Tools -Valve Spring Compressor
Assembly [A]:
5
Valve Spring Compressor Adapter, [B]:
Valve Installation
● Replace the oil seal with a new one.
●Apply engine oil to the oil seal lip. Apply a
thin coat of molybdenum disulfi de grease to
the valve stem before valve installation.
● Install the springs so that the closed coil
end faces downwards (the side painted in
green faces upwards).
● Valve[A] Valve spring[E]
Valve oil seal[B] Side Painted [F]
Spring lower seat[C] Spring upper seatG]
Closed coil end[D] Split Keepers[H]
5-25
CFMOTO
Valves
Valve Guide Removal

● Remove:
Valve (see Valve Removal)
Oil Seal
Spring Seat
● Heat the area around the valve guide to
120 °C< 150°C , and hammer lightly on
the valve guide arbor [A] to remove the guide
from the top of the head.
CAUTION
Do not heat the cylinder head directly.

This will warp the cylinder head. Soak
the cylinder head in oil and heat the oil.
Special Tool - Valve Guide Arbor: 4.5mm

diameter.
Valve Guide Installation

● Apply engine oil to the valve guide outer
surface before installation.
● Heat the area around the valve guide hole
to about 120 °C<150 °C.
● Drive the valve guide in from the top of
the head using the valve guide arbor. The fl
ange stops the guide from going in too far.
Special Tool - Valve Guide Arbor: 4.5mm

diameter.
● Wait until the cylinder head cools down
and then ream the valve guide with the valve
guide reamer [A] even if the old guide is
reused.
5-26
5 Engine Top End
Valves
o Turn the reamer in a clockwise direction
until the reamer turns freely in the guide.
Never turn the reamer counter-clockwise or
it will be dulled.
o Once the guides are reamed they must be
cleaned thoroughly.
Special tool - Valve Guide Reamer
φ 4.5
Valve-to-Guide Clearance Measurement

(Wobble Method)
● Insert a new valve [A] into the guide [B]
and set a dial gauge against the stem per-
pendicular to it as close as possible to the
cylinder head mating surface.
● Move the stem back and forth [C] to mea-
sure valve/valve guide clearance.
● Repeat the measurement in a direction
at a right angle to the fi rst.
5
NOTE
The reading is not actual valve/valve
guide clearance because the measuring
point is above the guide.
Valve/Valve guide clearance

Standard
EX: 0.07mm~ 0.14mm
IN: 0.02mm~ 0.08mm
Service limit
EX: 0.27mm
5-27
CFMOTO
Valves
Valve Seat Inspection

● Remove the valve (see Valve Removal).
● Check the valve seating surface [A]
between the valve [B] and valve seat [C].
Measure the outside diameter [D] of the
seating pattern on the valve seat.
★ If the outside diameter is too large or too
small, repair the seat (see Valve Seat
Repair).
Valve Seating Surface Outside Diameter
EX: 27.6mm ~ 27.7mm
IN: 32.6mm ~32.7mm
o Measure the seat width [E] of the portion

where there is no build-up carbon (white
portion) of the valve seat with a vernier caliper.
If the width is too wide [G], too narrow [H] or
uneven [J], repair the seat (see Valve Seat
Repair).
Valve Seating Surface Width
EX: 0.5 mm~1.0mm
IN: 0.5 mm~1.0 mm
Valve Seat Repair

● Repair the valve seat with the valve seat
cutters [A].
Special Tools -
Valve Seat Cutter Holder Bar [C]:
Valve Seat Cutter Holder[B]:
5-28
5 Engine Top End
Cylinder body/piston
Cylinder Removal
● Remove:
Cylinder Head (see Cylinder Head Removal)
Front Engine Mounting Bolts (Both Side) [A]
(see Engine Removal in the Engine Removal/
Installation chapter)
Front Engine Brackets (Both Side) [B] (see
Engine Removal in the Engine Removal/
Installation chapter)
Cylinder [C]
● Inspect and make sure the ball [A]and
spring [B] are in order like photo in upper
crankcase oil line (283MT no steel ball and
spring).
Cylinder Installation
NOTE 5
If a new cylinder is used, use a new pis-
ton ring at the same time.
● Install the dowel pins [A] and new cylinder
gasket [B].
● The piston ring openings must be posi-
tioned as shown in the figure. The openings
of the oil ring steel rails must be about 30
~40 degree of angle from the opening of the
top ring.
● Top Ring [A]
Second Ring [B]
Oil Ring Steel Rails [C]
Oil Ring Expander [D]
Hollow [E]
30° [F]
5-29
CFMOTO
●Apply molybdenum disulfi de oil solution
to the cylinder bore, piston rings and piston.
●Prepare two auxiliary head bolts with
their head cut.
●Install the two bolts [A] diagonally in the
crankcase.
●Position the crankshaft so that all the
piston heads are almost level.
●Install the cylinder block. Insert the piston
rings with your thumbs.
Piston Removal
●Remove the cylinder (see Cylinder
Removal).
● Place a clean cloth under the pistons
and remove the piston pin snap ring [A]
from the outside of each piston.
● Remove the piston pin
Special tool :Pistonpinpuller [A]

Bolt [B]
Piston [C]
Piston Pin Puller Adapter [D]
●Remove pistons.
●Carefully spread the ring opening with
your thumbs and then push up on the oppo-
site side of the ring [A] to remove it.
●Remove the 3-piece oil ring with your
thumbs in the same manner.
5-30
5 Engine Top End
Piston installation
● Install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] butt together.
●Install the oil ring steel rails, one above the
expander and one below it.
NOTE
Do not mix up the top [A] and second [C]
ring.
●Install the top ring [A] so that the “R” mark [B]
faces up.
●Install the second ring [C]so that the “RN” mark
[D] faces up.
NOTE
If a new piston is used, use new piston ring.
● Install the piston with its marking hollow fac-
ing forward.
● Fit a new piston pin snap ring into the side of
the piston so that the ring opening [A] does not 5
coincide with the slit [B] of the piston pin hole.
●Install piston pin.
●Use same way to install the other piston pin
ring.
oApply molybdenum disulfi de oil solution to the

piston pins and piston journals. When installing
the piston pin snap ring, compress it only enough
to install it and no more.
CAUTION
Do not reuse snap rings, as removal weak-
ens and deforms them. They could fall out
and score the cylinder wall.
5-31
CFMOTO
Cylinder/Piston
Cylinder Wear
● Since there is a difference in cylinder
wear in different directions, take a side-to-
side and a front-to-back measurement at
each of the two locations (total of four mea-
sure- ments) shown in the figure.
10mm [A]
60mm [B]
Cylinder Inside Diameter
Standard:83.00mm~83.02mm
Service limit:83.10mm
Piston wear
● Measure the outside diameter [A] of each
piston 10mm [B] (283MT is 14mm) up from
the bottom of the piston at a right angle to
the direction of the piston pin.
Piston diameter
Standard:82.975mm~82.995mm
Service limit : 82.90mm
Piston Ring, Piston Ring Groove Wear

● Check for uneven groove wear by in-
specting the ring seat.
5-32
5 Engine Top End
Cylinder/Piston
o The rings should fit perfectly parallel to

groove surfaces. If not, replace the piston and
all the piston rings.
● With the piston rings in their grooves, make
several measurements with a thickness
gauge [A] to determine piston ring/groove
clearance.
Top Ring/Groove Clearance

Top ring
Service limit : 0.17mm
Second Ring/Groove Clearance
Standard: 0.02mm~ 0.06mm
5
Piston Ring Groove Width
● Measure the piston ring groove width. Use
a vernier caliper at several points around the
piston.
Top Ring Groove Width[A]

Standard 0.92mm~0.94mm
Service limit:1.02mm
Second Ring Groove Width

Standard: 1.01mm ~1.03mm
★ If any groove’s wideness arrive the

service limit. Please replace the piston
5-33
CFMOTO
Cylinder/Piston
Measure the piston ring thickness:

Use the micrometer to measure at several
points around the ring.
Piston Ring Thickness

Top ring [A]
Standard: 0.865mm ~0.88mm
Second ring [B]

★ If any of the measurements is less than
the service limit on either of the rings, re-
place all the rings.
NOTE
When using new rings in a used piston,
check for un-even groove wear. The
rings should fit perfectly parallel to the
groove sides. If not, replace the piston.
Piston Ring End Gap

● Place the piston ring [A] inside the
cylinder, using the piston to locate the ring
squarely in place. Set it close to the bottom
of the cylinder, where cylinder wear is low.
● Measure the gap [B] between the ends
of the ring with a thickness gauge.
Piston Ring End Gap
Top ring
5-34
5 Engine Top End
Cylinder/Piston
Second ring
★ If the end gap of either ring is greater

than the service limit, replace all the rings.
5-35
CFMOTO
Intake manifold
Intakemanifoldinstallation
● Install the clamps [B] as shown and so that
their projections fi t [C] on the holes of intake
manifold. Be sure that the clamp bolt heads
[D] face outwards.
● Tighten screw [E].
Torque - Intake manifold screw
1 2 N ·m
5-36
6 Cltuch
Exploded View ………………………………………………………………………………………6-2
Specifications…………………………………………………………………………6-4
Special Tool and Sealant……………………………………………………………6-5
Clutch Cover …………………………………………………………………………6-6
Clutch Cover Removal……………………………………………………………6-6
Clutch Cover Installation…………………………………………………………-6-7
Release Shaft Removal…………………………………………………………6-8
Release Shaft Installation …………………………………………………………6-8
Clutch Cover Disassembly………………………………………………………6-9
Clutch Cover Assembly……………………………………………………………6-10
Clutch…………………………………………………………………………………6-11
Clutch Removal……………………………………………………………………6-11
Clutch Installation………………………………………………………………… 6-12
Clutch Plate, Wear, Damage Inspection ………………………………………6-16
Clutch Plate Warp Inspection ……………………………………………………6-16
Clutch Spring Free Length Measurement………………………………………6-16
Clutch Housing Finger Inspection………………………………………………6-17
Clutch Housing Spline Inspection………………………………………………6-17
6-1
CFMOTO
Exploded View
6-2
6 Cltuch
Exploded View
Torque
No. Fastener Remark
N·m kgf·m ft·lb
T ig h te n b y
1 T i m i n g c h e c k in g h o l e cap – – –
h and
T ig h te n b y
2 C P S c h e c k i n g h o le cap （ 25）（ 2 .5 ）（ 18）
h and
T ig h te n b y
3 O il f i lle r c a p – – –
h and
4 M o u n t b o lt, rig h t c o v e r 12 1 .2 1 0 6 in ·l b
5 B o l t , c lu t c h s p r in g 10 1 .0 8 7 i n · lb
6 N u t, c lu tc h 132 1 3 .5 98 L ,R
7 B o lt, o il p u m p s p ro c k e t 12 1 .2 1 0 6 in ·l b L ,L h
8 B o l t , c lu t c h r o d 7 .8 0 .8 0 6 9 i n · lb S
S cre w , o il pu m p c h a in
9 10 1 .0 8 7 i n · lb L
g u id e
10 B o l t , c lu t c h c a b l e b r a c k e t 10 1 .0 8 7 i n · lb L /S S
L
11 B o l t , c lu t c h c a b l e b r a c k e t 10 1 .0 8 7 i n · lb
CL: Apply cable lubricant.

EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease. 6
Lh: Left-hand threads
W: Apply cylindrical surface grease.
SS: Apply Silicone sealant
6-3
CFMOTO
Specifcations
Item Standard Service

Clutch lever free play 2 mm ～ 3m m(0.08 in～ 0 .12 in .) –––
Clutch 2.6mm (0.1 02 in.)
Disc pad thickness 2.7m m ～ 2 .9mm 0.3mm (0.0 12 in.)
(0 .10 6in～ 0.114 in .) 0.3mm (0.0 12 in.)
Disc pad distortion 0.15mm (0.006 in.) or less 32 .6m m (1 .2 8in .)
Steel pad distortion 0.15mm (0 .006in .) o r l ess
Clutch spring free play 33 .6mm (1.32in .)
6-4
6 Cltuch
Special Tool and Sealant
Clutch Holder Silicone Sealant
6-5
CFMOTO
Clutch Cover
Clutch Cover Removal

● Remove:
Engine Oil (Drain, see Engine Oil Change
in the Periodic Maintenance chapter)
Right Frame Cover (see Frame Cover
Clutch Cable Lower End [A]
Mounting Bolts, clutch Cover [B]
● Turn the release lever [A] toward the rear

as shown, and remove the clutch cover [B]
About 90°[C].
6-6
6 Cltuch
Clutch Cover,
Right Clutch Cover Installation
● Apply silicone sealant to the area [A] where
the mating surface of the crankcase touches
the clutch cover gasket and to the crankshaft
sensor lead grommet [B].
● Be sure that the dowel pins [C] are in

position.
●Replace the clutch cover gasket [D] with a

new one.
● Tighten the clutch cover mounting bolts
Torque - Clutch Cover Mounting Bolts:

12N·m
6-7
CFMOTO
Clutch Cover
Release Shaft Removal

CAUTION
Do not remove the realease shaft assy
unless it is necessary.If the shaft assy
is removed already. Please replace the
oil seal.
● Remove the clutch cover (see Clutch

Cover Removal).
● Pull the lever and shaft assembly straight

out of the clutch cover
Release Shaft Installation

●Apply high-temperature grease to the oil
seal lips on the upper ridge of the clutch
cover.
● Apply engine oil to the needle bearings in

the hole of the clutch cover.
● Apply molybdenum disulfide grease to the `

pusher-holding portion [A] on the release
shaft.
● Install the washer [B] and spring [C].
● Insert the release shaft straight into the

upper hole hole of theclutch cover.
CAUTION
When inserting the release shaft, be care-
ful not to remove the spring of the oil seal.
● Fit the spring [A] as shown.

Release Shaft [B]
Right Clutch Cover [C]
6-8
6 Cltuch
Clutch Cover
Right Clutch Cover Disassembly

● Remove:
Oil Seal [A]
Needle Bearings [B]
●Remove the oil level viewing window

[A].
6-9
CFMOTO
Clutch Cover
Clutch Cover Assembly

● Replace the needle bearings and oil
seal with new ones
NOTE
Install the needle bearings so that the
manufacture’s mark face out.
● Install the needle bearings [A] and oil

seal [B] position as shown.
Then press [C] the bearing so that the
bearing surface [D] is fl ush with the housing
end of clutch cover [E].
●Apply grease to the rubber of the oil

gauge [A] and press [B] it so that the ring
[C] face outside.
`
6-10
6 Cltuch
Clutch
Clutch Removal
● Remove:
in the Periodic Maintenance chapter) Clutch
Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B] (with thrust bearing
and pusher [C])
● Remove:
Friction Plates, Steel Plates
Clutch Hub Nut [A]
Holding the clutch hub [B]
Nut and washer. 6
Special Tool - Clutch Holder [C]
● Remove:
Clutch Hub Spacer
Washer, shaft sleeve
6-11
CFMOTO
Clutch
●Remove the oil pump sprocket bolt [A].
NOTE
The oil pump sprocket bolt has a left-hand
threads.
●Using the hole [B], pull out the sleeve [C].
●Remove the following as a set.
Clutch Housing [D]

Oil Pump Chain [E]
Oil Pump Sprocket [F]
●Unscrew the bolts [A] and remove the oil

pump chain guide [B].
Clutch Installation
●Apply a non-permanent locking agent to
the oil pump chain guide bolts and tighten
them.
Torque - Oil Pump Chain Guide Bolts:
1 0 N ·m
●Put the oil pump chain [A] on the clutch
housing gear [B] and the oil pump sprocket
[C].
6-12
6 Cltuch
Clutch
● Be sure that the spacer [A] is in position.
●Insert the following on the drive shaft.

Clutch Housing [A] with Chain [B] and
Sprocket [C]
● Align [E] the hole on the oil pump

sprocket with the oil pump shaft.
● Apply engine oil on the sleeve [D] and

insert to Clutch Housing [A].
NOTE
Insert the sleeve into the clutch housing,
noting its direction as shown.
Sleeve [A]
Oil Holes [B]
Long Distance [C]
Short Distance [D]
Clutch Housing [E]
6-13
CFMOTO
Clutch
● Install the following parts on the drive

shaft.
Spacer [A]
Clutch Hub [B]
Washer [C]
Elastic washer[D]
Nut [E]
o Install the washer so that the OUTSIDE

mark [A] faces outward.
o Replace the clutch hub nut with a new one

and apply screw fastening grease.
o Holding the clutch hub, tighten the clutch `
hub nut
Special Tool - Clutch Holder

Torque - Clutch Hub Nut: 132 N·m
6-14
6 Cltuch
Clutch
● Install the friction plates and steel plates,

starting with a friction plate and alternating
them
CAUTION
If new dry friction plates and steel plates
are installed, apply engine oil to the sur-
faces of each plate to avoid clutch plate
seizure.
o For the first and second steel plate [A], its

thickness is 2 mm The others are 2.5 mm
o Install the last friction plate [A] fi tting the

tangs in the grooves in the housing as
shown.
6
● Apply molybdenum disulfi de grease to

the pusher ends [A] and install it in the clutch
spring plate [B].
o Apply engine oil to the bearing [C].

●Install the clutch spring plate and springs
[D], and tighten the clutch spring bolts [E].
Torque - Clutch Spring Bolts: 10 N·m
●Install the clutch cover (see Clutch Cover

Installation).
6-15
CFMOTO
Clutch
Clutch Pad Wear, Damage Inspection
●Visually inspect the friction and steel plates
for si gns of seizure, overheati ng
(discoloration), or uneven wear
● Measure the thickness of each friction plate
[A] at several points.
★If any plates show signs of damage, or if
they have worn past the service limit, replace
them with new ones.
Friction Pad Thickness
Service Limit: 2.6 mm
Clutch Plate Warp Inspection

● Place each friction plate or steel plate on
a surface plate and measure the gap between
the surface plate [A] and each friction plate
or steel plate [B] with a thickness gauge [C].
The gap is the amount of friction or steel plate
warp. If any plate is warped over the service
limit, replace it with a new one. `
Friction and Steel Plate Warp
Standard: 0.15 mm or less
Clutch Spring Free Length Measurement

●Measure the free length of the clutch
springs [A].
★If any spring is shorter than the service
limit, it must be replaced.
Clutch Spring Free Length
Standard: 33.6 mm
6-16
6 Cltuch
Clutch
Clutch Housing Finger Inspection

● Visually inspect the clutch housing fingers
[A] where the friction plate tangs [B] hit them.
★If they are badly worn or if there are groove
cuts where the tangs hit, replace the housing.
Also, replace the friction plates if their tangs
are damaged.
Clutch Housing Spline Inspection

● Visually inspect where the teeth [A] on the
steel plates wear against the clutch hub
6
splines [B].
★ If there are notches worn into the splines,
replace the clutch hub. Also, replace the steel
plates if their teeth are damaged.
6-17
7 Engine Lubrication System
Exploded View………………………………………………………………………………………………7-2
Engine Oil Flow Chart………………………………………………………………………………………7-4
Specifications ………………………………………………………………………………………………7-6
Special Tools and Sealant ………………………………………………………………………………7-7
Engine Oil and Oil Filter…………………………………………………………………………………-7-8
Oil Level Inspection……………………………………………………………………………………7-9
Engine Oil Change………………………………………………………………………………………7-9
Oil Filter Replacement…………………………………………………………………………………7-9
Oil Pan…………………………………………………………………………………………………………7-10
Oil Pan Removal…………………………………………………………………………………………7-10
Oil Pan Installation………………………………………………………………………………………7-11
Oil Pressure Relief Valve…………………………………………………………………………………7-13
Oil Pressure Relief Valve Removal…………………………………………………………………7-13
Oil Pressure Relief Valve Installation……………………………………………………7-13
Oil Pressure Relief Valve Inspection……………………………………………………7-13
Oil Pump……………………………………………………………………………………7-14
Oil Pump Removal………………………………………………………………………7-14
Oil Pump Installation……………………………………………………………………7-15 7
Oil Pressure Measurement ………………………………………………………………7-16
Oil Pressure Switch………………………………………………………………………7-17
Oil Pressure Switch Removal …………………………………………………………7-17
Oil Pressure Switch Installation…………………………………………………………7-17
7-1
CFMOTO
Exploded View
7-2
Exploded View
Torque
No. Fastener Remark
N·m kgf·m ft·lb
1 Oil drain bolt 30 3.0 22
2 Oil strainer plate bolt 10 1.0 87in·lb L
3 Oil filter 17 1.75 13 EO,R
4 Oil filter mounting bolt 25 2.5 18 L
5 Oil pan bolt 12 1.2 106in·lb
6 Oil pipe I plate bolt 8 0.8 71in·lb L
7 Oil pressure limit valve 15 1.5 11 L
8 Oil pressure warning switch （15）（1.5）（11） Tighten by
9 Oil pump cover bolt 12 1.2 106in·lb L
10 Oil pump sprocket bolt 12 1.2 106in·lb L, LH
11 Main oil line screw plug 20 2.0 15 L
12 Lower fairing bracket bolt 12 1.2 106in·lb L
13 Oil pump chain conducting screw 10 1.0 87in·lb L
14 Lower crankcase cover bolt 10 1.0 87in·lb L
7
EO: Apply engine oil
G: Apply grease
L: Apply an on-permanent locking agent
Lh: Left-hand threads
MO: Apply molybdenum disulfi de oil solution
(Mixture of the engine oil and molybdenum disulfi de grease in a weight ratio10:1)
SS: Applysiliconesealant
7-3
CFMOTO
Engine Oil Flow Chart
7-4
Engine Oil Flow Chart
7-5
CFMOTO
Specifcations
Item Standard
Engine oil
Style ELF 10W-40/SJ JASO MA2
Viscosity 10W-40
Capacity 2.2L(2.3US qt)(With filter replaced)
2.6L(2.7US qt)(When engine is totally dried)
Level Between upper and lower line
216kPa ～ 294kPa(2.2kgf/cm2 ～ 3.0kgf/cm2,31psi ～ 43psi) at
Oil pressure
4000r/min(rpm), oil temperature is 90℃(194°F)
7-6
Special Tools and Sealant
Oil Pressure Gauge 10kgf/cm2 Oil Filter Wrench
Oil Pressure Gauge Adapter, PT3/8 Silicone Sealant
7-7
CFMOTO
Engine Oil and Oil Filter

WARNING
Motorcycle operation with insufficient,
deteriorated, or contaminated engine oil
will cause accelerated wear and may re-
sult in engine or transmission seizure,
accident, and injury.
Oil Level Inspection
● Check that the engine oil level is between
the upper [A] and lower [B] levels in the engine.
NOTE
o Situate the motorcycle so that it is per-

pendicular to the ground.
o If the motorcycle has just been used,

wait several minutes for all the oil to drain
down.
o If the oil has just been changed, start

the engine and run it for several minutes
at idle speed. This fills the oil filter with
oil. Stop the engine, then wait several
minutes until the oil settles.
CAUTION
Racing the engine before the oil reaches
every part can cause engine seizure. If
the engine oil gets extremely low or if the
oil pump or oil passages clog up or oth-
erwise do not function properly, the oil
pressure warning light will light. If this
light stays on when the engine is running
above idle speed, stop the engine imme-
diately and f nd the cause.
7-8
Engine Oil and Oil Filter
★ If the oil level is too high, remove the

excess oil, using a syring or some other
suitable device.
★ If the oil level is too low, add the correct
acmount of oil through the oil fi lter opening.
Use the same type and make of oil that is
already in the engine.
NOTE
o If the engine oil type and make are
unknown, use any brand of the specifi ed
oil to top off the level in preference to run-
ning the engine with the oil level low. Then
at your earliest convenience, change the
oil completely.
Engine Oil Change

●Refer to the Engine Oil Change in the
Oil Filter Replacement

● Refer to the Oil Filter Replacement in
7-9
CFMOTO
Oil Pan
Oil Pan Removal

● Remove:
Engine oil (Drain, see Engine Oil Change in
the Periodic Maintenance chapter)
Exhaust Pipe (see Exhause Pipe Removal
in the Engine Top End chapter)
Muffler body (see Muffler Body Removal in
the Engine Top End chapter)
Oil Pan Bolts [A]
Oil Pan [B]
Gasket [C]
Damper [D]
● Remove the following from the oil pan as

necessary.
Filter Plate Bolts [A]
Filter Plate [B]
Filter [C]
● Remove the following from the lower

crankcase when necessary.
Oil Screen [A]
Oil Pipe I Plate Bolt [B]
Oil PipeI Plate [C]
Oil Pipes I and III [D]
Oil Pressure Relief Valve [E]
7-10
Oil Pan
Oil Pan Installation

● Apply grease to the O-rings on the oil
pipes [A]
● Install the oil pipe I plate [B] so that its
guide
portion [C] fi ts the breather pipe [D] as
shown.
the oil pipe I plate bolt.
Torque: Oil Pipe I Plate Bolt [E]: 8N·m
★ If the oil pressure relief valve [F] was

removed, install it.
o Apply a non-permanent locking agent to the

threads [G] of the oil pressure relief valve, and
tighten it.
7
Torque: Oil Pressure Relief Valve:15N·
m
CAUTION
Do not apply too much non-permanent
locking agent to the threads. This may
block the oil passage.
● Apply grease to the O-ring [A] on the oil

screen [B] and install it on the lower crank-
case hald as shown.
● Be sure the damper [C] is on the end of

the breather pipe [D].
7-11
CFMOTO
Oil Pan
●Replace the oil pan gasket with a new one.
● When installing the oil pan, align [A] the

damper [B] on the breather pipe with the hol-
low [C] on the oil pan.
● Tighten Oil Pan Bolts
Torque: Oil Pan Bolts: 12N·m
7-12
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal

● Refer to the Oil Pan Removal.
Oil Pressure Relief Valve Installation

●Refer to the Oil Pan Installation
Oil Pressure Relief Valve Inspection

● Check to see if the valve [A] slides
smoothly when pushing it in with a wooden or
other soft rod, and see if it comes back to its
seat by spring [B] pressure
NOTE
o Inspect the valve in its assembled state

Disassembly and assembly may change
the valve performance.
★ If any rough spots are found during
above inspection, wash the valve clean 7
with a high-flash point solvent and blow
out any foreign particles that may be in
the valve with compressed air.
WARNING
Clean the oil pressure relief valve in a well

ventilated area, and take care that there
is no spark or flame anywhere near the
working area. Because of the danger of
highly flammable liquids, do not use
gasoline or low fash point solvent.
★ If cleaning does no solve the problem, re-

place the oil pressure relief valve as an
accessory. The oil pressure relief valve is pre-
cision made with no allowance for replace-
ment of individual parts.
7-13
CFMOTO
Oil Pump
Oil Pump Removal

