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CF500/CF500-A

1. Item Standard Service Limit Remark Valve Head Diameter IN 30 6 EX 27 0 IN 0 05 0 10 Valve Clearance He Ol EX 0 010 0 037 Clearance Between Valve IN 0 010 0 037 Guide and Valve Stem EX 0 030 0 057 Di t f Val POSE TARRE S AS NER EIS aas I aa Guide IN 4 975 4 990 Outer Diameter of Valve Stem EX 4 955 4 970 Valve Stem Play IN amp EX 0 05 Length of Valve Stem End IN amp EX 2 9 3 1 2 3 Valve Head Thickness IN amp EX 0 5 Play of Valve Head Seal IN amp EX 0 03 Width of Valve Seat Seal IN amp EX 0 9 1 1 Valve Spring Free Length IN amp EX 40 38 8 182 210N when Valve Spring Tension IN amp EX compressed to 31 5mm IN 33 430 33 490 33 130 Cam Height EX 33 500 33 560 33 200 Clearance Between 022 0 032 0 066 0 150 Camshaft Outer Diameter amp 017 5 0 028 0 059 0 150 Hole O22 21 959 21 980 Camshaft Outer Diameter 017 5 17 466 17 484 Inner Diameter of Camshaft 22 22 012 22 025 Hole 017 5 17 512 17 525 Camshaft Play 0 10 Inner Diameter of Rocker Arm IN amp EX 12 000 12 018 Out Di t f Rock oF heen eee IN amp EX 11 973 11 984 Arm Cylinder Head Distortion 0 03 0 05 lind H C Cy in or ead over 0 03 0 05 Dis
2. Front Wheel Item Standard Service Limit Play of wheel rim Vertical 1 0mm 2 0mm Front Horizontal 1 0mm 2 0mm Wheel Tire Groove 3 0mm Pressure 35kpa 0 35kgf cm Rear Wheel Item Standard Service Limit Play of wheel rim Vertical 1 0mm 2 0mm Rear Horizontal 1 0mm 2 0mm wheel Tire Groove 3 0mm Pressure 35kpa 0 35kgf cm Brake System Item Standard Service Limit Brake lever play Omm Mione brake Brake disc thickness 3 5mm 4mm Brake lever play 5 10mm Rear brake Brake Pedal Play Omm Brake disc thickness 7 5mm 6 5mm Battery Charging System Item Standard Model Permanent magnet AC type AC magneto Motor Output 3 phase AC Charging coil Resistance 20 C 0 2 0 30 Rectifier Three phase annular rectification Silicon controlled parallel connected regulated voltage Capacity 12V18Ah Terminal Fully charged 12 8V point Insufficient charge lt 11 8V Banery voltage Charging Standard 0 9A 5 10H current time Quick 4A 1H Ignition system Item Standard Ignition CDI ignition Type DPR7EA 9 NGK Spark Plug Optional DR8EA D7RTC Spark plug gap 0 8 0 9mm Ignition timing Max advanced angle 32 CA Peak voltage Ignition coil Above 200V Pulse generator 150V 1 8 1 Overhaul Information Light Instrument Switch Pickup coil Item Standard Fuse Main 20A Auxiliary 10A 15Ax3 Head light Hi Lo 12V 35W 35W Brake light tail light 12V 21W 5W Light Bu
3. Item Result Battery wire There should be voltage between red red terminal and frame body earth wire Earth wire Green terminal must be connected green with frame body earth wire z Charging coil Resistance between yellow 4P Connector yellow yellow terminals is 0 2 0 3Q at 20 C Rectifier Regulator yellow Ignition switch Black lead wire must be lead wire connected with black terminal black Installation Reverse the removal procedure for installation Note Wires hoses and cables should be routed properly Charpter1 Rectifier Regulator Inspection of AC magneto Remove left side panel 2 6 Disconnect connectors of AC magneto yellow yellow yellow and pickup coil black white green Measure the resistance between the yellow terminals of the AC magneto 3P connector Resistance 0 2 0 30 at 20 C Make sure the yellow terminal of AC magneto 3P connector is not connected with frame body earth wire Replace with a new AC magneto in case of any faults found in above check Engine maintenance manual 8 Battery Charging System 3P Connector Frame 3P Connector 8 8 A C Magneto 8 Battery Charging System 8 9 9 Ignition System Overhaul InfO ccccceeeeeeeeeeeeeea este eens 9 1 Pickup Coil ccceeeeeeeeeeeee ee eeees 9 6 Troubleshooting 9 3 Ignition Coil cceeeeeeeee pirritan 9 6 Inspection of Ig
4. Oil Type SAE10W 40 API SF or SG When changing 1900mI Wh Replaci 2000mlI _ Oil Capacity sia at ee a Filter Engine Repair 2200mI 13 7 Clutch Transfer 13 Engine Overhaul Information Item Standard Service Limit Remark Clutch Plate Inner diameter 140 00 140 15 140 50 Clutch Engagement Speed 1800 2400r min ween Clutch Lock Speed 3300 3900r min ween nnn Drive Belt Width 35 2 33 5 Free length of Secondary 168 160 Sheave Spring Shift Fork to Groove 0 10 0 40 0 50 Clearance Thickness of Left Shift Fork 58 59 Thickness of Right Shift Fork 5 8 5 9 Shift Fork Groove Width 6 0 6 2 Drive Output Gear Groove eee p goess OO o in Cooling System Item Standard Service Limit Remark Thermostat Valve Opening Temperature Thermostat Valve Lift 68 74 C 3 5 4 5mm at 95 C Radiator Cap Opening 93 3 122 7Kpa ween Pressure Water j 3 Resistance Q Corresponding Relation Temperature C Between Water temperature 50 154 16 Transducer resistance and 80 52 4 water temperature 100 27 3 120 16 2 Functioning Temperature of OFF ON 88C o o Thermoswitch ON OFF Ss OR f Coolant Type 35C antifreeze corrosion resistant high boiling point coolant 13 8 13 Engine Overha
5. Auxiliary Starting Relay III Odometer Sensor Ignition Coil ark J Plug Starting Motor Gr BLg Br AWD Diff lock Rear Brake Switch Signal Cx Switch 10A we Gear Sensor Reverse ear Sensor 9 7 10 Lighting Instruments Switches Overhaul Info ccceeeeeeeeeeees 10 1 Dashboard fis ciicsectcadiecs weaexindahs eee 10 9 Troubleshooting 20 ss 0beeeesee 10 2 Fuel SONSOM nesnesini 10 10 Replacing bulbs essseesseeeeeenn 10 3 WaterTemperature Transducer 10 12 Head Light 2 v seeees ncaa caressa 10 5 Ignition Switch eeen 10 6 Handlebar Switch ceeeeeeee 10 7 Brake Light Switch 10 8 FLOM ties tatoo a leh te te ich 10 8 Overhaul Information Warning 0 Headlight bulb will be very hot when it is turned on Do not touch it after it is just turned off Operation should be done when the bulb is cooled down Inspection of water temperature alarm may use fire source and liquid of high temperature Do not put flammable matters nearby and take care not to get burnt The temperature of headlight is quite high when turned on Replacing with bare hand or stained glove will cause oil stains on the glass face which may form hot spot and cause deformation of glass face and damage to bulb Pay attention to the following when replacing the bulb Do not replace the bulb when it is turned on Keep ignition
6. f either of valve seat or needle valve is worn replace both If both are fine adjust float height by bending the float tang Mon the float Install carburetor Check again the fuel level Carburetor Assembly Reverse the disassembly procedure for assembly 16 5 16 Carburetor Carburetor Installation vacuum breather hose starter cable carburetor joint engine intake manifold throttle valve cover throttle cable Carburetor joint air filter carburetor drain hose fuel inlet hose Note Align the installation mark of carburetor and carburetor joint 6 Carburetor Parameters Type MIKUNI BSR36 89 Aperture No 07G0 Throat size mm 36mm Pilot r min 1300 r min 100 r min Float height mm 10 1 Fuel level mm 3 5 0 5 Main jet MJ N102221 130 Main air jet MAJ MD13 24 35 Jet needle JN J8 5E26 Needle jet NJ 785 401011 P OM Pilot jet PJ N224103 22 5 Pilot screw PS 604 16013 1A Pilot air jeti PAJ1 MD13 24 65 Pilot air jet2 PAJ2 N211100 165 16 6 17 Cooling and Lubrication System Cooling System Illustration Engine Coolant Inspection of Cooling Circuit Inspection and Cleaning of Radiator and Water Hoses Inspection of Fan Motor Inspection of Water Temperature Sensor Inspection of Thermostat Water Pump Water Pump Removal and Disassembly Inspection Water Pump Assembly and Installation Lubrication System Illustration Inspection
7. Thread Parts See 10 10 10 11 13 14 14 Checks amp Adjustment Periodic Maintenance Procedures of Maintenance and Adjustment Valve Clearance Engine Idle Speed Spark Plug Air Filter Fuel Hose Carburetor Drive Belt Inspection of Lubrication System Inspection of Cooling System Inspection of Cylinder Pressure Inspection of Oil Pressure Inspection of Clutch Engagement and Lock up 14 1 14 Checks amp Adjustment Periodic Maintenance Table The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy Maintenance intervals are expressed in terms of kilometer miles and hours whichever occurs first Note More frequent maintenance may be required on vehicles that are used in severe conditions Interval Km Initial 200 Every 1000 Every 2000 Remark Miles Initial 100 Every 600 Every 1200 Item Hours Initial 20 Every 40 Every 80 Valve Clearance B i IN 0 05 0 10 EX 0 17 0 22 Idle Speed 1300 100r Min Spark Plug No carbon deposit Replace every 6000Km Gap 0 8 0 9mm Air Filter C C Replace every 2000Km Fuel Hose Carburetor Replace every 4 years Clutch Drive Belt R Engine Oil R R Oil Filter R R Coolant Level Water Hose amp Pipes Coolant Replace every 2 years l Inpec
8. Left Side panel 2 6 3 screws amp nuts for front fender 3 screws amp nuts for rear fender Bolt 1 Bolt 2 Bolt 3 Bolt 4 Left footrest board Installation Reverse the removal procedure for installation Right Footrest Board Refer to Left Footrest Board for removal and installation 2 Vehicle Body Muffler Front Fender Screw Nut Footrest Board LH Footrest Board LH Screw Nut Bolt 1 Footrest Board LH Bolt 2 Bolt 3 2 Vehicle Body Muffler Rear Fender Remove Seat 2 3 Rear rack 2 3 Rear top cover 2 5 Left amp right side panel 2 6 2 7 Battery fixing plate battery cover 8 4 Electric Components Remove battery Remove electrical components from rear fender Chapter 8 Disconnect wiring connectors from rear fender Chapter 8 Lift upward and remove rear fender Engine Skid Plate Front Engine Skid Plate Center Double Seat Protection Plate amp Engine Skid Plate Rear 1 Bolt 1 2 Bolt 2 3 Engine Skid Plate Front 4 Bolt 3 5 Bolt 4 A 6 Engine Skid Plate Center 7 Bolt 5 12 8 Bolt 6 9 Bolt 7 10 Bolt8 Q1 11 Double Seat Protection Plate 12 Engine Skid Plate Rear 13 14 Bolt 9 15 Bolt 10 14 13 2 10 Disassembly Note Side skid plate front side skid plate center side skid plate rear and double seat protection plate are located at the bottom of vehi
9. Press 35kPa 035k 35kPa 0 50k ure gf cm gf cm Tire 25x8 12 25x10 12 Size Tire Tread Check the tire tread Tread Height lt 3mm Replace with new tires Note When the tread height is less than 3mm the tire should be replaced immediately 3 Checks amp Adjustment Tire Pressure Gauge MA Over 3mm 3 8 Wheel Nut and Wheel Axle Check front and rear wheel axle nuts for looseness Loosened axle nuts gt Tighten Tightening Torque Front wheel axle nut 110 130N m 11 2kgf m 13 3kgf m Rear wheel axle nut 110 130N m 11 2kgf m 13 3kgf m Sway of Wheel Bearing Lift the front wheel Make sure there is loading on the vehicle Shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bearing Suspension System Park the vehicle on lever place press the vehicle Several times up and down as illustrated on the right In case of any rocking or abnormal noise check whether there is any oil leakage from absorbers or any damage or looseness of tightening parts 3 Checks amp Adjustment Nut Wheel Axle 3 9 Adjusting the Absorber Use special tools to adjust the length of absorber according to loading requirement Turn clockwise to adjust from high to low Gear Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the locknut
10. 15 Engine Removal Inspection amp Installation Rocker Arm When checking the rocker arm check the inner diameter of the valve rocker arm and wear of the camshaft contact surface Rocker Arm I D 000 12 018mm Tool Dial Calipers Assembly Note Intake rocker arm shaft A has oil holes Apply engine oil to rocker arms and shafts Install rocker arms and tighten rocker arm shaft to the specified torque Rocker Arm Shaft Bolt 28N m Cylinder Had Disassembly Remove intake pipe Remove water temperature sensor and thermostat cover 15 15 15 Engine Removal Inspection amp Installation Remove thermostat Compress the valve spring and remove valve cotter with tweezers Tools Valve Spring Compressor Tweezers Remove valve spring upper seat and valve spring Remove valve from the other side Remove valve stem seal ring and valve lower seat 15 16 15 Engine Removal Inspection amp Installation Cylinder Head Distortion Clean off carbon deposit from combustion chamber Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge Take clearance readings from several places If any clearance reading is out of the service limit replace with a new cylinder head Cylinder Head Distortion Service Limit 0 05mm Tool Thickness Gauge Valve Seat Width Coat the valve seat with color uniformly Fit the valve an
11. Brake fluid and coolant may damage coating plastic and rubber parts Flush these parts with water if splashed Install oil seal with the side of manufacturer s mark outward Do not fold or scratch the oil seal lip Apply grease to the oil seal lip before assembling When installing pipes insert the pipe till the end of joint Fit the pipe clip if any into the groove Replace the pipes or hoses that cannot be tightened Do not mix mud or dust into engine and or the hydraulic brake system 1 2 1 Overhaul Information 22 Clean the gaskets and washers of the engine casing before assembling Remove the scratches on the joint faces by polishing evenly with an oilstone 23 Do not twist or bend the cables too much Distorted or damaged cables may cause poor operation 24 When assembling the parts of protection caps insert the caps to the grooves if any 1 Overhaul Information VIN Number and Engine Number Vehicle Identification Number LCELDTS Engine Number CF188 VIN Number 1 Overhaul Information Main Data Table Item Parameter Model CF500 CF500 A Length 2120mm 2320mm Width 1170mm Height 1230mm Wheel base 1290mm 1490mm Engine type CF 188 Displacement 493ml Fuel type Unleaded gasoline 90 Octane or above Dry weight 337Kg 340Kg Number of Passengers 1 for CF500 2 for CF500 A including driver Max Load 150kg 225Kg Tire Front 25x8 12 R
12. Check the push rod movement If the push rod is stuck or there is a failure with spring mechanism replace the chain tensioner with a new one Cylinder Cylinder Distortion Check the gasket face of cylinder for distortion with a straightedge and thickness gauge and take clearance readings at 7 points as illustrated If the largest reading at any of the 7 points of the straightedge is out of the range replace the cylinder Cylinder Distortion Service Limit 0 05mm Tool Straightedge Thickness Gauge Cylinder Bore Check cylinder wall for scratches nicks or other damage Replace with a new one if any Measure cylinder bore diameter at three points of upper middle and lower Standard Cylinder Bore 87 500 87 522mm Tool Cylinder Gauge Set 15 24 15 Engine Removal Inspection amp Installation Piston Piston Diameter Use a micrometer to measure the diameter at the point 10mm above the piston end as illustrated on the right If the measurement is less that the limit replace the piston Standard 87 460 87 480mm Limit 87 380mm Tool Micrometer 75 100mm Calculate the piston to cylinder clearance according to the above measurement f the clearance is more than 0 15mm replace the cylinder or piston or both Piston Ring to Groove Clearance Use a thickness gauge to measure the side clearance of top ring and 2 ring f the clearance exceeds the limit replace both piston and piston rings
13. Coolant Replace every 2 years l Inpection and adjust or replace if necessary R Replace C Clean 3 1 3 Checks amp Adjustment Inspection amp Maintenance O Interval Item Intervals Part Item Daly 12 Annual Standard Year Handlebar Operalion P agility Damage O Steering condition of System Steering system steering 2 system Sway of ball stud gt Free play O O O pont lever end Omm Rear lever end Omm Brake lever Brake Efficiency k 2 o Looseness Connecting ron Slack and O O oil pipe amp Hose Brake damage System Front and rear Brake fluid should be brake fluid O O O above LOWER limit level Hydraulic brake Replace when the and brake disc Brake disc thickness of front damage and O O O brake disc is less than wear 2 5mm rear brake less than 6 5mm Front tire 35kPa 0 350kgf cm Tire pressure O O O Rear tire 35kPa 0 35kgf cm Chap and O O damage Groove depth O O No wear indication on Driving and abnormal the surface of tire the Wheel wear remained depth of groove should not be ee less than 1 6mm Loosened O O O wheel nut and axle Sway of front O O wheel bearing Sway of rear O O wheel bearing 3 2 3 Checks amp Adjustment Sway of Suspension Joint parts O arm rocker arm Buffer System damage y Shock Oil leakage z absorber and damage Function
14. N Clogged water passage or radiator Air in the cooling system insufficient coolant Clean Discharge air and add coolant Engine overheats 3 Faulty water pump Check and replace 4 Incorrect coolant Replace 5 Faulty thermostat Replace 6 Faulty fan motor or thermoswitch Check and or replace 1 Faulty thermoswitch Replace Engine coolant 2 Extremely cold weather Put on radiator cover overcools 3 Faulty thermostat Replace 4 Ignition System Complaint Symptom and Possible Causes Remedy 1 Faulty CDI Check and replace 2 Faulty spark plug Check and replace 3 Faulty Generator Check and replace No Sparking or 4 Insufficient battery voltage Check and replace Weak Sparking 5 Faulty ignition coil Check and replace 6 Faulty pickup coil Check and replace 19 5
15. Park the vehicle on level place slowly turn the handlebar left and right to see if it can turn freely In case there is any hindrance check if it is from the main cable assembly or other cables If no check the steering tie rod end and check if the steering stem bearing is damaged Note Make sure the steering can be operated freely An accident may occur if the handlebar is out of control Brake system Front brake lever free play Operate front brake lever and check brake efficiency and brake lever function Check free play of front lever end Free play Omm 3 Checks amp Adjustment 3 Checks amp Adjustment Master Cylinder Brake Fludi Reservoir OWER lt Fluid level gt Check the brake fluid level When the brake fluid level is near to the lower limit line check master cylinder brake hoses and joints for leakage Remove the two mounting screws on fluid reservoir cap Remove the cap add DOT3 or DOT4 brake liquid till the upper limit line e Do not mix with dust or water when adding brake fluid e Use only the recommended of brake fluid to avoid chemical reaction e Brake fluid may cause damages to the surface of the plastic and rubber parts Keep the fluid away from these parts e Slightly turn the handlebar left and right till the master cylinder is in horizontal then remove the fluid reservoir cap Brake Disc Brake Pad lt Wear of brake pad gt Check the brake pad wears from
16. Radiator Hose Inspection Check radiator hoses for leakage or damage Leakage or Damage Replace Check tightening of clamps Replace the clamps if necessary After inspection and cleaning of radiator and hoses check coolant level Fill coolant if necessary 17 Cooling and Lubrication System 17 Cooling and Lubrication System 1 Radiator 2 Radiator Cap Inspection of Fan Motor 3 Fan Motor 4 Mounting Bolt Fan Motor 5 Thermoswitch Remove fan motor from radiator Turn the vanes and check if they can turn smoothly Check fan motor Make sure that the battery applies 12 volts to the motor and the motor will run at full speed while the ammeter shall indicate the ampere not more than 5A lf the motor does not run or the ampere exceeds the limit replace the motor Installation Apply a little thread locker to the bolts and tighten to the specified torque Fan Motor Bolt Tightening Torque 10N m Inspection of Thermoswitch Remove thermoswitch Check the thermoswitch for closing or opening by testing it at the bench as illustrated Connect the thermoswitch to the circuit tester place it in a vessel with engine oil Place the vessel above a stove Heat the oil to raise the temperature slowly and take the reading from thermometer when the thermoswitch closes and opens Fan Motor Amperometer Tool ammeter Thermoswitch Operating Temperature Standard OFF ON Approx 88 C