● Drain:
Engine Oil (see Engine Oil Change in the
● Remove:
Clutch (see Clutch Removal in the Clutch
chapter)
Oil Pump Cover Bolts [A]
Oil Pump Cover [B]
● Remove:
Inner Rotor [A] for Scavenge Pump
Outer Rotor [B] for Scavenge Pump
● Remove:
Dowel Pin [A]
Pin [B]
Oil Pump Body [C]
● Remove:
Oil Pump Shaft [C] with Inner Rotor [A] and
Pin for Feed Pump
Outer Rotor [B] for Feed Pump
7-14
Oil Pump
Oil Pump Installation

●Apply molybdenum disulfi de grease to the
portion [A] of the oil pump shaft as shown.
● Install:
Outer Rotor [B] for Feed Pump
Inner Rotor [C] for Feed Pump
Oil Pump Shaft [D] and Pin [E]
Dowel Pin [F]
Oil Pump Body [G]
Pin [H] and Inner Rotor [I] for Scavenge Pump
Outer Rotor [J] for Scavenge Pump
Oil Pump Cover [K]
NOTE
o The scavenge pump rotors are wider 7

than the feed pump rotors.
●Apply a non-permanent locking agent to the

oil pump cover bolts and tighten them.
Torque: Oil Pump Cover Bolts: 12N·m
7-15
CFMOTO
Oil Pressure Measurement
Oil Pressure Measurement
● Remove the lower fairing (see Lower Fair-

ing Removal in the Frame chapter)
●Remove the oil passage plug, and attach

the adapter [A] and gauge [B] to the plug hole.
Special Tools:
Oil Pressure Gauge 10kgf/cm2
Oil Pressure Gauge Adapter, PT3/8
●Start the engine and warm up the engine
● Run the engine at the specifi ed speed,
and read the oil pressure gauge.
★If the oil pressure is much lower than the
standard, check the oil pump, relief valve, and/
or crankshaft bearing insert wear immediately.
★ If the reading is much higher than the
standard, check the oil passages for clogging
Oil Pressure
Standard: When RPM is at 4000r/min
(rpm), oil temperature shoule be
90 °C(194 °F) 216kPa~294kPa
( 2.2kgf/cm2~3.0kgf/cm2,31psi~43psi)
●Stop the engine
● Remove the oil pressure gauge and
adapter
WARNING
Take care against burns form hot engine
oil that will drain through the oil passage
when the gauge adapter is removed.

the oil passage plug, and install it.
Torque: Oil Passage Plug: 20N·m
7-16
Oil Pressure Warning Switch
Oil Pressure Switch Removal

● Remove:
Engine Oil (Drain, see Engine Oil Change in
the Periodic Maintenance chapter)
Switch Cover [A]
Switch Terminal Bolt [B]
Oil Pressure Warning Switch [C]
Oil Pressure Switch Installation

● Apply silicone sealant to the threads of the
oil pressure switch and tighten it.
Sealant: Silicone Sealant
Torque: Oil Pressure Switch 15N·m
●Tighten the terminal bolt securely

7
7-17
8 Engine removal and installation
Contents
Exploded View……………………………………………………………………………………………………8-2
Engine removal/installation ……………………………………………………………………………… 8-4
Engine removal…………………………………………………………………………………………………8-4
Engine installation ……………………………………………………………………………………………8-6
8-1
CFMOTO
Exploded view
8-2
Torque
No. Tighten part Remark
N·m kgf·m ft·lb
1 GB/T6186 Nut M10×1.25 40～45 4.08～4.59 29.5～33 S
4 GB/T5789 Bolt M8×25 25～30 2.55～3.0 18.5～22 S
5 GB/T5787 Bolt 40～45 4.08～4.59 29.5～33 S
6 GB/T5789 Bolt M8×28 25～30 2.55～3.0 18.5～22 S
8 GB/T6187 Nut M10×1.25 40～45 4.08～4.59 29.5～33 S
11 GB/T5787 Bolt 40～45 4.08～4.59 29.5～33 S
2:Engine front rubber pad LHⅡ
3:Engine front mounting sleeve RH
7:Engine rear upper mounting shaft
9: Engine front rubber pad LHⅠ
10:Engine front bracket
12:Engine rear lower mounting shaft
13:Engine rubber dust boot
14:Engine rear upper rubber
15:Engine rear upper rubber sleeve
16:Engine rear lower screw
17:M18 nut
S： Follow special tighten order
8-3
CFMOTO
Engine Removal/Installation
Engine Removal
ŸSupport the rear part of the swingarm with a
stand.
ŸSqueeze the brake lever slowly and hold it
with a band [A].
D an ge r
Hold the front break lever when
removing the engine. Or the
motorcycle will fall. It will cause
accident or injury.
W a rn in g
Hold the front break lever when B
removing the engine. Or the
motorcycle will fall. The engine or
motorcycle may damaged.
Ÿ Drain up the oil and coolant

Engine Oil (see Engine Oil Change in the C
Coolant (see Coolant Change in the Peri-
odic Maintenance chapter)
Remove:
Seat (see Seat Removal in the Frame
chapter)
Lower Fairing and Center Fairings (see
Fairing section in the Frame chapter)
Side Covers (see Side Cover Removal in
the Frame chapter)
Frame Covers (see Frame Cover Removal
Radiator and Hoses (see Radiator and
Radiator Fan Removal in the Cooling Sys-
tem chapter)
Unscrew the lower fairing bracket bolts
(both sides) [B] and remove the
brackets (both sides)[c].
ŸDisconnect the oil pressure switch terminal

[D].
8-4
Ÿ Disconnect the crankshaft sensor lead
con-nector [A].
Ÿ Remove
Exhaust Pipe (see Exhaust Pipe Removal in
Muffler Body (see Muffler Body Removal in
Fuel Tank (see Fuel Tank Removal in the
Fuel System (EFI) chapter)
Air Filter Housing (see Air Filter Housing
Throttle Body Assy (see Throttle Body Assy
Clutch Cable (see Clutch Cable Removal in
the Clutch chapter)
Ÿ Remove:
Stick Coils [A]
Baffle Plate [B]
Ÿ Remove or Disconnect:
Coolant Temperature Sensor Lead Connec-
8
tor [A]
Starter Motor Cable [B]
Engine Ground Cable Terminal Bolt [C]
Alternator Lead Connector [D]
Sidestand Switch Lead Connector [E]
8-5
CFMOTO
ŸRemove the engine sprocket cover (see
A
Engine Sprocket Removal in the Final Drive
chapter).
B
ŸRemove the shift pedal[E] (see Shift Pedal
Removal in the Crankshaft/Transmission
D
chapter). C
ŸDisconnect:
Oxygen Sensor Lead Connector [B] E
Neutral Switch Lead Terminal [C]
ŸRemove the bracket [D] and the engine F
sprocket [E] (see Engine Sprocket Re-
moval in the Final Drive chapter). G
ŸRemove:
H
Horn Leads [F] (Disconnect)
Horn Bolt [G]
Horn [H]
Ÿ Support the engine with a stand or jack

○ Put a wooden board[K] on the suitable
stand
Ÿ Remove the engine mounting bolt [1],[2]
Ÿ Remove engine front bracket bolt [3],[4]
(both sides)
Ÿ Remove front bracket bolt[5],[6],[7],[8]
Ÿ Remove the front bracket.
ŸRemove the engine [I]
Engine installation(Pic.8-7)
1 5 3 6
ŸPut the engine rear lower screw [16] on the
frame and tight M18 nut[17].Do not tight up
and make sure [16] can be moved.
ŸPut engine rear rubber pad [14] and rear

upper rubber sleeve [14] on the frame.
ŸFrom the engine front rubber pad [9] to en-

gine front bracket [10]
ŸPut engine front bracket[10] on the frame.

And tight (without tight up)with the bolt [4],[6]
7 4 8 2
8-6
ŸHang the engine into the frame and align the
hole position.
ŸInsert the mounting bolt[12] from engine left

side. Pre-tight by nut [1].
ŸInsert the mounting bolt[7] from right side.

Pre-tight by nut[8].
○ Position the collor[3], rubber sleeve [2],

Dust boot [13].
ŸTighten bolt [11] and bolt [5]
ŸTighten bolt [4] and bolt [6]
Torque-engine bracket bolt[4],[6]:25N·m～

30N·m(2.55kgf·m～3.0kgf·m,18.5ft·lb～22ft·lb)
ŸTighten the mounting nut[8]
Torque-engine mounting nut[8]:40N·m～45N·m

(4.08kgf·m～4.59kgf·m,29.5ft·lb～33ft·lb)
ŸTighten the mounting nut[1] See the picture in page 8-2

Torque-engine mounting bolt[1]:40N·m～
45N·m(4.08kgf·m～4.59kgf·m,29.5ft·lb～33ft·lb)
8
ŸTighten M18 nut[17]
ŸTighten bolt [11]and bolt[5].
Torque:40N·m～45N·m(4.08kgf·m～
4.59kgf·m,29.5ft·lb～33ft·lb)
ŸInstall the engine sprocket (see Engine

Sprocket Installation in the Final Drive
chapter).
ŸRun the leads, cables, and hoses correctly.

(See the leads,cables and hoses in appendix)
ŸInstall all removed parts(See related chapter)
ŸAdjust:Throttle cable (See throttle control-

ling inspection in periodic maintenance
chapter)
Clutch cable (See clutch inspection in peri-

odic maintenance chapter)
8-7
CFMOTO
Drive chain (See drive chain tightness in-
spection in periodic maintenance chapter)
ŸFill the engine oil (See engine oil replace-

ment in periodic maintenance chapter)
ŸFill the coolant in the cooling system and drain See the picture in page 8-2
out the air from it.(See coolant replacement in
periodic maintenance chapter)
ŸAdjust the idle speed(See idle speed adjust-

ment in periodic maintenance chapter)
8-8
9 Crankshaft /Transmission
Contents
Exploded view……………………………………………………………………………………………………9-3
Specification ……………………………………………………………………………………………………9-7
Crankcase Splitting……………………………………………………………………………………………9-10
Crankcase Splitting…………………………………………………………………………………………9-10
Crankcase Assembly………………………………………………………………………………………9-12
Crankshaft and Connecting Rods…………………………………………………………………………9-18
Crankshaft Removal……………………………………………………………………………………… 9-18
Crankshaft Installation…………………………………………………………………………………… 9-18
Connecting Rod Removal ……………………………………………………………………………… 9-19
Connecting Rod Installation …………………………………………………………………………… 9-19
Connecting Rod Bend………………………………………………………………………………………9-22
Connecting Rod Twist …………………………………………………………………………………… 9-22
Connecting Rod Big End Side Clearance………………………………………………………… 9-22
Connecting Rod Big End Bearing Insert/ Crankpin Wear………………………………………9-23
Crankshaft Side Clearance………………………………………………………………………………9-24 9
Crankshaft Runout……………………………………………………………………………………………9-25
Crankshaft Main Bearing Insert/Journal Wear………………………………………………………9-25
Balancer……………………………………………………………………………………………………………9-27
Balancer Removal………………………………………………………………………………………………9-27
Balancer Installation ………………………………………………………………………………………9-27
Insert/Journal Clearance…………………………………………………………………………………9-27
Transmission…………………………………………………………………………………………………… 9-29
Shift Pedal Removal………………………………………………………………………………………9-29
Shift Pedal Installation……………………………………………………………………………………9-29
Shift Mechanism Removal …………………………………………………………………………… 9-29
Shift Mechanism Installation………………………………………………………………………… 9-30
Shift Mechanism Inspection ………………………………………………………………………… 9-31
Transmission Assy Removal……………………………………………………………………………9-32
Transmission Assy Disassembly…………………………………………………………………… 9-33
9-1
CFMOTO
Transmission Assy Assembly …………………………………………………………………………9-34

Transmission Assy Installatiion……………………………………………………………………… 9-35
Transmission Shaft Disassembly…………………………………………………………………… 9-36
Transmission Shaft Assembly………………………………………………………………………… 9-36
Shift Fork Bending………………………………………………………………………………………… 9-39
Shift Fork/Gear Groove Wear……………………………………………………………………………9-39
Shift Fork Guide Pin/Drum Groove Wear……………………………………………………………9-39
Gear Dog and Gear Dog Hole Damage…………………………………………………………… 9-40
Ball and Needle Bearing Replacement………………………………………………………………9-40
Ball and Needle Bearing Wear ……………………………………………………………………… 9-40
9-2
Exploded view
9-3
CFMOTO
Exploded view
Torque
No. Tighten parts Remark
N·m kgf·m ft·lb
1 Connecting rod nut See test --- --- MO
2 CPS disc 40 4.1 30
3 Oil separator plate bolt 10 1.0 87in·lb L
4 Oil separator bolt 7 0.7 61in·lb L
5 Shift spring locking pin 29 2.9 22 L
6 Oil pipe bolt 10 1.0 87in·lb L
7 Crankcase bolt (M9,L=113mm) 44 4.5 32 MO,S
11 Crankcase bolt(M8,L=110mm) 27.5 2.8 20 S
12 Crankcase bolt (M8,L=50mm) 27.5 2.8 20 S
13 Crankcase bolt (M7) 20 2.0 15 S
14 Crankcase bolt 27.5 2.8 20 S
15. Do not apply any grease or oil.

G: Apply grease.
LG: Apply liquid gasket.
(mixture of the engine oil and molybdenum disulfi de grease in a weight ratio 10 : 1)
SS: Apply silicone sealant.
9-4
Exploded view
9-5
CFMOTO
Exploded view
Torque
No. Tighten part Remark
N·m kgf·m ft·lb
1 Locking rocker arm screw 12 1.2 106 in·lb L
2 Shifting room cover bolt 20 2.0 15 L
3 Locking gear bolt 12 1.2 106 in·lb L
4 Shifting drum bearing screw 5 0.50 43 in·lb L
5 Shifting fork plate screw 10 1.0 87 in·lb
6 Neutral sensor screw 5 0.50 43 in·lb L
7 Neutral sensor 15 1.5 11
8 Shifting axel cover screw 12 1.0 87 in·lb
9 Shifting axel cover bolt 5 0.50 43 in·lb L
G: Apply grease.
(mixture of the engine oil and molybdenum disulfi de grease in a weight ratio 10 : 1)
9-6
Specification
Crankshaft, connecting rod
Connecting rod parallelism 0.04/100 mm 0.2/100 mm
Connecting rod torsion 0.08/100 mm 0.2/100 mm

Connecting rod big end side clearance 0.15 mm～0.30 mm 0.55 mm
Connecting rod big end bearing/
0.03 mm～0.045 mm 0.08 mm
Connecting joint clearance
Connecting rod big end bearing/
0.032 mm～0.042 mm 0.08 mm
Connecting
Crankshaft connecting joint diameter: 37.984 mm～38.00 mm 37.97 mm
Mark:
2 37.984 mm～37.992 mm –––
1 37.993 mm～38.000 mm –––
Connecting rod big end hole diameter: 41.000 mm～41.016 mm –––
Mark:
1 41.000 mm～41.008 mm –––
2 41.009 mm～41.016 mm –––
9
Connecting rod bearing diameter
Mark:
Black 1.490 mm～1.495 mm –––
Blue 1.495 mm～1.500 mm –––
Green 1.500 mm～1.505 mm –––
Connecting rod big end hole/Joint/Bearing rigging：
Connecting rod big end mark Connecting joint mark Bearing color
1 1 Black
1 2
Blue
2 1
2 2 Green
9-7
CFMOTO
Specification

Crankshaft/upper crankcase
0.10 mm～0.30 mm 0.40 mm
locking clearance
Crankshaft radial runout 0.02 mm 0.05 mm
Main joint/Main joint clearance 0.025 mm～0.04 mm 0.07 mm
Main joint/Main joint clearance 0.020 mm～0.035 mm 0.07 mm
Main joint diameter 37.984 mm～38.00 mm 37.96 mm

Mark:
2 37.984 mm～37.992 mm –––
1 37.993 mm～38.000 mm –––
Crankcase main hole diameter: 41.000 mm～41.016 mm –––
Mark:
Yellow 41.000 mm～41.008 mm –––
Green 41.009 mm～41.016 mm –––
Main bearing thickness:
Mark：
Brown 1.496 mm～1.500 mm –––
Black 1.500 mm～1.504 mm –––
Blue 1.504 mm～1.508 mm –––
Crankcase main hole/Main joint/Main bearing
Crankcase main hole Crankcase main joint
Main bearing color
color diameter
Yellow 1 Brown
Yellow 2
Black
Green 1
Green 2 Blue
Balance bearing/shaft clearance 0.025 mm～0.04 mm 0.07 mm
Balance bearing/shaft clearance 0.023 mm～0.038 mm 0.07 mm
Balance joint diameter 27.987 mm～28.00 mm 27.96 mm
Mark:
1 27.987 mm～ 27.993 mm –––
2 27.993 mm～ 28.000 mm –––
9-8
Specification
Crankcase balance shaft

31.000 mm～31.016mm –––
clearance:
Mark:
Yellow 31.000 mm～31.008mm –––
Green 31.009 mm～31.016mm –––
Balance bearing thickness:
Mark：
Brown 1.490 mm～1.494mm –––
Black 1.494 mm～1.498mm –––
Blue 1.498 mm～1.502mm –––
Balance hole/shaft diameter/Bearing fitness
Balance hole Shaft diameter Bearing
Yellow 2 Brown
Yellow 1
Black
Green 2
Green 1 Blue
Transmission system： 9
Shift fork thickness 5.9 mm～6.0mm 5.8mm
Fork groove wideness 6.05 mm～6.15mm 6.25mm
Shift fork shaft diameter 6.90 mm～7.0mm 6.8mm
Shift drum groove wideness 7.1 mm～7.17mm 7.3mm
9-9
CFMOTO
Crankcase Splitting
Crankcase Splitting
● Remove:
Engine (see Engine Removal in the Engine
Removal/Installation chapter)
Cylinder (see Cylinder Removal in the Engine
Top End chapter)
Pistons (see Piston Removal in the Engine
Top
End chapter)
Stater Motor (see Starter Motor Removal in
the
chapter)
Transmission Assy (see Transmission Assy
Removal)
Alternator Rotor (see Alternator Rotor Re
moval in the Electrical System chapter)
● Remove the spring[B] and ball[A] in upper
body.(283MT has no spring and balls)
●Remove the upper crankcase bolts [A]
and the washers
●Remove the oil pan, relief valve, oil screen
and oil pipes (see Oil Pan Removal in the En-
gine Lubrication System chapter).
●Remove the lower crankcase bolts.
o Firstly loosen the M7 bolts, secondly the
M8 bolts and lastly the M9 bolts.
M7 Bolts [A]
M8 Bolts [B]
M9 Bolts [C] and Washers
9-10
Crankcase Splitting
● Tap lightly around the crankcase mating

surface
with a plastic mallet, and split the
crankcase.
Take care not to damage the crankcase.
★ If the oil pipe is to be removed, follow the

next procedure.
oUnscrew the bolts [A] and remove the oil
pipe [B].
oPrepare a 5 mm rod [A], and insert it to

the hole of the upper crankcase half.
9
o Remove the oil pipe [B], tapping [C] the
rod as shown.
★If the breather plate [A] is to be removed,

follow the next procedure
oRemove the oil pipe (see above).
oCut the gasket around the plate [B].
oRemove
Breather Plate Bolts [C]
Breather Plate with Pipe
9-11
CFMOTO
Crankcase Splitting
Crankcase Assembly
CAUTION
The upper and lower crankcase halves
are machined at the factory in the as-
sembled state, so the crankcase halves
must be replaced as a set.
● With a high-flash point solvent, clean off
the mating surfaces of the crankcases halves
and wipe dry.
● Using compressed air, blow out the oil
passages in the crankcase halves.
● If the oil plate [A] on the upper crankcase
half was removed, install it as shown.
the oil plate bolts and torque them.
Torque - Oil Plate Bolts [B]10N·m
●Press and insert [A] the new needle

bearing [B] for the shift drum until it is
bottomed.
● Press and insert [C] the new needle bear-
ing [D] for the shift shaft so that the bearing sur-
face is flush with the end of the hole.
Lower Crankcase Half [E]
● Apply silicone sealant to the breather plate
mating surface [A] 1 mm (0.04 in.) or more thick,
and then install the breather plate.
9-12
Crankcase Splitting
NOTE
Make the application finish within 7 min-
utes when the liquid gasket to the mating
surface of the breather plate is applied.
the threads and tighten the bolts [A].
Torque - Breather Plate Bolts 10N·m
9
●Install the breather pipe [A].Align the white
mark [B] on the pipe with the white mark [C]
on the breather fittling.
● Install the oil pipe [A] so that its flange [B]

touches to the surface [C] of the upper crank-
case half.
● Apply grease to the O-ring [D] on the oil
pipe.
9-13
CFMOTO
Crankcase Splitting
● Install the crankshaft assembly and the

balancer shaft assembly on the upper crank-
case half.
o Align [A] the timing mark on the balancer

gear [B] with the timing mark on the bal-
ancer drive gear [C] of the crankshaft
● Be sure to hang the camshaft chain [A]

on the crankshaft.
●Be sure that the dowel pins [A] are in

position.
●Set the bearing groove [A] on the posi-

tioning ring [B] as shown
9-14
Crankcase Splitting
● Apply liquid gasket [A] to the mating

surface of the lower crankcase half.
NOTE
Apply the sealant evenly on the mating
surfcae without cutting.
CAUTION
Do not apply liquid gasket around the
crankshaft main bearing inserts, and oil
passage holes.
o Do not apply liquid gasket to the oil pas-

sage [B].
9-15
CFMOTO
Crankcase Splitting
●Fit the lower crankcase half to the upper

crankcase half.
o Insert [A] the breather pipe [B] on the

upper crankcase half through the hole [C]
NOTE
o Make the application finish within
20 minutes when the liquid gasket to
the mating surface of the lower crank-
case half is applied.
o Moreover fi t the case and tighten

the case bolts just after fi nishing the
application of the liquid gasket.
● Apply molybdenum disulfide oil solution

to both sides [A] of the M9 bolts washers
and the threads [B] of the M9 bolts.
●Apply molybdenum disulfi de oil solution

to fl ange [A] and the threads [B] of the M8
bolts which is tightening order is [7~10] only
(see the next figure).
9-16
Crankcase Splitting
● Tighten the lower crankcase bolts using the

followwing steps.
o Tighten the M9 bolts [1, 2] L= 113 mm (4.45

in.) with washers.
Torque - Crankcase Bolts (M9): 44 N·m (4.5
kgf·m, 32 ft·lb)
o Tighten the M9 bolts [3, 4] L= 83 mm (3.27 in.)

with washers.
kgf·m, 32 ft·lb)
o Tighten the M9 bolts [5, 6] L= 113 mm (4.45

in.) with washers.
kgf·m, 32 ft·lb)
9
o Tighten the M8 bolts [7~10].
kgf·m, 26 ft·lb)
o Tighten the M8 bolts [A] (Do not apply molyb-

denum oil solution).
Torque - Crankcase Bolts (M8): 27.5 N·m (2.
8 kgf·m, 20 ft·lb)
o Tighten the M7 bolts [B].

kgf·m, 15 ft·lb)
o Tighten the upper crankcase bolts [A].

Torque - Upper Crankcase Bolts [A]: 27.5
N·m (2.8kgf·m,20 ft·lb)
● After tightening all crankcase bolts, check
the following items.Crankshaft and balancer
shafts turn freely.
9-17
CFMOTO
Crankshaft and Connecting Rods
Crankshaft Removal
●Split the crankcase (see Crankcase
Splitting).
●Remove the crankshaft [A].
Crankshaft Installation
CAUTION
If the crankshaft, bearing inserts, or
crankcase halves are replaced with
new ones, select the bearing inserts
and check clearance with a plastigage
(press gauge) before assembling en-
gine to be sure the correct bearing
inserts are installed.
● Apply molybdenum disulfi de oil solu-

tion to the crankshaft main bearing inserts.
Align [A] the timing mark on the balancer
gear [B] with the timing mark on the bal-
ancer drive gear [C] of the crankshaft.
● Install the crankshaft with the camshaft

chain [A] hanging on it.
9-18
Connecting Rod Removal

●Split the crankcase (see Crankcase
Splitting).
●Remove the connecting rod nuts [A].
●Remove the connecting rod.
●Remove the connecting rod bolts.
CAUTION
To prevent damage to the crankpin
surfaces, do not allow the connecting
rod bolts to bump against the
crankpins.
Connecting Rod Installation

CAUTION
9
To minimize vibration, the connecting
rods should have the same weight
mark. Always use new connecting rod
bolts and nuts.
Match Mark [A]

Connecting Rod [B]
Diameter Mark [C]
Weight Mark [D]
Connecting Rod Big End Cap [E]
CAUTION
If the connecting rods, big end bearing
inserts, or crankshaft are replaced with
new ones, select the bearing insert and
check clearance with a plastigage
(press gauge) before assembling en-
gine to be sure the correct bearing
inserts are installed.
9-19
CFMOTO
●Install the 2 connecting rod bolts.

● Apply molybdenum disulfide grease [B] to
the outer surface of the upper insert and the
inner surface of the connecting rod big end.
o The molybdenum disulfi de oil solution is a

mixture of engine oil and molybdenum disulfide
grease with a weight ratio (10 : 1).
o Do not apply any grease or oil [D] to the cap

inside, cap insert outside, connecting rod in-
ner hole upper surface and upper bearing sur-
face [B].
o Align the bearing lip [E] to upper groove on

connecting rod.
CAUTION
Wrong application of oil and grease
could cause bearing damage.
o When installing the inserts [A], be careful

not to damage the insert surface with the
edge of the connecting rod [B] or the cap [C].
o One way to install inserts is as follows.

Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Connecting Rod Bolts [H]
9-20
● Apply molybdenum disulfi de oil solu-

tion [MO] to the threads and seating
surfaces of the big end nuts and bolts.
●Install the crankshaft (see Crankshaft
Installation).
●Install each connecting rod on its origi-
nal crankpin.
● Install the connecting rod big end cover
align up the code.
NOTE
o Use angle way to tight up the connect-

ing rod nut,this can make the torque
tight and accurate.
● First tighten the 2 nuts of a connecting
rod alter nately to 40 N·m. Loosen the 2
9
nuts completely.Tighten them alternatly
to 29 N·m.
o After the connecting bolts are tightened

to 29 N·m, the connecting rod can turn freely.
●Turn the connecting rod nuts clockwise
100 degree. The final torque should be
between 65N·m and 90N·m.
o Check if the connecting rod turns freely. If

not, reinstall the connecting rod bearing.
9-21
CFMOTO
Connecting Rod Bend
●Remove the connecting rod big end bear-
ing inserts, and reinstall the connecting rod
big end cap.
● Insert the arbor [A] through the connecting
rod big end.
●Select an arbor of the same diameter as
the piston pin and at least 100 mm (3.94 in.)
long, and insert the arbor [B] through the
connecting rod small end.
● On a surface plate, set the big-end arbor
on V block [C].
●With the connecting rod held vertically, use
a height gauge to measure the difference in
the height of the arbor above the surface
plate over a 100 mm (3.94 in.) length to
determine the amount of connecting rod
bend.
★ If connecting rod bend exceeds the ser-
vice limit, the connecting rod must be
replaced.
Connecting Rod Bend Service Limit: 0.2
mm
Connecting Rod Twist
●With the big-end arbor [A] still on V block
[C].
●Hold the connecting rod horizontally.
Measure the arbor[B] hight different to see
the twist.
Connecting Rod Twist limit: 0.2mm
Connecting Rod Big End Side Clearance
● Measure connecting rod big end side
clearance.
First to let the connecting rod big end to
paste a side of the joint.Then insert a thick-
ness gauge [A] between the big end and
9-22
either crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard 0.15mm~0.30mm
o If the clearance exceeds the service limit,

replace the connecting rod with new one and
then check clearance again. If clearance is
too large after connecting rod replacement,
the crankshaft also must be replaced.
Crankpin/Connecting Rod Big End
Bearing
Insert Wear
● Measure the crankpin [A] diameter 9
using a micrometer
Crankpin Diameter Standards:
37.984mm~38.00mm
Service Limit: 37.97mm
★If any crankpin has worn past the service
limit, re place the crankshaft with a new one.
★ If the measured crankpin diameters are
not less than the service limit, but do not coin-
cide with the original diameter markings on
the crankshaft, make new marks on it.
Crankpin Diameter Marks:
2 :37.984mm~37.992mm
1 :37.993mm~38.000mm Connecting Rod Big End Inside Diam-

●Measure the connecting rod big end eter Marks：
inside diameter, and mark each connecting 1 :41.00mm~41.008mm
rod big end in accordance with the inside
2 :41.009mm~41.016mm
diameter.
9-23
CFMOTO
Match Mark[A]
Connecting Rod body[B]
Diameter Mark[C]
Weight Mark[D]
Connecting rod big end cover[E]
● Select the proper bearing insert [A]
according to the crankpin diameter mark and
the big end inside diameter mark. Size Color
[B]
Big end hole/Connecting

joint/Bearing
Big end Connecting
Bearing
hole joint
1 1 Black
1 2
Blue
2 1
2 2 Green
Crankshaft Side Clearance

● Insert a thickness gauge [A] between the
crankcase main bearing and the crank web at
the No.2 journal [B] to determine clearance.
Crankshaft Side Clearance Standard:
0.10mm~0.30mm
Service Limit：0.40mm
★ If the clearance exceeds the service limit,
replace the crankcase halves as a set.
9-24
Crankshaft Runout
●Measure the crankshaft runout
Crankshaft Runout Standard: 0.02mm
★ If the measurement exceeds the service
limit, replace the crankshaft.
Crankshaft Main Bearing Insert/Journal
Wear
●Using a micrometer, measure the diam-
eter of the main bearing journal [A].
Main Bearing Journal Diameter Stan-
dards
37.984mm~38.00mm
★ If the main bearing journal has worn past
the service limit, replace the crankshaft with a 9
new one.
★ If the measured main bearing journal diam-
eters are not less than the service limit, but do
not coincide with the original diameter mark-
ings on the crankshaft, make new marks on it.
Main Bearing Journal Diameter
Marks：
2 :37.984mm~37.992mm
1 :37.993mm~38.000mm
● Measure the crankshaft hole diameter on

the crankcase the diameter mark should be as
same as shaft. or make a new mark on it.
Crankshaft hole diameter marks
1:41.00mm~41.008mm
2:41.009mm~41.016mm
9-25
CFMOTO
● Select the proper bearing insert [A] in

accordance with the combination of the
crankcase and crankshaft coding. Size
Color [B]
Crankshaft hole/shaft neck/Bearing

Crank Crankshaft Bearing
hole mark neck mark color
Yellow 1 Brown
Yellow 2
Black
Green 1
Green 2 Blue
9-26
Balance shaft
Balance shaft removal

● Disassemble the crankcase(Refer to
crankcase assemble)
● Take the balance shaft out from
crankcase.
Balance shaft installation
● Pre-lubricate the balance shaft bearing.
● Aline [A] balance shaft mark [B]and crank
shaft mark[C].
● Assemble the crankcase(See crankcase
assemble).
Balance shaft neck/Balance bearing wear-
ing
● Use micrometer to measure the diam-
eter of balance shaft neck [A].
Balance shaft neck standard: 9
27.987mm～28.000mm
Service limit: 27.96 mm
★If balance bearing is out of service limit.
Replace the balance shaft.
Balance shaft with oil hole
Note
Balance shaft without oil hole cannot
mixed with the balance shaft with oil
hole.
★ If balance shaft diameter is out of service

limit but balance shaft diameter sign is different.
Remark again.
Balance shaft diameter sign:
Balance shaft with oil hole
2: 27.987mm～27.993mm
1: 27.994mm～28.000mm
9-27
CFMOTO
Balance shaft
● Measuer the balancer hole diameter on

crankcase. The diameter should be fit the
mark. Or mark again to the truth.
Crankcase Bearing Bore Diameter
Marking
1 :31.000mm~31.008mm
2 :31.009mm~31.016mm
● Select the proper bearing insert [A] in

accor dance with the combination of the
crankcase and the balancer shaft coding.
Size Color [B]
Balance shaft hole/Balance

shaft/Balance bearing
Balance Balance
Balance
shaft hole shaft bearing
shaft sign
sign color
Yellow 2 Brown
Yellow 1
Black
Green 2
Green 1 Blue
9-28
Transmission
Shift Pedal Removal

● Remove:
Shift Lever Bolt [A]
Shift Lever [B]
Shift Pedal Installation

● Align the mark [A] on the shift shaft with
the slit [B] on the shift lever.
● Tighten the shift lever bolt securely
External Shift Mechanism Removal

●Remove
in the
Periodic Maintenance chapter) 9
Shift Pedal (see Shift Pedal Removal)
Engine Sprocket (see Engine Sprocket
Removal
in the Final Drive chapter)
Neutral Switch Lead Connector
(Disconnect)
Shift Shaft Cover Bolts [A]
Shift Shaft Cover Screw [B]
Shift Shaft Cover [C]
● Remove the shift shaft assembly [A].
●Remove:
chapter).
9-29
CFMOTO
Transmission
Gear Positioning Lever Bolt [A]

Gear Positioning Lever [B], Spacer,
Washer and Spring.
External Shift Mechanism Installation
●Install the gear positioning lever [A] as
shown. Spring [B], Washer [C], Spacer [D],
Bolt [E]
o Hook the spring at gear positioning

lever, pushing up [F] the hook portion, as
shown.
● Apply a non-permanent locking agent
to the gear positioning lever bolt and tighten
it.
Torque - Gear Positioning Lever Bolt
: 1 2 N ·m
● Install the shift shaft assembly
o Apply [A] molybdenum disulfi de oil

solution to the rubbing surface between the
lever [B] and pawl [C] and move them two or
three times up and down to lubricate them.
o Be sure that the washer [A] is on the

shaft.
o Be sure that the spring hook portions [B]

are as shown.
9-30
Transmission
● When the new needle bearing [A] is in-

stalled in the shift shaft cover [B], press and
insert the new needle bearing until it is
bottomed.
●When the new oil seal [C] is installed in the
shift cover, press and insert the new oil seal so
that its surface is fl ush with the end of the hole.
Special Tool - Oil Seal Installer
● Install the shift shaft cover.
o Be sure that the dowel pins [A] are in

position.
oInstall the new gasket [B].

the shift shaft cover screw [A]. 9
o Do not apply a non-permanent locking
agent to the shift shaft cover bolts [B,C,D, E].
o Install the auxilary ground wire [F].

●Tighten the cover screw lastly.
Torque - Shift Shaft Cover Bolts:12N·m
Shift Shaft Cover Screw:5N ·m

External Shift Mechanism Inspection
●Inspect the shift shaft [A] for any damage.
★ If the shaft [A], spline [B] or shift board [D]
are bent or damaged. Replace the damaged
parts.
★ If the spring [C] damaged, replace the
spring.
9-31
CFMOTO
Transmission
●Check the return spring pin [A] is not

loose.
★ If it is loose, unscrew it, apply a non-
permanent locking agent to the threads, and
tighten it.
Torque - Shift Shaft Return Spring Pin
: 2 9 N ·m
● Check the gear positioning lever [A] and

its spring for breaks or distortion.
★ If the lever or spring are damaged in any
way, replace them.
●Visually inspect the shift drum cam [B].If
they are badly worn or if they show any
damage, replace it.
Transmission Assy Removal
●Remove
Shift Shaft Assembly (see External Shift
Mechanism Removal)
Neutral Switch Holder Bolt [A] Neutral
Switch
Holder [B] and Pin Shift Drum
Holder [C] and Pin
●Remove
Collar [A]
O-ring [B]
9-32
Transmission
●Remove:
chapter)
Transmission Case Bolts [A]
o If the transmission assy is to be

disassembed, remove the following.
Shift Rod Plate Bolt [B]
Shift Rod Plate [C]
Gear Positioning Lever Bolt [D]
Gear Positioning Lever [E] with Spring,
Washer and Spacer.
●Pull the transmission assy [A] out of the
crankcase.
9
Transmission Assy Disassembly
● Remove the transmission assy (see
Transmission Assy Removal).
●Remove the following from the transmis-
sion case [A].
Shift Rods [B]
Shift Forks [C]
Drive Shaft [D]
Output Shaft [E]
●Remove:
Shift Drum Cam Bolt [A]
Shift Drum [B] and Pin
Shift Drum [C]
9-33
CFMOTO
Transmission
Transmission Assy Assembly
● When the new ball bearings [A] are installed in
the transmission case [B], press and insert them
until they are bottomed.
●Install the following on the transmission case [A].
Shift Drum [B],Pin [C],Shift Drum Cam [D]
●Apply a non-permanent locking agent to the shift drum cam bolt [E] and tighten it.
Torque - Shift Drum Cam Bolt 10N·m
●Install the Drive Shaft [F] and output shaft [G].
● Install the forks as shown.
o Position the one [H] with shortest ears on the drive shaft and place the pin in the center
groove in the shift drum.
o The two forks [J] on the output shaft are identical install the shift rods, noting the groove
position.
● Install the fork rods [K] and [L]
●Apply molybdenum disulfide oil solution to the transmission gears shown with X marks
[M].
●Be sure that the spacer [N] is on the output shaft.
9-34
Transmission
Transmission Assy Installation
● Assemble the transmission assy (see
Transmission Assy Assembly).
● Be sure that the dowel pins [A] are in
position.
●Apply grease to the O-ring [B] on the oil
pipe.
● Install the transmission assy on the
crankcase.
● Cover the threadlocker on the bolt screw.
●Tighten the transmission case bolts.
Torque - Transmission Case Bolts 20N·
m
● Install the gear positioning lever (see
External Shift Mechanism Installation).
● Install the locking gear.
9
● Cover the threadlocker on the bolt and
tight up.
Locking gear bolt torque: 12N·m
●Set the gear positioning lever to the neu-
tral position [A].
●Install:
Pin [A],Shift Drum Holder [B]
Pin [C],Gear sensor [D]
Gear sensor screw[E]
o Apply the thread locker on screw [E] and

tight up.
Torque - Neutral Switch Holder Screw
5 N ·m
●Apply grease to the O-ring [A] and install
its position [B] on the output shaft.
●Apply grease to the lip of the oil seal [C].
●Install the collar [D].
9-35
CFMOTO
Transmission
Transmission Shaft Disassembly

●Remove the transmission assy (see
Transmission Assy Removal).
●Remove:
Shift Rods [A],Shift Forks [B]
Drive Shaft [C],Output Shaft [D]
● Remove the circlips, disassemble the
transmission shafts.
● Remove the fifth 5th gear
Transmission Shaft Assembly

●Apply engine oil to the collar, needle
bearing and the shaft.
●Install the collar to the shaft
●Replace all the removed circlips
●Install the circlips [A] so that the opening
[B] is aligned with a spline groove [C].
9-36
Transmission
● The drive shaft gears can be recog-

nized by size: the gear with the smallest
diameter is 1st gear, and the largest one is
6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and
washers are properly in place.
●Install the fifth gear and the bushing onto
the drive shaft.
●Install the 3rd/4th gear onto the drive
shaft with their oil holes aligned.
●Install the 6th gear and the bushing onto
the drive shaft with their oil holes aligned.
● The output shaft gears can be recog-
nized by size:the gear with the largest diam-
eter is 1st gear, and the smallest one is 6th
gear. Be sure that all parts are put back in 9
the correct sequence and all circlips and
washers are properly in place.
●Install the 3rd/4th gear and the bushings
onto the output shaft with their oil holes
aligned.
●Install the fifth gear onto the output shaft.

●Check that each gear spins or slides
freely on the transmission shafts without
binding after assembly.
9-37
CFMOTO
Transmission
1.1st gear 9.Toothed washer 17.Washer 25.Toothed washer
2.2nd gear 10.Circlip 28 18.Nut 26.Washerφ28
3.3re gear 11.Bushing 19.O-ring 27.Circlip φ30
4.4th gear 12.Washerφ30 20.Ball bearing 28.Washerφ25
5.5th gear 13.Needle bearing 21.Washer φ 39
6.6th gear 14.Circlip 22.Positioning ring
7.Ball Bearing 15.Oil seal 23.Washer φ38.5
8.Bushing 16.Collar 24.Bushing
9-38
Transmission
Shift Fork Bending

● Visually inspect the shift forks, and
replace any fork that is bent. A bent fork
could cause diffi culty in shifting, or allow the
transmission to jump out of gear when
under power. 90 degree [A]
Shift Fork/Gear Groove Wear

● Measure the thickness of the shift fork
ears [A], and measure the width [B] of the
gear grooves.
★If the thickness of a shift fork ear is less
than the service limit, the shift fork must be
replaced.
Shift Fork Ear Thickness
Standard : 5.9mm~6.0mm
9
★ If the gear groove is worn over the
service limit, the gear must be replaced.
Gear Groove Width
Standard : 6.05mm~6.15mm
Service limit :6.25mm
Shift Fork Guide Pin/Drum Groove Wear

●Measure the diameter of each shift fork
guide pin [A], and measure the width [B] of
each shift drum groove.
★If the guide pin on any shift fork is less
than the service limit, the fork must be
replaced.
9-39
CFMOTO
Transmission
Shift fork drum diameter

Standard： φ 6.9mm~ φ 7.0mm
Service limit ：φ 6.8mm
Shift Drum Groove Width
Standard： 7.10mm~7.17mm
Service limit：7.30mm
Gear Dog and Gear Dog Hole Damage

● Visually inspect the gear dogs [A] and
gear dog holes [B].Replace any damaged
gears or gears with excessively worn dogs
or dog holes.
Ball and Needle Bearing Replacement
● Using a press or puller, remove the ball

bearing and/or needle bearings.
● Using a press and the bearing driver
set [A], install the new ball bearing until it
stops at the bottom of its housing.
Ball and Needle Bearing Wear

●Spin [A] the bearing by hand to check
its condition.
★ If the bearing is noisy, does not spin
smoothly, or has any rough spots, replace it.
9-40
10 Tire and rim
Contents
Explode View……………………………………………………………………………………………………10-2
Specifications and service limit………………………………………………………………………… 10-4
Special Tools……………………………………………………………………………………………………10-5
Wheel (Rims)……………………………………………………………………………………………………10-6
Front Wheel Removal ……………………………………………………………………………………10-6
Front Wheel Installation …………………………………………………………………………………10-6
Rear Wheel Removal ……………………………………………………………………………………10-8
Rear Wheel Installation …………………………………………………………………………………10-8
Wheel Inspection…………………………………………………………………………………………… 10-10
Axle Inspection………………………………………………………………………………………………10-10
Balance Inspection …………………………………………………………………………………………10-11
Balance Adjustment…………………………………………………………………………………………10-11
Balance Weight Removal ………………………………………………………………………………10-11
Balance Weight Installation ……………………………………………………………………………10-11
Tire pressure inspection and adjustment………………………………………………………………10-13
Tire Removal…………………………………………………………………………………………………10-13
Tire installation………………………………………………………………………………………………10-13
10
Tire Repair……………………………………………………………………………………………………10-15
Hub Bearing …………………………………………………………………………………………………10-16
Hub Bearing Removal ……………………………………………………………………………………10-16
Hub Bearing Installation …………………………………………………………………………………10-16
Hub Bearing Inspection …………………………………………………………………………………10-16
10-1
CFMOTO
Exploded view
10-2
10 Tire and rim
Torque
N·m kgf·m ft·lb
1 Front wheel axel 108 11.0 80
2 Front axel locking screw 34 3.5 25
3 Rear Axel nut 108 11.0 80
G：Use grease
HG：Use high heat grease
R：Replace the parts
WL：Use soapy water or special rubber washing liquid.
10
10-3
CFMOTO
Specifications and service limit
Rim
Rim runout
Axial TIR0.5mm（0.02in.）or smaller TIR1.0mm（0.04in.）
Radial TIR0.8mm（0.03in.）or smaller TIR1.0mm（0.04in.）
W heel axle twisting angle TIR0.03mm （ 0.0012in. ） or TIR0.2mm（0.008in.）
/100mm （ 3.94in. ） Wheel smaller
balance ――
Balance weight 10g（0.35oz.）or smaller ――
10g（0.35oz.） ――
20g（0.71oz.），30g（1.06oz.）
Rim size ――
Front 3.50×17 ――
Rear 4.50×17
Tire
Tire pressure(cold)
Front 180kg（397lb）： ――
250kPa（2.50kgf/cm 2 ，36.3psi）
Rear 180kg（397lb）： ――
280kPa（2.80kgf/cm 2 ，40.6psi）
Tire pattern deepness
Front 6.5mm（0.26in.） 1mm（0.04in.）
（AT，CH，DE）1.6mm
（0.06in.）
Rear 9.0mm（0.35in.） Upto130km/h
（80mph）：
2mm（0.08in.）
Over130km/h
（80mph）：
3mm（0.12in.）
Tire standard Style Size
Front DUNLOP，SPORTMAX RADIAL 120/70ZR17M/C（58W）
D221FAJ
Rear DUNLOP，SPORTMAX D221J 160/60ZR17M/C（69W）
Warning
Use same supplier and same size rim and tire.
10-4
10 Tire and rim
Special tool
Bearing pressing tool Screw driver
Jack Jack accesesories
10
Bearing remover
10-5
CFMOTO
Wheel (Rim)
Front wheel removal

ŸRemove: A
Brake Caliper Mounting Bolts [A]
Front Brake Calipers [B]
ŸLoosen:
Axle Clamp Bolt[C]
ŸRemove the front axle [D]
ŸRemove the lower fairing (see Lower Fair-

ing Removal in the Frame chapter).
ŸRaise the front wheel off the ground with jack.
Special Tools - Jack
Jack Attachmen
ŸPull out the axle to the right and drop the front
wheel out of the forks.
C
D
Warning
Do not let the break disc down on the
ground, or the break disc will be
damaged or wrapped. Put a piece of
wood under it to avoid it touched the
ground.
Front Wheel Installation E

○The direction of the wheel rotation is shown
by an arrow [E]
ŸCheck the wheel rotation mark on the front
wheel and install it.
10-6
10 Tire and rim
Wheel (Rim)
A
Ÿ Apply high-temperature grease to the
grease seal lips.
ŸFit the collars [A] on the both sides of the

hub.
ŸInsert the front axle, and tighten the axle.

Ÿ Torque - Front Axle:108N·m(11.0kgf·m,
80ft·lb)
ŸBefore tightening the axle clamp bolt on the
right front fork leg, pump the front fork up and
down 4 or 5 times to allow the right front fork
leg to seat on the front axle.
NOTE
○Put a block in front of the front wheel to stop
moving
ŸTighten the axle clamp bolt [B]

ŸTorque - Front Axle Clamp Bolt :34N·m B
(3.5kgf·m,25ft·lb)
10
ŸInstall the lower fairing (see Lower Fairing
Installation in the Frame chapter).
ŸInstall the front brake calipers (see Caliper
Installation in the Brakes chapter).
ŸCheck the front brake effectiveness (see
Brake Operation Inspection in the Periodic
Maintenance chapter).
Warning
I n spe ct b re aki n g p erf o rm anc e
b efo re dri vi ng t o make sur e
saf ty .
10-7
CFMOTO
Rear Wheel Removal
ŸRaise the rear wheel off the ground with stand
[A].
ŸRemove
Cotter Pin [A]
Axle Nut [B] B
Axle [C] with Washer
A
ŸRemove the drive chain [D] from the rear

sprocket toward the left
ŸMove the rear wheel back and remove it.
Rear Wheel Installation

Ÿ Apply high-temperature grease to the
grease seal lips.
ŸFit the collars [A] on the both sides of the
hub.
10-8
10 Tire and rim
Wheel (Rim)
Ÿ Engage the drive chain with the rear

sprocket.
Install the caliper bracket [A] onto the swing-

arm stop [B].
A B
ŸInsert the axle from the right side of the wheel,
and tighten the axle nut.
Torque - Rear Axle Nut:108N·m(11.0kgf·m,

80ft·lb)
ŸInsert a new cotter pin [A].

Note
○When inserting the cotter pin, if the slots
in
the nut do not align with the cotter pin hole
in the axle, tighten th nut clockwise [B] up to
next alignment.
○It should be within 30°.
10
When groove goes the nearesr hole.Loose
again and bend the cotter pin on ght nut
Danger
Please check the vehicle breaking
performance. Or it may cause
accident.
ŸAdjust the drive chain slack after installa-

tion (see Drive Chain Slack Inspection in
the Periodic Maintenance chapter).
ŸInstall the rear brake caliper (see Caliper
Installation in the Brakes chapter).
ŸCheck the rear brake effectiveness (see
Brake Operation Inspection in the Periodic
Maintenance
chapter).
10-9
CFMOTO
Wheel Inspection
ŸRaise the front/rear wheel off the ground with
jack.
Special Tools – Jack, Jack Attachment
ŸSpin the wheel lightly, and check for rough-
ness or binding. If roughness or binding is
found, replace the hub bearingWheel Inspec-
tion
ŸInspect the wheel to see cracks,dent, bent
or other damage.
«If there is any damage to the wheel, replace
the wheel.
ŸRemove the wheel
ŸMeasure the rim runout, axial [A] and radial
[B], with a dial gauge
«If rim runout exceeds the service limit,
check the hub bearings.If the problem is not
due to the bearings, replace the wheel.
Rim run out standard
Axial TIR0.5mm(0.02in.) or less Warni ng
Radial TIR0.8mm(0.03in.) or less Do not try to repair the
Service limit: damaged wheel. If other
Axial TIR1.0mm(0.04in.) parts damaged together with
bearing. Wheel change is a
Radial TIR1.0mm(0.04in.) must for safety.
Axle Inspection
ŸRemove the front and rear axles (see Front/
Rear Wheel Removal).
ŸVisually inspect the front and rear axle
for damages.If the axle is damaged or
bent, replace it.
ŸPlace the axle in V blocks that are 100 mm
(3.94 in.) [A]apart, and set a dial gauge [B]
on the axle at a point halfway between the
blocks.Turn [C] the axle to measure the
runout. The difference between the highest
and lowest dial readings is the amount of
runout.
«If axle runout exceeds the service limit, re-
place the axle.
10-10
10 Tire and rim
Axle Runout/100mm(3.94in.)
Standard:TIR0.03mm(0.0012in.) Or
less
Service limit:TIR0.2mm(0.008in.)
Balance Inspection
ŸRemove the front and rear wheels (see Front/
Rear Wheel Removal).
ŸSupport the wheel so that it can be spun
freely.
ŸSpin the wheel lightly, and mark [A] the wheel
at the top when the wheel stops.
○Repeat this procedure several times. If the
wheel stops of its own accord in various
positions, it is well balanced.If the wheel al-
ways stops in one position, adjust the wheel
balance (see Balance Adjustment).
Balance Adjustment
«If the wheel always stops in one position,
10
provisionally attach a balance weight [A] on
the rim at the marking using adhesive tape.
Ÿ Rotate the wheel 1/4 turn [B], and see
whether or not the wheel stops in this position.
If it does, correct the balance weight .
«If the wheel rotates and the weight goes up
replace the weight with the next heavier size.
If the wheel rotates and the weight goes down,
replace the weight with the next lighter size.
ŸRotate the wheel another 1/4 turn and then
another 1/4 turn to see if the wheel is correctly
balanced.
ŸPermanently install the balance weight.
Balance Weight Removal
ŸInsert a regular tip screwdrivers [A] [B] be-
tween the rib [C] and the weight [D] as shown.
ŸPry the balance weight with two screwdriv-
ers and remove the balance weight..
ŸDiscard the used balance weight.
10-11
CFMOTO
W a rning
D o n o t k no ck t he scr ew d rivers . O r the r im
w ill be d a m ag ed .
Balance Weight Installation

ŸCheck if the weight portion has any play
on the blade [A] and clip [B]. If it does, dis-
card it.
W a rning
If t h e rim b alan c e po sit io n h as any
clear an ce. An d pell ers h as bee n p ull ed.
R ep lace the balan ce w e ig ht g ot lo os ed.
D o no t reu se the b alan ce w eig ht . A n d
w hee ls un b ala n ced c an ca use d an g ero us
situ atio n .
Balance Weight
No. Balance weight