17. Service Limit Top ring 0 18mm 2 ring 0 15mm Standard width of piston ring groove Top ring 1 03 1 05mm 2 ring 1 22 1 24mm Oil ring 2 51 2 53mm Standard thickness of piston ring Top ring 0 970 0 990mm 2 ring 1 170 1 190mm Tools Thickness gauge Micrometer 0 25mm 15 25 15 Engine Removal Inspection amp Installation Piston Ring Free End Gap and End Gap Before installing piston rings use vernier caliper to measure the free end gap of each ring and then fit ring into the cylinder Use thickness gauge to measure each ring end gap if any ring has an excess end gap replace the piston ring Piston ring free end gap limit Top ring 8 9mm 2 ring 9 5mm Piston ring end gap limit Top Ring 0 60mm 2 ring 0 60mm Tool Vernier caliper Thickness gauge Piston Pin and Pin Bore Use a bore gauge to measure the inner diameter of piston pin bore Use micrometer to measure outer diameter of piston pin f out of limit replace both piston and piston pin Piston pin bore limit 23 030mm Use micrometer to measure piston pin outer diameter at three points Piston pin outer diameter limit 22 980mm Tools Bore gauge 18 35mm Micrometer 0 25mm 15 26 15 Engine Removal Inspection amp Installation Connecting Rod Crankshaft Connecting rod small end I D Use a dial gauge to measure the I D of connecting rod small end If the measurement exceeds the limit repl
18. Store the coolant properly and keep it away from reach of children e Check radiator fins for mud block and or damage Correct the bent fins Clean off the mud with water and compressed air Replace with a new one if the damaged fin area reached 20 e The overhauling of the water pump can be done without removing the engine e Add coolant through reservoir tank Do not open the radiator cap except when disassembling the cooling system for adding or drainage of coolant e Do not stain the plastic parts with coolant In case of any coolant stains flush with water immediately e After disassembly of the cooling system check the joints for leakage with a radiator cap tester available in the market e Refer to Chapter 10 for overhauling of temperature transducer Inspection standard Item Standard Full capacity 1140ml oe Reservoir tank capacity 340ml Standard density 30 Opening pressure of radiator cap 108kpa 1 1kgf cm Valve open temperature 7242 C Thermostat Full open Temperature 88 C Full open lift 3 5 4 5mm Tightening torque Drainage bolt water pump 8N m 0 8kgf m Thermoswitch 10N m 1 0kgf m 4 1 4 Cooling System Trouble Shooting Sharp rise of water temperature Faulty radiator cap Air in cooling system Faulty water pump Faulty thermostat thermostat is not open Clogged radiator pipe or cooling pipes Damage or clogged radiator fin Coolant is not enough Faulty or
19. Use together with digital muitimeter available in the market with input resistance over 10MQ DCV 9 Ignition System Troubleshooting Engine cannot be started Check fuel and air channels for any faults If the fuel and air channels are normal check the ignition system Inspect ignition system for the following items 1 Spark inspection Check in the following steps Remove spark plug Remove spark plug cap Set high tension flexible cable end to earth Check spark arc It is normal if spark arc is more than 8mm while it is weak if it is less than 5 mm If the spark is normal check the spark plug A faulty spark plug may be caused by the following reasons 1 Spark plug is too wet and drowned This is because the gas mixture is too thick Cut the fuel and start the engine several times 2 Carbon deposit on spark plug Mixture too thick or oil combustion in the combustion chamber Clean and burnish the spark plug 3 Cracks with spark plug insulator 4 Spark plug electrodes have short circuit or it is obstructed between negative pole and thread or positive pole and input end 2 Faulty spark includes no spark and weak spark Inspect the following aspects if there is no spark 1 Inspect ignition coil with multimeter or measurement in the following steps 1 Measure primary bobbin resistance usually it is about 10 2 Measure secondary bobbin resistance usually it is about 4 2K 3 Measure damp resistance usually it is abou
20. gt Tire pressure is too high Noise With Front Absorbers gt Faulty front shock absorbers gt Loosened tightening parts of front shock absorbers Poor Brake Efficiency gt Faulty brake adjustment gt Stained brake disc gt Worn brake shoes 6 Front Wheel Front Brake Suspension Steering Front wheel Removal Securely support the front wheels Remove Wheel cap 4 bolt from wheel hub Front wheel Inspection Rim Damage warpage or serious scrapes Replace Replace with a new one if any Slowly turn the wheel measure the rim vibration with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Assembling Press rim into wheel Install rim on the wheel hub Tightening Torque Mounting Bolt Rim Bolt Wheel hub 50 60 N m Front Wheel Hub Disassembly Remove Front wheel 6 3 Brake Caliper Front brake caliper 6 4 Rim axle nut Wheel Hub Brake disc and wheel hub 4 bolts of front brake disc Wheel hub Bolt Brake Disc Brake Disc Installation Reverse the removal procedure for installation Torque Rim axle nut 110 130N m 6 Front Wheel Front Brake Suspension Steering Brake System 4 4 Front caliper w Remove Mi A Front wheel 6 3 2 bolts from arm Front Brake Calipe Front caliper Inspection Check cracks of brake calipers and oil leakage from the tightening parts If any replace Installation
21. Balancer shaft driven gear should be aligned to the mark as illustrated Drive Gear Driven Gear Crankshaft Balancer Crankshaft Balancer Main Shaft Counter Shaft Install main shaft and counter shaft 15 Engine Removal Inspection amp Installation Shift Cam Shift For Install shift can and shift fork Check each part for smooth turning Install low range driven gear to counter shaft Spray adequate engine oil to each part Drive Bevel Gear Install drive bevel gear and tighten to the specified torque Drive bevel gear tightening torque 32N m Right Crankcase Driven Bevel Gear Install driven bevel gear and tighten to the specified torque Driven bevel gear tightening torque 25N m Check bevel gear backlash Refer to 12 44 Front Output Shaft Install front output shaft to right crankcase 15 Engine Removal Inspection amp Installation Apply sealant to the mating face of right crankcase Note Apply sealant evenly in an uninterrupted thin line Install 2 dowel pins Assemble crankcase and tap slightly with a rubber hammer so that the crankcase is properly fitted Install bolt and tighten to the specified torque Crankcase bolt tightening torque M6 10N m M8 25N M Note Crankcase bolts should be tightened diagonally in several steps Place the steel ball and install gear positioning bolt and tighten the bolt to the specified torque Gea
22. Replace 14 Checks amp Adjustment External Oil Pipe 14 9 Inspection of Cooling System Check initially at 40 hours or 1000km replace coolant every 2 years Check radiator reservoir tank and water hoses Leakage or Damage Replace Check coolant level by observing the upper and the lower limit on the reservoir tank If the level is below lower limit fill coolant until the level reaches the upper limit Replacing Coolant Remove radiator cap and reservoir tank cap Place a pan below water pump and drain coolant by removing drain plug and water hose Drain coolant from reservoir tank Warning Do not open radiator cap when engine is hot you may be injured by escaping hot liquid or vapor Engine coolant is harmful If coolant splashes in your eyes or clothes thoroughly wash it away with water and consult a doctor If coolant is swallowed induce vomiting and get immediate medical attention Keep coolant away from reach of children Clean radiator with fresh water if necessary Connect water hose and tighten drain bolt securely Fill the specified coolant into the radiator Loosen bleed bolt on water pump when coolant flow from bleed bolt tighten the bolt Install radiator cap securely after filling coolant Start the engine and keep it running for several minutes After warm up and cooling down the engine open radiator cap and check coolant Fill th
23. Reverse the removal procedure for installation Tightening Torque Fixing Bolt Brake Caliper 40 50N m 6 4 6 Front Wheel Front Brake Suspension Steering Brake disc Remove Front wheel 6 3 Brake caliper 6 4 Front brake disc and wheel hub 4 bolts from brake disc Brake disc Inspection Brake disc thickness lt 2 5mm Replace Installation Install brake disc Fixing bolt brake disc 25 30N m Front Brake Master Cylinder Disassembly Remove Bolt 1 Bolt 2 Separate front brake master cylinder from handlebar Do not remove front brake master cylinder from cylinder vehicle unless when assembly replacing master NOTE Do not hang master cylinder on braking hose Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position and fix it to the handlebar Refer to Chapter 1 for proper routing of brake hose Check brake efficiency after installation Brake Disc Bolt 6 5 6 Front Wheel Front Brake Suspension Steering Disassembly Remove Footrest board 2 9 Front right inner fender 2 12 Bolt 1 Bolt 2 Separate foot brake master cylinder from vehicle Foot Brake Master Assembly Cylinder Reverse the removal procedure for installation NOTE Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep t
24. 120 C 16 42 Transducer out of range Replace Install transducer Connect water temperature transducer connector Fill coolant and discharge air Reverse the removal procedure for installation of plastic parts and seat 10 Lighting Instruments Switches Water Temperature Transducer Multimeter Transducer 10 12 11 Circuit Diagram Wiring Diagram Please reference to PDF document LINK CF500 amp CFS500A_Circuit Diagram Wiring Diagram PDF 12 Troubleshooting Operation Noticess 2 4 acta Raia sal de ee ed 12 1 Starting Failure Hard Starting ccceeceeeeeee eee e eee terete eset ea neta ea eeeeeaes 12 1 Unstable Engine Running or Engine Stops ceeeceeeeeee eee ee eee ee eee nents 12 2 Poor Engine Performance in High speed Range or Slow Speed Rising 12 3 Unstable Idle Speed nanea a eee ceee ects nee a EE i E eaa Eia 12 4 Poor Engine Performance in Middle or High Range 12 5 Operating Notice This chapter is a general explanation of major troubleshooting of the whole engine Refer to the relevant chapters for troubleshooting not listed in this chapter Starting Failure Hard Starting In case of starting failure or hard starting refer to chapter of starting system Engine maintenance notebook for troubleshooting and check the starting system whether have problems or not Loosen drain screw check if fuel has reached PaIDurstor Reached No Fuel R
25. 50 60N m Install Water outlet and inlet hoses to engine with proper clamps Positive and negative starting wires to engine Connect all the connectors Spark plug cap Gearshift rod to engine Air filter carburetor and removed parts Removal and Installation of Front and Rear Axle Support the vehicle with jack make sure the vehicle will not fall Remove Plastic parts for frame Chapter 2 Front and rear wheels and arms Chapter 6 Air filter engine service chapter Carburetor engine service chapter Engine Rear brake caliper 7 4 R i a NUNS jz SS ES Oy y 2 we IA UY Ban gt 1 Nut 2 Bolt 1 3 Bolt 2 4 Front Axle 5 Bolt 3 6 Front Drive Shaft 7 Clamp 8 Breather Hose Front Axle 9 Bolt4 10 Rear Axle 11 Breather Hose Rear Axle 12 Rear Brake Disk 13 Bolt 5 14 Rear Drive Shaft 5 5 5 Removal and Installation of Engine Drive Train and Gearshift Unit Remove nut and bolt of front axle from frame Bolt Rear Axle Remove nut and bolt of rear axle from frame 5 Removal and Installation of Engine Drive Train and Gearshift Unit Remove the 18 bolts for drive shafts and front and rear axles Refer to P 5 5 Bolt 3 of Part No 5 Remove Front and rear axles drive shafts rear brake disc Installation Reverse the removal procedure for installation Tightening torque Bolt front axle 40 50N m Bolt
26. 6 18 6 Front Wheel Front Brake Suspension Steering Steering Bearing Oil Seal Remove l l Oil Seal 1 Front wheel 6 2 Bearing Retainer Steering stem 6 18 S Remove front left amp right arms upper amp lower 6 9 Oil Seal 2 Bearing Remove steering bearing and oil seal from frame with special tool Special tools Bearing removal tool set Rotor puller Removal tool shaft Removal tool hammer Installation Reverse the removal procedure for installation Special tools Tool A Bearing Race Tool shaft Note Use special tools for installation of bearing Reverse the removal procedure for installation of the steering system NOTE Check steering after installation 6 19 Overhaul Info c cece eee eee eee eeeees Troubleshooting Rear Mheer a aa Overhaul information Note Oa ea rim Overhaul standard 7 Rear Wheel Rear Brake Suspension Rear Fork Rear Shock Absorber Securely support the vehicle when overhauling the rim and suspension system Use genuine parts of bolts and nuts for rear rim and suspension Do not overexert on the wheels to avoid possible damage to the wheels When removing tire from rim use special tire lever and rim protector to avoid damage to the Item Standard Limit f Longitudinal 2 0mm pun aipiadon Horizontal 2 0mm Rear Remained Tire Wheel T Tread 1 6mm Tire Pressure 35kpa 0 3
27. Brake Suspension Right Rear Absorber Removal Note Securely support the vehicle when removing rear left and right absorbers Suspend wheels from ground Maintenance of rear absorbers only does not require removal of rear suspension Remove the following parts for rear right shock absorber Bolt 10 Nut 7 25 27 19 Bolt 7 28 28 Nut 8 Remove rear right shock absorber Installation Reverse the removal procedure for installation Rear Right Arm Refer to Front Left Upper Arm in Chapter 13 for the removal inspection and installation of Rear Right Arm Rear Left Suspension Refer to Rear Right Suspension for the removal inspection and installation of Rear Left Suspension 7 6 8 Battery Charging System Charging System Layout 0 08 8 1 Inspection of Charging System 8 5 Overhaul INfO ccccceeeeeeeeeeeeeeeeeeeees 8 2 Rectifier Regulator cseeeeeeeee 8 6 Troubleshooting c eeeeeeeteeeeeeeee tees 8 3 Inspection of AC Magneto 8 8 Batle ry 2cts cstie nce eae ee 8 4 Charging System Layout Ignition Switch OFF T Tet R R p B Vehicle Load z Circuit i y i ed L Battery R W 2 Rectifier Regulator 8 Battery Charging System Overhaul information Note Usually no hydrogen will be generated during charging except when overcharged Keep away from fires when charging Electrolyte is highly corro
28. Drive Shaft 1 M14 1 5 97 Nut Drive Bevel Gear 1 M22 1 145 Nut Dri Bevel Soa TEA te 1 M16 1 5 150 Gear Fixing Nut Clutch 1 M18 1 5 70 Counter Clockwise Limit Nut Drive Bevel i 1 M60 110 Apply Thread Locker Gear Bearing Nut Uni Joint Counter Clockwise u niversa M55 80 Yoke Apply Thread Locker Bolt Rock A ee ee 2 M14 1 25 28 Shaft Oil Drain Bolt 1 M12 1 5 30 Bolt Overridin a 6 M8 26 Apply Thread Locker Clutch Bolt Magneto Stator 3 M6 10 Apply Thread Locker Screw CVT Plate 3 M6 10 Apply Thread Locker Bolt Oil Pipe 2 M14 1 5 18 Bolt Oil Pump 3 M6 10 Bolt P olt ressure 9 M6 10 Release Valve Bolt Dri Bevel olt rive eve 4 M8 32 Gear Cover Bolt Dri Bevel olt riven eve 4 M8 25 Gear Cover Bolt Gear Limit 1 M14x1 5 18 Bolt Recoil Starter 1 M10x1 25 55 13 10 13 Engine Overhaul Information Tightening Torques Item Quantiti Thread Size Tightening Torque Remark es mm N m Bolt Crankcase 14 M6 10 3 M8 25 Bolt Driven Sector Gear 1 M6 12 Bolt Oil Filter 1 M20x1 5 63 Bolt Oil Starter Motor 2 M6 10 Bolt Cylinder Head 4 M10 38 Bolt Cylinder Head 2 M6 10 1 M8 25 Bolt Cylinder Upper amp acct re 4 M6 10 Sc Cylinder Head 42 M6 40 Bolt Chain Tensioner 2 M6 10 Nut Chain Tensioner 1 M8 8 Bolt Fan Motor 3 M6 10 Bolt Thermostat Housing i S Bolt Water Pump Cover 3 M6 6 Bolt Water Pump 2 M6 10 Feni Bolt Timing 2
29. O Front axle ansmiss O n lubrication Rear axle Petes O n lubrication Remove filling bolt Drive Transmissio add oil till oil level Gear box eee O Train n lubrication reaches edge of filling hole Finatehat O of joint parts l Sway of Drive shaft Spline O Spark plug gap Ignition Spark plug 2 0 8 0 9mm Device Ignition O timing Electrical Terminal System Battery Joint O Looseness Wiring and damage O of joints Fuel device Fuel leakage O Throttle O Throttle grip clearance 3 5mm Engine Coolant level O Cooling system Coolant O leakage 3 Checks amp Adjustment Lighting device and f Function O turning indictors Aamo ano Function O lock device Instruments Function O Looseness or damage Exhaust pipe caused by improper O and muffler installation Function of muffler O Pame Looseness and or O damage Others Lubrication amp grease of O frame parts Abnormal parts which Make sure if there is any can be abnormal with relative determined parts when driving 3 4 Steering Stem Park the vehicle on level place hold steering handlebar and shake in the direction as illustrated on the right and see if there is any sway In case of any sway check if it is the problem of the steering stem or other parts and then do the maintenance accordingly In case of sway of the steering stem tighten the locknut or disassemble the steering stem for further check
30. Removal b e LA I 2 Zi i SSW p ra i CY A T CDD Perr O Disassemble the carburetor in the following serial number Serial No Description Qty Serial No Description Qty 1 Idle Adjust Shaft 1 10 Drain Screw 1 2 Vacuum Chamber Cover 1 11 Float Chamber 1 3 Spring 1 12 Float 1 4 Jet Needle Holder 1 13 Needle Valve Set 1 5 Spring 1 14 Main Jet MJ 1 6 Jet Needle Set 1 15 Needle Jet NJ 1 7 Vacuum Diaphragm 1 16 Pilot Jet PJ 1 8 Piston Valve 1 17 Starter Jet GS 1 9 Enriching Diaphragm 1 18 Pilot Air Jet PAJ 1 16 2 16 Carburetor 2 Inspection Check carburetor body for cracks or damage Cracks or damage Replace Check carburetor float chamber fuel passage for dirt or clog Clean these parts Check float float tang for damage Damage Replace Check valve seat needle valve O ring for damage abnormal wear or dirt Damage or wear or dirty Replace Note Valve set needle valve should be replaced as a set Check piston valve for scratches abnormal wear or damage Scratches wear or damage Replace Check diaphragm for tears Tears Replace Check vacuum chamber cover spring for damage or cracks Damage or cracks Replace 16 3 16 Carburetor Check the diaphragm for tears Tears Replace Check the spring cover for damage and tears D
31. Remove O ring Note Do not reuse the O ring Remove the overflow tube Release water pump cover screws water pump cover and gasket Remove E ring and impeller Remove seal ring Mand rubber seal 17 8 17 Cooling and Lubrication System Remove mechanical seal with special tool Mechanical Seal Note The mechanical seal does not need to be removed if there is no abnormal condition Note Do not reuse a removed mechanical seal Puta rag on the water pump body Remove oil seal Oil Seal Note The oil seal does not need to be removed if there is no abnormal condition Note Do not reuse a removed oil seal Remove bearing with special tool Note The bearing does not need to be removed if there is no abnormal noise Note Do not reuse a removed bearing Inspection of Water Pump Bearing Check the play of bearing by hand while it is still in the water pump body Turn inner race of bearing to check for abnormal noise and smooth rotation Replace the bearing if there is abnormal condition Mechanical Seal Check mechanical seal for damage pay special attention to the seal face In case of leakage or damage replace the mechanical seal If necessary also replace the seal ring 17 9 Oil Seal Check oil seal for damage Pay special attention to the oil seal lip Incase of damage or leakage replace the oil seal Water Pump Body Check the ma