1 10g (0.35oz.)
2 20g (0.71oz.)
3 30g (1.06oz.)
NOTE
○Balance weights are available from cfmoto
dealers in 10, 20, and 30 grams (0.35, 0.
71, and 1.06 oz.) sizes.
An imbalance of less than 10 grams (0.35
oz.) will not usually affect running stability.
○ Do not use four or more balance weight
(more than 90gram, 3.17 oz.). If the wheel re-
quires an excess balance weight, disas-
semble the wheel to find the reason.
ŸSlip the balance weight [A] onto the rib [B]
by pushing or lightly hammering [C] the clip
[D].
Left Side [E]
Right Side [F]
ŸBe sure to install the balance weight.
○Check that the blade [A] and clip [B] are
fully seated on the rim [C] and that the clip is
hooked over the rib [D].
Left Side [E]
Right Side [F]
10-12
10 Tire and rim
Tire Pressure Inspection/Adjustment
ŸRefer to the Air Pressure Inspection in the Periodic Maintenance chapter.
ŸRefer to the Wheel/Tire Damage Inspection in the Periodic Maintenance chapter.
Tire Removal
ŸRemove
Wheel (see Front/Rear Wheel Removal)
Valve Core (Let out the air)
ŸTo maintain wheel balance, mark the valve stem
position on the tire with chalk so that the tire can
be reinstalled in the same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]
ŸLubricate the tire beads and rim fl anges on both

sides with a soap and water solution or rubber
lubricant. This helps the tire beads slip off the rim
flanges.
Warning
Do not use engine oil or petro element to
lubricate. Because it will damage the
tires.
10
ŸRemove the tire from the rim using a suitable
commercially available tire changer.
NOTE
○The tires cannot be removed with hand tools
because they fit the rims too tightly. Dangerous
Use same supplier’s tire in front and rear
wheels.
Tire Installation
ŸInspect the rim and tire, and replace them
if necessary.
ŸClean the sealing surfaces of the rim and
Warning
tire, and smooth the sealing surfaces of t
Replace the air inject valve together with
he rim with a fine emery cloth if necessary.
the tire. Do not reuse the air inject valve.
ŸRemove the air valve and discard it.
10-13
CFMOTO
ŸInstall a new valve in the rim.
○Remove the valve cap, lubricate the stem
seal [A]
with a soap and water solution or rubber
lubricant, and pull [B] the valve stem through
the rim from the inside out until it snaps into
place.
Warning
Do not use the oil or petro element to
lubricate the valve rod. That will make the
rubber becoming bad.
○The air valve is shown in the figure.
Valve Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
ŸCheck the tire rotation mark on the front and
rear tires and install them on the rim
accordingly. Tire Rotation Mark [A] Rotating
Direction [B]
ŸPosition the tire on the rim so that the valve
[A] align with the tire balance mark [B] (the
chalk mark made during removal, or the yel-
low paint mark on a new tire).
ŸInstall the tire bead over the rim fl ange us-
ing a suitable commercially available tire
changer.
Danger
Make sure the valve is on and do not over
400kPa(4.0kgf/cm2,57psi).To much injection
will cause the tire explosion makes people
injure or death.
ŸLubricate the tire beads and rim flanges with
a soap and water solution or rubber lubricant
to help seat the tire beads in the sealing sur-
faces of the rim while infl ating the tire.
ŸCenter the rim in the tire beads, and infl ate
the tire with compressed air until the tire beads
seat in the sealing surfaces.
10-14
10 Tire and rim
ŸCheck to see that the rim lines [A] on both
sides of the tire sidewalls are parallel with the
rim flanges.
«If the rim flanges and tire sidewall rim lines
are not parallel, remove the valve core.
ŸLubricate the rim flanges and tire beads.
ŸInstall the valve core and inflate the tire again.
ŸAfter the tire beads seat in the rim flanges,
check for air leakage.
○ Inflate the tire slightly above standard
inflation.
○ Use a soap and water solution or sub-
merge the tire, and check for bubbles that
would indicate leakage.
ŸAdjust the air pressure to the specified pres-
sure (see Air Pressure Inspection in the Peri-
odic Maintenance chapter).
ŸInstall the air valve cap.
ŸAdjust the wheel balance (see Balance
Adjustment).
Tire Repair 10
ŸCurrently two types of repair for tubeless tires
have come into wide use. One type is called
a temporary (external) repair which can be
carried out without removing the tire from
the rim, and the other type is called perma-
nent (internal) repair which requires tire
removal. It is generally understood that
higher running durability is obtained by
permanent (internal) repairs than by tempo-
rary (external) ones. Also, permanent
(internal) repairs have the advantage of
permitting a thorough examination for sec-
ondary damage not visible from external
inspection of the tire. For these reasons,
CFMOTO does not recommend temporary
(external) repair. Only appropriate perma-
nent (internal) repairs are recommended.
indicated by the manufacturer of the
Repair methods may vary slightly from
repair tools and materials so that safe
make to make. Follow the repair methods
results can be obtained.
10-15
CFMOTO
Hub Bearing Removal
ŸRemove the wheel (see Front/Rear Wheel
Removal), and take out the following.
ŸSleeve
Collars Coupling (Out of rear hub)
Grease Seals
ŸUse the bearing remover to remove the hub
bearings [A].
Special Tools :Bearing Remover Head:
20x22[B] Bearing Remover Shaft, 13 [C]
W arn ing
Do not let the wheel disc dow n to the
ground. Or the disc w ill be damaged.
Make a heel block under it to avoid the
disc touch the ground.
Hub Bearing Installation

ŸBefore installing the hub bearings, blow any
dirt or foreign particles out of the hub with com-
pressed air to prevent contamination of the
bearings.
ŸReplace the bearings with new ones.
NOTE
○Install the bearings so that the marked side
faces out.
ŸInstall the bearings by using the bearing driver
set which does not contact the bearing inner
race.
ŸPress in each bearing [A] right until they are
bottomed.
Special Tool - Bearing Driver Set [B]
ŸReplace the grease seals with new ones.
ŸPress in the grease seals [A] so that the seal
surface is fl ush [B] with the end of the hole.
○ Apply high-temperature grease to the
grease seal lips
Special Tool - Bearing Driver Set [C]:
Hub Bearing Inspection
«Since the hub bearings are made to ex-
tremely close tolerances, the clearance can not
normally be measured.
10-16
10 Tire and rim
NOTE
○Do not remove any bearings for inspection.
If any bearings are removed, they will need to
be replaced with new ones.
ŸTurn each bearing in the hub back and forth
[A] while checking for plays, roughness or
binding.
«If bearing play, roughness or binding is
found, replace the bearing.
ŸExamine the bearing seal [B] for tears or
leakage.
10
10-17
11 Chain drive system
Contents
Exploded View…………………………………………………………………………………………………11-2
Specifications …………………………………………………………………………………………………11-4
Special Tools …………………………………………………………………………………………………11-4
Drive Chain ……………………………………………………………………………………………………11-5
Drive Chain Slack Inspection………………………………………………………………………… 11-5
Drive Chain Slack Adjustment ……………………………………………………………………… 11-5
Wheel Alignment Inspection/Adjustment……………………………………………………………11-5
Drive Chain Wear Inspection………………………………………………………………………… 11-5
Drive Chain Lubrication …………………………………………………………………………………11-5
Drive Chain Removal ……………………………………………………………………………………11-5
Drive Chain Installation …………………………………………………………………………………11-6
Sprocket, Coupling……………………………………………………………………………………………11-9
Engine Sprocket Removal………………………………………………………………………………11-9
Engine Sprocket Installation……………………………………………………………………………11-10
Rear Sprocket Removal…………………………………………………………………………………11-10
Rear Sprocket Installation…………………………………………………………………………………11-10
Coupling Installation ………………………………………………………………………………………11-11
Coupling Bearing Removal………………………………………………………………………………11-11
Coupling Bearing Installation……………………………………………………………………………11-11
Coupling Bearing Inspection……………………………………………………………………………11-12 11
Coupling Bearing Oil Seal………………………………………………………………………………11-12
Coupling Damper Inspection……………………………………………………………………………11-12
Sprocket Wear Inspection………………………………………………………………………………11-12
Rear Sprocket Warp Inspection ………………………………………………………………………11-13
11-1
CFMOTO
Exploded view
11-2
Torque
N·m kgf·m ft·lb
1 Engine sprocket nut 125 12.7 92 MO
2 Rear axel nut 108 11.0 80
3 Chain sprocket nut 59 6.0 44
4 Speed sensor bolt 7.8 0.80 69in·lb L
5 Speed sensor bracket bolt 9.8 1.0 87in·lb
G：Use grease
HG：Use high heat grease
HO：Use heavy oil
L：Use permanent thread locker
MO：Use molybdenum disulfide lubricant
（Mix with engine oil in ratio 10:1）
11
11-3
CFMOTO
Chain specification and service limit
Drive chain
Chain looseness 30 mm～40mm（1.2 in～1.6in.） ――
Chain wearing（20 pieces）in 317.5 mm～318.2mm（12.50 in～ 320mm（12.6in.）
standard 12.53in.） ――
Suppliers RK or DID ――
Style 520×S01 ――
Pcs 116
Sprocket
Rear sprocket wearing 0.4mm（0.016in.）or less 0.5mm（0.02in.）
Special tool
Inner retainer pliers Bearing tools
11-4
Drive Chain
Drive Chain Slack Inspection
ŸRefer to the Drive Chain Slack Inspection in
the Periodic Maintenance chapter
Drive Chain Slack Adjustment
ŸRefer to the Drive Chain Slack Adjustment
in the Periodic Maintenance chapter.
Wheel Alignment Inspection/Adjustment
ŸRefer to the Wheel Alignment Inspection in
Drive Chain Wear Inspection
ŸRefer to the Drive Chain Wear Inspection in
Drive Chain Lubrication
ŸRefer to the Drive Chain Lubrication Condi-
tion Inspection in the Periodic Maintenance
chapter.
Drive Chain Removal
NOTE
○Since the drive chain is installed through
the swingarm, the chain cannot be removed
other than by cutting it.Prepare the new link
pin, link plate, grease seals, and tools for re-
joining the chain
11
ŸUsing a suitable tool, cut the drive chain by
removing the link pins.
Recommended Tool:RK
Warning
Read the tool user’s manual first
before removal.
Body [A]
Handlebar [B]
Cutting and Riveting Pin [C]
For Cutting [D]
Riveting [E]
Plate Holder (a)[F]
Plate Holder (b)[G]
Gauge [H]
ŸGrind [A] the pin head to make it flat.
ŸSet the cutting and riveting pin[B]as shown
11-5
CFMOTO
ŸScrew the pin holder until it touches chain
pin
ŸBe sure that the cutting pin hits center of
chain pin.
ŸScrew the handlebar [A] into body.

ŸTurn the pin holder with wrench [B] clock-
wise to extract chain pin.
Drive Chain Installation

ŸEngage the new drive chain to the old drive
chain and pull the end of the old drive chain
until they are changing the position.
ŸRemove the old drive chain from the new
drive chain.
ŸApply grease to the link pins [A] and
grease seals [B] [C]
ŸEngage the drive chain on the rear
sprocket
ŸInsert the link pins in the drive chain ends.
ŸInstall the grease seals [C].
ŸInstall the link plate so that the mark [D]
faces out.
ŸPush the link plate by hand or plier to fix
it.
ŸIn case of grease seal chain, be sure
to set the grease seals correctly.
ŸSet the plate holder (a) [A] and plate
holder (b) [B] on the body.
11-6
ŸFit the plate holder (a) to link plate
ŸTurn the pin holder by hand until plate holder
(b) touches the other link plate.
ŸTurn the pin holder by wrench clockwise until

two pins of link come into groove of plate holder
(a).
ŸTake off the plate holder (a).
ŸSet the plate holder (b) [A] and cutting and riv-
eting pin [B]as shown.
ŸTurn the pin holder until riveting pin touches link 11

pin.
ŸTurn the wrench clockwise until tip of riveting

pin hits of link pin.
ŸRivet it.
ŸSame work for the other link pin.
11-7
CFMOTO
ŸAfter staking, check the staked area of the
link pin for cracks.
ŸMeasure the outside diameter [A] of the link
pin and link plates width [B].
Link Pin Outside Diameter
Standard:5.45mm～5.55mm
Link Plates Outside Width
S t a n d a r d : 1 7 . 2 5 m m ～1 7 . 4 5 m m ( 0 .
679in～0.687in.)
«If the reading exceeds the specified length,
cut and rejoin the chain again.
ŸCheck
Movement of the Rollers
ŸAdjust the drive chain slack after installing
the chain (see Drive Chain Slack Adjustment
11-8
Sprocket, Coupling
Engine Sprocket Removal
ŸRemove: B
Engine Sprocket Cover Bolts [A] A
Engine Sprocket Cover [B]
ŸRemove:
Speed Sensor Bracket Bolts [A]
Speed Sensor Bracket [B]
ŸFlatten out the bended washer [A] A

ŸRemove the engine sprocketnut [B] amd
washer
NOTE
○When loosening the engine sprocket nut,
hold the rearbrake on.
ŸRaise the rear wheel off the ground with
stand. 11
ŸRemove the axle cotter pin, and loosen the
rear axle nut.
ŸLoosen the drive chain (see Drive Chain
Slack.
Adjustment in the Periodic Maintenance
chapter).
Ÿ Remove the drive chain from the rear

sprocket toward the right.
ŸPull the engine sprocket [A] with drive chain
[B] off the output shaft [C].
ŸDisengage the drive chain from the engine
sprocket.
11-9
CFMOTO
Engine Sprocket Installation
ŸReplace the sprocket washer and axle cot-
ter pin.
ŸInstall the engine sprocket [A] so that “OUT-
SIDE” letters face outward.
ŸApply molybdenum disulfide oil solution to
the threads of the output shaft and seating sur-
face of the engine sprocket nut.
ŸAfter torquing the engine sprocket nut, bend
the one side of the washer [B] over the nut.
NOTE
○Tighten the engine sprocket nut while ap-
plying the rear brake
Ÿ Tighten：
Engine Sprocket Nut:125N·m(12.7kgf·m,
92ft·lb)
Speed Sensor Bracket Bolts:
ŸInstall the engine sprocket cover, and tighten
the bolts.
ŸAdjust the drive chain slack after installing
the sprocket (see Drive Chain Slack Adjust-
ment in the Periodic Maintenance chapter).
ŸBend the end of axle cotter pin surely after
tightening the axle nut (see Rear Wheel In-
stallation in the Wheels/Tires chapter).
Rear Sprocket Removal
ŸRemove the rear wheel (see Rear Wheel
Removal in the Wheels/Tires chapter).
W arn ing
Do not let the break disc or chain Rear Sprocket Installation
sprocket down to the ground or the
sprocket or disc will be damaged. Put a ŸInstall the sprocket facing the tooth number
heel block under the ground to avoid
touch the ground. marking [A] outward.
ŸRemove the rear sprocket nuts [A]. ŸTighten the rear sprocket nuts.
Rear Sprocket Nuts torque:59N·m(6.
ŸRemove the rear sprocket [B].
0kgf·m,44ft·lb)
Install the rear wheel (see Rear Wheel In-
stallation in the Wheels/Tires chapter).
11-10
Coupling Installation
ŸApply high-temperature grease to the coupling
grease seal lips [A].
ŸApply grease to the coupling internal surface
[B].
ŸGrease the following

Wheel Flange Portion [A]
O-ring [B]
Install the collar [C]
Coupling Bearing Removal

Ÿ Remove：
Coupling
Grease Seal
Circlip [A]
11
ŸRemove the bearing [A] by tapping from the

wheel side.
Coupling Bearing Installation

ŸReplace the bearing with a new one.
ŸPress in the bearing [A] until it is bottomed.
ŸReplace the circlip with a new one.
11-11
CFMOTO
ŸReplace the grease seal with a new one.
ŸPress in the grease seal so that the seal
surface is fl ush with the end of the hole.
○ Apply high-temperature grease to the
grease seal lips.
Coupling Bearing Inspection
«Since the coupling bearing is made to ex-
tremely close tolerances, the clearance can
not normally be measured.
NOTE
○It is not necessary to remove the coupling
bearing for inspection. If the bearing is
removed, it will need to be replaced with a
new one.
ŸTurn the bearing in the coupling back and
forth [A] while checking for plays, roughness
or binding. If the bearing play, roughness or
binding is found, replace the bearing.
ŸExamine the bearing seal [B] for tears
or leakage.
«If the seal is torn or is leaking, replace the
bearing.
NOTE
○Since the coupling bearing is packed with
grease and sealed, lubrication is not required.
Coupling Damper Inspection

ŸRemove the rear wheel coupling, and inspect
the rubber dampers [A].
ŸReplace the damper if it appears damaged
or deteriorated.
11-12
Sprocket Wear Inspection
ŸVisually inspect the engine and rear sprocket
teeth for wear and damage.
«If the teeth are worn as illustrated, replace
the sprocket, and inspect the drive chain wear
(see Drive Chain Wear Inspection in the Pe-
riodic Maintenance chapter).
Worn Tooth (Engine Sprocket)[A]
Worn Tooth (Rear Sprocket)[B]
Direction of Rotation[C]
NOTE
○ If a sprocket requires replacement, the
chain is probably worn also.
Rear Sprocket Warp Inspection?

●Raise the rear wheel off the ground with
stand so that it will turn freely.
●Set a dial gauge [A] against the rear spro-
cket [B] near the teeth as shown, and rotate
[C] therearwheel to measure the sprocket
runout (warp).
●The difference between the highest and
lowest dial gauge readings is the amount 11
of runout (warp) .
●If the runout exceeds the service limit,
replace the rear sprocket.
Rear Sprocket Warp
Standard: 0.4 mm (0.016 in.) or less
Service Limit: 0.5 mm (0.020 in.)
11-13
12 Breaking system
Contents
Front braking explosive view……………………………………………………………………………… 12-3
Rear braking explosive view……………………………………………………………………………… 12-5
Specification………………………………………………………………………………………………………12-7
Special tool ………………………………………………………………………………………………………12-8
Brake handle/pedal……………………………………………………………………………………………12-9
Front brake handle adjustment…………………………………………………………………………12-9
Rear brake pedal inspection……………………………………………………………………………12-9
Rear brake pedal position……………………………………………………………………………… 12-9
Rear brake pedal removal……………………………………………………………………………… 12-9
Rear brake pedal assembly……………………………………………………………………………12-10
Braking caliper…………………………………………………………………………………………………12-12
Front braking caliper removal…………………………………………………………………………12-12
Rear braking caliper removal……………………………………………………………………………12-12
Front braking caliper disassembly …………………………………………………………………12-13
Rear braking caliper disassembly……………………………………………………………………12-13
Front braking caliper assembly…………………………………………………………………………12-13
Rear braking caliper assembly ………………………………………………………………………12-13
Braking caliper seal damaged ………………………………………………………………………12-13
Rear caliper dust boot and sleeves…………………………………………………………………12-13
12
Break caliper piston or cylinder damaged…………………………………………………………12-14
Rear braking caliper seat wearing……………………………………………………………………12-14
Braking pad ……………………………………………………………………………………………………12-15
Front braking pad removal………………………………………………………………………………12-15
Front braking pad installation …………………………………………………………………………12-15
Rear braking pad removal ………………………………………………………………………………12-15
Rear braking pad installation……………………………………………………………………………12-15
Breaking pad wearing inspection……………………………………………………………………12-15
Main cylinder ……………………………………………………………………………………………………12-16
Front main cylinder removal……………………………………………………………………………12-16
Frong main cylinder installation ………………………………………………………………………12-16
Rear braking cylinder removal…………………………………………………………………………12-17
Rear braking cylinder installation………………………………………………………………………12-17
Front braking main cylinder disassembly………………………………………………………… 12-17
Rear braking main cylinder disassembly …………………………………………………………12-17
Main cylinder assembly……………………………………………………………………………………12-17
12-1
CFMOTO
Main cylinder inspection………………………………………………………………………………………12-18

Brake disc…………………………………………………………………………………………………………12-19
Brake disc removal ………………………………………………………………………………………12-19
Brake disc installation……………………………………………………………………………………12-19
Brake disc wearing ………………………………………………………………………………………12-19
Brake disc bended…………………………………………………………………………………………12-19
Braking fluid………………………………………………………………………………………………………12-20
Braking fluid inspection……………………………………………………………………………………12-20
Braking fluid replacement…………………………………………………………………………………12-20
Drain out the air in pipes……………………………………………………………………………………12-21
Braking hose ……………………………………………………………………………………………………12-21
Braking hose removal/installation………………………………………………………………………12-22
Braking hose inspection…………………………………………………………………………………12-22
ABS trouble code………………………………………………………………………………………………12-23
12-2
12 Breaking system
Front braking explosive view
12
12-3
CFMOTO
Torque
N·m kgf·m ft·lb
1 Drain out valve 7.8 0.80 69in·lb
2 Braking hose flow bolt 25 2.5 18
3 Braking lever mounting bolt 1.0 0.10 9in·lb Si
4 Braking lever mounting nut 5.9 0.60 52in·lb
5 Front braking disc bolt 27 2.8 20 L
6 Front braking switch screw 1.0 0.10 9in·lb
7 Front braking fluid tank cover 1.0 0.10 9in·lb
8 Front caliper mounting bolt 34 3.5 25
9 Front cylinder mounting bolt 8.8 0.90 78in·lb S
B：Use braking fluid

L：Use thread locker；
R：Replace the part；
S：Tighten in special order；
T、Si：Use silicon oil(Such as PBC)
12-4
12 Breaking system
Rear braking exploded view
12
12-5
CFMOTO
Torque
N·m kgf·m ft·lb
1 Drain out valve 7.8 0.80 69in·lb
2 Braking hose flowin g bolt 25 2.5 18
3 Brake pedal mounting bolt 8.8 0.90 78in·lb
4 Rear breaking d isc mounting bolt 27 2.8 20 L
5 Rear caliper m ounting bolt 25 2.5 18
6 Rear main cylinder mounting bolt 25 2.5 18
Rear breaking cylinder rod locking
7 18 1.8 13
nut
B：Use braking fluid；

G：Use grease；
R：Replace the part；
Si：Use silicon grease（Such as PBC）
12-6
12 Breaking system
Specification

Brake handle / pedal
Brake handle position 5 positions can adjust
Brake handle clearance Cannot adjust
―――
Brake pedal clearance Cannot adjust
Pedal Under the foot pedal top about
40mm（1.6in.）
Brake pad thickness
Front： 4.0mm（0.16in） 1mm（0.04in）
Rear： 5.0mm（0.20in） 1mm（0.04in）
Brake disc clearance
Front： 4.3 mm～4.7mm（0.17 in～0.19in） 4.0mm（0.16in）
Rear： 4.8 mm～5.2mm（0.19 in～0.20in） 4.5mm（0.18in）
Run out： Less than 0.15mm（0.006in） 0.3mm（0.01in）
Brake fluid DOT4 ―――
12
12-7
CFMOTO
Special tool
Retainer plier Jack
Jack accessories
12-8
12 Breaking system
Brake Lever , Break padel
Brake Lever Position Adjustment
ŸThe brake lever adjuster can be adjusted to
suit the operator’s hand
○The distance from the grip to the lever is A
minimum at 103mm and maximum at 118mm.
Brake Pedal Position Inspection

ŸCheck that the brake pedal [D] is in the
correct position
ŸFootpeg [E] C
Pedal position standard
Lower than front foot rest top:40mm
(1.6in.)[C]
«If it is incorrect, adjust the brake pedal
position. E
D
NOTE
○ Usually it is not necessary to adjust the
pedal position, but always adjust it when the
push rod locknut has been loosened. F
Brake Pedal Position Adjustment G

12
ŸRemove:Frame Cover (see Frame Cover
Bolts [F]
Right footrest brecket[G]
ŸLoosen the locknut[A]and turn the push rod A

with the hex head [B]to achieve the correct
pedal position C
B
«If the length [C] shows 53±1mm(2.087±0.
04in.)
The rear breaking pedal position should be in
standard.
ŸTighten torque
Footpeg Stay Bolts :30N·m
Rear Master Cylinder Push Rod nut (3.1kgf·m,22ft·lb)
:18N·m(1.8kgf·m,13ft·lb) ŸCheck the brake light switch operation (see
ŸInstall the foot peg stay, and tighten the Brake Light Switch Operation Inspection in
bolts the Periodic Maintenance chapter).
12-9
CFMOTO
Brake Pedal Removal
ŸRemove:
Frame Cover (see Frame Cover Removal F
Bolts [A] G
Right Footpeg Stay [B]
ŸRemove:
Cotter Pin[A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D] D C
ŸRemove the mounting bolt [E] and take out
the brake pedal.
E B
Brake Pedal Installation
ŸApply grease to the pivot shaft [A] and in-
stall the washer [B].
ŸInstall:
Brake Pedal [C]
Washer [D]
Brake Pedal Bolt [E]
Torque - Brake Pedal Bolt:

8.8N·m(0.90kgf·m,78in· lb)
ŸInstall the spring [F]
ŸReplace to new cottor pin F

ŸInsert the cottor pin [G] and bend up like [H]
points
G
12-10
12 Breaking system
ŸInstall the foot rest bracket and tight up
to standard torque
Torque - Footpeg Rest Bolts :30N·m
○Depress the brake pedal [A] and then
align the bolts holes of the master cylin-
der [B].
Torque - Rear Master Cylinder Mounting B A
Bolts:
25N·m(2.5kgf·m,18ft·lb)
ŸCheck the brake pedal position (see Brake
Pedal Position Inspection).
12
12-11
CFMOTO
Breaking Caliper
Front Caliper Removal
ŸLoose the front caliper LH mounting bolt [A]
and remove the caliper from break disc [B] A
B
ŸLoose the front caliper RH mounting bolt [D]
and remove the caliper from break disc [E]
CAUTION
Immediately wash away any brake fluid

that spills
Rear Caliper Removal C
ŸUse display stand to lift up the rear wheel.
ŸRemove: Cottor pin [A] and rear wheel axel
nut [B]
ŸPull out the rear wheel axel [C]
ŸSaperate the caliper from rear breaking disc D
[D]
ŸInstall rear caliper and breaking hose lower
side.
○Replase the washer on the hose each side
into new.
ŸTighten torque：
Rear Caliper Mounting Bolts
D
Front:34N·m(3.5kgf·m,25ft·lb)
Rear:25N·m(2.5kgf·m,18ft·lb)
B
Breaking hose bolt:25N·m(2.5kgf·m,
18ft·lb)
ŸCheck the oil level in breaking fluid reservior.
ŸDrain out the air of the breaking pipe
(See air draining chapter)
ŸInspect the breaking performance to see the
leaking.
A
Danger C
Inspect the breaking performance before
driving or it may cause accident.
12-12
12 Breaking system
Front Caliper Disassembly
ŸRefer to the Caliper Rubber Parts Replace-
ment in the Periodic Maintenance chapter
Front Caliper Assembly
ment in the Periodic Maintenance chapter.
Rear Caliper Disassembly
ment in the Periodic Maintenance chapter.
Rear Caliper Assembly
ment in the Periodic Maintenance chapter
Caliper Fluid Seal Damage
ŸThe fluid seal (piston seal) [A] is placed
around the piston to maintain clearance be-
tween the pad and the disc. If the seal is in a
poor condition, it could lead the pad to wear
excessively or the brake to drag, which may
cause the temperature of the discs or the
brake fluid to increase.
«Replace the fluid seal if it exhibits any of the
conditions listed below. 12
○Brake fluid leakage around the pad
○Brakes overheat
○Considerable difference in inner and outer
pad wear.
○Seal and piston are stuck together
«If the fluid seal is replaced, replace the
dust seal [B]
If the washer relaced.Replace all the sealing
part together.
Rear Caliper Dust Boot and Friction Boot.
Damage
ŸCheck that the dust boot [A] and friction
boot [B] are not cracked, worn, swollen, or
otherwise damaged.
«If they show any damage, replace it.
12-13
CFMOTO
Caliper Piston and Cylinder Damage

ŸVisually inspect the pistons [A] and cylinder
surfaces [B].
«Replace the caliper if the cylinder and pis-
ton are badly scores or rusty.
Rear Caliper Holder Shaft Wear

The caliper body must slide smoothly on the
caliper holder shafts [A]. If the body does
not slide smoothly, one pad will wear more
than the other, pad wear will increase, and
constant drag on the disc will raise brake
and brake fluid temperature.
ŸCheck to see that the caliper holder shafts

are not badly worn or stepped, and that the
rubber friction boots are not damaged.
«If the rubber friction boot is damaged, re-
place the rubber friction boot. To replace the
friction boot, remove the pads and the cali-
per bracket.
«If the caliper holder shaft is damage, re-
place the caliper bracket.
12-14
12 Breaking system
Brake Pad
Front Brake Pad Removal
ŸRemove the front caliper with the hose in-
stalled (see Front Caliper Removal).
ŸDraw out the holder shaft pin [A], and take
off the holder shaft [B].
ŸRemove the pad [C] on the piston side.
ŸPush the holder [D] towards the piston, and
remove the pad of the other side [E] from the
holder shaft [F].
Front Brake Pad Installation
ŸPush the caliper pistons in by hand as far as
they will go.
ŸInstall the anti-rattle spring in its correct Danger
position. Inspect the breaking performance first
before driving. Make sure it is well
ŸInstall the pad on the piston side first, then working.
install the other pad on the holder.
Ÿ Install the front caliper (see Caliper
Installation).
Rear Brake Pad Removal

ŸRemove the rear caliper with the hose in-
12
stalled (see Rear Caliper Removal)
ŸDraw out the holder shaft pin [A], and take
off the holder shaft [B].
ŸRemove the pad [C] and [D]
Rear Brake Pad Installation

ŸPush the caliper piston in by hand as far as
it will go.
ŸInstall the anti-rattle spring in its correct po-
sition
ŸInstall the pad on the piston side first, then
install the other pad on the holder.
Ÿ Install the rear caliper (see Caliper Danger
Installation). Inspect the breaking performance first
before driving. Make sure it is well
working.
Brake Pad Wear Inspection

•Refer to the Brake Pad Wear Inspection in
12-15
CFMOTO
Master Cylinder
Front Master Cylinder Removal
ŸRemove the banjo bolt [A] to disconnect the

brake hose from the master cylinder [B]
(see Brake Hose Removal/Installation).
ŸDisconnect the front brake light switch con-

nectors [A].
ŸUnscrew the clamp bolts [B], and take off the

master cylinder as an assembly with the
reservoir, brake lever and brake switch
installed.
CAUTION
Immediately wash away any
brake fluid that spills.
Remove:
ŸBrake Lever Pivot Bolt [A] and locknut
ŸBrake Lever [B]
ŸFront Brake Light Switch [C]
Front Master Cylinder Installation

ŸMake sure the mark [A] to the front when in-
stall the front master cylinder.
ŸTight up the upper tighten bolt [B] first then
the lower one [C] The tighten place needs
several clearance.
Torque - Front Master Cylinder Clamp
Bolts:
ŸReplace the washers on each side of the
hose fitting with new ones.
ŸTighten the brake hose banjo bolt.
Torque - Brake Hose Banjo Bolt:
ŸDrain out the air in breaking system
(See breaking system air draining way)
ŸCheck the brake for good braking power, no
brake drag, and no fluid leakage.
12-16
12 Breaking system
Rear Master Cylinder Removal
ŸUnscrew the brake hose banjo bolt [A] on
themaster cylinder (see Brake Hose Removal/ A
Installation).
ŸUnscrew the master cylinder mounting bolts D

B
[A].
ŸRemove the cotter pin [B].
NOTE
○ Pull off the joint pin while pressing down
the brake pedal.
C
ŸPull off the reservoir hose lower end [C], and
drain the brake fluid into a container.
ŸRemove the master cylinder.
Rear Master Cylinder Installation

ŸReplace the cotter pin [A] with a new one.
ŸReplace the washers on each side of hose
fitting with new ones.
ŸTighten the following bolts.
Torque - Rear Master Cylinder Mounting
12
bolts
:25N·m (2.5kgf·m,18ft·lb)
Brake Hose BanjoBolt:25N·m
ŸDrain out the air in breaking system (See break-
ing system air draining way)
ŸCheck the brake for good braking power, no
brake drag, and no fl uid leakage.
Front Master Cylinder Disassembly
ŸRefer to the Master Cylinder Rubber Parts Re-
placement in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
ŸRefer to the Master Cylinder Rubber Parts
Replacement in the Periodic Maintenance
chapter.
Master Cylinder Assembly
ŸRefer to the Master Cylinder Rubber Parts Re-
placement in the Periodic Maintenance chapter.
12-17
CFMOTO
Master Cylinder Inspection

Front master cylinder[J]
ŸRemove the master cylinders (see Front/
Rear Master Cylinder Removal).
ŸDisassemble the front and rear master cyl-
inders
ŸCheck that there are no scratches, rust or
pitting on the inner wall [A] of each master
cylinder and on the outside of each piston [B].
«If a master cylinder or piston shows any
damage, replace them.
ŸInspect the primary cup [C] and secondary
cup [D].If a cup is worn, damaged softened
(rotted), or swollen, the piston assembly
should be replaced to renew the cups.
«If fluid leakage is noted at the brake lever,
the piston assembly should be replaced to
renew the cups.
Rear Master Cylinder [K]

ŸCheck the dust covers [E] for damage
«If they are damaged, replace them.
ŸCheck the piston return springs [F] for any
damage.If the springs are damaged, replace
them.
ŸCheck that relief port [G] and supply port [H]
are not plugged.
«If the relief port becomes plugged, the brake
pads will drag on the disc. Blow the ports
12-18
12 Breaking system
Brake Disc
Brake Disc Removal
ŸRemove the wheel (see Front/Rear Wheel
Removal in the Wheels/Tires chapter).
ŸUnscrew the mounting bolts, and take off the
disc.
ŸRemove the gaskets
Brake Disc Installation
ŸReplace the gaskets with new ones.
ŸInstall the brake disc on the wheel so that
the marked side [A] faces out.
ŸApply a non-permanent locking agent to the
threads of the front and rear brake disc
mounting bolts [B].
ŸTighten torque
Brake Disc Mounting Bolts :27N·m(2.
8kgf·m,20ft·lb)
Brake Disc Wear
ŸMeasure the thickness of each disc [A] at
the point where it has worn the most.
«If the disc has worn past the service limit,
replace it.
12
Measuring Area [B]
Brake Discs Thickness Standard:
Front: 4.3mm~4.7mm(0.17in~0.19in.)
Rear: 4.8mm~5.2mm(0.19in~0.20in.)
Service limit:
Front: 4.0mm(0.16in.)
Rear: 4.5mm(0.18in.)
Brake Disc Warp
ŸRaise the wheel off the ground with jack (see
Front/Rear Wheel Removal in the Wheels/
Tires chapter).
Special Tools - Jack, Jack Attachment
○For front disc inspection, turn the handle-
bar fully to one side. «If runout exceeds the service limit, replace
ŸSet up a dial gauge against the disc [A] as the disc.
shown and measure disc runout, while turn Disc Runout
ing [B] the wheel by hand. Standard :0.15mm(0.006in.) or less
Service limit :0.3mm(0.01in.)
12-19
CFMOTO
Brake Fluid
Brake Fluid Level Inspection
ŸRefer to the Brake Fluid Level Inspection in
the Periodic Maintenance chapter
Brake Fluid Replacement
ŸRefer to the Brake Fluid Change in the Peri-
odic Maintenance chapter.
Brake Line Bleeding
The brake fluid has a very low compression
coefficient so that almost all the movement
of the brake lever or pedal is transmitted
directly to the caliper for braking action. Air,
however, is easily compressed. When air
enters the brake lines, brake lever or pedal
movement will be partially used in com-
pressing the air. This will make the lever or
pedal feel spongy, and there will be a loss
in braking power.
CAUTION
Be sure to bleed the air from the brake
line whenever brake lever or pedal action
feels soft or spongy after the brake fluid is
changed, or whenever a brake line fitting
has been loosened for any reason
NOTE
○The procedure to bleed the front brake line
is as follows. Bleeding the rear brake line is
the same as for the front brake.
ŸRemove the reservoir cap [A]
ŸFill the reservoir with fresh brake fluid to the
MAX level line in the reservoir.
ŸSlowly pump the brake lever several times
until no air bubbles can be seen rising up
through the fluid from the holes at the bottom
of the reservoir.
○Bleed the air completely from the mas-
ter cylinder by this operation.
ŸRemove the rubber cap from the bleed
valve [A] on the caliper.
ŸAttach a clear plastic hose [B] to the bleed
valve, and run the other end of the hose into a
container.
12-20
12 Breaking system
Drain out the air in breaking line

○Repeat this operation until no more air can
be seen coming out into the plastic hose.
1.Pump the brake lever until it becomes
hard, and apply the brake and hold
it [A].
2.Quickly open and close [B] the bleed
valve while holding the brake
applied.
3.Release the brake [C].
NOTE
○The fluid level must be checked often
during the bleeding operation and replen-
ished with fresh brake fluid as necessary.
If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding
operation must be done over again from
the beginning since air will have entered
the line.
○Tap the brake hose lightly from the cali- C 12
per to the reservoir for more complete
bleeding.
○ Front Brake: First bleeding the right
caliper then repeat the above steps for the
left caliper.
ŸRemove the clear plastic hose.
ŸInstall the diaphragm and reservoir cap
ŸTighten torque:
Front Brake Reservoir Cap Screws:1.
0N·m(0.10kgf·m,9in·lb) ŸTighten the bleed valve, and install the rub-
ŸFollow the procedure below to install the ber cap.
rear brake fluid reservoir cap correctly. Torque - Bleed Valve:7.8N·m(0.80kgf·m,
○First, tighten the rear brake fluid reser- 69in·lb)
voir cap [B] clockwise [C] by hand until ŸCheck the fluid level (see Brake Fluid
slight resistance is felt indicating that the Level Inspection in the Periodic Mainte-
cap is seated on the reservoir body, then nance chapter).
tighten the cap an additional 1/6 turn [D] ŸAfter bleeding is done, check the brake for
while holding the brake fluid reservoir body good braking power, no brake drag, and no
[A]. fluid leakage.
12-21
CFMOTO
Danger
When working with the disc brake, observe the precautions listed below.：
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left unsealed or that has
been open for a long time.
3. Do not mix two types and brands of fluid for use in the brake. This
lowers the brake fluid boiling point and could cause the brake to be
ineffective. It may also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of time to avoid
moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong wind is blowing.
6. Except for the disc pads and disc, use only disc brake fluid, isopropyl
alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any
other fluid for cleaning these parts. Gasoline, engine oil, or any other
petroleum distillate will cause deterioration of the rubber parts. Oil spilled
on any part will be diff cult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that no disc brake fluid
or any oil gets on them. Clean off any fluid or oil that inadvertently gets
on the pads or disc with a high-f ash point solvent. Do not use one which
will leave an oily residue. Replace the pads with new ones if they cannot
be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be
completely wiped up immediately.
9. If any of the brake line fittings or the bleed valve is opened at any time,
the AIRMUSTBEBLEDFROM THE BRAKE LINE.
Brake Hose Removal/Installation

Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter
Brake Hose Inspection
Refer to the Brake Hose Damage and Installation Condition Inspection in the Periodic
Maintenance chapter
12-22
12 Breaking system
ABS Trouble code
C1D90 Front wheel speed sensor trouble
C1D91 Front wheel speed sensor physical trouble
C1D92 Front wheel speed sensor period trouble
C1D93 Front wheel speed sensor self-testing failure
C1D94 Front wheel speed sensor signal phase trouble
C1D95 Front wheel speed sensor frequency testing failure.
C1DA0 Rear wheel speed sensor trouble
C1DA1 Rear wheel speed sensor physical trouble

C1DA2 Rear wheel speed sensor period trouble
C1DA3 Rear wheel speed sensor self-testing failure
C1DA4 Rear wheel speed sensor signal phase trouble
C1DA5 Rear wheel speed sensor frequency testing failure.
C1DD3 OSEK deadly fault
C1DF0 Pump wrong function （MAB damaged） 12

C1DF1 Pump connection trouble（MAB damaged）
C1DF2 Hardware trouble（MAB damaged）
C1DF5 Inner hardware trouble
C1DF3 Low voltage
C1DF4 Low voltage
C1DF7 High voltage
C1E59 Wrong vehicle number

C1E5A ABS Switch trouble
12-23
13 Suspension system
Contents
Front shock exploded View…………………………………………………………………………………13-2
Rear shock exploded View…………………………………………………………………………………13-4
Specifications………………………………………………………………………………………………… 13-6
Special Tools……………………………………………………………………………………………………13-7
Front Shockabsorber…………………………………………………………………………………………13-8
Front shockabsorber removal …………………………………………………………………………13-8
Front shockabsorber Installation………………………………………………………………………13-8
Rear shockabsorber……………………………………………………………………………………… 13-10
Spring Preload Adjustment ………………………………………………………………………… 13-10
Rear Shock Absorber Removal…………………………………………………………………… 13-10
Rear Shock Absorber Installation………………………………………………………………… 13-11
Rear Shock Absorber Inspection ………………………………………………………………… 13-11
Swingarm………………………………………………………………………………………………………13-12
Swingarm Removal ……………………………………………………………………………………13-12
Swingarm Installation …………………………………………………………………………………13-12
Swingarm Bearing Removal ……………………………………………………………………… 13-13
Swingarm Bearing Installation …………………………………………………………………… 13-13
Swingarm Bearing, Sleeve Inspection…………………………………………………………… 13-14 13
Swingarm Bearing Lubrication…………………………………………………………………………13-15
Chain Guide Inspection……………………………………………………………………………………13-15
13-1
CFMOTO
Front fork exploded view
13-2
Torque
N·m kgf·m ft·lb
1 Front wheel shaft locking screw 34 3.5 25
Front shock absorber locking
2 20 2.0 15 AL
screw（L）
Front shock absorber locking
3 20 2.0 15
screw（U）
13
13-3
CFMOTO
Rear swing arm exploded view
13-4
Torque
N·m kgf·m ft·lb
1 Rear shock absorber bolt 59 6.0 44
2 Rear shock absorber nut 59 6.0 44
3 Rear rocker arm mounting nut 180 18.0 133
G：Use grease
13
13-5
CFMOTO
Specifications
N ame Ite m S tandard

Inner Tube O uts ide
φ 43m m
D iam eter
Front O il s tyle TO P 46# or s am e level
shock O il only： 400m L±3 m L
C apac ity
absorbe r Total dry： 445m L±3m L
S hoc k s pring length 300m m ， S ervic e lim it: 295m m
Free length： 165m m ， C ontinuous ly adjus table: -

S pring and pre-load
4m m ～ + 5m m
R e ar shock P res s ure 1MP a， No adjus table
absorbe r
Tolerant 4th， C loc kw is e add dam p，
R ec overing dam p
C ounterc low is e dec reas e dam p from level 1 to 7.
During the change of the order,the above parameters maybe different with real vehical.
13-6
Special tool
Retainer plier Jack
Front shock absorber handle Front shock absorber oil seal remover
Shock absorver cylinder head adjuster Shock absorber oil gauge
13
Oil seal bearing remover Jack accessories
Bearing pressor Valve rod bearing pressor
Washer
13-7
CFMOTO
Front Shockabsorber
Front Shockabsorber removal
ŸRemove:
Front Wheel (see Front Wheel Removal in
the
Wheels/Tires chapter)
A
Front Fender (see Front Fender Removal in
the
Frame chapter)
«If you want to remove the shockabsorber, Re-
move the locking bolts [A] first and turn the shock
absorber and pull it out.
Front shockabsorber installation

ŸInstall the fork with the upper end of the inner
tube flush [A] against the top surface of the
stem head [B]
ŸTighten torque:
Front Fork Clamp Bolt(lower):20N·m(2.
0kgf·m,15ft·lb)
Front Fork Top Plug:25N·m(2.5kgf·m,
18ft·lb)
NOTE
○Tighten the top plug before tightening the
upper Fork clamp bolt.
○Tighten the two clamp bolts alternately two
times to ensure even tightening torque.
ŸTighten torque:
Front Fork Clamp Bolt (Upper):
ŸInstall the removed parts (see appropriate
chapters)
Front Fork Oil Replacement

Ÿ Remove the front fork (see Front Fork
Removal).
ŸRemove
Top Plug [A] with O-ring Collar [B]
Fork Spring Seat [C] Fork Spring [D]
13-8
Compress [A] the fork [B] upside down to
draw out the oil into the suitable container
[C].
ŸPour in the specified amount of oil.
Shockabsorber oil viscosity:
KAYABAKHL34-G10 or equivalent
Amount (Per Side)
Replace the oil only:
About 390mL(13.2US oz)
Total dry:
458mL±4mL(15.5US oz±0.14US oz)
NOTE
○ Move the outer tube up and down a few
times, to remove the air that is trapped in the
fork oil in order to stabilize the oil level.
ŸHold the outer tube vertically in a vise and
compress the Fork completely
ŸWait until the oil level stabilizes
ŸUse the fork oil level gauge [A] to measure
the distance between the top of the inner tube
to the oil level.
13
Special Tool - Fork Oil Level Gauge
○Set the oil level gauge stopper [B] so that
the distance [C] from the bottom of the
stopper to the lower end of the pipe is the
standard oil level distance.
○ A correct measurement can not be ob-
tained unless the level gauge pipe is
placed in the center of the inner tube.
Oil Level (fully compressed, without
spring) Standard:
115mm±2mm(4.5in±0.08in.)
ŸRepeat the same procedure for adjusting the
○Place the stopper of the level gauge at the
other fork.
top [D] of the inner tube [E] and pull the
ŸInstall the fork spring [A], fork spring seat
handle slowly to draw out the excess oil
[B] and collar [C].
from fork into the gauge, thus attaining the
ŸInspect the top plug O-ring and replace it with
standard level.
a New.
○If not oil is drawn out, there is not enough
ŸInstall the front shock absorber(See front
oil in the fork.Pour in some more oil and
shockabsorber installation)
measure again.
13-9
CFMOTO
Rear shockabsorber
Spring Preload Adjustment
ŸUsing the hook wrench [A], turn the adjust-
ing nut [B] to adjust the spring preload.
○Riders in average level 68kg(150lb) with no
passenger and no accessories is 3rd
position.
Spring Preload Setting
Standard Position: 3rd position
Adjustable Range: 1st to 7th position
ŸIf the compression of the spring is not suited
to the operating conditions, adjust it to an ap-
propriate position by referring to the table
below.
Spring Preload Adjustment
Shock Road
Adjuster Damping Absorber Driving
Load Conditio
Position Force Speed
Hardness ns
1st weak Soft Light Good Low speed

↑ ↑ ↑ ↑ ↑ ↑
↓ ↓ ↓ ↓ ↓
↓
Hard
7th Strong Heavy Bad High speed
Rear Shock Absorber Removal

Remove:
Frame Covers (see Frame Cover Removal
Muffler Body (see Muffler Body Removal in
the Engine Top End Chapter)
Raise the rear wheel off the ground with jack
Special Tools – Jack Jack Attachment
ŸSqueeze the brake lever slowly and hold it
with band[A].
WARNING
Be sure to hold the front brake when
removing the shock absorber, or the
motorcycle may roll over. It could cause an
accident and injury.
13-10
ŸRemove:
Upper Shock Absorber Bolt [A]
B
Lower Shock Absorber Nut and Washer C
Lower Shock Absorber Bolt[C]
ŸRemove shockabsorber [B] from backward.
A
Rear Shock Absorber Installation

ŸInstallation is the reverse of removal.
ŸApply grease to the lip of oil seals
○Be sure to install the oil seals to the shock
absorber
ŸTighten torque:
Rear Shock Absorber Bolt:59N·m(6.
0kgf·m,44ft·lb)
Rear Shock Absorber Nut:59N·m(6.
0kgf·m,44ft·lb)
chapters).
13
Rear Shock Absorber Inspection
ŸRemove the rear shock absorber (see Rear
Shock Absorber Removal)
ŸVisually inspect the following items. Smooth
Stroke Oil Leakage Crack or Dent
«If there is any damage to the rear shock
absorber, replace it.
«If it shows any signs of damage, replace it.
13-11
CFMOTO
Swingarm
Swingarm Removal
ŸRemove:
Chain Cover Bolts [A] and Cover [B]
ŸRemove:
Left, right side cover (see Side Cover Re-
moval in the Frame chapter)
Left, right foost rest bracket (see Foot Rest
Bracket Remobal in Frame chapter)
ŸRemove the brake hose banjo bolt from the A
rear caliper,free the brake hose [A] from the
clamps [B], and removethe foot peg stay with
the rear master cylinder.(see Rear Caliper
Removal in the Brakes chapter)
ŸRemove
Muffl er Body (see Muffl er Body Removal in
Rear Wheel (see Rear Wheel Removal in
the Wheels/Tires chapter)
ŸRaise the rear wheel off the ground with
A
jack
Special Tools - Jack Jack Attachment

ŸRemove the lower shock absorber nut and
bolt [A].
ŸRemove the drive chain (see Drive Chain
Removal in the Final Drive chapter).
ŸUnscrew the swingarm pivot shaft nut [A].
ŸPull off the pivot shaft [B], and remove the B
swingarm.
Swingarm Installation
ŸInstallation is the reverse of removal
○Apply grease to the lip of the oil seals.
C
○Be sure to install the oil seal and collar to
the swingarm.
ŸTighten the pivot shaft nut.
Swingarm Pivot Shaft Nut Tighten
torque:
180N·m(18.0kgf·m,133ft·lb) chapters).
13-12
Swingarm Bearing Removal
ŸRemove:
Swingarm (see Swingarm Removal)
Collar [A]
Oil Seals [B]
Sleeve [C]
Circlip [D]
Ÿ Remove the ball bearing and needle

bearings.
Special Tool - Oil Seal & Bearing Remover
[A]
13
Swingarm Bearing Installation

ŸReplace the ball and needle bearings [A]
with new ones
ŸInstall the ball and needle bearings so that
the manufacturer’s marks face out.
Special Tools - Bearing Driver Set:
Stem Bearing Driver 28[B]
Spacer φ 28
13-13
CFMOTO
ŸInstall the needle bearings [A], ball bearing [B]
and oil seals [C] position as shown.
25mm(0.98in.)[E]
17mm(0.67in.)[F]
1mm(0.04in.)[G]
0.5mm(0.02in.)[H]
1mm(0.04in.)[I]
23.5mm(0.93in.)[J]
6mm(0.24in.)[K]
B
Swingarm Bearing, Sleeve Inspection
CAUTIO N
Do not remove the bearing fo r A
inspection. R emoval may d amag e
them.
ŸInspect the needle bearings [A] and ball bearing installed in the swingarm.
○The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage.
«If the needle bearing and sleeve [B] show any sings of abnormal wear, discoloration, or
damage, replace them as a set.
13-14
ŸTurn the bearing in the swingarm back and
forth [A] while checking for plays, roughness, A
or binding.
«If the bearing play, roughness, or binding is

found, replace the bearing.
ŸExamine the bearing seal [B] for tears

or leakage. B
If the seal is torn or is leaking, replace the

bearing.
Swingarm Bearing Lubrication
NOTE
○ Since the bearings are packed with
grease and sealed lubrication is not
required.
Chain Guide Inspection

ŸRefer to the Chain Guide Wear Inspection 13
in the Periodic, Maintenance chapter.
13-15
14 Steering system
Contents
Explosive view……………………………………………………………………………… 14-2