32. a new one Inspect drive belt for width if width is out of service limit replace drive belt with a new one Service Limit 33 5mm Tool Vernier Caliper Installation Reverse the removal procedure for installation Pay attention to the following Insert drive belt as low as possible between secondary sliding sheave and primary fixed sheave Hold secondary sheave with a special tool and tighten the nut to the specified torque Nut Secondary Sheave 115 N m Install primary sheave and nut Hold the primary sheave with a special tool and tighten the nut to the specified torque Nut Primary Sheave 115N m Turn primary sheave until the drive belt is properly seated and both the primary and secondary sheaves rotate together smoothly and without slipping Caution Fit the drive belt with the arrow on the drive belt points toward normal turning direction The drive belt contact surface of the driven face should be thoroughly cleaned Install CVT cover 14 Checks amp Adjustment 14 Checks amp Adjustment Inspection of Lubrication System Replace engine oil and oil filter initially at 20 hours or 200km and every 80 hours or 2000km thereafter Check Engine Oil Level Keep the engine in a plan position Remove the fixture A fixture B then remove the left side cover 1 Remove oil dip rod 2 Clean oil dip rod insert oil dip rod but do not tighten it Take out oil dip rod and chec
33. adjust bolt make sure it slightly contacts the feeler gauge tighten bolt and nut 14 Checks amp Adjustment 14 3 Take out the feeler gauge measure the clearance If the clearance is incorrect repeat the above steps until the proper clearance is obtained Locknut 10 N m Caution Securely tighten the locknut after completing adjustment Install 2 valve adjusting cover Inspection cap Recoil starter Cover plate Apply a small quantity of THREAD LOCKER to recoil starter fixing bolts Tools Valve adjuster Feeler gauge Material Thread Locker ENGINE IDLE SPEED Inspect initially at 20 hours run in and every 40 hours or 1000km thereafter Start the engine and warm it up for several minutes measure engine speed with a tachometer Set the engine idle speed between 1200 1400 r min by turning the throttle stop screw of carburetor Engine idle speed 1300r min 100r min Note Make this adjustment when the engine is hot Tool Tachometer SPARK PLUG Inspect initially at 20 hours run in and every 80 hours or 2000km thereafter Replace every 6000km Remove the spark plug with a special tool Specification DER7EA 9 NGk If the electrode is extremely worn or burnt or spark plug has a broken insulator damaged thread etc replace the spark plug with a new one 14 Checks amp Adjustment 2 an Clearance 1 Nut 2 Valve Adjust Screw 3 Rocker Arm 4 Valve To Ignition C
34. between A as d d21 5mm Armature Coil Check for continuity between each segment and between each segment and armature shaft using a multimeter If there is no continuity between the segments or there is continuity between segments and shaft replace the armature with a new one Oil Seal Check Oil Seal Lip for damage or leakage Damage or leakage Replace with a new starting motor 18 Electrical System 18 5 18 Electrical System Starter Relay Apply 12V to the terminals and check for continuity between the positive and negative terminals using a multimeter if the starter relay clicks and continuity is found the starter relay is OK If there is no continuity when without the 12V the relay is OK Note Do not apply the battery voltage to the starter relay for more than 2 seconds This may cause overheat and damage the relay coil Measure the coil resistance between the terminals using a multimeter If the resistance is out of the specified value replace the starter relay with a new one Set multimeter to 1x100 position Starter relay coil resistance 3 50 Auxiliary Starter Relay Apply 12V to starter relay positive and negative terminals and check for continuity between A and B using a multimeter lf the starter relay clicks and continuity is found the starter relay is OK If there is no continuity when without the 12V the relay is OK Earthing Set multimet
35. bolt and tighten to the specified torque Tightening torque 10N m Incorrect Engine Top Side Piston Install the piston rings in the order of oil ring ring Correct and ring The first member to go into the oil ring groove is spacer after placing the spacer fit the two side railsQ Warning when installing the spacer do not overlap its two ends in the groove Install the second ring A and first ring B Note ist ring and 2nd ring differ in shape 15 62 12 Engine Removal Inspection and Installation 1st and 2nd rings have letter R marked on the side Be sure to bring the marked side to the top when fitting them to the piston Position the gaps of the three rings as illustrated on the right Before installing the piston into the cylinder check that the gaps are so located Upper Side Rall Piston Pin Centerline Apply a light coat of moly oil to the piston pin i e Top Ring Install piston pin into holes of piston and conrod Spacer small end Note When installing the piston the IN mark on piston top is located to the intake side Place a clean rag beneath piston and install piston pin circlip Note while rotating crankshaft pull the cam chain upward or the chain will be caught between sprocket and crankcase Install the dowel pins and the new cylinder gasket Note Use a new cylinder gasket to prevent oil leakage 15 63 12 Engine
36. cable wiring should be routed properly Roht Handlebar Switch Installation of Throttle Cable Remove 3 screws Right handlebar top cover Throttle Cable Install Throttle cable Right handlebar switch top cover 6 14 6 Front Wheel Front Brake Suspension Steering Installation of Left Handlebar Switch Left Handlebar Switch Match the limit pin of left handlebar switch with positioning hole on handlebar Tighten with Screw 1 and 2 from under Switch Insert connector of left handlebar switch into socket of main cable Connector Handlebar Switch ight Handlebar Switch Installation of Right Handlebar Switch Match the limit pin of right handlebar switch with positioning hole on handlebar Tighten with Screw 1 and 2 from under Insert connector of right handlebar switch into socket of main cable Connector Handlebar Switch 6 15 6 Front Wheel Front Brake Suspension Steering Installation of Left and Right Grip Clean off stains and grease from handlebar and inner Hand Grip left and right grips Dry completely Apply glue between handlebar and left and right grips Install left and right grips NOTE Wait several hours till the glue dries after the left and right grips are installed Installation of Master Cylinder Keep the UP mark on master cylinder upward Install master cylinder NOTE Main cable throttle cable brake hose and wiring should b
37. chapter Clamp Water Inlet Hose Remove screw Remove gearshift rod Remove clamp Remove water outlet hose Remove Sleeve Remove connectors of magneto enriching device lead pickup water temperature transducer gear sensor as illustrated on the right Water Outlet Hose Engine Water Inlet Hose Engine Clamp Connectors Clamp Gear Shift Rod 5 2 5 Removal and Installation of Engine Drive Train and Gearshift Unit Remove spark plug cap from cylinder Remove protection sleeve of starter relay Remove Nut Disconnect positive wire of starter relay Remove nut Remove negative wire of starter relay Remove Bolt 1 and Nut 1 of upper engine hanger Bolt 1 Upper Engine Hanger Nut 1 Upper Engine Hanger 5 3 5 Removal and Installation of Engine Drive Train and Gearshift Unit Remove Bolt 2 and Nut 2 of upper engine hanger Remove Bolt 1 and Nut 1 of lower engine hanger Remove Bolt 2 and Nut 2 of lower engine hanger Bolt 2 Upper Engine Hanger ngine Hanger Nut 2 Upper Bolt 1 Nut 1 Lower Engine Hanger Bolt 2 Nut 2 Lower Engine Hanger 5 4 5 Removal and Installation of Engine Drive Train and Gearshift Unit Engine Installation Put engine onto the frame install the two lower mounting bolts and nuts Then install the upper and lower engine hangers Tightening torque Engine upper hanger bolt 35 45N m Engine lower hanger bolt
38. install set Assembly Reverse the removal procedure of primary sliding and fixed sheave for installation Pay attention to the following Apply grease to inner bore and oil seal lip Note Wipe off any excessive grease thoroughly Take care not to attach any lubricant grease Apply Lubricant i Grease to contact surface of drive belt Material Lubricant grease Cam Damper Roller Position 8 rollers Oon the primary sliding sheave Install 4 dampers to cam Install cam to primary sliding sheave Notes When inserting the spacer press down the cam so that the rollers will not come out of position 15 31 15 Engine Removal Inspection amp Installation Install spacer Secondary Sheave Disassembly Use special tool and holder to hold the secondary sheave Remove secondary sheave nut with special tool Caution Do not remove the ring nut before attaching the clutch spring compressor Tool Nut Wrench Sheave Holder Attach special tool to the secondary sliding sheave and compress it by turning in the tool handle Note Make sure that spring end A is inserted into slot B of the tool handle Remove ring nut Tool Secondary sliding sheave spring compressor Note Since a high spring force applies to the secondary sliding sheave take special care that the secondary sliding sheave will not come off abruptly Slowly loo
39. left crankcase cover Install bolts Recoil Starter Install recoil starter 1 Install O ring 2 Note Use a new O ring and apply lubricant grease to the O ring Install washer 3 and bolt 4 tighten to the specified torque Recoil starter bolt tightening torque 55N m 12 Engine Removal Inspection and Installation Water Pump Install water pump Install water pump fixing bolts Note Before tightening the bolts be sure to insert oil pump shaft into groove of water pump shaft Sector Gear Install the parts as illustrated on the right 1 sector gear cover and gasket 2 dowel pin 3 drive sector gear 4 driven sector gear 5 driven sector gear bolt Note When the shift cam is in the neutral position the mark of drive sector gear should be between the two marks of the driven sector gear Driven sector gear tightening torque 14N m install gearshift rocker arm Install rocker arm bolt 7and washer 8 15 61 12 Engine Removal Inspection and Installation Oil Filter Apply Grease Install oil filter bolt and tighten to the specified torque Oil filter bolt tightening torque 63 N m Apply engine oil to O ring Install oil filter turn it by hand until the filter gasket contacts the mating surface Tighten the bolts to the specified torque Tool Oil Filter Wrench Starting Motor Apply engine oil to new O ring Install starting motor Install
40. malfunction of fan motor No rise or slow rise of water temperature Faulty thermostat thermostat is not closed Faulty circuit of water temperature display Coolant leakage Faulty water seal O rings are aged damaged or improperly sealed Washers are aged damaged or improperly sealed Improper installation of pipes or hoses Pipes and or hoses are aged damaged or improperly sealed Check and Maintenance Checking coolant density Note Open the radiator cap after coolant is fully cooled Remove Front top cover 2 4 Radiator cap counter clockwise Check with a densimeter if the coolant density adapts to the local temperature Check coolant for stains or impurities Inspection of radiator cap Note Open the radiator cap after the coolant is fully cooled Remove Front top cover 2 4 Radiator cap 4 3 Note Apply coolant on the sealing surface of radiator cap before attaching the tester to the radiator cap Install the radiator cap tester to the radiator cap Apply the specified pressure radiator cap opening pressure for 6 seconds and make sure that there is drop in pressure Opening pressure of radiator cap 108kpa 1 1kgf cm 4 Cooling System Radiator Cap Tester Radiator Cap Pressure testing of cooling system Install the radiator cap tester to the radiator cap Apply the specified pressure radiator cap opening pressure for 6 seconds and make sure that there is drop
41. not twist or wring the element or it will tear Immerse the element in engine oil B and then squeeze out the excess oil leaving the element slightly wet 14 Checks amp Adjustment A Non flammable cleaning solvent B Engine oil SAE 30 or SAE10W 40 Warning Never use with gasoline or low flash point solvents to clean the filter element Inspect the filter element for tears torn element must be replaced Note If driving under dusty conditions clean the air filter element more frequently The surest way to accelerate engine wear is to operate the engine without the element or with torn element Make sure that the air filter element is in good condition at all times Remove the drain plug of air box to drain out any water Fuel Hose Inspect every 80 hours or 2000 km replace every 4 years Inspect the fuel hose for damage and fuel leakage If any damages are found replace the fuel hose with a new one Drive Belt Removal Remove CVT cover Hold the primary sheave with special tool and loosen primary sheave nut Special Tool Rotor Holder Remove primary sliding sheave 1 Hold the secondary sheave with special tool and loosen secondary sheave nut Remove secondary sheave together with drive belt Special Tool Rotor Holder Remove drive belt from secondary sheave 14 6 Inspection Inspect drive belt for wear and damage If any cracks or damages are found replace drive belt with
42. of Lubrication System Inspection of Oil Pump and Relief Valve 17 1 4 Water Pump 1 Water Inlet Hose 2 Left Crankcase 3 Left Side Cover 5 Water Hose 6 Cylinder Body 7 Cylinder Head 8 Water Temperature Sensor 11 Water Outlet Hose 12 Radiator 10 Thermostat 13 Fan Motor 9 Thermostat Housing 15 Reservoir Tank 14 Thermoswitch 16 Radiator Cap 17 Cooling and Lubrication System Cooling System Illustration 17 2 17 Cooling and Lubrication System Engine Coolant Anti Freeze The coolant used in cooling system is a mixture of 50 Densit distilled water and 50 ethylene glycol antifreeze This 50 50 mixture provides the optimized corrosion resistance and fine heat protection The coolant will protect the cooling system from freezing at temperature above 30 C If the vehicle will be operated at the environmental temperature below 30 C the mixing ratio of coolant should be increased to 55 or 60 according to the figure on the right Note Use high quality ethylene glycol base antifreeze and mixed with distilled water Never mix an alcohol base antifreeze and different brands of antifreeze The ratio of antifreeze should not be more than 60 or less than 50 Do not use anti leak additive Warning DO NOT open radiator cap when the engine is still hot Or you may be injured by scalding fluid or steam Coolant is harmful DO NOT swallow or stain your skin or eyes with coo
43. plug Clogged float valve Clogged fuel filter Clogged fuel tank cap breather hole Stained damaged and color changed and check it Stained or damaged spark plug Improper spark plug heat value Ai Plug Remove spark plug and mount it Weak spark or Faulty spark plug or stained spark plug to spark plug cap get and check spark it earthed No spark gt Faulty Ignition coil Faulty high tension coil or short circuit cal Spark Faulty ignition switch Faulty pickup coil Faulty CDI unit Measure compression with pressure meter Normal ae pressure Low or no Worn Cylinder and piston ring compression Faulty cylinder gasket pressure pressure Check ignition timing p Faulty pickup coil Correct v Check caburetor mixture scre Faulty CDI unit Improper adjustment gt Refer to Engine Service Correct adjustment Vv Check if there is secondary air into 7 Air intake gt Faulty tightening of carburetor joint carburetor joint No secondary air device wire lead check continuity Remove fuel enrichment No continuity Broken cable of fuel enrichment device andj S Faulty fuel enrichment device Normal Continuity 12 2 12 Troubleshooting Connect fuel enrichment device wire lead with battery for 5 Minutes With Air current Connect ethylene pipe Faulty fuel enrichment device with fuel increment lo
44. rear axle 40 50N m Bolt front and rear drive shafts 40 50N m Gearshift Unit Remove Left and right side panel 2 6 Fuel tank top cover 2 8 Front fender 2 8 Bolt 1 Gearshift rod Remove the 2 bolts Remove gearshift unit Installation Reverse the removal procedure for installation Make sure that gearshift is flexible In case of any inflexibility adjust the gearshift rod to ensure the gear engagement A Gear Shift Unit 5 7 Overhaul Info cece cece eeseeeee ee eeee es 6 1 Troubleshooting e eceeeeeeeeeeeeees 6 2 Front Wheel ccccccce eee iesin ees 6 3 Overhaul Information Operating cautions Notes 6 Front Wheel Front Brake Suspension Steering Front Brake nari era a e eens 6 4 SUSPENSION ecececee cece eee eee ees 6 7 Steering 2 2 ecee eee eee eeeeeeeeeeeeees 6 12 Securely support the vehicle when overhauling the front wheel and suspension system Refer to chapter 10 for overhaul and inspection of lighting instruments and switches Do not overexert on the wheel Avoid any damage to the wheel When removing tire use the special tire lever and rim protector Maintenance Standard Item Standard Service Limit Rim Longitudinal 0 8mm 2 0mm Vibration Lateral 0 8mm 2 0mm Tire Remained groove 3 0mm Tire Pressure 35kpa 0 35kgf cm is Front brake Free play bra
45. specified torque Secondary sheave tightening torque 115 N m Tool Rotor Holder Note Turn the primary fixed sheave until the belt is seated in and both primary and secondary sheaves move together smoothly without slip CVT Case Cover Install the new gasket and dowel pins 12 Engine Removal Inspection and Installation Install CVT case cover bolts and tighten diagonally in several steps Engine Left Oil Pump Sprocket and Chain Install oil pump drive sprocket Install oil pump driven sprocket Install oil pump drive chain Gone Install oil pump sprocket bolt Install sprocket retainer with a long nose pliers Tool Long Nose Pliers 8 8 8 8 Dual Gear Idle Gear Install dual gear shaft and dual gear Install dual gear dual gear Mand bush Starting Driven Gear l i amp MSarewevcsescecocsessse Install starting driven gear 8 8 8 8 8 8 8 8 8 8 8 12 Engine Removal Inspection and Installation Install starting driven gear Driven Gear Magneto Rotor Install woodruff key into crankshaft groove Install magneto rotor 1 Note Degrease the tapered part of rotor and crankshaft Use nonflammable solvent to clean off the oily or greasy matter and fully dry the surfaces Left Crankcase Cover Install dowel pin2 and gasket 3 Note Use a new gasket Apply Lubricant grease to oil sea lip Install
46. strainer Check oil strainer and O ring for damage Damaged oil strainer Replace Clean the surface of oil strainer with engine oil Relief Valve Check the valve body valve and spring O ring for damage or wear Damage or wear Replace Drive Bevel Gear Usea clean rag to protect the drive bevel gear shaft clamp it to the pliers Loosen drive bevel gear nut 3 remove the drive bevel gear 4 and adjust washer 5 Check the drive bevel gear 4 and output driven gear 2 for rust scratch wear or damage Replace if any Check if the bearing 8 turns smoothly replace with a new bearing if necessary Adjust Washer 5 if any of right crankcase drive bevel gear 4 or drive bevel gear cover 1 is replaced Refer to bevel gear adjustment for details Apply engine oil to bearing 8 when assembling and tighten nut 3 to the specified torque Drive bevel gear nut Tightening torque 145N m 1 Drive bevel gear cover 5 Adjust washer 2 Output driven gear 6 Drive bevel gear shaft 3 Drive bevel gear nut 7 Bearing press 4 Drive bevel gear 8 Bearing 15 42 15 Engine Removal Inspection amp Installation Front Output Shaft Check bearing 7 for smooth turning and abnormal wear Check oil seal 5 for damage Wear or damage Replace Apply lubrication oil to bearing 7 and oil seal 5 lip before assembly Apply thread locker to bearing limit nut 6 left thread and ti
47. switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil stains on the glass surface If the Inspection has to be done with battery check if the battery is normal Inspection of switch continuity can be done without removing the switches from the vehicle After the inspecting and overhauling of each part cables and wires should be routed properly chapter 1 Refer to Chapter 2 for removal and installation of taillight and rear turning lights Overhaul Standard Item Standard Main 20A Fuse Sub fuse 10A 15AX3 Headlight Hi Lo 12V 35 35W Brake light Tail light 12V 21 5W Light bulb Turning light 12V 10W X 4 Dashboard indicator 12V 1 7W Indicators 12V 3 4W Troubleshooting Head Light Cannot Turn On VVVV Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch 10 Lighting Instruments Switches 10 2 Replacing Bulb Headlight Bulb Warning Headlight bulb will be very hot when it is turned on Do not touch it after it is just turned off Operation should be done when the bulb is cooled down Remove headlight 10 5 Disconnect headlight Remove dust proof cap headlight connector circlip and replace with a new bulb Warning gt Wear clean gloves when replacing b