Special tool………………………………………………………………………………………………14-4
Steering bearing removal……………………………………………………………………………14-5
Steering bearing installation ………………………………………………………………………14-6
Steering bearing lubrication …………………………………………………………………… 14-7
Steering cloumn bended ……………………………………………………………………………14-8
Handle bar…………………………………………………………………………………………………14-9
Handle bar removal ………………………………………………………………………………14-9
Handle bar installation ……………………………………………………………………………14-9
Clutch handle bar installation…………………………………………………………………………14-10
14
14-1
CFMOTO
Exploded view
35
23
24
25 36
26
18
34 28
29
33
27 26 25 24
23
30
2
4
32 31
3
5
6
7
10
20
8 11
1 9
18 1
12
19 7
21 13 6
1
1 15
22 17 14 13
16
18
14-2
14 Steering system
Torque
Num. Tighten part Remark
N·m kgf·m ft·lb
1 Front shock absorber locking screw（L） 20 2.0 15 AL
1 Front shock absorber locking screw（U） 20 2.0 15
1 Handlebar locking screw 25 2.5 18 S
34 LH switch locking screw 3.5 0.36 31in·lb
28 RH switch locking screw 3.5 0.36 31in·lb
8 Upper plate locking screw 108 11.0 80
16 Steering column locking nut 20 2.0 15
AD：Use glue；
AL：Tight the bolt in criss cross way to make sure the tighten torque
is average.
G：Use grease；
R： R e p la ce th e pa rts ；
S： Tighten in special order
14
14-3
CFMOTO
Special tool
Steering rod tighten wrench Steering rod bearing remover
Bearing pressor Steering bearing removin adapter
14-4
14 Steering system
Steering bearing removal
ŸRemove
Front Wheel (see Front Wheel Removal in
the Wheels/Tires chapter)
Headlight Assy (see Headlight Removal/
Installation in the Electrical System chapter)
Handlebar (see Handlebar Removal)
Steering Stem Head Bolt Plug [A]
Steering Stem Head Bolt [B] and Washer
Front Fork Clamp Bolts (Upper) [C] B C B
(Loosen)
Steering Stem Head [D]
ŸRemove:
Under Bracket [A] (see Upper Fairing
A
Bracket Removal in the Frame chapter)
Front Forks (see Front Fork Removal in the
Suspension chapter
ŸBend the claws of the claw washer straighten.
ŸRemove the steering stem locknut [B] and 14

claw washer [C].
ŸPushing up the stem base, and remove the
steering stem nut [A] with stem cap [B].
Special Tool - Steering Stem Nut
Wrench [C]
ŸRemove the steering stem [D] under side.
ŸRemove the upper stem bearing inner race
and bearing.
Ÿ To remove the bearing outer races [A]

pressed into the head pipe [B], insert a bar
[C] into the recesses of head pipe, and ap-
plying it to both recess alternately hammer it
to drive the race out.
NOTE
○If either steering stem bearing is damaged,
it is recommended that both the upper and
lower bearings (including outer races) should
be replaced with new ones.
14-5
CFMOTO
ŸRemove the lower bearing inner race [A]
which is pressed onto the steering stem with A
a suitable commercially available chisel [B].
Steering bearing installation
ŸReplace the bearing outer races with new

ones
ŸApply grease to the outer races, and drive
them into the head pipe at the same time
Special Tool - Bearing Driver Set [A]
ŸReplace the bearing inner races and oil seal
with new ones.
ŸApply grease to the oil seal.
ŸDrive the lower ball bearing inner race ap-
B A
plied the grease onto the stem.
Special Tools - Steering Stem Bearing
Driver,
Steering Stem Bearing Driver Adapter
ŸApply grease to the lower ball bearing [A],

and install it onto the stem.
ŸApply grease to the upper ball bearing [B]
and inner race [C].
ŸInstall the stem [A] through the head pipe and

install the ball bearing [B] and inner race [C]
on it.
ŸInstall the stem cap [D] and steering stem
nut [E].
14-6
14 Steering system
ŸSettle the inner races in place as follows.
○Tighten the steering stem nut with 39 N•m
(4.0 kgf•m, 29ft•lb) of torque fi rst, and loosen

it a fraction of a turn untilit turns lightly. After-
ward tighten it again withspecifi ed torque
using a stem nut wrench [A] in the direction
shown.
Check that there is no play and the steer-
ing stem turns smoothly without rattles. If not,
the steering stem bearings may be
damaged.
Special Tool - Steering Stem Nut

Wrench
Torque - Steering Stem Nut:20N·m
ŸInstall the claw washer [A] so that its bent
side [B] faces upward, and engage the bent
claws with the grooves of stem locknut [C].
ŸHand tighten the stem locknut until it touches 14
the claw washer.
ŸTighten the stem locknut clockwise until the
claws arealigned with the grooves (ranging
from 2nd to 4th) of stem nut [D], and bend
the 2 claws downward [E].
ŸInstall the stem head.
ŸInstall the washer, and tighten the stem head
bolt with specified torque.
ŸInstall the front forks (see Front Fork Instal-
lation in the Suspension chapter).
NOTE
○Tighten the upper fork clamp bolts fi rst,
next the stem head bolt, last the lower fork
clamp bolts.
○Tighten the two clamp bolts alternately two
times to ensure even tightening torque.
Torque - Front Fork Clamp Bolts
(Upper):20N·m
14-7
CFMOTO
Steering Stem Head Bolt:108N·m(11.
0kgf·m,80ft·lb)
Front Fork Clamp Bolts (Lower):20N·m
WARNING
Do not impede the handlebar turning by
routing the cables, harnesses and hoses
improperly.
ŸInstall the steering stem head bolt plug.

chapters).
Stem Bearing Lubrication

ŸRefer to the Steering Stem Bearing Lubri-
cation in the Periodic Maintenance chapter.
Steering Stem Warp

•Whenever the steering stem is removed,
or if the steering cannot be adjusted for
smooth action, check the steering stem for
straightness.
«If the steering stem [A] is bent, replace the

steering stem.
Steering parts damaged

«Replace the stem cap if its oil seal [A]
shows damage.
14-8
14 Steering system
Handlebar
Handlebar Removal C A
ŸRemove:
Clutch Lever Assembly [A]
Left Switch Housing [B]
Left Handlebar Weight [C]
ŸRemove:
Front Brake Master Cylinder[A] A
(see Front Master Cylinder Removal in the
Brakes chapter)
Right Switch Housing [B]
Right Handlebar Weight [D]
Throttle Grip [C]
B C D
ŸRemove the handlebar holder bolts [B] and 14

then pull out the handlebar. A
Handlebar Installation B
Torque - Handlebar Holder Bolts:25N·m

14-9
CFMOTO
Clutch lever assy installation
(see Clutch Lever Installation in the Clutch

chapter)
ŸApply adhesive cement to the inside of the

left handlebar grip.
left handlebar weight bolt.
ŸInstall the left switch housing. Fit the projec-
tion [A] into a small hole [B] in the handlebar.
Torque - Left Switch Housing Screws
ŸInstall:
Throttle Grip
Throttle Cable Tips [A]
Right Switch Housing
○Fit the projection [B] into a small hole [C]
in the handlebar.
Torque - Right Switch Housing Screws:
right handlebar weight bolt.
ŸInstall the front brake master cylinder (see
Front Master Cylinder Installation in the
Brakes chapter).
14-10
15 Body covering
Contents
Seat removal and installation ………………………………………………………………………15-2
Frame plate removal and installation ……………………………………………………………… 15-2
Seat side plate removal and installation…………………………………………………………… 15-3
Seat lock removal and installation ………………………………………………………………… 15-4
Fuel tank side plate removal and installation………………………………………………………15-5
Rediator front plate removal and installation…………………………………………………… 15-5
Rediator side plate removal and installation…………………………………………………… 15-6
Inner plate removal and installation………………………………………………………………… 15-7
Windshield removal and installation …………………………………………………………………15-7
Headlight upper cover removal and installation……………………………………………………15-8
Head cover removal and installation ……………………………………………………………… 15-8
Front lower covering plate removal and installation …………………………………………… 15-9
Front steering light removal and installation ………………………………………………………15-9
Front covering plate removal and installation…………………………………………………… 15-9
Steering light mounting bracket removal and installation…………………………………… 15-10
Headlight removal and installation…………………………………………………………………15-10
Dashboard removal and installation ………………………………………………………… 15-10
Dashboard cover removal and installation…………………………………………………15-11
Rediator rear side plate removal and installation ……………………………………………15-11
15
Rediator rear mid plate removal and installation………………………………………………15-12
Front fender removal and installation………………………………………………………………15-12
Engine side plate removal and installation …………………………………………………… 15-12
Rear rocker arm fender removal and installation………………………………………………15-13
Rear handlebar removal and installation ………………………………………………………15-13
Taillight side plate removal and installation………………………………………………………15-14
Taillight removal and installation……………………………………………………………………15-14
Rear fender removal and installation………………………………………………………………15-14
Rearview mirror removal and installation ………………………………………………………15-15
Fuel tank removal and installation…………………………………………………………………15-15
Rearview mirror removal and installation ………………………………………………………15-15
Frame inspection ……………………………………………………………………………………15-16
15-1
CFMOTO
Seat removal and installation 4
1
Seat removal
ŸPress the seat by following the arrow [1]
direction.
ŸUse the key to turn the seat lock [2] by
following the arrow [3] direction.
ŸPull out the seat pad by following the arrow 3
[4] direction. 2
Seat installation 1 4
2 3 5
ŸPut point [1] to point [2](LH & RH)
ŸPut point [3] into point [4] (LH & RH)
ŸLock the hook[5] into the lock [6].Until you
heard the click sound.
Note：After installed the seat. Shake

the seat to make sure it is tight enough.
Frame plate removal and installation
Frame plate LH removal

ŸRemove locking screw[1]
2
ŸPull the plate[2] to remove it.
15-2
15 Body covering
Frame panel LH installation 3 5 2
ŸInsert the plate[1] point [2] into point [3]
7
ŸPoint [4] to point [5] 6
ŸPoint [6] to point [7]
ŸPoint [8] to point [9]
ŸTight the mounting screw
4
9
1
8
Note: The frame panes RH use the

same way installation removal with the
LH.
Seat side plate removal and installation

5 3
Seat side plate LH removal
ŸRemove the seat(Refer to 15-2)
ŸRemove the frame side plate LH(Refer to
15-2)
ŸRemove the screw [1] 15
ŸRemove the clip [2]
ŸRemove the screw [3]
ŸRemove the bolt [4]
6
ŸRemove tighten bolt [5] 4 2 1
ŸRemove the bolt [6]
ŸRemove the seat cable [7]
ŸRemove the seat side plate 7
Seat side plate LH installation

ŸReverse the removal prodedure for installation
Note: The seat side plate RH

Use the same method for installation and
removal
With out seat cable removal.
15-3
CFMOTO
Seat lock removal and installation
4 1 2
Seat lock cover removal 3
ŸRemove seat side plate LH(See 15-3)
ŸRemove the screw[1]
ŸRemove the seat lock cover[4]
Seat lock installation

ŸReverse the removal proce-
dure for installation 1 2
Seat lock bracket removal

ŸRemove seat locking bolt[1]
ŸRemove seat locking bolt[2]
ŸPut the seat bracket out from the
clearance. Take out the cable [3] from the
hook [4].
ŸRemove the seat bracket [5]
Seat lock bracket installation

3
dure for installation.
15-4
15 Body covering
Fuel tank side plate removal and 1
installation
Fuel tank side plate LH removal

ŸRemove the seat side plate LH(See 15-3)
ŸPull the plate [1] out.
Fuel tank side plate LH installation

ŸPoint [1] into hole [2]
ŸPoint [3] into hole [4] 2 4 6 8 10 12
ŸPaste point [9] and [10] to-
gether
ŸInsert point [11] into tank hole
[12]
Note: The fuel tank side plate RH use

same removal and installation method 15
with the LH.
1 3 9 11
Radiator front plate removal and 5 7
installation
1
Radiator front plate removal
ŸRemove fuel tank side plate(see 15-5)
ŸRemove the clip [1](Both sides)
ŸRemove the locking screw[2](Both sides) 2
ŸRemove the locking screw[3](Both sides)
ŸRemove the locking screw[4](Both sides)
ŸRemove reservior front plate [5] 3
Radiator front plate installation

dure for installation
5 4
15-5
CFMOTO
Reservior side plate removal and
installation
Reservior side plate LH removal

ŸRemove reservior front plate(see 15-6)
1
ŸRemove two locking screws[1]
ŸRemove the locking screw [2]
ŸRemove the reservior side plate LH [3]
Reservior side plate RH removal

ŸRemove the reservior front plate(See 15-6)
ŸRemove the locking bolt [1]
ŸOther steps are the same as the LH.
15-6
15 Body covering
Reservior side plate LH installation 2 1

ŸInsert point [1] to hole [2]
ŸInsert point [3] to hole [4]
ŸInstall 2 screws and one bolt then tight up.
(See 15-6 removal procedure)
3
4
Inner plate removal and installation
LH inner plate removal

ŸRemove 3 clips[1]
ŸRemove screw [2]
ŸRemove the LH inner plate
LH inner plate installation 15

1 1 2 1
Note: RH inner plate use the same
method to removal and installation.
Windshield removal and installation
Windshield removal 1
ŸLoose 4 screws [1] up
ŸRemove the windshield
Windshield installation
15-7
CFMOTO
Head light upper cover removal
and installation
Headlight upper cover removal

ŸRemove the windshield(See 15-7)
1
ŸRemove 2 plastic clips [1]
ŸRemove the headlight upper cover
Headlight upper cover installation

Headcover removal and installation
Headcover removal
ŸReservior side plate(See 15-6)
1
ŸRemove inner side plate(See 15-7)
ŸRemove the headlight upper cover(See
15-8)
ŸRemove 4 screws [1]
ŸRemove screw [2]
ŸRemove 4 tighten bolt [3](Both sides)
ŸRemove the head cover.
Head cover installation

dure for installation 2
Note：The head cover including

the cover, front plate LH & RH,
Steering light connecting plate,
Front lower plate and steering light.
15-8
15 Body covering
Front lower plate removal and
installation.
Front lower plate removal

ŸRemove the head cover(See 15-8)
ŸLoose 6 screws [1] 1
ŸRemove the plate
Front lower plate removal

ŸReverse the removal procedure for
installation.
Front and rear steering light removal 1

and installation (LH).
Front steering light removal(LH)
ŸRemove the front plate(See 15-9)
ŸRemove 3 screws [1]
ŸRemove front steering light(LH)
Front steering light installation(LH)
ŸReverse the removal procedure for installa-
tion
15
Note：Front steering light(RH) use
same method of removal and instal-
lation with LH. It is unnecessary to
remove the head cover when
working.
Front plate removal and installation

Front plate LH removal
ŸRemove front lower plate(See 15-9)
1
ŸLoose 3 screws [1]
ŸLoose 1 screw [2]
ŸRemove front plate LH
Front plate LH installation
2
installation.
Note:The front plate RH use the same
method for removal and installation in
symmertrical direction.
15-9
CFMOTO
Steering light mounting bracket
removal and installation
1
Steering light mounting bracket LH
removal
ŸRemove front cover LH(See 15-9)
ŸRemove plastic clip[1]
ŸRemove steering light mounting bracket
LH
Steering light mounting bracket LH

installation
Note：Steering light mounting

bracket RH use the same method of
1
removal and installation as the LH in
symmertrical way.
Headlight removal and installation

Headlight removal
Ÿ Remove the head cover(See 15-8)
Ÿ Remove 2 nuts [1]
2
Ÿ Remove 2 tighten bolts [2]
Ÿ Remove the headlight assy
Headlight installation
Dashboard removal and installation

Dashboard removal
Ÿ Remove the headlight assy(See 15-10)
Ÿ Unplug the dashboard(See chap 16)
Ÿ Remove 3 locking nut [1] 1
Ÿ Remove the dashboard.
Dashboard assembly
15-10
15 Body covering
Dashboard cover removal and in-
2
stallation
3
Dashboard cover removal
Ÿ Remove the screw [1](Both sides)
Ÿ Remove windshield left moving rod[2]
1
Ÿ Remove windshield right moving rod[3]
Ÿ Follow [4] and [5] direction to pull out the
point[6]
Ÿ Remove the dashboard cover
Dashboard cover installation 4

ŸReverse the removal procedure for installa-
tion
Rediator rear side plate removal and 15

installation.
Rediator rear side plate LH removal 3

ŸRemove rediator and fan(See chapter 04)
ŸRemove 2 plastic clips[1]
1
ŸLoose tighten bolt[2] 2
ŸRemove reservior side plate LH[3]
Rediator rear side plate LH installa-

tion
installation.
Note: The reservior rear side plate RH

use the same method to removal and
installation in symmertrical direction.
15-11
CFMOTO
Radiator rear mid plate removal
and installation
Radiator rear mid plate removal

ŸRemove the radiator side plate(both sides)
(See 15-11)
ŸRemove tighten bolts [1]
1
ŸRemmove radiator rear mid plate.
Radiator rear mid plate installation

1
Front fender removal and installa- 3
tion
Front fender removal

Ÿ Remove 3 line holder [1]
Ÿ Remove 6 screws [2](Both sides)
2
Ÿ Remove plastic clips[3]
Ÿ Remove front fenders
Front fender installation

dure for installation 1
Engine side plate removal and in-

stallation
Engine side plate LH removal

Ÿ Loose up 3 screws [1]
Ÿ Remove the engine side plate LH
Engine side plate LH installation

Ÿ Reverse the removal proce-
Note：Engine side plate RH re-
moval and installation is the same
as LH.
15-12
15 Body covering
Rear rocker arm fender removal
and installation 2 1
Rear rocker arm fender removal

ŸUnplug the line holder [1]
ŸLoose 3 screws[2] up
ŸRemove the fender
Rear rocker arm fender installation

installation.
15
Rear handlebar removal and instal-
lation
Rear handlebar removal

ŸRemove the seat(See 15-2)
2
ŸRemove two tighten screws[1] 1
ŸLoose 2 screws [2] up
ŸRemove the handlebar
Rear handlebar installation

installation.
15-13
CFMOTO
Taillight side plate removal and
installation
Taillight side plate LH removal

Ÿ Remove the rear handle bar(See 15-13)
Ÿ Remove the plastic clip [1]
Ÿ Loose 2 screws up [2]
Ÿ Remove taillight side plate
1 2
Taillight side plate LH installation
Note:Taillight side plate RH use the

same method removal and installation
with LH in symmertrical direction.
1
Taillight removal and installation
Taillight removal
Ÿ Remove taillight side plates (See 15-14)
Ÿ Remove 2 plastic clips[1]
Ÿ Disconnect the connector
Ÿ Remove the taillight
Taillight installation
Rear fender removal and installation

Rear fender removal
Ÿ Remove the seat pad(See 15-2)
1 1
Ÿ Disconnect the rear steering light(both
sides) and the licence light
Ÿ Remove 4 tighten bolt from the bottom [1]
Ÿ Remove the rear fender
Rear fender installation

15-14
15 Body covering
Frame bottom plate removal and
installation
Frame bottom plate removal
Ÿ Remove the taillight(See 15-14)
Ÿ Remove rear fender(See 15-14)
Ÿ Remove the screw [1] 1
Ÿ Frame bottom plate
Frame bottom plate installation

Ÿ Reverse the removal procedure for installa-
tion
Fuel tank removal and installation

Fuel tank removal
1
Ÿ Remove the seat(See 15-2)
Ÿ Remove related covering parts (See 15-3,
15-5)
Ÿ Remove mounting bolt [1] [2]
Ÿ Disconnect fuel sensor connector
Ÿ Disconnect fuel pump connector
Ÿ Remove fuel hose.
Ÿ Pull out the fuel tank 15
Fuel tank installation
Ÿ Reverse the removal procedure for installa- 2
tion
Rearview mirror removal and in-

stallation
Rearview mirror removal
Ÿ Push the dust boot[A] out to shows up the
adjusting nut [B].
Ÿ Loose the adjusting nut [B]
Ÿ Loose the mirror rod to remove the mirror.
Rearview mirror installation
Ÿ Reverse the removal procedure for installa-
tion
(Becareful with the safty angle)
Note:The drawing shows the rearview

mirror LH. RH is the same.
15-15
CFMOTO
Frameinspection
•Inspect the frame to see the cracks, hurt, bent or

other damage.
○If any damaged inspected on the frame. Replace the frame.
Warning
Repaired frame may be defect on driving. And may
cause accident. If any damage inspect on the frame.
Replace the frame into new one.
15-16
16 Electric system
Electric system
Electric system ……………………………………………………………………………16-1

1.Specification ………………………………………………………………………………16-2
2.Special tool…………………………………………………………………………………16-3
3.Part position ………………………………………………………………………………16-4
4.Caution………………………………………………………………………………………16-6
5.Wire…………………………………………………………………………………………16-7
6.Battery………………………………………………………………………………………16-8
7.Charging system…………………………………………………………………………16-16
8.Ignition system……………………………………………………………………………16-24
9.Starting system……………………………………………………………………………16-35
10.Lighting system……………………………………………………………………………16-42
11.Radiator fan system…………………………………………………………………… 16-49
12.Dashboard………………………………………………………………………………16-52
13.Switch and sensor……………………………………………………………………… 16-60
14.Relay and fuses………………………………………………………………………… 16-63
16
16-1
CFMOTO
Electric system form
Item Standard
Battery
Style Full sealed battery
Model YTX12-BS
Capacity 12V10Ah
Voltage 12.8V or higher
Charging system
Style AC 3-phase
Magneto output voltage 4000r/min (rpm) 42V or higher
Stator coil resistance 0.18Ω～0.27Ω
Charging voltage 14.2 V～15.2V
Ignition system
CPS resistance 376Ω～564Ω
CPS peak voltage 1.9V or higher
First level coil resistance 1.1Ω～1.5Ω
Secondary coil resistance 10.816kΩ
First level coil resistance 88V or higher
Spark plug
Spark clearance 0.8 mm～0.9mm (0.03 in～0.04in)

Start system
Start motor：
Brush length 12mm (0.47in) (Service limit: 6.0mm ,
Commutator diameter 0.24in)
28mm (1.10in) (Service limit: 27mm ,
1.06in )
Switch and sensor
Rear breaking light switch Pedal clearance 10mm(0.39in) then on
Oil pressure switch Engine stop：ON
Engine running：OFF
Thermo sensor resistance See below
16-2
16 Electric system
Electric system
Tool
AVO meter Auxilary testing line
Magneto rotor puller Pin fitter
Peak voltage tester

16
Magneto rotor locking wrench
16-3
CFMOTO
Electric system
Part position
4.Speed 1.Dash- 2. 3.Start
sensor board Thermosensor motor 5.Start relay
6.Flash 7.Fan 8.Magneto 9.Neutral 10.Side 11.Rectifier 12.

relay motor switch stand Battery
13.ECU 14.Fuel pump switch
15.Breaking 16.Rollover 17.Throttle 18.CPS 19.Oxygen

20.Ignition coil
light switch sensor body sensor
16-4
16 Electric system
Electric system
Part position
1. Dashboard 14.Fuel pump In tank

2. Thermosensor 15.Breaking light switch
3. Startmotor 16.Rollover sensor
4. Speed sensor 17.Throttle body
5. Start relay 18.CPS
6. Flasher 19.Oxygen sensor
7. Fan motor 20.Ignition coil
8. Magneto
9. Neutral switch
10.Side stand switch
11.Rectifier
12.Battery
13.ECU
Note:The wiring diagram is the appendix.
16
16-5
CFMOTO
Electric system
Caution
There are many pre-cautions when repairing the electric system.Please becareful
with the rules below.
1.Do not connecting the battery wrong. Or the diode will be burnt.
2.Inspect the battery first when working on electric system. Make sure the battery
is fully charged.
3.Do not knock hardly or drop the electric parts. Or the extremly shock will dam-
age the parts.
4.When the ignition switch ON or engine on running. Do not loose the wire or
other electric connection to avoid electric parts damaged.
5.As the current is large. Do not keep the start switch on if the start motor not run.
Or the motor coil will be burned and finally cause damaged.
6.Do not use the bulb not in standard. Or it may cause the dashboard or tester
melted.
7.Becareful not to let the (+) pole touch the ground wire. Or it will cause the shortcut.
8.The trouble may cause by one part or different parts. So do not replace the
trouble part without finding the real reason. If the trouble causes from other part(s).
Replace them together, or the new parts will get trouble very soon.
9.Make sure all the connectors is clean without loose. And check the wire if got
burned or wearing. If the wire or bad connection can cause the electric system
running unstable.
10.Measure the coil’s resistance when the parts cooled down.
Color sign:
R:red R/W:red/white R/G:red/green B:Black B/W:Black/White B/Y:Black/Yellow B/Br:
Black/Brown
B/L:Black/Blue G:Green Gr:Grey Lg:Light green Lg/G:Light green/Green Lg/Y:Light
green/Yellow Sb:Light blue
Sb/W:Light blue/White Y:Yellow O:Orange L:Blue P:Purple Br:Brown W:White
16-6
16 Electric system
Electric system
Wire basic
Connector [A]
Connector [B]
Wiring inspection
●Inspect the wiring to see burned, wearing 16
or other damage.
If any damage inspected. Replace the
wiring.
●Disconnect all the connector [A] to see any
corrosions, dirt or other damage.
●If connector got corrosion or dirt. Clean the
connector carefully. If any damage inspected,
replace the connector.
●Inspect the wiring connection by using the
AVO meter.Follow the wiring diagram to see
the wiring may got trouble.
● Set the tester to x1 Ω rate and read te
data.
● If tester is not 0 Ω. The cable may got
trouble.
Replace the wire or cable if need.
16-7
CFMOTO
Battery
Battery removal
●Remove the seat.
●Disconnect (-) pole and cable [A].
●Slide out the (+) pole cover [B] and (+) pole.
Warning
Disconnect the (-) pole cable first
●Remove the battery.

Battery installation：
● Place the battery in front of the rear
fender.
●Cover a little grease on the pole to avoid
corrosion.
●Connect (+) pole and cable [A] first.
●Use the sleeve (B) to cover (+) pole.
●Connect (-) pole and cable (C).
Battery activation
Electrolyte filling
●Make sure the electrolyte mode [A] is fit
for battery model[B]. This is a must.
Battery model for CF650: YTX12-BS.
Warning
Because of the electrolyte capacity and
weight depends on battery. Make sure
the electrolyte container size is fit for
the battery to avoid overflow. Or the
battery reliability may be bad cause the
performance bad.
Warning
Do not open aluminum cover [A] until
start using. Fill the electrolyte from holes
[B] and make sure the capacity is right.
●Put the battery on a flat surface
● Make sure the aluminum cover has no
damage
●Remove the cover.
16-8
16 Electric system
Battery
Note
Battery is vaccum sealant. If any air into the
battery. It will take more time to charge the
battery.
●Remove the plastic bag of the electrolyte.

●Remove the cap [A] from the container and
set aside for seal the battery.
Note
Do not use pin or other way to open the sealed
electrolyte container [B].Do not try to seperate
the singal unit.
●Put 6 sealed unit into battery injecting hole.

Then up side down. Hold the container
horizontally. Break all the unit sealing part. You
can see bubbles up to each unit.
Note
Do not tilt the container.
●Inspect the electrolyte flow.
If no air bubbles [A] are coming up from the 16
filler ports, or if the container cells have not
emptied completely, tap the container [B] a
few times.
● Keep the container in place for 20 min-
utes or more. Don’t remove the container from
the battery until it’s empty, the battery requires
all the electrolyte from the container for proper
operation.
CAUTION
Removal of the container before it is ● Gently remove the container from the
completely empty can shorten the battery.
service life of the battery. Do not re- ●Let the battery sit for 30 minutes prior to
move the electrolyte container until it charging to allow the electrolyte to permeate
is completely empty and 20 minutes into the plates for optimum performance.
have elapsed. NOTE
Charging the battery immediately after filling
can shorten service life. Let the battery sit
for at least 30 minutes after filling.
16-9
CFMOTO
Battery
Initial Charge
●Place the strip [A] of caps loosely over the
filler ports.
●Newly activated sealed batteries require
Charging rates will vary depending on how

long the battery has been stored,
temperature, and the type of charger used.
Let battery sit 30 minutes after initial
charge, then check voltage using a
voltmeter.
If it is not at least 12.8 V, repeat charging
cycle.
●After charging is completed, press down
firmly with both hands to seat the strip of caps
[A] into the battery (don’t pound or hammer.).
When properly installed, the strip of the caps
will be level with the top of the battery.
CAUTION
Once the strip of the caps [A] is in-

stalled onto the battery, never remove
the caps, nor add water or electrolyte
to the attery.
NOTE
To ensure maximum battery life and cus-

tomer satisfaction, it is recommended the
battery be load tested at three times its
amp-hour rating for 15 seconds. Recheck
voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below
12.8 V the battery is defective.
16-10
16 Electric system
Battery
Precautions
1) No need of topping-up.
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly
prying off the seal cap to add water is very dangerous. Never do that.
2)Refreshing charge.
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery
has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in
the specification (see Specifications).
When a fast charge is inevitably required, do it following precisely the maximum charge
current and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged
according to the method specified above. However, the battery’s performance
may be reduced noticeably if charged under conditions other than given above.
Never remove the seal cap during refresh charge. If by chance an excessive
amount of gas is generated due to overcharging, the relief valve releases the
gas to keep the battery normal.
3)When you do not use the motorcycle for months.

Give a refresh charge before you store the motorcycle and store it with the negative cable
removed. Give a refresh charge once a month during storage.
4)Battery life.
16
If the battery will not start the engine even after several refresh charges, the battery has
exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has
no problem).
5)Battery change
Sealed battery should be fit the vehicle electrical system. So, make sure the battery is sealed
style original before replacement.
WARNING
Keep the battery away from sparks and open flames during charging, since the
battery gives off an explosive gas mixture of hydrogen and oxygen. When
using a battery charger, connect the battery to the charger before turning on
the charger. This procedure prevents sparks at the battery terminals which
could ignite any battery gases. No fire should be drawn near the battery, or no
terminals should have the tightening loosened. The electrolyte contains sul-
furic acid. Be careful not to have it touch your skin or eyes. If touched, wash it
off with liberal amount of water. Get medial attention if severe.
Note
If motorcycle use normal battery as original. The sealed battery will shorter life period after
replaced into.
16-11
CFMOTO
Battery
Charging Condition Inspection
Battery charging condition can be checked

by measuring battery terminal voltage with a
digital voltmeter [A].
● Remove：
Seat (see Seat Removal in the Frame
chapter)
Battery Cable Cap (see Battery Removal)
●Disconnect the battery terminals.
CAUTION
Be sure to disconnect the negative (-)
cable first.
●Measure the battery terminal voltage.
NOTE
Measure with a digital voltmeter which can
be read one decimal place voltage.
If the reading is 12.8 V or more, no refresh
charge is required, however, if the read is
below the specified, refresh charge is
required.
Battery Terminal Voltage Standard
:12.8V or higher
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]
Refreshing Charge
● Remove the battery [A] (see Battery
Removal).
●Do refresh charge by following method ac-
cording to the battery terminal voltage.
WARNING
This battery is sealed type. Never
remove sealing cap [B] even at
charging. Never add water. Charge
with current and time as stated below.
16-12
16 Electric system
Battery Charge
Terminal Voltage:11.5V～12.8V
Standard Charge:1.2A X5-10h(See
form below)
Quick Charge:5Ax1h
If possible, do not quick charge. If quick
charge is done unavoidably, do stan-
dard charge later on.
Terminal Voltage less than 11.5V Charg-
ing Method 1.2Ax20h
NOTE
Increase the charging voltage to a maxi-
mum voltage
of 25 V if the battery will not accept current
initially. Charge for no more than 5 min-
utes at the increased voltage then check if
the battery is drawing current. If the battery
will accept current decrease the voltage
and charge by the standard charging
method described on the battery case. If
the battery will not accept current after 5
16
minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
●Determine the battery condition after re-
fresh charge.
Determine the condition of the battery left
for 30
minutes after completion of the charge by
measuring the terminal voltage according to
the table below.
Standard Judgement
12.8V or higher OK
12.0V~12.8V Unfully charged
Lower then 12.0V Replace
16-13
CFMOTO
Charging System
Alternator Cover Removal
●Remove:
Lower Fairing (see Lower Fairing Removal
in the
Frame chapter)
Alternator Lead Connector [A]
●Place a suitable container under the alter-

nator cover [A], and remove the cover bolts
[B].
●Pull the alternator cover outside.
Alternator Cover Installation

●Apply silicone sealant to the alternator lead
grommet and crankcase halves mating sur-
face [A] on the front and rear sides of the cover
mount.
●Check that dowel pins [B] are in place on
the crankcase.
● Install a new gasket and the alternator
cover.
● Tighten:
Torque - Alternator Cover Bolts ：9.
8 N ·m
Stator Coil Removal

●Remove Alternator Cover
●Remove the magneto rubber sleeve [B].
●Remove stator coil mounting bolt [D].
●Remove the stator coil.[E]
16-14
16 Electric system
Charging system
Stator Coil Installation
the threads of the stator coil bolts and tighten
them.
Torque - Stator Coil Bolts :12N·m
●Secure the alternator lead with a holding
plate, and tighten the bolt.
Torque - Alternator Lead Holding Plate
Bolt: 9.8N·m
● Apply silicone sealant to the circumfer-
ence of the alternator lead grommet, and fit
the grommet into the notch of the cover
securely.
●Install the alternator cover

Magneto Rotor Removal
●Remove the alternator cover
●Remove the starter idle gear, torque lim-
iter and shafts.
●Wipe oil off the outer circumference of the
rotor. 16
●Hold the alternator rotor steady with the
rotor holder [A], and remove the rotor bolt
[B] and washer.
Special Tool: Rotor Locker
●Using the flywheel puller [A], remove the
alternator rotor from the crankshaft.
Special Tool - Flywheel Puller Assembly
CAUTION
Do not attempt to strike the alternator
rotor itself. Striking the rotor can
cause the magnets to lose their
magnetism.
Magneto Rotor Installation

●Using a cleaning fluid, clean off any oil or
dirt on the following portions and dry them
with a clean cloth.
Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]
16-15
CFMOTO
Charging system
●Install the start gear [A] and washer [B]
●Clean the bevel [C] of the crankshaft and

clean it up.
●Install magneto rotor [A] and turn counter-

clockwise [B].
●Install the washer [A].

NOTE
Confirm the alternator rotor fit or not to the
crankshaft before tightening it with speci-
fied torque.
●Install the rotor bolt [B] and tighten it with
70 N·m (7.0 kgf·m, 52 ft·lb) of torque.
●Remove the rotor bolt and washer.
●Check the tightening torque with flywheel
puller.
«If the rotor is not pulled out with 20 N·m (2.0
kgf·m, 15 ft·lb) of drawing torque, it is installed
correctly.
«If the rotor is pulled out with under 20 N·m
(2.0 kgf·m, 15 ft·lb) of drawing torque, clean
off any oil dirt or flaw of the crankshaft and
rotor tapered portion, and dry them with a
clean cloth. Then, confirm that it is not pulled
out with above torque.
●Tighten the alternator rotor bolt while hold-
ing the alternator rotor steady with the rotor
holder.
Special Tools - Rotor Locker

Torque - Alternator Rotor Bolt:155N·m
16-16
16 Electric system
Charging system
● Install the starter double gear [B] and
starter idle gear [C].
●Install the alternator cover.
Magneto inspection
There are three types of alternator failures:
short, open (wire burned out), or loss in
rotor magnetism. A short or open in one of
the coil wires will result in either a low
output, or no output at all. A loss in rotor
magnetism, which may be caused by drop-
ping or hitting the alternator, by leaving it
near an electromagnetic field, or just by
aging, will result in low output.
To check the alternator output voltage, do
the following procedures.：
●Turn off the ignition switch.
●Disconnect the alternator lead connector
[A].
●Connect the hand tester as shown
in the table 1. 16
●Run it at the rpm given in the table 1.
● Note the voltage readings (total 3
measurements).
Table 1 Alternator Output Voltage
AVO Connecting pin

4000rpm
meter （+）（-）
250V Black line Another black 40V or
AC line higher
●If the output voltage shows the value in the

table, the alternator operates properly.
●If the output voltage shows a much higher
than the value in the table, the regulator/rec-
tifier is damaged.
●A much lower reading than that given in
the table indicates that the alternator is
defective.
16-17
CFMOTO
Charging System
Check the stator coil resistance as follows.
●Stop the engine.
●Connect the hand tester as shown
in the table 2.
● Not e th e r e a di n g s ( to t a l 3
measurement).
Connecting pin
AVO meter Meter standard
（+）（-）
Black line Another black
×1Ω 0.10Ω~0.3Ω
line
●If there is more resistance than shown in the table, or no hand tester reading (infinity) for
any two leads, the stator has an open lead and must be replaced.
●Much less than this resistance means the stator is shorted, and must be replaced.
Follow the steps below to inspect the resis-

tance between stator and stator.
●Stop the engine
●Connect the AVO meter follow the
form below.
● Not e th e r e a di n g s ( to t a l 3
measurement).
Connecting pin
AVO meter Data
（+）（-）
Highest Magneto random
Engine case ∞
resistance black line
●Using the highest resistance range of the hand tester, measure the resistance between
each of the black leads and chassis ground.
Any hand tester reading less than infinity ( ) indicates a short, necessitating stator
replacement.
«If the stator coils have normal resistance, but the voltage check showed the alternator to be
defective; then the rotor magnets have probably weakened, and the rotor must be replaced.
16-18
16 Electric system
Charging System
Regulator/Rectifier
Regulator/Rectifier Removal
●Remove Bolts [A]
●Disconnect the connector [A].

●Remove the regulator/rectifier [B].
16
16-19
CFMOTO
Charging System
● Using a hand tester, measure the resis- ●After is the engine is running(at 5000 r/
tance be tween the following pair of terminals. min), when the magneto is normal and the
If any reading is out of the specifi cation, re- battery is fully charged, if the voltage between
place the regulator/rectifi er with a new one the red and green terminals is more than 15V
Set the hand tester to Diode range (mV). or less than 13.5V, replace the regulator/rectifi
er with a new one.
NOTE
If the hand tester displays less than 1.4 V
when the probes are not connected, replace
the batteries.
16-20
16 Electric system
Charging System
Overriding clutch
Overriding Clutch Removal/Installation
● Refer to the Alternator Rotor Removal/
Installation.
Overriding Clutch inspection
●Remove alternator cover
● Remove starter idle gear and starter
double gear.
● Turn the starter motor clutch gear [A] by
hand. The starter motor clutch gear should turn
clockwise [B] freely, but should not turn coun-
terclockwise [C].
«If the starter motor clutch does not operate
as it should or if it makes noise, go to the next
step.
●Disassemble the starter motor clutch, and
visually inspect the clutch parts.
«If there is any worn or damaged part, re-
place it.
16
NOTE
«Examine the starter motor clutch gear as
well. Replace it if it worn or damaged.
Overriding clutch removal

●Remove magneto rotor clutch bolt [A].
●Remove the overriding clutch [B].
Overriding clutch installation

the threads of the starter motor clutch bolts
and tighten them.
Torque: 34N·m
16-21
CFMOTO
Charging System
Charging System Troubleshooting Chart
Charging system trouble
Main fuse No Replace
OK
No 1． Clean terminal
Battery 2． Recharge.
OK
Charging voltage OK
Start the engine and keep it at the Charging system OK
speed of 5000rpm，The voltage
should be in 13.5V~15V
Note ： Battery must be fully ﹥15V Replace rectifier
charged
<13.5V
No
Stator resistance inspection Replace the stator
OK
No
Cable inspection Repair or replace
OK
Replace the rectifier
16-22
16 Electric system
Charging system
Charging wiring diagram
1.Battery 2.Start relay

3.Start motor 4.Rectifier
5.Magneto 6.Ignition switch 16
7.Fuse box
16-23
CFMOTO
Ignition system
WARNING
The ignition system produces ex-
tremely high voltage. Do not touch
the spark plugs or stick coils while
the engine is running, or you could
receive a severe electrical shock.
WARNING
Do not disconnect the battery cables
or any other electrical connections
when the ignition switch is on, or while
the engine is running. This is to pre-
vent ECU (Electric Control Unit)
damage.Do not install the battery
backwards. The negative side is
grounded. This is to prevent damage
to the ECU.
Crankshaft Position Sensor Removal
Remove:
● Lower Fairing (see Lower Fairing Re-
moval in the Frame chapter)
●Right frame cover(See frame chapter).
●Crankshaft position sensor connector[A]
Remove:
●Bolt[A].
●Oil pressure switch connector[B].
●Clutch cover
Remove:
●Rubber sleeve(Slide out)[A].
● CPS [B].
●Remove rubber sealing sleeve [C].
16-24
16 Electric system
Ignition system
CPS installation
●Connect the CPS line in the right way.
CPS tighten torque:6N·m

●Apply silicone sealant [A] to the crankshaft
sensor lead grommet.
●Install the removed parts (see appropriate
chapters).
CPS inspection
CPS resistance inspection
Removal:
●Right Frame Cover (see Frame Cover Re-
moval inthe Frame chapter)
●Crankshaft Sensor Lead Connector [A].
Measure the CPS resistance
●Set the meter [B]on x 100 ohm position
Meter(+)→ Black line
Meter(-)→ Green line
«If there is more resistance than the speci-
fied value, the coil has an open lead and 16
must be replaced. Much less than this resis-
tance means the coil is shorted, and must
be replaced.
CPS resistance:250Ω~300 Ω( In 20℃)
Measure the resistance to the ground

●Set the AVO meter [B] on highest resistance
level
Meter(+)→Black line or green line
Resistance to the ground：∞
●Using the highest resistance range of the
tester, measure the resistance between the
crankshaft sensor leads [A] and chassis
ground.
«Any tester reading less than infinity (∞)
indicates a short, necessitating replacement
of the crankshaft sensor assembly.
16-25
CFMOTO
Ignition system
CPS peak voltage inspection
Note
●Using the peak voltage adapter [A] is a
more reliable way to determine the condition
of the crankshaft sensor than crankshaft sen-
sor internal resistance measurements
Remove:
●Crankshaft Sensor Lead [A] Connector
(see Crank shaft Sensor Removal)
●Set the hand tester [B] to the DC 10 V
range, and connect it to peak voltage
adapter.
●Connect the positive terminal of the
adapter [C] to green lead and connect the
negative terminal of the adapter to black lead
in the crankshaft sensor connector.
●Turn the ignition switch and engine stop
switch ON.
●Pushing the starter button, turn the engine
4~5 seconds with the transmission gear in
neutral to measure the crankshaft sensor
peak voltage.
●Repeat the measurement 5 or more times.
Standard: 1.9 V or higher
If the tester reading is not specified one,
check the crankshaft sensor.
Timing Rotor Removal

Remove
●Clutch Cover (see Clutch Cover Removal
in the Clutch chapter)
●Remove the timing rotor bolt [A].
●Remove the timing rotor.[B]
Timing Rotor Installation:

●Fit the rotor to the crankshaft.
●Tighten the rotor bolt.
Torque - Timing Rotor Bolt：40N·m
16-26
16 Electric system
Ignition system
Ignition coil
Ignition coil removal
●Remove air filter.
● Disconnect the ignition coil connectors
[A].
●Pull the ignition coils [B] off the spark plugs.
CAUTION
Do not pry the connector part of the coil

while removing the coil.
Ignition Coil Installation

●Insert the coil as shown being careful of
the coil heads [A] direction.
●Connect the connectors
CAUTION
Do not tap the coil head while installing the

coil.
Ignition Coil Inspection

●Remove the ignition coils (see Ignition Coil
(Ignition Coil together with Spark Plug Cap)
Removal). 16
●Measure the primary winding resistance
[A] as follows.
●Connect the AVO meter between the coil
terminals.
●Set the tester to the x 10 ohm range, and
read the tester.
● Measure the secondary winding resis-
tance [B]
●Connect the tester between the plug ter-
minal and (-) coil terminal.
● Set the tester to the x1 k Ω range and
read the tester.
Primary Windings resistance：1.1Ω～

1. 5 Ω （ 2 0 ℃ ）
Secondary Windings resistance：11k
Ω～1 5 k Ω（2 0 ℃）
«If the tester does not read as specified, re-
place the coil.
16-27
CFMOTO
Ignition system
Ignition coil
Ignition Coil Primary Peak Voltage
Be sure the battery is fully charged
● Remove the ignition coils, but without
sparkplug.
Measure the primary peak voltage as
follows.：
●Install the new spark plug [A] into each ig-
nition coil [B], and ground them onto the
engine.
●Connect the peak voltage adapter [C] into
the hand tester [D] which is set to the x DC
250 V range.
●Connect the adapter to the lead wire-peak
voltage adapter [E] which is connected be-
tween the ignition coil connector and igni-
tion coil.
ECU [F]
Battery [G].
WARNING
To avoid extremely high voltage shocks, do

not touch the spark plugs or tester
connections.
● Turn the ignition switch and the engine

stop switch ON.
●Pushing the starter button, turn the engine
4~5 sec onds with the transmission in neu-
tral to measure the primary peak voltage.
●Repeat the measurements 5 times for one
ignition coil.
Spark Plug
Stick Coil Primary Peak Voltage
Spark Plug Removal
Standard: 88 V or more
●Refer to the Spark Plug Replacement in
●Repeat the test for the other stick coil.
«If the reading is less than the specified
Spark Plug Installation
value, check the following.
●Refer to the Spark Plug Replacement in
●Ignition Coils
●Crankshaft Position Sensor
Spark Plug Condition Inspection
● ECU
●Refer to the Spark Plug Condition Inspec-
tion in the Periodic Maintenance chapter.
16-28
16 Electric system
Ignition system
Interlock Operation Inspection
●Raise the rear wheel off the ground with
stand.
1st Check
●Start the engine to the following conditions.
Condition:
Transmission Gear：Not neutral
Clutch Lever: Release
Side stand: Down or up
●Turn the ignition switch ON and push the
start button.
●Then the starter motor should not run when
the starter system circuit is normality.
«If the engine start. Inspect the neutral switch,
auxilary relay and start relay.
«If their parts are normality replace the ECU.
2nd Check
●Start the engine to the following conditions.
Condition:
Transmission Gear:Not neutral
Clutch Lever:Pulled in 16
Sidestand: Up
●Turn the ignition switch ON and push the
starter button.
●Then the starter motor should turn when the
starter system circuit is normality.
«If the engine start. Inspect the neutral switch,
auxilary relay and start relay.
3rd Check A
●Running the engine as below
Condition:
Transmission Gear: Not neutral
●Set the sidestand on the ground, then the
Clutch Lever: Pulled in
engine will stop. If whichever may not be
Sidestand: Up
stopped, inspect the neutral switch, clutch
switch, sidestand switch and relay box.
ECU
●The IC igniter is built in the ECU
16-29
CFMOTO
Ignition System
Ignition System Troubleshooting Chart
Ignition trouble shooting

Ignition trouble(No spark)
Battery inspection No Charge or replace
OK
No Maintain the wiring and
Ignition system wiring and replace damaged parts
connection
OK No
Spark plug inspection Replace the spark plug
OK
No
Ignition coil inspection Replace ignition coil
OK
No
Ignition coil peak voltage Voltage lower than standard
OK
Inspection:
Replace ignition 1.Adaptor wrong connection or
coil adaptor defective.
2.Inspect the fuel pump relay
3. CPS peak voltage
No
OK
Replace defective
parts
Replace ECU.
16-30
16 Electric system
Ignition System(64 pin ECU for CF650-3)
Ignition System Diagram
16
16-31
CFMOTO
Ignition System(64 pin ECU for CF650-3)
1.Fuel pump relay 13. Ignition coil and spark plug 2

2.Trigger 14. Oxygen sensor 1
3. Ignition switch 15. Oxygen sensor 2
4. Fuse box 16. TPS
5. Start button 17. Thermo sensor
6. Engine stop switch 18. Roll over sensor
7. Start auxilary relay 19.TPS
8. Start relay 20. Sidestand switch
9. Battery 21. Fuel pump
10. Neutral switch 22. Injector 1
11. ECU 23. Injector 2
12. Ignition coil and spark plug 1 24. Clutch switch
16-32
Ignition System(48 pin ECU for CF650-3C)
16-33 16-34
16 Electric system
Starting system
Start motor
CAUTION
Do not tap the starter motor shaft or body.
Tapping the shaft or body could damage the
motor.
Start motor removal

●Slide out the rubber sleeve [A].
●Remove start motor cable nut [B].
●Remove mounting bolt [C].
●Pull out the start motor [D].
Start motor installation

●When installing the starter motor, clean the
starter motor legs [A] and crankcase [B]
where the starter motor is grounded.
●Apply grease to the O-ring.

●Tight up the bolt.
Torque - Starter Motor Mounting Bolts:
16
9 . 8 N ·m
●Install the start motor cable.
Torque - Starter Motor Cable Terminal
Nut: 6.0N·m
Starter Motor Test
●Using a cable as thick as or thicker than
starter motor cable [A], connect the 2 termi-
nals of starter relay [B].
Starter Motor [C]
Battery [D]
Be sure the battery is fully charged.
«If the starter motor turns, that indicates it’s
normal.
Otherwise, the starter motor is defective
and needs to be replaced.
16-35
CFMOTO
Starting system
Start relay
Start relay removal
●Remove the tank
●Disconnect the connectors [A].
●Disconnect the start motor cable[C] on start
relay[D]and battery (+) cable [B].
Start relay test

●Connect the hand tester [A] and 12 V bat-
tery [B] to the starter relay [C] as shown.
CAUTION
The battery positive (+) cable with the rubber
cap is connected directly to the battery
positive (+) terminal even when the ignition
switch off, so take care not to short the
removed cable to chassis ground.
When battery is connected:0 Ω

When battery is disconnected:∞Ω
«If the relay does not work as specified, the

relay is defective. Replace the relay.
Start Relay Resistance Measurement

●Connect the hand tester [A] and starter re-
lay [B] as shown.
Starter Relay Resistance:3 Ω～5 Ω
（2 0 ℃）
«If the reading is out of specification, the re-
lay is defective. Replace the relay.
«Using the relay connection and disconnec-
tion test is a more reliable way to determine
the condition of the starter relay than starter
relay resistance measurements.
16-36
16 Electric system
Starting system
Start auxilary relay
Start auxilary removal
●Remove the tank.
●Take out the auxilary relay[A] with rubber
sleeve [B] from the frame.
●Disconnect the connector [C].
Start auxilary relay test

●Connect the hand tester [A] and 12 V bat-
tery [B] to the starter auxilary relay [C] as
shown.
When battery is connected:0 Ω
When battery is disconnected:∞Ω
«If the relay does not work as specified, the
relay is defective. Replace the relay.
16
Start Auxilary Relay Resistance Mea-

surement
● Connect the hand tester [A] and starter
auxilary relay [B] as shown.
Starter Auxilary Relay Resistance:90
Ω～1 0 5 Ω（2 0 ℃）
«If the reading is out of specification, the re-
lay is defective. Replace the relay.
«Using the relay connection and disconnec-
tion test is a more reliable way to determine
the condition of the starter relay than starter
relay resistance measurements.
16-37
CFMOTO
Starting system
Starting Logic Table
Side stand switch Start or
Gear position Clutch
cannot
Up To ground Neutral To ground Loose Disconnect Start
to ground
Up To ground Neutral To ground Hold To ground Start
Up To ground Not Disconnect Neutral Disconnect Cannot
Neutral to ground to ground
Up To ground Not Disconnect Hold To ground Start
Neutral to ground
Down Disconnect Neutral To ground Neutral Disconnect Start
to ground to ground
Down Disconnect Neutral To ground Hold To ground Start
to ground
Down Disconnect Not Disconnect Neutral Disconnect Cannot
to ground Neutral to ground to ground
Down Disconnect Not Disconnect Hold To ground Cannot
to ground Neutral to ground
●Start the engine according to the Starting Logic Table above, otherwise, the engine can
not be started.
●Starting logic is controlled by ECU.
●If the engine can not be started in accordance with the logic table, check sidestand switch,
gear position sensor, clutch switch, engine stop switch, ignition switch, starter switch, ECU,
fuse, starter relay, starter motor clutch, double gear,etc.
16-38
16 Electric system
Starting system
Starting system trouble shooting
Start failure (according to Starting

Logic
Main fuse and fuse box No Replace
OK
No
Battery voltage inspection Charge or replace.
OK
Inspect starter motor (using a thick

lead, bypass the 2 terminals of the No
starter relay. Check if the starter Replace the motor
otor run.).
OK
No
Inspect starter relay continuity. Replace the start relay
OK
No 16
Inspect starter auxiliary relay Replace the start auxiliary
continuity. relay
OK
No
Inspect auxiliary starter relay, Maintain or replace
engine stop
OK
No
Inspect sidestand switch, clutch Maintain or replace
switch,
OK
No
Inspect starting system wiring Maintain or replace
OK
No
Inspect ECU ground and power. Maintain
Replace ECU and re-test
16-39
CFMOTO
Starting system(64 pin ECU for CF650-3)
R G
12V10Ah 8
ON
+ -
OFF 1
6
2 3
Y/R
B/Br
Gr/R G/P
5 G/P
Gr/R
M
7
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
4 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63
1.Ignition switch
2.Engine stop switch
3.Start switch
4.ECU
5.Start auxilary relay
6.Start relay
7.Start motor
8.Battery
16-40
16 Electric system
Starting system(48 pin ECU for CF650-3C)
R G
12V10Ah 8
ON
+ -
O FF 1
6
2 3
5 G/ P
Gr /R
M
7
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
16
4 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
1.Ignition switch
2.Engine stop switch
3.Start switch
4.ECU
5.Start auxilary relay
6.Start relay
7.Start motor
8.Battery
16-41
CFMOTO
Lighting system
Then motorcycle use fila light with relay.The

headlight goes on when the ignition switch
and the light switch are turned on.Meanwhile,
the head light beam can be switched be-
tween high beam and low beam.
Headlight horizontal adjustment