48. the mark as indicated Replace the brake pad if the wear has reached position of wear limit trough Note The brake pad must be replaced with a whole set Checking and replacing the brake disc Front brake disc thickness lt 2 5 mm Replace Rear brake disc lt 6 5 mm Replace Min limited thickness of the front brake disc 2 5mm Min limited thickness of the rear brake disc 6 5mm Change the Brake Fluid lt Changing Brake Fluid gt Change the brake fluid once every year Brake Disc 3 Checks amp Adjustment Wheels Lift front wheel on level place and make sure there is no loading on the wheels Shake the front wheel left and right to check whether the joint of front wheel is tightened and check whether it sways Not tighten enough Tighten it Sway Replace the rocker arm Front Toe in size Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out of the range Adjust the locknut of tie rod Locknut Note After the toe in has been adjusted slowly run the vehicle to check whether the direction of vehicle can be controlled by handlebar 3 7 Tire Pressure Check the pressure of the tires with a pressure gauge Note Check the tire pressure after tires are cooled Driving under improper tire pressure will reduce the comfort of operation and riding and may cause deflected wear of the tires Specified pressure tire Front wheel Rear wheel
49. to adjust the length of gearshift rod Fuel Device Status of the fuel system Remove the seat 2 3 Check the fuel hose for any aging or damage Aged or damaged fuel hose Replace Check if there is cracks or bending with the vacuum tube Cracked or bended vacuum tube Replace 3 Checks amp Adjustment Gear Shift Unit CORES RS s ii S a P a J lt 0 gt FAS fei Q Dr Fuel Hose 3 10 3 Checks amp Adjustment Checking the Throttle Lever Throttle Lever Check the free play of throttle lever Free play 3 5mm Out of range Adjust Loosen locknut of throttle cable turn the regulator and adjust free play of throttle lever After adjusting tighten locknuts and install throttle cable sleeve Replace with a new throttle cable if the specified free play could not be acquired by adjusting the regulator or if there is still stickiness with the throttle Locknut Throttle Cable Adjusting the Speed Limiter The speed limiter is to limit the opening of throttle Check the maximum length of limiter screw thread Maximum screw thread a 12mm Adjust with a cross driver Note For beginners the speed limit should be fully tightened Drivers with certain skills may adjust the throttle with speed limiter Maximum length of screw thread is 12mm It is recommended to adjust the thread length to 3 5mm 3 11 3 Checks amp Adjustment Cooling System Note Check cool
50. 21 Torque Wrench For measuring the tightening torque General purpose and Auxiliary Tools 22 Alcohol Burner Heating up 23 Magnetic Stand For micrometer 24 Slab Auxiliary tool for measuring 25 V block For measuring the play 26 Tweezer For installation of valve cotter 27 Circlip Pliers For removal and installation of circlips 28 Long Nose Pliers For removal and installation of retainers 29 Impact Driver For removal of cross headed bolts 30 Driver 31 Driver 13 12 Special Tools 13 Engine Overhaul Information No Description Specifications Purpose 1 Spark Plug Wrench Removal and installation of spark plug 2 Clutch Holder For removing installing clutch carrier nuts 3 Oil Filter Wrench Removal and installation of oil filter cartridge 4 Piston Pin Puller For removal of piston pin 5 Flywheel Puller For removal of magneto rotor 6 Crankcase Separating Tool For separation of left and right crankcase 7 Crankshaft Remover For removal of crankshaft from left crankcase 8 Crankshaft Installation Set For installing crankshaft to left crankshaft 9 Valve Spring Compressor For removal and installation of valve spring 10 Valve Seat Cutter For valve seating 11 Ring Nut Wrench Removal installation of CVT secondary sheave 12 Sheave Holder Removal installation of CVT secondary sheave 13 Sheave Spring
51. 5kgf cm m Rear Brake Lever Free Play 10 20mm Brake Tightening torque Rear wheel axle nut 110 130N m Rim mounting bolt 50 60N m Upper mounting bolt Shock absorber 40 50Nem Lower mounting bolt Shock absorber 40 50Nem 7 Rear Wheel Rear Brake Suspension Troubleshooting Rear Wheel Wobbles Rim warpage Faulty tire Tire pressure too low Improper wheel balance Improper tightening of wheel axle nut Loosened wheel nut VVVVVV Rear Shock Absorber Is Too Soft gt Weak spring gt Oil leakage from rear shock absorber Rear Shock Absorber Is Too Hard gt Bent rear shock absorber gt Tire pressure is too high Poor Brake Efficiency gt Improper brake adjustment gt Stained brake pad or brake disk gt Worn or damaged brake pad 7 2 7 Rear Wheel Rear Brake Suspension Rear Wheel Removal Refer to front wheel removal 6 3 Inspection Rim Damage warpage serious scrapes Replace Slowly turn the wheel measure the rim vibration with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Installation Refer to front wheel installation 6 3 Wheel Hub Remove Rear wheel 7 3 Rim axle nut Wheel Hub Installation Reverse the removal procedure for installation Tightening torque Rim Axle Nut 110 130N m Nut Rim Axle 7 3 Rear Brake Rear Brake Caliper Remove Rear left wheel 7 3 2 bolts from arm Brake caliper Inspection Brake Cal
52. C MmoOTO SS Xx 7k 3S E CF500 CF500 A Service Manual 2006 By Chunfeng Holding Group Co Ltd First Edition August 2006 All Rights Reserved Any reproduction or unauthorized use of this manual without written permission of CFMOTO is extremely prohibited FOREWORD This manual contains an introductory description of procedures for inspection maintenance overhaul disassembly amp assembly removal and installation of components and parts troubleshooting and service data together with illustrations of our All Terrain Vehicle Model CF500 and CF500 A Chapter 1 general service information tools vehicle structure and technical data Chapter3 key points for inspection and adjusting service guide Chapter 2 and after Chapter 3 disassembly of parts and components installation overhaul and troubleshooting The manufacturer reserves the right to make improvements or modifications to the products without prior notice Overhaul and maintenance should be done according to the actual state and condition of the ATV INDEX Vehicle Service Information Vehicle Body Muffler Inspection amp Adjustment Cooling System Removal and Installation of Engine Drive Train and Gearshift Unit Front Wheel Front Brake Suspension Steering Rear Wheel Rear Brake Suspension Battery Charging System Ignition System Lighting Instruments amp Switches Circuit D
53. Compressor Removal installation of CVT secondary sheave 14 Couple Gear Middle Shaft f Tool Removal installation of the coupling gear nut 15 Bearing Driver Set For installation of bearing and oil seal 16 Bearing Removing Tool Set For removal of bearing 17 Oil Seal Removing Tool For removal of oil seal 18 Universal Joint Holder For removal installation of the universal joint yoke nut 13 13 Materials for Operation and Fixing Materials for engine operation engine oil grease and coolant Fixing materials include sealant thread locker 13 Engine Overhaul Information etc Description Type Application Area Remark capacity SAE10W 30 Cylinder bore 1900ml aT or SAE10W 40 Crankcase for changing oil Lubricating eer Oil Engine Oil or Sneeu oe ons Refer to Engine Lubrication 2000ml API service classifications System 14 14 for replacing filet SF or SG 2200ml for engine repairing Molybdenum piston pin valve stem valve lubrication oil oil seal camshaft Oil seal lip O ring and o 3 MoS Lithium Base sealing faces of omer Lubricating Grease Gede rubber seal materials bearings with seals CVT bearing and collar 35 C antifreeze Cooling system Water seal Capacity according to Coolant corrosion resistant high boiling point coolant radiator and water hose system Joint Face Sealant Joint face of crankcase crankcase and cylinder cylinder head and cover Thread Locker
54. Front Cylinder Head Tensioner Plate 15 4 15 15 15 23 15 64 Side Cylinder Timing Chain Guide 15 4 15 24 15 23 15 64 Piston 15 5 15 25 15 62 Starting Motor 15 5 15 3 15 62 Oil Filter 15 6 15 9 15 62 Sector Gear 15 6 15 62 Water Pump 15 7 15 7 15 61 Engine Sheave Drum 15 7 15 48 15 60 Left Side Left Crankcase Cover Magneto Stator 15 7 15 48 15 60 Magneto Rotor 15 7 15 47 15 60 Starting Driven Gear 15 8 15 47 15 59 Starting Dual Gear Idle Gear 15 8 15 48 15 59 Oil Pump Sprocket and Chain 15 8 15 59 CVT Cover 15 9 15 51 15 58 Drive Belt 15 9 15 36 15 57 Engine Primary Sheave Secondary Sheave 15 9 15 30 15 57 Right CVT Housing Clutch Outer Face 15 10 15 51 15 57 Side Clutch 15 10 15 28 15 56 Timing Chain 15 10 15 23 15 56 Engine Center Gear Position Bolt 15 11 15 56 Right Crankcase 15 11 15 52 15 56 Front Output Shaft Components 15 11 15 43 15 55 Driven Bevel Gear Components 15 11 15 43 15 55 Shift Cam 15 12 15 40 15 55 Guide Bar Fork 15 12 15 39 15 55 Drive Bevel Gear Components 15 12 15 42 15 55 Main Transmission Shaft 15 12 15 38 15 54 Transmission Counter Shaft 15 12 15 38 15 54 Balancer Shaft 15 12 15 46 15 54 Crankshaft 15 13 15 27 15 54 Oil Pump Pressure limiting Valve 15 13 15 41 15 53 Left Crankcase 15 52 Notes Arrowhead direction is for engine removal orders Reverse the direction for assembly and installation 15 1 15 Engine Removal Inspection a
55. M6 15 Apply Thread Locker Other Bolts M5 4 5 6 M6 8 12 M8 18 25 13 11 Maintenance Tools Measurement Tools 13 Engine Overhaul Information No Description Specification Purpose 1 Vernier Caliper 0 150mm For measuring the length and thickness Micrometer 0 25mm For measuring outer diameters of rocker arm valve stem and camshaft 3 Micrometer 25 50mm For measuring the max lift of camshaft 4 Micrometer 75 100mm For measuring piston skirt 5 Cylinder Gauge For measuring cylinder bore diameter 6 Small Bore Gauge 10 34mm Fore measuring inner gauge of rocker arm piston pin bore connecting rod small end bore 7 Dial Indicator 1 100 For measuring the play 8 Straightedge Gauge Plane measuring 9 Feeler Gauge Plane and valve clearance measuring 10 Fuel Level Gauge 11 Thickness Gauge 12 Spring Balance For measuring the carburetor fuel level For measuring the clearance For measuring the spring tension 13 Tachometer For measuring engine speed 14 Oil Pressure Gauge For measuring oil pressure 15 Compression Gauge amp Adapter For measuring cylinder compression 16 Radiator Cap Tester For measuring radiator cap opening pressure 17 Ohmmeter For measuring resistance and voltage 18 Ammeter For measuring current switches 19 Thermometer For measuring liquid temperature 20 Timing Light For checking the ignition timing
56. ON OFF Approx 82 C Note Avoid sharp impact on thermoswitch Avoid contact of thermoswitch with thermometer or vessel Installation Use a new O ring and tighten the thermoswitch to the specified torque Thermoswitch Tightening Torque 17N m Check coolant level after installation of thermoswitch Fill coolant if necessary 17 5 17 Cooling and Lubrication System Inspection of Water Temperature Sensor Place a rag under water temperature sensor and remove it from cylinder head Check the resistance of water temperature sensor as illustrated on the right Connect the temperature sensor to the circuit tester place it in a vessel with engine oil Place the vessel above a stove Heat the oil to raise the temperature slowly and take the reading from thermometer and ohmmeter Water Temperature and Resistance Temperature C 50 80 100 120 Resistance Q 154416 5244 2743 1642 Installation Apply a little thread locker and install it to the cylinder head by tightening to the specified torque Ge Engine Oil Water Temperature Sensor Tightening Torque 10N m Note Avoid sharp impact on temperature sensor Thread Locker Avoid contact of temperature sensor with thermometer or vessel After installation check the coolant level Fill coolant if necessary Inspection of Thermostat Remove thermostat case Remove thermostat 17 6 Check
57. Removal Inspection and Installation Cylinder Apply engine oil to piston skirt and cylinder wall Hold each piston ring with proper position insert piston into the cylinder Tighten the cylinder base bolts temporarily Note When installing the cylinder and cylinder head pull the cam chain upward or the chain will be caught between sprocket and crankcase Install chain guide Fit the dowel pin and new cylinder cover gasket Note Use a new cylinder cover gasket to prevent oil leakage Cylinder Head Install the cylinder cover tighten the cylinder head bolts diagonally to the specified torque Cylinder head bolt tightening torque Initial 25 N m Final 38N m Tighten the cylinder head nuts to the specified torque Cylinder head nuts tightening torque M6 10 Nm M8 Initial 10 N m Final 25 N m Tighten the cylinder top nuts and cylinder base to the specified torque Tightening torque 10 N m 15 64 12 Engine Removal Inspection and Installation Install chain tensioner Camshaft Align mark A on magneto rotor with mark B on crankcase Note while rotating crankshaft pull the cam chain upward or the chain will be caught between sprocket and crankcase Align the mark A on the camshaft so that they are parallel with the mating surface of the cylinder head Note Do not rotate the magneto rotor while doing this when the sprocket is not p
58. ace the connecting rod Connecting rod small end I D 23 040mm Tool Dial Gauge 18 35mm Connecting Rod Deflection Check the movement of the small end of the rod and inspect the wear of the small end This method is also applicable to check and inspection of big end Connecting Rod Deflection 3 0mm Tools Dial Gauge Magnetic stand V block Connecting Rod Big End Side Clearance Push the big end to one side and use thickness gauge to measure the other side clearance If out of limit replace with a new crankshaft Connecting Rod big end side clearance 1 0mm Tool Thickness Gauge Crankshaft Run out Support crankshaft with V blocks as illustrated Put the dial gauge slowly turn the crankshaft and measure run out with a dial gauge f the run out exceeds the limit correct or replace the crankshaft Run out limit 0 08mm Tools dial gauge Magnetic stand V block 15 27 15 Engine Removal Inspection amp Installation Clutch Clutch Shoes Check clutch for chipping scrape uneven wear or heat discoloration At the same time check depth of the grooves of clutch shoes If any of the clutch shoes has no groove replace the clutch Note clutch should be replaced as a set Clutch Wheel Check the inner clutch wheel for scratches scuffs or blue discoloration or uneven wear If any damage is found replace the clutch wheel with a new one Check oil seal lip for wear o
59. act pattern and Incorrect contact at tooth top Correct Incorrect contact at tooth bottom If tooth contact is correct Contact continue the next procedure f tooth contact is not correct and adjust the thickness of the washer of drive bevel gear Repeat above steps to check tooth contact until it is correct Adjustment Tooth Contact Washer Adjustment Contact at tooth top Increase Thickness Contact at tooth Decrease Thickness bottom Note After adjusting the tooth contact the backlash must be checked again lf the backlash is adjusted but tooth contact is still out of specification replace the drive and driven bevel gears Both tooth contact and backlash should be within the required specification 15 45 15 Engine Removal Inspection amp Installation Balancer Shaft Remove the parts as illustrated on the right Check each part for abnormal wear or damage Wear or damage Replace Balancer shaft gear Woodruff key 3 Balancer shaft Balancer shaft sprocket Washer Bolt Magneto Rotor Remove starter clutch nut 15 46 15 Engine Removal Inspection amp Installation Check starter clutch roller and holder for abnormal wear or damage Wear or damage Replace Install the starter clutch in the correct direction Note When install the starter clutch to the magneto rotor make sur
60. ainage assemble with a new seal gasket drain bolt and tighten Reservoir Tank Reservoir Tank Remove Seat 2 3 Left side panel 2 6 2 Mounting bolts Water hose of reservoir tank Remove reservoir tank discharge coolant Flush reservoir tank Install reservoir tank Install water pipe 4 5 4 Cooling System Adding Coolant Add coolant through filling port Start the engine and discharge air from cooling system Check from filling port that air is fully discharged from cooling system and install the radiator cap Remove reservoir tank cap and add coolant till the upper limit Note Refill Port Check coolant level when the vehicle is on an even ground Air Discharge Discharge the air from cooling system according to the following steps 1 Remove drain bolt 4 5 discharge air and install it 2 Start the engine and run it several minutes at idle speed 3 Quickly increase throttle 3 4 times to discharge air from cooling system Add coolant till filling port Repeat step 2 amp 3 till no more coolant can be refilled Check coolant level in reservoir tank and refill till upper limit 7 Install reservoir tank cap our Lower Limit 4 Cooling System Cooling System Chart Radiator Cap Overflow Pipe Reservoir Tank Water Inlet Hose Radiator maa To Thermostat Ld w Fan Motor Reservoir Tank Radiator To Wa
61. ale The reading should be taken from the widest part Tool Plastid Gauge Note Do not turn the camshaft with plastic gauge in place If the camshaft journal oil clearance exceeds the limit measure the outer diameter of camshaft Replace either cylinder head set or the camshaft if the clearance is not correct 15 22 15 Engine Removal Inspection amp Installation Camshaft Journal O D Measure camshaft journal O D with a micrometer If the O D is out of range replace camshaft with a new one Camshaft journal O D service limit Sprocket end 22 959 mm 21 980mm Other end 17 466mm 17 484mm Tool micrometer 0 25mm Camshaft Run out Measure the run out with a micrometer Replace camshaft is the run out is out of range Service limit 0 10mm Timing Sprocket and Chain Check timing sprocket and chain for wear or damage Replace with new parts if abnormal wear or damage is found Tensioner and Chain Guide Check contact surface of tensioner and chain guide for wear and damage Replace with news parts if abnormal wear or damage is found Chain Tensioner Chain Guide 15 23 15 Engine Removal Inspection amp Installation Chain Tensioner Inspection Check tensioner for any damage or poor function Damage poor function Replace Insert screw driver into the slotted end of adjusting screw turn it clockwise to loosen the tension and release the screwdriver
62. amage or tears Replace Check the jet needle mail jet needle jet pilot air jet pilot jet starter jet and starter plunger for wear and bends Wear or bends Replace Check above jets for clog Blow out the jets with compressed air Insert piston valve into carburetor body and check the free movement Check free movement of throttle valve Replace with a new one if it s stuck 3 Measurement and Adjustment Keep the carburetor in a upside down position Measure distance a from the mating surface of float chamber without gasket to the top of float Note The float arm should rest on the needle valve Do not compress the needle valve Float Height 10 1mm 16 Carburetor f float height is not within the specification check the valve seat and needle valve f either of valve seat or needle valve is worn replace both If both are fine adjust float height by bending the float tang Won the float Measure float height again till its within the specification Fuel Level Place carburetor on a level surface Connect fuel level gauge with drain pipe Tool Fuel Level Gauge Loosen drain screw Keep fuel level gauge vertical next to the float chamber line and read the fuel level a Fuel Level 3 5 0 5mm If the fuel level is not within the specification adjust the fuel level Remove carburetor Check valve seat and needle valve