●Refer to headlight inspection in mainte-
nance chapter.
Low
Headlight vertical adjustment beam Posi-
● Refer to headlight inspection in mainte-
tion
nance chapter. High
light
beam
16-42
16 Electric system
A F
Lighting System
Headlight Removal/Installation
●Remove body covering parts[B],[C],[D],[E].
●Remove the windshield [A].
●Remove plastic parts [F].
●Remove 3 bolts [A].
●Disconnect the headlight connector.
Reverse the removal procedure for installa- B C D E
tion
Taillight/ breaking light removal
16
●Loose 4 bolts on rear handle [A].
●Disconnect the connector
A
●Remove the taillight.
Taillight/ breaking light installation
● Reverse the removal procedure for

installaion
● Reverse the whole taillight/breaking assy,
because it cannot be seperated.
16-43
CFMOTO
Lighting System(64 pin ECU for CF650-3)
Headlight and position light wiring diagram
1.Headlight(High beam) 2.Headlight (Low beam)

3.High beam indicator 4.Dashboard indicator
5.Position light 6.High beam relay
7.Low beam relay 8.Dimmer switch
9.Light switch 10.Front breaking switch
11.Rear breaking switch 12.Taillight/breaking light
13.Rear licence light 14.Battery
15.Start relay 16.Fuse box
17.Ignition switch
16-44
16 Electric system
Lighting System(48 pin ECU for CF650-3C)
Headlight and position light wiring diagram
16
1. Front position light 14. Fuse box
2. Front position light 15. Ignition switch
3. Low/High beam light 16. CPS
4. Dashboard light 17. Magneto
5.Warning light switch 18. Rectifier
6.Beam switch 19. Start relay
7. Start switch 20. Battery
8. Engine stop switch 21. Start motor
9. Front Breaking switch 22. Taillight
10. High beam relay 23. Rear Licence light
11. Low beam relay 24. ECU
12. Start auxilary relay 25. Rear breaking switch
13. Main relay
16-45
CFMOTO
Lighting System
Turn Signal Light
B
Front Turn Signal Light Assy RH Re-
placement
●Loose 4 bolts [A].
●Remove the front plate [B].
●Remove front steering light RH connector.
●Loose 3 steering light mounting screws.
●Remove front steering light RH.
A
● Reverse the removal procedure for
installation.
Front Turn Signal Light Assy LH Re-
placement
●The method is the same as the front turn
signal light RH replacement.
Rear Turn Signal Light Assy RH Re-

placement
●Remove the seat
●Remove 4 mounting bolts for ECU.
● Unplug the rear turn signal light RH
connector.
●Loose up the bolt[A].
●Remove the steering light [B].
● Reverse the removal procedure for A
installation.
Rear Turn Signal Light Assy LH Re-

placement
●The method is the same as the front turn
signal light RH replacement.
B A
16-46
16 Electric system
Lighting System
Turn Signal Light
Flasher
Flasher removal
●Remove the bodycovering parts
●Remove the flasher [A].
Flasher inspection
●Connect a 12 V battery and turn signal light
as shown and count how many times the fl
asher blinks in one minute.
Flasher [A]
Turn Signal Light [B]
12 V Battery [C]
«If the flasher does not blink as specifi ed,
replace the flasher. 16
Test the flasher
Steering lights Blinks(Timis/Min)

1## 150 times or more
2 60~120
1##: Means one light burned.
16-47
CFMOTO
Light system
Steering light
Steering wiring diagram
1.Front turn signal light LH 2.Turn indicating light LH

3.Front turn signal light RH 4.Turn indicating light RH
5.Flasher 6.Turn signal switch
7.Indicating switch 8.Rear turn signal light RH
9.Rear turn signal light LH 10.Battery
11.Start relay 12.Fuse box
13.Ignition switch
16-48
16 Electric system
Radiator fan cooling system
Fan motor
Fan motor inspection
●Disconnect the connector[A].
●Use auxilary line to connect the power and
fan motor.
«If fan motor doesn’t turn. Replace the motor.
Fan relay
Fan relay inspection
A
●Reove the seat
●Remove body covering parts on the tank.
●Remove the tank.
●Slide out the relay [A] with rubber ring from
the frame.
●Unplug the relay.
16
Fan Relay Test
●Refer to Auxiliary Starter Relay Test.
Fan Relay Resistance Measurement
●Refer to Auxiliary Starter Relay Resistance
Measurement.
«Fan relay and fan motor can be tested with

PDA. Using active diagnosis/fan relay test to
control fan operation, if it runs, that indicates
fan relay and motor , along with the circuit are
normal.
16-49
CFMOTO
Radiator fan cooling system(64 pin ECU for CF650-3)

Radiator fan cooling system wiring diagram
1.Engine stop switch 2.ECU

3.Battery 4.Start relay
5.Fan motor 6.Fan relay
7.Fuse box 8.Ignition switch
9.ECU
16-50
16 Electric system
Radiator fan cooling system(48 pin ECU for CF650-3C)
Radiator fan cooling system wiring diagram
1. Battery 2. Start relay 16

3. Ignition switch 4. Fuse box
5.Fan motor 6. Fan relay
7.Main relay 8. Engine stop switch
9. ECU
16-51
CFMOTO
Dashboard
Dashboard removal
● Remove the wind shield and headlight
Assy (see Headlight Removal/Installation)
● Disconnect the connector [B]。
●Remove the mounting screw [C] to remove A
the dashboard
Dashboard inspection
● Remove the dashboard [A](See dash-
board removal). C
PIN function:
NO Function NO Function NO Function NO Function
1 Parking 9 NC 17 Back light 25 BATT+
2 K-LINE 10 NC 18 High beam 26 IGN+
3 GND 11 NC 19 Right turn 27 Left turn
4 Speed signal 12 NC 20 NC 28 NC
5 RPM Signal 13 Oil pressure 21 EFI signal 2
6 Out put G 14 Gear 22 EFI signal 1
7 NC 15 Fuel level 23 ABS
8 NC 16 NC 24 FI
Warning
A
Make sure the dashboard face always up.
Or the dashboard will not work after a
while.
16-52
16 Electric system
Dashboard
LCD inspection
●Using the auxiliary wires, connect the 12 V
battery to the meter unit connector as follows.
●Connect the battery positive pole to [25].
●Connect the battery nagetive pole to [3].
+ -
10V 15V
~
A
●Rpm gauge [A] goes up, Indicator flashing.

650MT
●Connect the pin [17] to connector [3]. 16

● When connector connected. LCD back
light and dashboard light will be on.
«If LCD and dashboard light not on. Replace
the dashboard.
●Disconnect the connector [17]. + -
●LCD light and dashboard light off.
10V 15V
«If the lights not off. Replace the dashboard. ~
650MT
16-53
CFMOTO
Dashboard
Speedometer test
●Use ”LCD inspection ” to connect the
battery and connector.
●If cubical wave signal into pin [14] The fre-
quency will shows up on oscillator [A]. + -
●If the frequency nearly 105Hz,the speed A 10V 15V
is almost 60km/h. ~
If you don’t have oscillator, Inspect the speedom-
12v
eter in this way.
0
●Install the dashboard.
● Raise the rear wheel off the ground with

stand.
●Turn on the ignition switch.

●Rotate the rear wheel by hand.
● Check that the speedometer shows the + -
speed. 10V 15V
«If the speedometer does not work, check the ~
speed sensor electric source voltage and
speed sensor.
«If power voltage and speed sensor is normal,
replace the dashboard.
Mileage meter test
●Use the same way as speedometer to in-
spect the mileage meter.
+ -
«If mileage meter number cannot raise up,
10V 15V
replace the dashboard. ~
Fuel level gauge Gear position inspection
●Use the same way in ”LCD inspection”. ●Use the same way in ”LCD inspection”.
connect the battery and connector. connect the battery and connector.
●As the drawing shows. Connect the re-
●As the drawing shows connect the
sistance(0kΩ～60kΩ) to battery(-) pole
resistande (0ohm～100 ohm)to battery(-) and connector [14].
pole and connector [15]. ●When the resistance is 0Ω the position
●If the resistance is less than 13 ohm fuel is neutral.
●When the resistance is 60k Ω the posi-
gauge shows full.
tion is 1
●When the resistance is higher than 95 ohm.
Fuel indicator flashing tion is 2.
tion is 6.
16-54
16 Electric system
Dashboard
RPM meter
●Use the same way in ”LCD inspection”.
connect the battery and connector.
●If cubical wave signal into pin [1]。
●The RPM data will shows on oscillator + -
[A] A 10V 15V
«If input frequency nearly 100Hz.The indica-
~
12v
tor shows almost 6000rpm.
0
E D
A F
Indicator Lights Inspection
●Use the same way in ”LCD inspection”.
connect the battery and connector.
Neutral indicator (LED)[A] C
MIL indicator (LED)[B] 650MT
Oil pressure warning indicator(LED)[C]

Right turn signal indicator (LED)[D]
Left turn signal indicator(LED)[E]
High beam indicator(LED)[F] B 16
Parking incicator (LED)[G] G
ABS indicator (LED)[H] H
Neutral indicator(LED)
●Battery(-)pole to dashboard [14].
«If battery nagetive (-) pole to connector [14]
the neutral gear indicator should be on. If the
battery nagetive (-) pole disconnect the con-
nector [14]. The neutral gear should be off.
Replace the dashboard if the function is
wrong. + -
10V 15V
~
16-55
CFMOTO
Dashboard
High beam indicator

●Battery positive(+) pole to pin[18].
«If battery positive (+) pole connect to dash-
board pin[18]High beam indicator shoudl be
on.If battery positive (+) pole disconnect to
pin [18] High beam indicator should be off. If + -
function is wrong.Replace the dashboard. 10V 15V
~
Steering indicator
Steering indicator LH(LED)
Battery pole(+) connect to pin [27]
Steering indicator RH(LED)
Battery pole(+) connect to pin [19]
«If battery (+) pole connect to pin[19] or [27]

The left or right steering indicator should be
on. If battery(+) pole disconnect to pin[19] or
[27] The left or right steering indicator should
+ -
10V 15V
be off.If function is wrong, Replace the
dashboard.
~
Oil Pressure Warning Indicator Light

●Connect the battery and negative pole of
the dashboard
●When the engine is at 1000rpm.,The bat-
tery (–) pole to pole [13], indicator off.
«Replace the dashboard if wrong function

+ -
10V 15V
~
16-56
16 Electric system
Dashboard
Trouble indicator
●Battery Negative (-) pole to pin [24].

«If battery (-)pole connect to pin [24]. Neu-
tral indicator should be on. If the battery(-)
pole disconnect to pin [24]. The neutral indi-
cator should be off. If function is wrong, re-
+ -
10V 15V
place the dashboard
~
Parking indicator
●Battery Negative (-) pole to pin[1].

«If battery (-)pole connect to pin[1]. Neutral
indicator should be on. If the battery(-)pole
disconnect to pin [1] The neutral indicator
should be off. If function is wrong, replace the
dashboard. + - 16
10V 15V
~
16-57
CFMOTO
Dashboard(64 pin ECU for CF650-3)

Dashboard wiring diagram
1.Dashboard 2.Fuse box

3.Ignition switch 4.Oil pressure indicator
5.Main fuse 6.Start relay
7.Battery 8.Water temp sensor
9.ECU 10.Side stand switch
11.Fuel level sensor 12.Speed sensor
16-58
16 Electric system
Dashboard(48 pin ECU for CF650-3C)
Dashboard wiring diagram
1. Dashboard 16
2. EFI mode switch
3. Engine stop switch
4. Main relay
5. Fuse box
6. Ignition switch
7. Oil pressure switch
8. Start relay
9. Battery
10. Neutral switch
11. ECU
12. Sidestand switch
13. Speed sensor
16-59
CFMOTO
Switches and sensors
Brake Light Timing Inspection
●Refer to the Brake Light Switch Operation
Inspection in the Periodic Maintenance
chapter.
Brake Light Timing Adjustment
●Refer to the Brake Light Switch Operation
Inspection in the Periodic Maintenance
chapter.
Switch Inspection
●Using a hand tester, check to see that only
the connections shown in the table have con-
tinuity (about zero ohms).
●For the switch connections and continuity,
refer to the tables given below.
«If the switch has an open or short, repair it
or replace it with a new one.
Front and rear breaking switch
Color W/G G/Y
Press the break pedal（ON）
Release the break pedal
（OFF）
Side stand switch connection

Color Br/B W /G Y/B
UP
DOWN
Neutral switch connection

Color SW. pin Ground
In neutral
Not in neutral
Oil pressure warning light（When the engine well lubricated）

Color SW .pin Ground
Engine stop
Engine running
Clutch switch
Color R/G L/G
Hold（ON）
Loose（OFF）
16-60
16 Electric system
Switches and Sensors

Water temp sensor
Water temp sensor inspection
● Remove the water temp sensor(See EFI
chapter removal and installation).
coolant so hat the temperature-sensing pro-
jection [C] and threaded portion [C] are
submerged.
●Suspend an accurate thermometer [B] with
temperature-sensing projection located in al-
most the same depth.
NOTE
The sensor and thermometer must not touch
the container side or bottom.

coolant while stirring the coolant gently.
●Using the hand tester, measure the inter-
nal resistance of the sensor
16
«If the hand tester does not show the speci- A， C pin resis tance
fied values, replace the sensor.
Tem p.（ ℃） Resistance（ kΩ）
-20 12~ 18
0 5~7
Water Temperature Sensor Resistance 20 2~ 3
«See the right table.
80 0.3 ~0 .35
100 0.12 ~0.18
B pin resistance
Temp.（ ℃ ） Resistance（ Ω）
50 135 ~2 20
12 0 16~20
16-61
CFMOTO
Switches and Sensors
Water temp sensor
Water temp sensor inspection
● Disconnect the speed sensor lead con-
nector [A].
● Remove the engine sprocket cover
(see Engine Sprocket Removal in the Fi-
nal Drive chapter).
A
● Remove :Bolt[A]
● Remove :Bolt[B]
Speed Sensor Installation
●Installation is the reverse of removal. B
A
Torque - Speed Sensor Bolt：7N·m

● Remove the speed sensor (see Speed
Sensor Removal).
●Connect the speed sensor connector [A]
with the battery [B] 10k Ω resistor [C] and
hand tester [D] as shown.
●Set the tester to the DC 25 V range.
● Trace [A] each side of the speed sensor
surface with the screw driver.
●Then the tester indicator should flick [B].
«If the tester indicator does not flick, replace
16-62
16 Electric system
Relay and Fuse
Hi Beam Relay & Lo Beam Relay
Hi Beam Relay Removal
●Remove the fuel tank
●Remove the bolt [A].
High beam relay installation
●Installation is the reverse of the removal.
High beam relay inspection

●Follow the drawing use AVO meter[A] and
12V battery[B] to test the high beam relay [C].
When battery connected:0 Ω
When disconnected:∞Ω
«If the relay is wrong function. It shows the relay
got trouble. Replace the relay.
16
High beam relay resistane inspection
●Follow the drawing use AVO meter [A]and

high beam relay [B].
High beam relay resistance:90 Ω～
1 0 5 Ω（2 0 ℃）
«If the relay is wrong function. It shows the relay
got trouble. Replace the relay.
«It is more reliable to use battery connect-
ing inspection then using resistance
measurement.
Low beam relay

Low beam relay use the same method as the
high beam relay.
16-63
CFMOTO
Relay and Fuse
Main fuse
Main fuse removal
●Remove left side cover
●Remove starter relay [A].
●Disconnect the leads connector[B]
●Pull out the main fuse[C]
Main Fuse Installation

●Installation is the reverse of removal.
Fuse removal
●Remove the seat
●Pull out the fuse box cover[A].
●Fuses on use [B].
Auxilary fuse [C].
Fuse Box Fuse Installation

●Installation is the reverse of removal.
Fuse Inspection
●Remove the fuse .
●Inspect the fuse element.
●If it is blown out, replace the fuse. Before
replacing a blown fuse, always check the am-
perage in the affected circuit. If the amper-
age is equal to or greater than the fuse rating,
check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
CAUTION
When replacing a fuse, be sure the new

fuse matches the specified fuse rating for
that circuit. Installation of a fuse with a
higher rating may cause damage to wiring
and components.
16-64
17 PDA
PDA
PDA Connections……………………………………………………………………………………………………17-2
PDA function…………………………………………………………………………………………………………17-3
Language………………………………………………………………………………………………………………17-4
Auto diagnosis………………………………………………………………………………………………………17-5
Read DTC………………………………………………………………………………………………………………17-5
Clear DTC………………………………………………………………………………………………………………17-6
Data stream……………………………………………………………………………………………………………17-7
Actuator test……………………………………………………………………………………………………… 17-12
Lamp off………………………………………………………………………………………………………………17-12
Read ECU ID…………………………………………………………………………………………………………17-13

ECU Reset……………………………………………………………………………………………………………17-13
17
17-1
CFMOTO
PDA connections:
Open the seat connect the PDA and diag-

nose cable [A].
Note
Turn off the ignition switch when connecting.
And turn the ignition switch on after
connected.
Button functions:
Power[H]:PDA power button
Up[C]:Move the arrow up side.
Down[F]:Move the arrow down side.
Left[B]:Turn the page from the left side.
Right[D] :See the items data.

Turn the page from the right.
OK button [G] :Confirm
EXIT[E]:Cancel
Back to upper level:
Back to main menu:
17-2
17 PDA
PDA functions
Connect the PDA turn the ignition switch on.

Then turn the PDA on. It will shows the
CFMOTO sign（FIG1）；
After 3s will shows “按确定键换下一步操作”

(FIG2)；
Press OK button to choose function slection. 17

Choose“春风摩托” to next step. The
screen shows like(FIG3):
1.春风摩托
2.演示程序(Cannot be seted, do not choose)
Press up or down arrow button to choose

“语言(LANGUAGE)” .Then press OK button
to continue. The screen shows like this(FIG4)
1.车辆诊断测试
2.语言（LANGUAGE）
3.历史测试记录
4.系统参数设置
5.数据流参数维护
6.帮助
17-3
CFMOTO
LANGUAGE
Press up and down arrow to move the arrow.

Choose”语言 LANGUAGE FIG5” Then
press OK button to choose languages. The
screen will shows like below(FIG6):
1.中文(Chinese)
2.英文(English)
Press up and down button to move the arrow

to choose “ 英文 English” Then press OK
button to back to upper level.
Auto diagnosis

to choose AUTO DIAGNOSIS item. Then
press the OK button to enter the item.
（FIG7）
The PDA screen will shows (FIG8)

1.UAES ME3.0 SYSTEM
2.DUCATI SYSTEM
3.DELPHI SYSTEM
4.CF650
5.CF_MOTO_ABS
6.CF_MOTO_EPS
7.UAES ME6.0 SYSTEM
FIG8
17-4
17 PDA
Press up and down arrow to choose UAES

ME6.0 SYSTEM to read the ECU.
Press OK button to enter the function list. The

screen will shows up like below:
READ ECU ID
READ DTC
CLEAR
DATASTREAM
ACTUATOR TEST
ECU RESET
17
READ DTC
Press up and down to move the arrow to

READ DTC. Then press the OK button.
Press left and right button to choose the

trouble code. Then press OK button to enter
the trouble code to see trouble discriptions.
17-5
CFMOTO
Press EXI button to back to the trouble code

list. Then press the EXIT button again to en-
ter the testing date. After entered the date the
screen will shows the tested date.
Without entering work. Press EXIT button to

back the upper level.
CLEAR DTC
Press up or down button to move the arrow to

CLEAR DTC. Then press the OK button.
17-6
17 PDA
After you pressed the OK button the screen

will shows “Clear DTC command has sent!
Read DTC again?”
Press OK button the screen will shows

”Syetem is OK”（FIG18）
17
Press the EXIT button to enter the tested date.
（F IG1 9 ）
Without entering. Press the EXIT button to
upper level.
DATASTREAM
Press up and down to move the arrow to
DATASTREAM. Then press the OK button.
17-7
CFMOTO
Ater pressed the OK button. The datastream
will be show up.Like right side. Press left or
right button to turn pages.
Datastream contents
1.BATT VOLT
2.ENG SPD
3.TARGET IDLE
4.DYNAMIC TARGET IDLE
5.VHL SPD
6.ENG TEMP SEN VOLT
7.ENG TEMP
8.IAT SEN VOLT
9.IAT
10.IAP SEN VOLT
11.IAP
12.IAV
13.STEP MOTOR TARGET POSIT
14.TP VOLT SIG
15.TP ANGLE SIG
16.RELATIVE TP
17.CANI CNTRL VLV DUTY
18.CHARGING TIME
19.INJ PW
20.CY1 SPK ADV
21.O2S SHORT MODIFY
22.O2S VOLT
23.O2S LONG MODIFY
24.MODULE IAT
25.ENG RELATIVE LOAD
26.CANISTER CENTRL RELATIVE IN
27.CANI PURGING RATE
28.CANI LOAD
29.AMBIENT PRESSURE
30.IDLE AEV ACTUATOR OPENING
31.ALTITUDE MODIFY EFFICIENCY
32.INJ PHASE
33.WORKING TIME
35.Throttle Motor PWM control
CYL2 Injection PWM
Group2 O2S integral value
17-8
17 PDA
CF_MOTO_ABS
Press up and down button to move the arrow.

Choose CF_MOTO_ABS. Then press the
OK button to see the function slection
（FIG32）
FIG32
After press the OK button the screen will
shows like FIG 33.
READ ECU ID
READ DTC
CLEAR DTC
DATASTREAM
ACTUATOR TEST
ECU RESET
FIG33 17
READ DTC
Press up and down button to choose READ

DTC. Then press the OK button to see the
DTC list（FIG34）
FIG34
Press left and right button to choose the

trouble code and press OK button to see the
trouble discription（FIG12）
FIG35
17-9
CFMOTO
Press the EXIT button to return the code list.

Then press the EXIT button again to enter the
tested date. The screen shows the date
upper level list（FIG37）
CLEAR DTC
FIG37

. Choose the CLEAR DTC and press the OK
button（FIG38）
FIG38
After press the OK button. The screen

shows ”Clear DTC command has sent!
Read DTC again?”（FIG39）
FIG39
17-10
17 PDA
Press OK button shows ”System is OK ”

（F IG4 0 ）
FIG40
Press the EXIT button to return the code list.

Then press the EXIT button again to enter the
tested date. The screen shows the date
（FIG41）
upper level.
FIG41
DATASTREAM
17
Choose the DATASTREAM and press the OK
button（FIG42）
After press the OK button. The screen will

shows the data stream. The screen will shows
like below（FIG43）
FIG42
Datastream item
1.ABS Switch-raw signal
2.ABS Switch, system status
3.Reference Voltage
4.Pump
5.Connector PIN 30
6.External Vcc
7.Front Sensor
8.Rear Sensor
FIG43
17-11
CFMOTO
ACTUATOR TEST
Press the up and down button to move the

arrow. Choose ACTUATOR TEST and press
the OK button.（FIG44）
FIG44
After pressed the OK button the screen will

shows the testing items for choose like FIG
45.
FIG45
Lamp OFF

Choose the “Lamp OFF” item.
Press OK button the screen shows on testing.
（F IG4 6 ）
FIG46
After 3s. The screen shows NO ACTUATOR
CONTROL LIMIT. Then press the EXIT but-
ton to upper level.（FIG47）
Then Lamp on and Lamp blinking test are

handle in the same way.
FIG47
17-12
17 PDA
READ ECU ID
Press the up and down button to move the

arrow. Choose READ ECU ID.（FIG48）
FIG48
Press the OK button to see the ECU version
information that the screen will shows.
（FIG49）
Press EXIT button to upper level.
ECU RESET FIG49

17
Press up and down arrow to move the arrow.
Choose ECU RESET and press the OK
button.（FIG50）
FIG50
After press the OK button. The screen will

shows “Communicate with auto ECU error!”
（FIG51）
Press EXIT button to upper level.
FIG51
17-13

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vehicle. 1st brand

Notice…………………………………1-1 Model Identification …………………1-8

Do not touch the turning or movable pieces

Cleaning Vehicle Before Removal

Storage of Removed Parts

Gasket and O-ring

Liquid Gasket,Non-permanent Locking

Bearing & oil seals

Ball Bearing and Needle Bearing

Oil seal & Grease Seal

Apply specified grease to the lip of the seal

Circlips, Cotter Pins

Direction of Engine Rotation

Temperature Conversion Table

Torque Specifcations for tighten parts…………………………………………………………………………2-6

Air Pressure Inspection……………………………………………………………………………………2-25

Brake Hose and Pipe Damage and Installation Condition Inspection………………………………2-31

Periodic Maintenance Chart

Break-in Maintenance Schedule

Periodic Maintenance Schedule

Torque Specifcations for tighten parts

Basic Torque for General Fasteners

Air Pre ssure (wh en C old):

Caplier, inner circlip Extension tube

Wrench, lock nut of steering column Adjustor, screw

Attention 2. Element Comp.

ŸClean the element element [A] in a bath of

ŸCheck the throttle grip free play [A].

the throttle cable.

ŸWith the engine idling, turn the handlebar to

5. Handlebar turning direction

ŸCheck the idle speed.

«Replace the fuel line if any fraying, cracks

ŸCheck that the hose joints are securely con-

Radiator Hose Damage and Installation Con-

● Remove the cylinder head cover (see

● Unscrew the upper [A] and lower [B]

● Check the valve clearance when the

● Using a wrench [A] to turn the crankshaft

● Using the feeler gauge [A], measure the

Valve Clearance Standard:

★ If the valve clearance is not within the

● To change the valve clearance, remove the

ment Charts. ● Remeasure any valve clearance that was

0.08～0.13 Spe cifie d Clearance/No Ch ang e Require d

0.46～0.47 4.02 4.04 4.06 4.08 4. 1 4.12 4.14 4.16 4.18

0.48～0.49 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.50～0.51 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.52～0.53 4.08 4. 1 4.12 4.14 4.16 4.18

0.54～0.55 4.1 4.12 4.14 4.16 4.18

0.56～0.57 4.12 4.14 4.16 4.18

0.58～0.59 4.14 4.16 4.18

0.60～0.61 4.16 4.18

1.Measure the clearance (when engine is cold).

Pre sent Shim Example

0.20～0.26 Specified Clea rance /No Change Requ ired

1.01～1.02 4 4.02 4. 04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

1.05～1.06 4.04 4.06 4. 08 4.1 4.12 4.14 4.16 4.18