63. ant level from reservoir tank Do not check from radiator If the radiator cap is opened while the engine is hot over 100 C the pressure of the cooling system will drop down and the coolant will get boiled rapidly DO NOT open the radiator cap until the coolant temperature drops down Coolant is poisonous DO NOT drink or splash it to skin eyes and clothes In case the coolant gets to the skin and clothes wash with soap immediately In case the coolant gets into eyes rinse with plenty of water and go to consult the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach of children Coolant level Reservoir Tank Coolant might reduce due to natural evaporation i A Check the coolant level regularly Note Coolant can prevent rust and resist freeze Ordinary water may cause engine rust or cracks in winter due to freezing Park the vehicle on level ground for checking of the coolant Inclined vehicle body will cause incorrect judging of the coolant level Check the coolant after the engine is warmed up Upper Limit Lower Limit Start and warm up engine Stop the engine Remove left side panel 2 6 Check if the coolant level is between the upper and lower limit 3 12 3 Checks amp Adjustment When the coolant level is below the LOWER limit Upper Limit remove reservoir tank cap and add coolant till upper l
64. arance Bearing cannot turn freely or clearance out of range Replace 6 9 6 Front Wheel Front Brake Suspension Steering 45 Bearing motion end Cap buffering collar Bolt 1 23 45 2 Front right absorber 24 Buffering collar 46 Big clamp motion end 3 Nut 1 25 Bolt 7 47 Rzeppa universal joint 4 Front right arm upper 26 Bolt 4 48 Wire circlip 5 Circlip bearing 27 Slotted nut 49 Wire circlip 2 6 Upper ball pin 28 Front right arm lower 50 Spacing shim 7 Bearing hub 29 Cotter pin 51 Dust boot motion end Brake disc guard 30 Nut 5 52 Front left shaft 9 Bolt 2 31 Cap buffering collar 53 Dust boot fixed end 0 Bolt 3 32 Buffering collar 54 Wire clamp 1 Bolt 4 33 Cap buffering collar 55 Left CV drive shaft left front 2 Circlip 34 Bolt 8 axle 3 Right Steering Knuckle 35 Nut 6 56 Nut 7 14 Circlip 36 Buffering collar 15 Bolt 5 37 Cap buffering collar 16 Bottom ball pin 38 Bolt 9 17 Nut 2 39 Bolt 10 18 Cap buffering collar 40 Rzeppa universal joint 19 Buffering collar 41 Big clamp fixed end 20 Bolt 6 42 Bearing fixed end 21 Bolt 3 43 Small clamp fixed end 22 Nut 3 44 Small clamp fixed end 6 10 6 Front Wheel Front Brake Suspension Steering Constant Velocity Drive Shafts NOTE The disassembly inspection and installation of left and right constant velocity drive shafts of front rear axles are the same The following will give
65. aulig Dise Rear Hydraulic Disc Se Suspension Sving Ar Frame Welded steel tube and plate type 1 Overhaul Information Overhaul Datasheet Lubricating device Standard Service Item ee limit Engine Oil Volume when replacing 1900m Capacity Full capacity 12200 m Recommended Oil see original e Specially for 4 stroke Temperature amp Viscosity motorcycle SAE 10W 40 20W 50 Substitutes must be used in the following range eAPI type SE or SF grade eSAE type Choose from the left chart according to the environmental temperature 10 20 30 40T Temperature Gap between inner 0 07 0 15mm 0 20mm Oil pump and outer rotors Rotor Gap between outer 0 07 0 17mm 0 25mm rotor and body End face gap 0 05 0 10mm 0 12mm Fuel Device Item Standard Fuel Tank Capacity Full capacity 19 0 Type MIKUNI BSR36 89 Main jet N102221 130 Carburetor Idle jet N224103 22 5 Idle speed 1300 100r min Cooling Device Item Standard Coolant Full Capacity 1140m t Reservoir tank capacity 340m capacl y Standard density 30 Opening pressure of radiator cap 108kpa 1 1kgf cm Temperature valve open 72 2C Thermostat Temperature valve full open 88 C Overall lift 3 5 4 5mm 1 Overhaul Information
66. cable Faulty fuel enrichment device Faulty fuel enrichment device 12 5 13 Engine Overhaul Information Conversion Table Item Conversion Press 1kgf cm 98 0665KPa 1KPa 1000Pa 1mmHg 133 322Pa 0 133322KPa Torque 1kgf m 9 08665N m Volume 1ml 1cm 1cc 11 1000 cm Force 1kgf 9 80665N Warning Caution Note Please read this manual and follow is instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay attention to the messages highlighted by these signal words Warning Indicates a potential hazard that could result in injury or death Caution indicates a potential hazard that could be result in vehicle damage Note provides key information to make procedures easier or instruction clearer Please note however that the warnings and cautions contained in this manual can t possibly cover all the potential dangerous information to the servicing or lack of the vehicle Except WARNINGS and CAUTIONS stated in this manual mechanic should have a basic understanding of the mechanical ideas and the procedure of machine repair If mechanic can t master all the troubleshooting operation please consult with qualified mechanic for advice 13 Engine Overhaul Information General Precautions Fuel Oil and Coolant Brake in Engine Exterior and Engine No Engine Specification Overhaul Data 13 1 13 Engine Overhaul Informat
67. cle The maintenance person should have to work under the vehicle bottom when disassembling the above parts For safety purpose make sure that the vehicle should be firmly parked Engine Skid Plate Front Remove Bolt 1 Bolt 2 Bolt 3 Bolt 4 Engine skid plate Front Installation Reverse the removal procedure for installation Engine Skid Plate Center Remove Bolt 5 Bolt 6 Engine skid plate center Installation Reverse the removal procedure of installation Double Seat Protection Plate Remove Bolt 7 Bolt 8 Double seat protection plate Note This part is not available for single seat vehicle Installation Reverse the removal procedure of installation Engine Skid Plate Rear Remove Bolt 9 Bolt 10 Engine skid plate rear Installation Reverse the removal procedure for installation 2 Vehicle Body Muffler 2 11 Front Right Inner Fender Remove Bolt 1 Bolt 2 Front right inner fender Installation Reverse the removal procedure for installation Note The clasp of front right inner fender should hook water pipe when it is assembled Front Left Inner Fender Remove Bolt 1 Bolt 2 Front left inner fender Installation Reverse the removal procedure for installation Front Left Protector Remove Bolt 1 Pull backward and remove front left protector Installation Reverse the removal procedure for installation Front Rig
68. crankcase Wrap a screwdriver with a rag and insert it into the speed sensor hole of left crankcase to fix the drive bevel gear Install special tool and micrometer Tool Bevel gear side clearance dial gauge Micrometer a 46mm Turn the driven bevel gear in each direction and measure the backlash NOTE Measure four points in the mutual vertical direction lf the backlash is not within the specification adjust the thickness of the driven bevel gear adjust washer Re check the backlash until the backlash is correct Bevel Gear Backlash 0 1 0 2mm 15 Engine Removal Inspection amp Installation Adjustment Measured Backlash Washer Thickness Adjustment lt 0 1mm Decrease washer thickness 0 1 0 2m Correct gt 0 2mm Increase washer thickness 15 44 15 Engine Removal Inspection amp Installation Tooth Contact After adjusting the backlash check the tooth contact according to the following procedures 1 Remove drive and driven bevel gear shafts from crankcase Clean and degrease every tooh of drive and driven bevel gear Coat the driven bevel gear with machinist s layout dye or paste Install drive and driven bevel gear Rotate the driven bevel gear several turns in both directions Remove drive and driven bevel gear shafts and check the coated teeth of the drive bevel gear Refer to the illustration on the right for tooth cont
69. d tap the coated seat with the valve face in a rotating manner To get a clear impression of the seating contact use a valve lapper to hold the valve head The ring like dye impression on the valve face should be continuous without any break The width of the dye ring which is the visualized seat width should be within the following range Valve Seat Width 0 9 1 4mm Tool Valve Lapper Valve Stem and Valve Guide Lift the valve about 10mm from valve seat Check the valve stem deflection in the directions of X and Y perpendicular to each other with a dial gauge If the deflection measured is out of the limit replace either the valve or the valve guide If the valve stem is worn to the limit and the clearance is found to be in excess of the limit replace the valve If the valve stem is within the limit replace the valve guide Double check the clearance after replacing the valve stem or the guide Valve Stem Deflection IN amp EX 0 35mm Tool Micrometer Magnetic Stand 15 Engine Removal Inspection amp Installation Valve Stem O D Measure valve stem O D with a micrometer Service Limit IN 4 975 4 990mm EX 4 955 4 970mm Tool Micrometer 0 25mm Valve Stem Run out Support valve stem with V block as illustrated on the right Check the run out with a dial gauge Service Limit 0 05mm Tool Magnetism Stand Dial Gauge 1 100 V block Valve Head Radial Run out Measure the valve head radial run ou
70. e specified coolant until the level is between the upper and lower lines on the reservoir tank Caution Repeat the above procedures several times and make sure the radiator is filled with coolant and air is discharged 14 Checks amp Adjustment 14 10 14 Checks amp Adjustment Fill coolant into the reservoir tank till between upper and lower limit Install reservoir tank cap Warning Never mix with other brand Inspection of Radiator Hose Perform inspection every 40 hours or Check radiator hose and clamp Leakage or Damage Replace Inspection of cylinder pressure Check cylinder pressure is necessary Cylinder Pressure 1000kpa A lower cylinder pressure may be caused by Excessive wear of cylinder Wear of piston or piston ring Piston ring jam in groove Poor closure of valve seat Damaged cylinder gasket or other defects Note When cylinder pressure too low check the above items Testing Cylinder Pressure Note Before testing of cylinder pressure make sure that cylinder head bolts are tightened to the specified torque and valve clearance has been properly adjusted Warm up the engine before testing Make sure battery is fully charged Remove spark plug 1 Install cylinder pressure gauge 2 in spark plug hole and tighten nut Keep throttle full open Press start button crank the engine a few seconds Record the maximum reading of cylinder pressure Tools Cylinder Press
71. e j f Sverheats 5 rue level in float chamnet is too low Aejusi fuel level 6 Air leakage from air intake pipe Tighten or replace 7 Incorrect engine oil Change engine oil 8 Faulty cooling system 16 5 19 2 19 Troubleshooting Complaint Symptom and Possible Causes Remedy Valve Chatter 1 Excessive valve clearance Replace 2 Worn or broken valve spring Replace 3 Worn rocker arm or camshaft Replace Noise from Piston 1 Worn piston Replace 2 Worn cylinder Replace 3 Carbon deposit in combustion chamber Clean 4 Worn piston pin or pin hole Replace 5 Worn piston ring or piston ring groove Replace Noise from Timing chain 1 Stretched chain Replace chain amp sprocket 2 Worn sprocket wheel Replace chain amp sprocket 3 Faulty chain tensioner Repair or replace Engine is Noise from Clutch noisy 1 Worn or damaged crankshaft spline Replace crankshaft 2 Worn inner race spline Replace inner race Noise from Crankshaft 1 Rattling bearing Replace 2 Worn or burnt crank pin bearing Replace 3 Excessive thrust clearance Replace Noise from CVT 1 Worn or slipping drive belt Replace 2 Worn rollers in primary sheave Replace Noise from Transmission 1 Worn or damaged gear Replace 2 Worn or damaged input or output shafts Replace 3 Worn bearing Replace 4 Worn bushing Replace 1 Worn or damaged clutch shoes Replace d clutch sh i Repl Slipping eset C z oe spring aie Clutch orn clu a
72. e routed properly Install Rear view mirror 6 13 Dashboard 6 10 Dashboard front and rear cover 6 14 6 16 Steering System 6 Front Wheel Front Brake Suspension Steering Bolt 1 Rubber Right Bracket Dashboard Left Bracket Dashboard Alum Cover Handlebar Bolt 2 Front Bracket Dashboard Bolt 3 Lock Pad 10 Adapter Plate 11 Bush 12 Bushing Steering Stem oO ON Oa FR WN 13 14 15 17 18 19 20 21 22 23 24 Seal Ring 25 Tie Rod 26 Nut 4 Screw 2 27 Steering Knuckle 2 Cotter Pin Nut 1 Washer 1 Pitman Arm Washer 2 Nut 2 Steering Knuckle 1 Nut 3 Steering Lock 6 17 6 Front Wheel Front Brake Suspension Steering Steering Stem Remove Steering Stem Dashboard front cover 6 12 Front wheel 6 2 Disconnect handlebar switch connector Hammer the lock pad flat with a flat screwdriver and hammer Remove Bolt 1 and Bolt 2 Steering stem bushing adapter plate Cotter pin Tie rod nut and washer Press down steering tie rod and separate from steering stem Cotter Pin Tissue Washer Remove fixing bolt of steering stem Lift steering stem with handlebar from vehicle Installation Reverse the removal procedure for installation NOTE Check steering after installation 3 3 Main cables and wires shall be routed properly chapter 1 Rear Cover Dashboard Steering Stem Handlebar Dashboard
73. e side A is in the right direction Face arrow mark B to the engine side Apply engine oil to starter clutch Apply thread locker to bolt and tighten to the specified torque Tightening torque of starter clutch bolt 26N m Material Thread Locker Install the starter driven gear Make that the starter driven gear turns in the opposite direction of the arrow mark B The gear cannot turn in the direction of the arrow Check starter driven gear bearing In case of anything unusual replace the bearing Remove starter driven gear bearing with special tool Install starter driven gear bearing with special tool Tool Bearing Installer Remover 15 47 15 Engine Removal Inspection amp Installation Electric Starter Gear Check the gear surface for scrap or damage Scrape or Damage Replace LEFT CRANKCASE COVER Check magneto stator coil 2 pickup coil 3 for damage burn or short circuit if any replace with new one Check bearing 4 for smooth turning If it is stuck replace with a new one Check oil seal 5 for damage Replace it if it s damaged Apply thread locker to the bolt when assembling Tightening torque for magneto coil bolt 10N m Apply lubrication oil to bearing 4 and lubricant grease to lip of oil seal 5 when assembling Recoil Starter _ Reply Thread Disassembly T Locker 1 Recoil starter 2 Bolt 3 Washer 4 Start
74. ear 25x10 12 Ground Clearance 275mm Min turning diameter 4 5m 4 8m Starting Electrical starting Recoil starting Engine type Single cylinder 4 stroke Liquid cooled 4 valves OHC Combustion chamber type Triangle Bore x stroke Valve Driving type SOHC chain driving 87 5mm X 82 0mm Engine Compression Ratio 10 2 1 Max power 24Kw 7000 rpm Max torque 36N M 5500 rpm Lubrication type Pressure amp Splash Oil pump type Rotor Oil filter type Full flow filter screen Cooling type Closed coolant circulation 1 5 1 Overhaul Information Item Parameter Air Filter type Sponge element filter Fuel Type Vacuum Diaphragm type device Carburetor Di MIKUINLE S209 iameter of mixing 36mm valve Type Wet auto centrifugal Clutch Operation mode Automatic CVT Parking amp Gear shifting a rae Gear type Bevel gear Initial Transmission Reduction ratio 2 938 Secondary Gear type Bevel Gear transmission Reduction ratio 2 938 Type Automatic CVT Parking amp Gear shifting Gearing Function Auto centrifugal Transmission ratio 2 88 0 70 Gear Final Ratio 1 333 24 18 bevel gear Secondary 1 952 41 21 Gapo Ratio Ratio Gears Low Gear 2 25 36 16 High Gear 1 35 27 20 Reverse Gear 3 828 Total Low Gear 5 857 High Gear 3 514 Reverse Gear 3 828 Steering angle Right 2 Brake tyne Front Pyar
75. embly Reverse the removal procedure for assembly Pay attention to the following Use new retainers Pay attention to the direction of the retainers Fit to the side where the thrust is as illustrated Coat the gears and shafts with engine oil before assembly Note Do not reuse the retainers Do not expand of the gap end of new retainers too Sharp Edge wide when assembling Make sure that all the retainers are properly fitted 15 40 15 Engine Removal Inspection amp Installation When assembling the guide bar take care not to assemble the two shift forks and springs in the opposite direction 7 1 Guide bar 2 Retainer 3 Left shift fork 4 Shift fork Spring small 6 5 Right shift fork 6 shift fork spring big 2 7 Spring seat 5 7 4 3 A H 2 d U ee f OIL PUMP Disassembly oil pump as illustrated 1 Oil pump housing 2 Dowel pin 3 Oil pump shaft 4 Straight pin 5 Inner rotor oil pump 6 Outer rotor oil pump 7 Oil pump cover Check oil pump housing and cover for cracks and damage Crack or damage Replace Measure top clearance a between inner and outer rotors and side clearance b between outer rotor and oil pump housing If the clearance exceeds the limit replace with new one Top Clearance 0 03 0 10mm Service Limit 0 15mm Side clearance 0 03 0 10mm Service Limit 0 12mm 15 41 15 Engine Removal Inspection amp Installation Oil
76. emove spark plug and mount it to spark plug cap get it earthed and check spark _ Weak spark or p No spark Normal spark Measure compression pressure Normal compression pressure Low or no gt Compression Try starting as operation Nearly start but starting failure hairs cannot be started Remove spark plug and check Wet spark plug gt again Dry spark plug Remove carburetor over 30 minutes connect ethylene pipes with fuel increment loop and blow No Air current No fuel in fuel tank Clogged fuel hose Clogged float valve Clogged fuel filter Clogged fuel tank cap breather hole Faulty spark plug Stained or damaged spark plug Faulty high tension coil or short circuit Faulty Ignition coil or short circuit Faulty ignition switch Faulty CDI unit Faulty pickup coil Faulty cylinder head Engine Service Worn or damaged Cylinder and piston ring Faulty cylinder gasket Deteriorated fuel Improper idle speed adjustment Secondary air intake into air intake pipe Improper ignition time Clogged air filter Carburetor overflow Excessive opening of throttle Clogged air filter Faulty fuel enrichment device 12 1 12 Troubleshooting Unstable Engine Running or Engine Stops Loosen drain screw and check No petrol in fuel tank the if fuel has reached carburetor No fuel Clogged fuel hose With Fuel 4 Remove spark
77. er pully Inspection Check sheave drum for burrs cracks or rust In case of any abnormal replace 15 48 15 Engine Removal Inspection amp Installation Recoil Starter Ifthe recoil starter works normally it s not necessary to disassemble it Cap Handle Handle Friction Plate Spring Clamp Pawl Spring Sheave Drum Boh Spri Coil Spring Nut 1 2 3 4 5 6 T 8 9 10 DISASSEMBLY Remove nut 10 Remove the parts from the starter housing WARNING The coil spring may quickly unwind and cause injury when the sheave drum is opened Wear proper hand and eye protection beforehand Inspection Check all the parts for damage Damage Replace 15 49 15 Engine Removal Inspection amp Installation Assembly Reverse the removal procedure for installation and pay attention to the following Install sheave drum rope coil spring damper Wind the rope clockwise around the sheave drum three times and hook the rope at a of sheave drum WARNING The coil spring may quickly unwind and cause injury when the sheave drum is opened Wear proper hand and eye protection beforehand Install coil spring and sheave drum Apply lubricant grease to spring Hook coil spring end to the starter housing wind the coil spring clockwise Hook the other end of coil spring to hook part of sheave drum Install spring clamp frict
78. er to 1x1000 position Auxiliary starter relay coil resistance 90 1000 Battery 18 6 Ignition System Fuse Switch Ignition Coil Ignition Coil Primary Peak Vaoltage Remove spark plug cap install a new spark plug into cap and connect as illustrated on the right with cylinder head as ground Connect multimeter and peak voltage adaptor as under Probe Green lead wire or Ground Probe Black Yellow lead wire Note Make sure battery voltage 212V ignition coil lead wire is connected Refer to user s manual when using multimeter and peak voltage adaptor Shift the gear to neutral position and turn the ignition switch to the ON position Press the starter button and crank the engine several seconds then measure the ignition coil primary peak voltage Repeat above steps several times and take the measured highest ignition coil primary peak voltage Set the multimeter to AC position 18 Electrical System Wave Form a JArrangemeng Ignition Power Circuit Source Circuit 9 Converts Ignition Coil Bk Ignition Coil Spark Plug 18 7 18 Electrical System Ignition Coil Primary Peak Voltage 2150V aution Do not touch the tester probes or the spark plug to avoid electric shock Ifthe voltage is lower than the standard value check ignition coil and pick up coil Ignition Coil Resistance Disconnect ignition coil lead wire and spark plug cap Remo
79. f battery tester VVV WV If the open voltage is less than 12 4V charge the battery normally to raise the open voltage Overhaul standard 8 Battery Charging System Item Standard Model Permanent magnet alternator AG magneto Output 3 phase AC Resistance of charging coil 20 C 0 2 0 30 3 phase loop rectification Rectifier Type controllable parallel connection regulated voltage Capacity 12V10Ah Current Leakage Less thanimA Voltage between Fully charged 12 8V Battery terminals Insufficient charge Less than 11 8V Charging current time Standard 0 9A 5 10hours Fast charge 4A 60minutes Troubleshooting Battery overflow Check battery with recommended test meter YUASA BM310 or equivalent Correct Faulty Battery Disconnect rectifier and measure current leakage again Measure the current leakage of battery 8 5 Current less than 1mA Current below 1mA Incorrect Correct Inspect the charging coil of AC magneto Correct Incorrect Resistance 0 2 0 3Q Incorrect Inspect monomer voltage of battery and record it 8 4 Start engine turn on headlight with high beam Inspect battery s voltage between terminals at the engine speed of 5000rpm 8 5 Short circuit with main cable Faulty ignition switch Faulty rectifier e AC magneto has short or open circuit gt Standard monomer voltage lt charge Correct Charging sys
80. ghten to the specified torque Bearing limit nut Tightening torque 80N m Tighten Nut 1 to the specified torque Front output shaft nut tightening torque 97N m Driven Bevel Gear Remove nut 19 washer 18 coupler 17 and oil seal 16 Protect end thread of driven bevel gear with proper device Fix bevel gear cover 14 and press out driven bevel gear Place a clean rag under bevel gear cover Remove bearing limit nut 10 with special tool and remove bearing Check driven bevel gear 8 surface for scratches wear Scratch or wear gt Replace Check free turning of bearing 9 and 11 Replace with a new one if any abnormal is found Use new oil seal 16 and O ring 12 when assembling Adjust washer 13 if any of right crankcase driven bevel gear 8 or driven bevel gear cover 14 is replaced Refer to bevel gear adjustment for details Apply lubrication oil to bearing 9 and 11 and oil seal 16 O ring Apply thread locker to nut 10 and tighten to the specified torque Tightening torque 110N m Tool driven bevel gear nut wrench Driven bevel gear nut tightening torque 150N m Bevel Gear Washer Adjustment Adjust washer and when replacing crankcase and or bevel gear and or bevel gear cover 19 43 Bevel Gear Note Proper bevel gear engagement depends on that the gear backlash and tooth contact are within the proper range Bevel Gear Backlash Install drive and driven gears to the
81. he master cylinder in the installation position and fix it to the frame Refer to Chapter 1 for proper routing of brake hose P T Pipe Brake Hose Check brake efficiency after installation j Brake Hose T Pipe Remove Front right inner fender 2 12 Bolt 1 T Pipe Installation Reverse the removal procedure for installation Note Check front and rear brake linkage after installation Bolt 1 Bolt 2 Brake Hose Cross Pipe S Remove Front right inner fender 2 12 Bolt 1 Bolt Brake hose cross pipe Cross Pipe Brake Hose 6 6 6 Front Wheel Front Brake Suspension Steering Installation Reverse the removal procedure for installation NOTE Note Check front and rear brake linkage after installation Front Suspension system Front left Suspension NOTE DO NOT remove both left and right suspension at the same time to avoid fall down of the vehicle Park the vehicle on a level ground and securely support front part of the vechicle Removal Front wheel 6 3 Front wheel hub 6 3 Front brake caliper 6 4 Bolt 1 Nut 1 Bolt 2 Nut 2 Bolt 3 Nut 3 Bolt 4 Nut 4 Remove slotted nut Remove tie rod Pull out steering knuckle from CV joint Remove front left suspension Nut Shock Absorber Bolt w3 Front Left Absorber Front Left Arm Bolt 3 Lower Bolt 1 Front right absorber Nut 1 Front right arm upper Circlip bearing Up
82. ht Protector Repeat the above procedure of removal and installation for front right protector 2 Vehicle Body Muffler Front Right Inner Fender Bolt Bolt 1 Bolt 2 Front Protector LH Bolt 1 2 Vehicle Body Muffler Rear Left Protector Rear Protector LH Bolt 1 Bolt 2 Remove Bolt 1 Bolt 2 Rear left protector Installation Reverse the removal procedure for installation Rear Right Protector Repeat the above procedure of removal and installation for rear right protector Bumper Bumper Protector Remove 2 bolts from engine skid plate front Bolt Bumper Bolt 1 Bolt 2 Bolt 3 Bolt 4 Remove bumper with bumper protector Bolt 1 Bolt 2 Bolt 3 Bolt 4 Remove Bolt 5 and Bolt 6 for bumper and front rack Bolt 5 Bolt 6 2 Vehicle Body Muffler Bumper Protector Remove Remove bumper with bumper protector 2 13 Remove tapping screw of protector from bumper Installation Reverse the removal procedure for installation Bumper Cap Remove There are four pieces of bumper caps each at the end of bumper pipe Pull bumper cap out from the end of bumper Cap Bumper Installation Press bumper cap into bumper pipe 2 14 2 Vehicle Body Muffler Front Vent Grille Remove Front fender 2 8 Bumper 2 13 Bolt 1 Bolt 2 Bolt 3 Bolt 4 Front vent grille Note For removal of front vent grille only Just remove 2 fi
83. iagram Wiring Diagram Troubleshooting Engine Engine Overhaul Information Checks amp Maintenance Engine Removal Inspection and Installation Carburetor Cooling and Lubrication System Electrical System Troubleshooting Conversion Table Item Example Conversion Pressure 200Kpa 2 00kgf cm 1kgf cm 98 0665kpa 1kpa 1000pa 33kpa 250mmHg 1ImmHg 133 322Pa 0 133322Kps Torque 18N m 1 8kgf m 1kgf m 9 80665N m Volume 419ml 1ml 1cm 1cc 11 1000cm Force 12N 1 2kgf 1kgf 9 80665N 1 Overhaul Information CAUUIONS 93 cscs a eaa a aa 1 1 Tightening Torque 4 1 10 VIN Number amp Engine Number 1 4 Lubricant Sealing Agent 1 11 Main DataTable iscsi cus souesy nee Gugee oes 1 5 Cable Routing 66 1 12 Overhaul Data Tabless css de eoccc ued soesesdstteaes 1 6 Cautions Safety Cautions 1 Hazardous components in exhaust Do not run the engine in a enclosed or poorly ventilated place for long time 2 Do not touch the engine or muffler with bare hands after the engine has just stopped to avoid scalding Wear long sleeve work clothes and gloves for operation 3 Battery liquid dilute sulfuric acid is highly caustic and may cause burns to skin and eyes Flush with water if splashed to skin and get immediate medical attention Flush with water if splashed to clothes to avoid burns Keep battery a
84. imit Add coolant or diluted original liquid Recommended coolant CFMOTO coolant Standard density 50 Freezing temperature of coolant varies according to the different mixture ratio Adjust the mixture ratio according to the lowest temperature in the place where the vehicle is used If the coolant reduces very fast check if there is any leakage The cooling system may be mixed with air when there is no coolant in the reservoir tank and the air should be discharged before adding coolant Reservoir Tank Lower Coolant Leakage Check radiator hose water pump water pipes and joints for leakage In case of any leakage disassemble and do further check Refer to Chapter 4 Check the radiator hose for aging damages or cracks The rubber hose will naturally get aged after a period of service time The aged hose may get cracked when the cooling system is heated Nip the hose with fingers and check if there are any tiny cracks In case of any abnormal replace with a new hose Check the clamps of the coolant pipes and hose Tighten properly in case of any looseness Check radiator fins for mud and dust clog or damage Correct the bent fins clean the mud with water and compressed air When the damaged area of the radiator fin is over 20 replace with a new radiator 3 13 3 Checks amp Adjustment Check Water Temperature Gauge When engine is not working the water temperature should be in the 0 p
85. in pressure Note Do not apply pressure over the specified pressure 108kpa 1 1kgf cm7 or the cooling system may be damaged In case there is any pressure leakage check the pipe joint parts joints of water pump and drainage 4 5 Replacing Coolant Air Discharge Preparation of coolant Coolant is toxic DO NOT drink or splash it to skin eyes and clothes lf coolant splashes in your eyes thoroughly wash your eyes with water and consult a doctor lf coolant splashes on your clothes quickly wash it away with water and then with soap and water lf coolant is swallowed induce vomit immediately and see a physician Store the coolant properly and keep it away from reach of children Note Mix the coolant undiluted with soft water according to the temperature 5 C lower than the actual lowest local temperature Coolant should be made from undiluted coolant with soft water Standard density of coolant 30 Recommended coolant CFMOTO coolant Direct application without having to be diluted Drainage of coolant Remove radiator cap cover Note Open the radiator cap after the coolant is fully cooled Remove Front top cover 2 8 Radiator cap 4 3 4 Cooling System Desnsimeter Radiator Cap Undiluted Coolant N Coolant Radiator Cap 4 4 4 Cooling System Remove drain bolt Remove drain bolt seal gasket from water pump and drain coolant After dr
86. instruction only on the disassembly inspection installation of Left Constant Velocity Drive Shaft of front axle Refer to Left Constant Velocity Drive Shaft for disassembly inspection installation of other drive shafts 55 Left Constant Velocity Drive Shaft Front Axle Disassembly NOTE Maintenance of Left Constant Velocity Drive Shaft of front axle only does not require removal of front suspension Remove Front wheel 6 3 Front left brake caliper 6 4 Front left wheel hub 6 3 Check dust boot Damaged dust boot Replace Shake constant velocity drive shaft check the agility of rzeppa universal joint free turning of bearing and any gap between rzeppa constant velocity joint and spline Stagnated turning noise gap with spline gt Replace Warning An accident may occur if the rzeppa constant velocity joint cannot run freely because of the loss of control of wheel steering Installation Press ball pin into arm with special tool Reverse the removal procedure for installation Note There should be no rocking or sway with the installed left and right arms Tightening Torque 40 50 Nem 6 11 6 Front Wheel Front Brake Suspension Steering Steering system gsy Rear Cover Dashboard Tapping Screw 1 Handlebar Tapping Screw 2 Dashboard Front Cover Disassembly Remove 2 tapping screws Bolt1 Dashboard front cover Installation Reverse the removal procedure for installat
87. into crankcase Remove tensioner plate Cylinder Head Remove cylinder head bolt Remove cylinder head bolts diagonally Remove cylinder head Note Take care not to drop dowel pin into crankcase Cylinder Remove dowel pin and cylinder head gasket Remove timing chain guide 15 Engine Removal Inspection amp Installation Remove cylinder bolt Remove cylinder Note Take care not to drop dowel pin into crankcase Remove dowel pin and cylinder gasket Note When performing above removal process be sure to hook up timing chain to prevent it from falling into crankcase Piston Remove piston pin circlip with long nosed pliers Note Put a clean rag under piston so as not to drop piston pin circlip into crankcase Remove piston pin and piston Notes When installing piston make sure its identification conforms to that of cylinder When removing piston pin clean off burrs of piston pin hole and groove If it s difficult to remove the piston DO NOT hammer use a special remover Tool Piston Pin Remover AEngine Left Side Starting Motor Remove 2 bolts of starting motor Remove starting motor Oil Filter Remove oil filter with special tools Tool Oil filter Remover Sector Gear Remove bolt 1 of gearshift rocker arm Remove gasket 2 and gearshift rocker arm 3 Remove bolt of sector gear housing cover Remove wire clip and sector gear h
88. ion Right Handlebar Switch Remove Front top cover 2 4 Right handlebar switch connector 2 bolts Right handlebar switch Installation Install right handlebar switch 6 15 6 Front Wheel Front Brake Suspension Steering Left Handlebar Switch Disassembly Remove 2 Screws Left handlebar switch connector Left handlebar switch Installation Install left handlebar switch 6 15 Rear View Mirror Disassembly Turn counter clockwise and loosen nut Remove left rear view mirror by turning it counter clockwise Note Left rear view mirror is right threaded Turn counter clockwise for removal Connector Handlebar Switch Turn clockwise and loosen nut Remove right rear view mirror by turning it clockwise Note Right rear view mirror is left threaded Turn clockwise for removal Rear View Mirror LH Installation Reverse the removal procedure for installation 6 13 6 Front Wheel Front Brake Suspension Steering Handlebar Dashboard Rear Cover Disassembly Remove Dashboard front cover 6 12 Left amp right handlebar switch 6 12 Separate left amp right master cylinders from handlebar Remove Screw1 Screw2 Screw Rear Cover Dashboard Dashboard rear cover 4 fixing bolts Handlebar Installation Reverse the removal procedure for installation Tightening Torque 20 30N m 2 0 3 0kgf m Note Main cable throttle cable brake hose
89. ion GENERAL PRECAUTIONS Warning Proper service and repair procedures are important for the safety of operator and the safety and reliability of the vehicle When two or more persons work together keep reminding each other for safety purpose When start the engine indoors make sure that the exhaust gas is forced outdoors f use hazardous or flammable material please strictly operate according to manufacturer s operation manual Operate in a well ventilated place Never use gasoline as a cleaning solvent Do not touch the engine oil radiator or muffler with bare hands to avoid scalding before it is cooled Check all the lines and fittings related to the system for leakages after repairing fuel cooling lubricating or exhaust system Do not dispose used oil coolant or defective parts optionally for environmental purpose CAUTION Use genuine CFMOTO parts or their equivalent Place and store the disassembled parts separately in order for correct assemble Use special tools according to service manual Make sure that all parts used in reassembly are clean lubricated them when specified Use the special lubricants sealants and greases Pre tighten the bolts nuts and screws then tighten according to the specified torque from big to small and from inner side to outer side Fix torque screw with torque wrench clean grease or oil from the screw thread before fixing Check the parts after disassembling c
90. ion plate and bolt Turn sheave drum three times for pretension of coil spring Install handle and handle cap Tie aknot on handle and release knot Lead the rope through the hole of the starter housing and tie a knot so that the rope would not be drawn back 15 Engine Removal Inspection amp Installation CVT Cover Remove screw 5 oil seal limitator 4 Remove oil seal 3 with special tool Check bearing 2 for free turning In case of any abnormal remove with special tool and replace with a new bearing Apply lubrication oil to outer ring of bearing and install bearing with special tool Check bearing for smooth turning Apply grease to bearing inner side Apply grease to oil seal lip and install oil seal with special tool Note Use a new oil seal Install oil seal limitator and tighten screw after applying thread locker Tool Bearing Remover Oil Seal Remover Bearing Installer CVT Case Check bearing 5 for smooth turning In case of any abnormal remove screw 3 and bearing retainer 4 and replace with a new bearing Check oil seal 7 In case of any damage replace it Apply grease to oil seal lip and install with special tool Apply lubrication oil to bearing 5 and install with special tool Check bearing for smooth turning The seal side of bearing 5 should face bearing retainer 4 Install bearing retainer 4 and screw 3 Install oil seal 1 into clutch housing 2 with s
91. ious burn Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done after the engine is just stopped Gasoline is highly flammable smoking is strictly forbidden in the work place Keep alert on the electrical sparks Besides vaporized gasoline is highly explosive so work should be done in a well ventilated place Be careful that your hands or clothes not get nipped by the turning or movable parts of the driving system Note The vehicle should be parked on hard and level ground Periodic Maintenance Table The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy Maintenance intervals are expressed in terms of kilometer miles and hours whichever occurs first Note More frequent maintenance may be required on vehicles that are used in severe conditions Interval Km Initial 200 Every 1000 Every 2000 Remark Miles Initial 100 Every 600 Every 1200 Item Hours Initial 20 Every 40 Every 80 Valve Clearance B i IN 0 05 0 10 EX 0 17 0 22 Idle Speed 1300 100r Min Spark Plug No carbon deposit Replace every 6000Km Gap 0 8 0 9mm Air Filter C C Replace every 2000Km Fuel Hose Carburetor Replace every 4 years Clutch Drive Belt R Oil Filter R R Coolant Level Water Hose amp Pipes
92. iper Cracks Oil leakage Replace Installation Reverse the removal procedure for installation Note Refer to Chapter 1 for brake hose routing Rear Brake Disc Remove Rear left wheel 7 3 Rear drive shaft Rear brake caliper 7 4 6 shear bolts Parking brake 7 4 Rear brake disc 6 3 Inspection Brake Disc Thickness lt 6 5mm Replace Installation Reverse the steps of removal for installation Note Refer to Chapter 1 for brake hose routing Parking Brake Remove Rear left wheel 7 3 Rear drive shaft Rear brake caliper 7 4 6 shear bolts Parking brake 7 Rear Wheel Rear Brake Suspension Fi Za rif MParking Brak Retainer t a o i Fr 4 7 4 Rear Suspension System Rear Right Suspension NOTE 7 Rear Wheel Rear Brake Suspension DO NOT remove both left and right suspension at the same time to avoid fall down of the vehicle 11 10 Disassembly Stabilizer Bar Remove Bolt 1 6 Bolt 2 7 Bolt 3 10 Remove Stabilizer Bar 3 Installation 17 Bolt 4 Nut 2 Bolt5 Right Ball Pin Nut 3 Rear Right Upper Arm Rear Right Lower Arm Bolt 7 11 12 13 14 15 16 Bolt 6 17 18 19 20 Bolt 8 Bolt 4 11 Bracket 8 and 5 Rubber Support 4 and 9 Nut 2 2 Nut 10 12 Reverse the removal procedure for installation Nut 7 Left Ball Pin 1 Right Ball Pin 14 7 Rear Wheel Rear
93. k if oil is between upper and lower limit If the engine oil is insufficient fill more oil until the sufficient oil is obtained Engine Oil SAE10W 40 classification SF or SG Note Keep the engine in a plan position 7 Lower Limit Do not tighten oil dip rod when measuring oil level Replacing Engine Oil Remove left side cover 1 oil dip rod 2 drain bolt 3 and washer 4 Drain out the engine oil while the engine is still warm Clean oil dip rod drain bolt and washer with solvent Install washer and drain bolt Drain Bolt 30N m Fill engine oil about 1900ml 14 8 Install oil dip rod start the engine and allow it to run for several minutes at idling speed Turn off the engine and wait for about 3 minutes and then check the oil level on the dipstick Caution The engine oil should be changed when the engine is warm If the oil filter should be replaced replace engine oil at the same time Replacing Oil Filter Remove relative parts see Replacing Engine Oil Remove oil filter with the special tool Install washer and drain bolt Install new oil filter with the special tool Fill engine oil about 2000ml and check see Replacing Engine Oil Tool Oil Filter Wrench Engine Oil Capacity When replacing oil 1 9L When replacing oil filer 2 0 L Engine overhaul 2 2 L Inspection of External Oil Pipe Check external oil pipe for leakage or damage Leakage or Damage
94. ke lever Omm Tightening torque Nut Tie rod 40 50N m Lock nut steering stem 110 120N m Nut front wheel axle 110N m Fixing bolt nut absorber 40 50N m Nut front rim 50 60N m Nut front wheel axle 110 130N m 6 Front Wheel Front Brake Suspension Steering Special tools Rod bearing remover Head 10mm bearing remover Handle A Driving Tool Sleeve Driving Tool Guide tool 10mm Locknut spanner Bearing remover set Rotor puller Remover shaft Remover hammer Assembling tool shaft 28x30 Troubleshooting Heavy Steering gt Upper thread is over tightened gt Steering bearing is damaged or worn gt Inner amp outer bearing races are damaged worn or stepped gt Steering stem is distorted gt Tire pressure is too low gt Low tire pressure gt Worn tire Shaking Handlebar gt Steering bearing is damaged or not well tightened gt Right and left shock absorbers are not matched gt Deflected tires gt Deformed frame gt Worn tires gt Shaking of wheel bearing Vibration of Front Wheel Wheel rim distorted Faulty wheel bearing Faulty tire Improper tightening of wheel axle Improper balance of wheels VV VYY Wheel Cannot Turn Freely gt Steering bearing is damaged or worn gt Front wheel axle is bended gt Brake drag Front Suspension Is Too Soft gt Weakened front shock absorbers gt Tire pressure is too low Front Suspension Is Too Hard gt Front shock absorber is bended
95. l leakage aged oil seal damage Replace 6 8 6 Front Wheel Front Brake Suspension Steering Installation Reverse the removal procedure for installation Refer to Front Right Shock Absorber for disassembly installation and inspection of Front Left Absorber Suspension Arms Note This vehicle has 8 suspension arms The removal disassembly inspection and installation of the 8 arms are the same This service manual will only introduce the removal disassembly inspection and installation of Front Left Upper Arm Front Left Lower Arm Refer to Front Left Upper Arm Front Left Lower Arm for removal disassembly inspection and installation of other suspension arms Front Right Arm Disassembly Remove Front right absorber 6 8 Bolt 9 38 and Nut 7 56 Bolt 8 34 and Nut 5 30 Bolt 7 25 and Nut 3 22 Bolt 6 21 and Nut 2 17 Remove wheel brake caliper and wheel hub before removing absorber Remove tie rod before removing bolts Pull out steering knuckle from CV drive shaft before removing front right arm Inspection Ball Pin Check if Upper Ball Pin 6 for Front Right Upper Arm 4 and Lower Ball Pin for Front Right Lower Arm 28 can turn freely in all directions Check clearance of upper and lower ball pins Clearance out of range no free turning Replace Ball pin Right Steering Knuckle Inspection Damaged steering knuckle Replace Check wheel hub bearing for free turning and cle
96. lant In case of accidental swallow or stains flush with plenty of water and Boiling Point 120 consult the doctor immediately Keep coolant away from reach of children 110 100 Inspection of Cooling Circuit Remove radiator cap and connect tester to 0 10 20 30 40 50 60 filler Density Warning Do not open the radiator cap when the engine is still hot Give a pressure of 120 kPa and check if the cooling system can hold this pressure for 10 seconds f the pressure drops during this 10 seconds it indicates that the there is leakage with the cooling system In this case check the complete system and replace the leaking parts or components Warning When removing the radiator cap tester put a rag on the filler to prevent splash of coolant Warning Do not allow a pressure to exceed the radiator cap release pressure Inspection and Cleaning of Radiator and Water Hoses Radiator Cap Remove radiator cap Install radiator cap to cap tester Slowly increase pressure to 93 3 122 7 kPa and check if the cap can hold the pressure for at least 10 seconds f the cap cannot meet the pressure requirement replace it Radiator Cap Valve Opening Pressure Standard 93 9 122 9 kPa Tool Radiator Cap Tester Radiator Inspection and Cleaning Remove dirt or trash from radiator with compressed air Correct the radiator fins with a small screwdriver
97. lb Turning light 12V 10Wx4 Dashboard indicator light 12V 1 7W Other indicators 12V 3 4W 1 9 1 Overhaul Information Tightening torque Item Torque N m kgf m Item Torque N m kgf m 5mm Bolt nut 5 0 5 5mm Screw 4 0 4 6mm Bolt nut 10 1 0 6mm Screw 9 0 9 8mm Bolt nut 22 2 2 6mmSH Bolt with flange 10 1 0 10mm Bolt nut 34 3 5 6mm Bolt with flange nut 12 1 2 12mm Bolt nut 54 5 5 8mm Bolt with flange nut 26 2 7 10mm Bolt with flange nut 39 4 0 For others not listed in the chart refer to the standard tightening torque Notes 1 Apply some engine oil on the part of screw thread and contact surface ien Thread Dia Quantity Torque mm N m kgf m Front Upper Bolt Engine M8x60 35 45 Rear Upper Bolt Engine M10x1 25x110 1 40 50 Front Upper Bolt Engine Bracket M8x14 1 35 45 Rear Upper Bolt Engine Bracket M8x14 1 35 45 Lower Mounting Bold Engine M12x1 25x140 2 50 60 Bolt Swing Arm M10x1 25x70 1 40 50 Bolt Rear Absorber M10x1 25x50 4 40 50 Bolt Front Absorber M10x1 25x50 4 40 50 Bolt Rear Wheel Support M10x1 25x100 4 40 50 Mounting Nut Rim 901 07 00 02 M20 1 50 60 Nut Rim Shaft 901 07 00 03 M10 4 110 130 Mounting Screw Rear Brake Pump M6x25 2 18 22 Bolt Rear Brake Caliper M10x1 25x20 2 40 50 Bolt Front Brake Disc 901 08 00 03 M8 8 25 30 Bolt Front Brake Caliper M8x14 4 35 45 B
98. lean the parts before measuring Check parts for tightness and proper operation after assembling Replace the disassembled washers o rings seals locknuts lockwashers cotter pins circlips with new ones 13 2 13 Engine Overhaul Information FUEL OIL COOLANT Fuel Use unleaded gasoline with octane number over 90 OIL Use a premium quality 4 stroke motor oil to ensure ERREN 20W W 4 lt k l i me longer service life of your vehicle Use only oils that mpi meet API service classifications SF or SG and that aler lt i have a viscosity rating of SAE10W 40 If oil with a ETT rating of SAE 10W 40 is not available select an Pe 30 20 10 0 10 20 30 40 alternative according to the chart par 22 4 14 32 50 68 86 104 ENGINE COOLANT Since antifreeze also has corrosion and rust inhibiting properties always use coolant containing antifreeze even if the atmospheric temperature does not go below the freezing point It is suggested that the freezing point of antifreeze should be 5 C lower than the lowest ambient temperature where the vehicle is used Recommended Coolant 35 C antifreeze corrosion resistant high boiling point coolant arning Coolant is poisonous Never drink it Store it properly aution DO NOT mix coolant with that of other engines BREAK IN PROCEDURES During manufacturing only the best possible material are used and all machined parts are finished to a very high standard It is still
99. lever Continuity Release the brake lever No continuity No continuity Replace brake light switch Horn Inspection Remove front vent grille 2 15 Disconnect horn Connect with a fully charged 12V battery and check if the horn sounds Faulty Horn Replace Removal and Installation Remove horn plug Remove fixing bolt and horn Reverse the removal procedure for installation Dashboard Run the vehicle at low speed and check if the speed indicator moves Faulty speedometer Replace Removal and Installation Remove front top cover 2 4 Remove front cover of dashboard 3 12 Disconnect dashboard wire connector Remove fixing nut and remove dashboard in the direction as illustrated on the right Reverse the removal procedure for installation Note Main cables and wires shall be routed properly 10 Lighting Instruments Switches Dashboard Connector Dashboard 10 9 10 Lighting Instruments Switches Fuel Sensor Fuel Sensor Remove Fuel tank top cover 2 8 4 fixing bolts Fuel sensor Disconnect 2P connector Inspection Remove fuel sensor refer to above steps Connect 2P connector Turn ignition switch to ON Shake fuel sensor float with hand locate the float position and check if it conforms to the fuel gauge reading Non conformity check main cable for damage or short circuit Check fuel sensor and fuel gauge Connector Fuel Sens
100. lty CDI unit Incorrect Refer to fuel system Engine Service Air intake Faulty tightening of carburetor joint Faulty reed valve seal washer gt joint No Air intake Remove spark plug and mount it Weak spark or Stained or damaged spark plug to spark plug cap get it earthed No spark Faulty Ignition coil and check spark Normal spark Faulty high tension coil or short circuit Faulty ignition switch Faulty CDI unit REMOVE Vel Cnucainent Aice No Continuity Broken cable of fuel enrichment device wire lead and check continuity Faulty fuel enrichment device Normal Continuity Connect device wire battery Connect uel enrichment lead with for 5 Minutes ethylene pipe with fuel increment loop and blow No air ine With Air current Faulty fuel enrichment device Clogged carburetor gt 12 4 12 Troubleshooting Poor Engine Performance in Middle or High Range check ignition timing Correct 4 check carburetor Normal Correct Clogged gt Remove fuel enrichment device wire lead and check continuity Normal continuity Connect fuel enrichment device wire lead with battery for 5 Minutes Connect ethylene pipe with fuel increment loop and blow Not air current With Air current _ Faulty pulse generator Faulty CDI unit Clean Broken starting enriching
101. m disassembly only after the muffler is cooled down Remove Seat 2 3 Right side panel 2 7 Nut1 Nut 2 for exhaust pipe elbow Remove Bolt 1 Remove Bolt 2 Bolt 3 Remove muffler Installation Reverse the removal procedure for installation Note Replace sealing gasket when installing the muffler 2 Vehicle Body Muffler 2 Vehicle Body Muffler Visible Parts Top Cover Fuel Tank Rear Cover Dashboard p Front Cover Dashboard Ornament Panel Front Rack Ornament Panel Rear Rack Front Rack Seat Rear Top Cover Front Top Cover Bumper Rear Rack Side Panel Footrest Board Bumper Protector Front Fender Rear Fender Rear Protector l Front Prbtector Inner Fender 3 Checks amp Adjustment Overhaul Info 2 c eeeeee eee eees 3 1 Suspension System 2 605 3 9 Inspection amp Maintenance 3 2 Gear Shifting Fuel Device 3 10 Steering Stem Brake System 3 5 Cooling System 0 ceseeee ees 3 12 Wheels esiis girder devine unaia 3 7 Lighting System c ceeeeeeeeees 3 14 Overhaul info Operation Cautions Note DO NOT keep the engine running for long time in a poorly ventilated or enclosed place because of the harmful components like CO etc in the exhaust gas The muffler and engine are still very hot when the engine is just stopped Careless contact may cause ser
102. move Bolt 1 Bolt 2 Remove rear rack Installation Reverse the removal procedure for installation Tightening Torque Fixing Bolt Rear Rack 35 N m 45N m Ornament Panel Front Rack Remove Remove four tapping screw from front rack Installation Reverse the removal procedure for installation Ornament Panel Rear Rack Repeat above procedure for removal and installation of ornament panel rear rack Front Top Cover Remove Remove front rack 2 2 Push upward plastic screw from front fender bottom with a flat screwdriver Remove plastic screw and plastic screw seat Separate clasps of top cover from fuel tank and front fender as illustrated on the right Push forward and remove front top cover 2 Vehicle Body Muffler Bolt 1 Bolt 2 il yew Ornament Panel Front Rack Plastic Screw Seat Front Top Cover Front Top Cover Installation Reverse the removal procedure of installation Rear Top Cover Remove Rear rack 2 3 Separate clasps of rear top cover from rear fender Remove rear top cover Installation Reverse the removal procedure and direction for installation 2 Vehicle Body Muffler 2 5 2 Vehicle Body Muffler Left Side Panel Top Cover Fuel Tank Remove Seat 2 3 Remove Bolt 1 for left side panel and fuel tank top cover Left Side Panel Bolt 1 Bolt 2 Remove Bolt 2 for left side panel and front fender Front Fender Remove screw for lef
103. mp Installation I Engine Removal APreparation before engine removal Prepare a proper tray used for load of components Prepare necessary removal and assembly tools Drain up engine oil 11 8 Drain up coolant 11 10 A Engine Periphery Water Hose Pipe Remove water hose clamp and Remove water hose Remove screw and water hose Left Side Cover Remove 6 bolts M6X20 of left side cover Remove left side cover Recoil Starter Remove 4 bolts M6X12 of recoil starter Remove recoil starter Inspection Plug Remove inspection plug with screwdriver AEngine Front Side Spark Plug Remove spark plug with special wrench Tool Spark Plug Wrench Turn crankshaft align T D C line Aon magneto rotor with mark B of left crankcase 15 Engine Removal Inspection amp Installation pis Cylinder Head Cover Remove valve adjusting cover Remove1z2 bolts of cylinder head cover Remove cylinder head cover Timing Chain Tensioner Remove screw plug insert a flat screwdriver into slot of timing chain tensioner adjuster turn it clockwise to lock tensioner spring Remove tensioner fix bolt Remove tensioner and gasket Camshaft Loosen timing sprocket bolt Remove timing sprocket bolt and lock 15 3 Remove C ring D Remove timing sprocket from camshaft remove camshaft Note Take care not to drop spacer bolt bolt lock and C ring
104. nal blue yellow green Turn ignition switch to the ON position and start engine Peak voltage over 0 8V Note When measuring the voltage do not touch the terminal with finger to avoid electric shock If peak voltage obtained from CDI unit connector is improper measure again the peak voltage on the AC magneto 2P connector 9 Ignition System CDI Unit 2P Connector Pickup Coil Pickup Remove AC magneto connector Water pump inlet hose and outlet hose and drain coolant Chapter 4 Crankcase breather hose Engine Service Muffler Chapter 2 Engine right side cover Engine Service Note Stator is installed on the right side cover and is attached by the magnet of rotor Be careful not to hurt the fingers when removing Disconnect primary terminal of ignition coil Loosen bolt remove AC magneto stator and pickup Installation Reverse the removal procedure for installation Ignition Coil Remove left side panel 2 6 Remove spark plug cap from spark plug Engine Service Loosen bolt and remove ignition coil Installation Reverse the removal procedure for installation Note Wires cables and hoses should be routed properly Chapter 1 9 Ignition System Stator A C Magneto Connector Ignition Coil Ignition Coil 9 Ignition System Ignition System Diagram Ignition Switch CDI Unit Spark Plug R Starting Relay
105. nd liquid away from reach of children 4 Coolant is poisonous Do not drink or splash to skin eyes or clothes Flush with plenty of soap water if splashed to skin If splashed into eyes flush with water and consult the doctor If drinking the coolant induce vomit and consult the doctor Keep coolant away from reach of children 5 Wear proper work clothes cap and boots If necessary were dust glass gloves and mask 6 Gasoline is highly flammable No smoking or fire Also keep against sparks Vaporized gasoline is also explosive Operate in a well ventilated place 7 When charged Battery may generate hydrogen which is explosive Charge the battery in a well ventilated place 8 Be careful not to get clamped by the turning parts like wheels and clutch 9 When more than two people are operating keep reminding each other for safety purpose Cautions for Disassembling and Assembling Use genuine CFMOTO parts lubricants and grease Clean the mud dust before overhauling Store the disassembled parts separately in order for correct assemble Replace the disassembled washers o rings piston pin retainer cotter pin with new ones OV ce E Co Elastic retainers might get distorted after disassembled Do not use the loosened retainers 1 1 10 11 12 13 14 15 16 17 18 19 20 21 1 Overhaul Information Clean and blow off the detergent after disassembling the parts Apply lubricants on the s
106. necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life Refer to the following break in engine speed recommendations For better performance and durability a new engine requires a run in time of 20 hours as under 0 10 Hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of vehicle from time to time Do not operate it at one set throttle position 10 20 Hours Avoid prolonged operation above 3 4 throttles Rev the vehicle freely but do not use full throttle at any time Note Keep the daily maintenance during the run in time and eliminate the troubles if any After 20h run in time do the maintenance according to the owner s manual for normal operation of the ATV 13 3 13 Engine Overhaul Information Engine Exterior and Engine No Remove cover to see Engine Number View From Engine Right Side 13 4 13 Engine Overhaul Information Engine Specification REF ITEM Type SPECIFICATION NO 1 Type Single Cylinder 4 Storke Liquid cooled 4 Valve SOHC 2 Bore and stroke 87 5mmx82 0mm 3 Displacement 493ml 4 Compression ratio 10 2 1 5 Lowest continuous idle speed wi
107. nes produces abnormal noise or vibration or lacks power output Any of these symptoms could be caused by wear of camshaft Note Do not try to disassemble the camshaft automatic decompression assembly It is not serviceable f Water Temperature Sensor Apply Lubricant G 15 21 15 Engine Removal Inspection amp Installation Automatic Decompression Move the automatic decompression weight with hand and check if it is operating smoothly If it is not working smoothly replace with a new camshaft automatic decompression assembly Cam Wear Worn cams can often cause mistimed valve operation resulting in reduced power output The limit of cam wear is specified for both IN and EX cams in terms of cam height a Measure with a micrometer the cam height Cam height out of range Replace Cam height service limit IN 33 130mm EX 33 200mm Tool micrometer 25 50mm Camshaft Journal Wear Check whether each journal is worn to the limit by measuring camshaft journal oil clearance with the camshaft installed Camshaft journal oil clearance Service limit 0 45mm Check according to the following steps Clean off materials from cylinder head and cover Install camshaft with plastic gauge Install cylinder head cover and tighten bolts evenly and diagonally to the specified torque Tightening torque 10 N m Remove cylinder head cover read the width of the compressed plastic gauge with envelop sc
108. nition System 600 9 4 Ignition System Diagram 0 9 7 Overhaul information Note Exhaust gas contains toxicant DO NOT keep the engine run for a long time in a closed or poorly ventilated place Inspect ignition system in the order of the content in troubleshooting table Refer to 9 7 for ignition system diagram Ignition advancer is integrated in the CDI so the ignition system will automatically adjust ignition time Be careful with CDI overhaul Dropping or strong impact may cause damage to CDI In addition overvoltage may be generated on CDI and cause damage to return circuit when removing or joining the connectors and terminals with switch ON Always shut the ignition switch when overhauling Most of the failures of ignition system are caused by faulty contacts between connectors and terminals Check all the connections for any faults before overhauling Select spark plug of proper heat value Improper spark plug may cause malfunction or damage of engine Refer to Chapter 10 for inspection of switches 9 Ignition System Overhaul standard Item Standard Ignition CDI battery DC digital ignition Spark Plug Standard DPR7EA 9 NGK Optional DR8EA D7RTC Spark plug gap 0 8 0 9mm Ignition timing Maximum advance 34 CA angle Peak voltage Ignition coil gt 200V Impulse generator 4V Special tool Peak voltage oscillograph 07HGJ 0020100
109. nnect charger s positive wire to battery s positive pole Connect charger s negative wire to battery s negative pole Charging current time Standard 0 9A 5 10hours Fast charge 4 0A 60mins Note gt Keep the electrolyte temperature under 45 C Reduce current to adjust the temperature if it is too high gt Fast charge will reduce battery s life or cause damage to battery Do not use fast charge unless in emergency case Inspection of Charging System Inspect charging status gt Remove battery 15 4 and install a fully charged battery gt Keep ignition switch at OFF position gt Connect voltmeter between battery s terminals after engine is started and warmed up Note gt Avoid short circuit when measuring gt Overvoltage may be generated when removing or joining the battery terminals with switch ON and will damage the multimeter and the electrical parts Operation should be done with ignition switch OFF gt Use a fully charged battery for inspection Start engine and turn on high beam Increase engine speed slowly Check voltage between battery terminals Voltage between terminals at engine speed of 5000r min 13 5 15V Standard Battery s monomer voltage lt charging voltage lt 15V 5000rpm Electric Leakage Test Remove seat 2 3 Remove battery fixing plate 2 3 Open battery cover Keep ignition switch at the OFF position and remove negative wire from batte
110. nt Center Rear Troubleshooting 2 0ceeeeeeeeeeeeeeeeeeeees 2 1 Double Seat Protection Plate 2 10 Front Rack Bolt Cap 2 2 Front Inner Fender RH LH Front Protector RH LH 2 12 Seat Seat Support amp Rear Rack 4 2 3 Rear Protector RH LH Bumper Bumper Protector 2 13 Front amp Rear Rack Panels Front Top Cover 2 4 Bumper Cap crror porer as a aaa a atan ley beaten 2 14 Rear Top Covet 2 c ccececeeeeeeeeeeeeeeeaees 2 5 Front Vent Grille Fuel Tank 2 15 Left Side Panel ccccccesceeeeeeeeeaeenees 2 6 Bottom Plate Fuel Tank cccecceeceeeeeeeeeeeeeeees 2 16 Right Side Panel 2 c ceeeeeeeeeeeeeeees 2 7 Mute tie ie ei e eta gett teal lv ieee net eae 2 17 Fuel Tank Top Cover Front Fender 2 8 Description of Visible Parts 2 18 Footrest Board LH RH ecce 2 9 Overhaul Information Operation Cautions Warning Gasoline is highly flammable therefore smoke and fire are strictly forbidden in the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove and Install muffler after it is fully cold This chapter is on the disassembly and installation of rack visible parts exhaust pipe muffler and fuel tank Hoses cables and wiring should be routed properly Replace the gasket with a new one after m
111. oil 14 4 14 Checks amp Adjustment In case of carbon deposit clean with a proper tool SPARK PLUG GAP Measure the spark plug gap with a feeler gauge Out of specification Adjust Spark plug gap 0 8 0 9mm Caution Check the thread size and reach when replacing the ee oe spark plug If the reach is too short carbon will be deposited on the screw portion of the spark plug hole and engine damage may result Installation Caution To avoid damaging the cylinder head threads first tighten the spark plug with fingers and then tighten it to the specified torque using the spark plug wrench Tightening Torque 18 N m Tool Spark Plug Wrench Feeler Gauge Air Filter Inspect every 40 hours or 1000 km clean it if necessary If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the air filter as following Remove fixing clamp and top cover Note Be careful not to drop the o ring into the air filter box that is attached to the air filter top cover Loosen screw remove filter element separate support filter element and filter element seat Fill a wash pan of a proper size with a non flammable cleaning solvent A Immerse the filter element in cleaning solvent and wash it Press the filter element between the palms of both hands to remove the excess solvent Do
112. oil Note Do not reuse the valve stem seal Insert the valves with stems coated with moly oil all around Note When inserting the valve be careful not to damage the lip of the stem seal 182N 210N amp Moly Oil m Moly Oil 15 19 15 Engine Removal Inspection amp Installation Install valve spring with small pitch end b facing oa cylinder head Big pitch end a is marked Put on the valve spring retainer Use the valve spring compressor to press down the spring Fit the two cotter halves to the stem end and release compressor to allow the cotter to wedge in between seat and stem Make sure that the rounded lip of the cotter fits into the groove in the stem end Tool Valve Spring Compressor Tweezers NOTE Knock the valve end with rubber hammer Make sure valve cotter is fit into groove Check the sealing effectiveness of cylinder head Dip clean solution into valve IN EX and check for any leakage of valve seat after a few minutes 15 20 15 Engine Removal Inspection amp Installation Install thermostat Install thermostat cover Install water temperature sensor apply thread locker to the thread part tighten it to the specified torque Water temperature sensor Tightening torque 10 N m Install intake pipe apply lubricant to O ring Camshaft Check camshaft for wear and run out of cams and journals if the engi
113. olt Handlebar M8x55 4 20 30 Nut Tie rod M10x1 25 4 40 50 Locknut Steering Stem M14x1 5 1 100 120 Rear Mounting Bolt Muffler M8x30 1 30 50 Bolt Exhaust Pipe M8x14 1 30 35 Mounting Bolt Muffler M8x40 1 30 35 Mounting Bolt Rear Axle M10x1 25x110 2 40 50 Mounting Bolt Front Axle M10x1 25x90 1 40 50 Mounting Bolt Front Axle M10x1 25x25 2 40 50 Bolt Front Axle Support M8x14 2 35 45 Bolt Rear Transmission Shaft Rear End 901 30 00 01 6 40 50 Bolt Rear Transmission Shaft Front End 901 29 00 01 4 35 45 Bolt Front Transmission Shaft 901 29 00 01 8 35 45 Thermoswitch CF250T 420500 1 28 30 Bolt 1 Front Rack M8x14 2 35 45 Bolt 2 Front Rack M6x12 2 25 30 Bolt Rear Rack M8x14 4 35x45 1 10 1 Overhaul Information Lubricant Sealing Agent Application Areas Cautions Lubricants amp Grease Oil Seal Lip Steering Stem Pivot Rear Brake Pedal Multi purpose Lubricating Joints Throttle Cable Grease Throttle Lever Dust proof Seal Lip Front 5 Absorber Oil Shock absorber Inner surface Handlebar Engine Oil 1 Overhaul Information Cable Routing Throttle Cable Ignition Switch Connectors at Cable Routing at Centre Part See Pic 2 Wire Clip Hose Water Outlet Hose Rear Brake Hose Reservoir Tank amp Radiato Engine Speedometer Sensor Engine 5 l 2 3 8 4 9 10 1 Connector Fan Motor 2 Connector CDI 1 Ignition Coil 2 Water Temperature Sensor 3 CDI 4 Wi
114. op and blow No air current Clogged carburetor Poor Engine Performance in Hi speed Range or Slow Speed Rising Run vehicle at high engine speed No rise of Clogged air filter on an flat asphalt road Engine speed Clogged fuel hose and filter Clogged fuel tank cap breather hole Clogged muffler Engine speed rises 4 Check ignition timing Incorrect _ gt Faulty pickup coil Faulty CDI unit Correct Yy Measure compression pressure Low or no Worn Cylinder and piston ring with pressure meter T Compression Pressure Faulty cylinder gasket Normal compression pressure Check carburetor Clogged Clogged carburetor Not clogged Check spark plug Stained damage and color changed Spark plug stained and damaged Improper spark plug heat value Normal Spark Plug Check the engine for Overheated Faulty mixture gas overheating a Faulty fuel Carbon deposit in combustion Chamber Too much advanced ignition timing Overheated Accelerate or continuous Cylinder knock Carbon deposit in combustion chamber high speed operation No cylinder knock Clutch slip 12 3 Unstable Idle Speed check ignition Timing Correct check carburetor mixture screw Correct Check if secondary air intake into carburetor 12 Troubleshooting Incorrect ____ Faulty pulse generator Fau
115. or Remove fuel sensor 2P connector Connect multimeter between 3P connector terminals Shake float with hand and measure the resistance of float at different positions Connection Terminal Upper Blue White Green 4 10 9 20 C Lower Blue White Green 90 100 2 20 C 2P Connector Faulty fuel sensor Replace Fuel Sensor 10 10 10 Lighting Instruments Switches Installation Put fuel sensor into installation hole of fuel tank Fuel sensor should be fitted properly No fuel leakage is allowed Connect 2P connector Inspection of Fuel Gauge Switch on power supply and check if fuel level gauge functions normally Connector Fuel Sensor If fuel gauge works normally Reverse the removal procedure for installation of plastic parts and seat 10 11 Water Temperature Transducer Warning Be careful not to get scalded and do not place flammables nearby Warning gt Coolant must reach the switch thread and the depth from vessel bottom to sensor top should be over 40mm gt Keep liquid temperature for three minutes before measuring and do not raise temperature sharply gt The thermometer should not contact the vessel bottom Disassembly Remove right side panel 2 7 Disconnect and remove transducer Put the transducer into a vessel with coolant slowly heat up the liquid and measure the transducer resistance Temperature Resistance 50 C 154 162 88 C 52 40 100 C 27 49
116. osition Start the engine to check if the indicator works If the indicator is not working do the maintenance in time Water Temperature Gauge Dashboard Lighting System Adjusting headlight light beam Turn the headlight beam adjusting screw with a cross screwdriver and adjust the high low beam to meet the requirement Adjusting Screw Headlight Beam 3 14 4 Cooling System Overhauling Info c cceeeeeeeeee eee 4 1 Adding Coolant ccceeeeeeeeeeeeeeeeees 4 7 Trouble Shooting sceeeceeeeeeeeeeees 4 2 Cooling System Chatt cceeeeeeeee ees 4 10 Check and Maintenance 6 0 4 3 Reservoir Tank 2 0ceceeeeeee cee eens ee eees 4 5 Overhaul Information Note e If the radiator cap is opened when the coolant temperature is above 100 C the pressure of coolant will drop and get boiled rapidly The steam jet may cause danger and injury Cover the cap with a piece of rag after the coolant temperature goes down and open the cap slowly e Inspection of coolant should be done after the coolant is fully cooled e Coolant is toxic Do not drink or splash it to skin eyes or cloth lf coolant splashes in your eyes thoroughly wash your eyes with water and consult a doctor Ilf coolant splashes on your clothes quickly wash it away with water and then with soap and water lf coolant is swallowed induce vomit immediately and see a physician
117. ositioned correctly turn the sprocket Engage the chain on the sprocket with the locating pin B as illustrated on the right Recheck if the position of mark A and C is correct If not reassemble until it is correct 12 Engine Removal Inspection and Installation Install crankshaft C ring Install lock washer so that it covers the locating pin Apply thread locker to the bolts before installing and tighten them to the specified torque Sprocket bolt tightening torque 15 N m Bend up the lock washer to lock the bolts Cylinder Head Cover Clean the mating surface of cylinder head and cylinder head cover Install dowel pin to the cylinder head Apply sealant to the mating surface of the cylinder head cover Install cylinder head cover bolts tighten diagonally to the specified torque Cylinder head cover bolt tightening torque 10 N m Note When tightening the cylinder head cover bolts the piston must be at top dead center on the compression stroke 15 66 12 Engine Removal Inspection and Installation Gasket Sealant Applying Place N N W Chain Tensioner Insert screwdriver into slotted end of chain tension adjuster turn it clockwise to lock the tensioner spring install the chain tensioner and the new washer 1 Install the bolt 2 tighten it to the specified torque Chain tensioner bolt tightening torque 10 N m Afte
118. ossible Causes Remedy 1 Week valve spring Replace 2 Worn camshaft Replace 3 Fouled spark plug Clean or replace 4 Insufficient spark plug gap Adjust or replace Poor engine 5 Improper valve timing Replace running in 6 Faulty ignition coil Adjust float chamber fuel level high speed range 7 Low fuel level in float chamber Clean or replace 8 Dirty air filter Clean 9 Clogged fuel hose resulting in poor fuel Clean supply 10 Clogged fuel valve Clean 1 Excessive engine oil Check oil level and drain 2 Worn piston ring Replace 7 3 Worn valve guide Replace Exhaust smoke is dirty or thick 4 Scored or scuffed cylinder wall Replace 5 Worn valve stem Replace 6 Worn valve stem oil seal Replace 1 Improper valve clearance Adjust 2 Weak valve spring Adjust 3 Improper valve timing Adjust 4 Worn cylinder Replace 5 Worn piston ring Replace 6 Improper valve seating Replace or Correct Engine lacks 7 Fouled spark plug Clean or replace power 8 Improper spark plug gap Clean or replace 9 Clogged carburetor jet Clean or replace 10 Improper fuel level in fuel chamber Adjust fuel level 11 Dirty air filter Clean or replace 12 Worn rocker arm or rocker arm shaft Replace 13 Air leakage from air intake pipe Tighten or replace 14 Excessive engine oil Check oil level and drain 1 Carbon deposit on piston top Clean 2 Insufficient or excessive engine oil Check level add or drain 3 Faulty oil pump Replace 4 Clogged oil passage Clean Engin
119. ousing cover Remove dowel pin and gasket Remove drive sector gear 4 Remove bolt 5 of driven sector gear Remove washer 6 and driven sector 7 15 Engine Removal Inspection amp Installation 15 6 15 Engine Removal Inspection amp Installation Water Pump Screw out bolt of water pump Remove water pump Sheave Drum Remove the sheave drum by using a suitable bar Remove washer and sheave drum Left Crankcase Cover Remove bolts Remove left crankcase cover Remove dowel pin and gasket Magneto Rotor Install attachment 1 to crankshaft end Install special tool to rotor thread Remove rotor and woodruff key Tool Rotor Remover 15 7 15 Starting Motor Gear Remove driven gear 1 and needle bearing Remove spacer 2 Remove dual gear and shaft 3 Remove idle gear and shaft 4 Oil Pump Sprocket and Chain Remove drive sprocket nut 5 Remove C ring 6 Remove oil pump drive and driven sprockets and chain Engine Removal Inspection amp Installation eX va A w on a 8 8 8 8 8 8 amp 8 8 8 9 00 a0 00 2000 e000 aoe0 ao a2 15 8 15 Engine Removal Inspection amp Installation A Engine Right Side CVT Cover O Remove bolt of CVT cover EEMNES og Remove CVT cover x Y Remove gasket and dowel pin CVT Continuously Variable Transmission Remove primary sheave nut with special tool Remove primar
120. pecial tool Tool Oil Seal Installer Bearing Installer 1 CVT Cover 2 Bearing 3 Oil Seal 4 Limitator Oil Seal 5 Screw 6 Bolt l Oil Seal 5 2 Clutch Housing 3 Screw 4 Bearing Retainer CVT 5 Bearing 6 CVT Case 7 Oil Seal 15 51 Crankcase Note Check bearing for smooth turning after installation OMONOARWN gt 15 Engine Removal Inspection amp Installation Right Crankcase 10 Bearing 11 Gear Sensor Oil Seal 12 Left Crankcase Bearing 13 Screw Bearing 14 Oil Pipe Bearing 15 Link Bolt Oil Seal 16 Washer Washer Reverse Gear Sensor 17 Bearing Reverse Gear Sensor 18 Bearing Clean and grease the bearings turn the inner race of bearing and check the play noise and smooth turning In case of any abnormal remove bearing with special tool and replace Check all the oil seals for over wear or damage In case of any over wear or damage remove with special tool and replace with a new oil seal Remove gear sensor 11 and check for continuity with reverse gear sensor 9 with a multimeter Remove link bolt and oil pipe 14 and check oil pipe for crack or clog Replace with a new one if any Remove oil drainage bolt 27 and clean it Bearing Bearing Bearing Oil Dip Rod O ring Speed sensor Bolt Washer Oil Drainage Bolt 15 52 15 Engine Removal Inspection amp Installation Install new O ring and apply grease Install gea
121. pecified value Set Multimeter to AC Position Generator Non load Performance gt 200V AC at 5000r min 18 Electrical System Regulator Rectifier 18 2 18 Electrical System Nee lt a E W e N ile JN I Regulator Rectifier Measure the resistance between the terminals using a multimeter If any of the resistance is not within the specified value replace the regulator rectifier NOTE If the multimeter reads under 1 4V when the probes are not connected replace the multimeter battery Sas er oe ee Yew T fos raw fone fen S ww aC amien wee Black ESE ESE 18 3 92e g 18 Electrical System Starting System Start Button Starter Motor Brake Switch Starter Relay C D Parking O Q Neutral Gear C K Gear Starting Motor Bracket Brush Seat Brush Spring O ring Shims Motor Housing Washers Armature Coil Washer Kit Inner Bracket D O ring 18 4 Brushes Check brushes for abnormal wear cracks or moothness in the brush holder Wear cracks or non smoothness Replace Commutator Check Commutator for discoloration abnormal wear or undercut Abnormal wear or Damage Replace lf the commutator is discolored polish with a sand paper and clean with a clean and dry cloth lf there is undercut scrape out insulator B and make its distance
122. per ball pin Bearing hub Brake disc guard Bolt 2 Bolt 3 Bolt 4 Circlip Right steering knuckle Circlip Bolt 5 Bottom ball pin Nut 2 Cap buffering collar Buffering collar Bolt 6 Bolt 3 Nut 3 Cap buffering collar Buffering collar Bolt 7 Bolt 4 Slotted nut 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 Front right arm lower 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 6 Front Wheel Front Brake Suspension Steering 29 Cotter pin 30 Nut 5 31 Cap buffering collar 32 Buffering collar 33 Cap buffering collar 34 Bolt 8 35 Nut 6 36 Buffering collar 37 Cap buffering collar 38 Bolt 9 39 Bolt 10 40 Rzeppa universal joint 41 Big clamp fixed end 42 Bearing fixed end 43 Small clamp fixed end 44 Small clamp fixed end 45 Bearing motion end 46 Big clamp motion end 47 Rzeppa universal joint 48 Wire circlip 49 Wire circlip 2 50 Spacing shim 51 Dust boot motion end 52 Front left shaft 53 Dust boot fixed end 54 Wire clamp 55 Left CV drive shaft left front axle 56 Nut 7 57 Nut 8 Disassembly Note Replacing the front shock absorber does not require removal of other parts Remove Bolt 10 39 and Nut 8 57 Remove front right shock absorber Inspection Oi
123. per continuity R B G B W Remove Remove front cover of dashboard 6 12 Remove rear cover of dashboard 6 14 Disconnect 4P connector of ignition switch Remove bolt and ignition switch Reverse the removal procedure for Handlebar Switch Remove front top cover 2 4 Disconnect left and right handlebar switches Check according to the following table the continuity of the terminals Lighting Switch B Br Br W L Start Switch OFF ON ee B Br Gr R Dip Switch OFF ON e__ _ W L W L 10 Lighting Instruments Switches Ignition Switch _ Connector Ignition Switch Button Electric Start Connector Handlebar Switch 10 7 10 Lighting Instruments Switches Turning Light Switch O Gr Sb L e o PUSH R 7 Horn Switch OFF ON Turning Indicator Switch Horn Button Br L L Overriding Switch OFF ON e o B Br Gr B 2 WD 4 WD 4WD Diff Lock Switch B L IL B G IL JBJB Lg G r J tr ir Jf r jr B IGIB GJ jl Ir R GIW R G 2WD ele o o 4WD e o o jo LOC K e_e ee ee Faulty handlebar switch Replace 6 12 Brake Light Switch Disconnect brake light switch connector and check terminators for continuity Hold the brake
124. perly installed If the spark plug is removed the peak voltage will rise Remove left side panel 2 6 Keep spark plug in the cylinder head install qualified spark plug on the spark plug cap and earth the engine Open rubber cover of ignition coil keep the ignition wire connected and connect peak voltage oscillograph between primary wire terminal and frame body earth wire Special tool Peak voltage oscillograph Use together with digital multimeter available from the market with input impedance over 10MQ DCV Connecting terminals black yellow frame earth wire Turn ignition switch to the ON position and start engine Peak voltage above 150V 9 Ignition System Digital Multimeter Above 10M9 DCV Peak Voltage ST Oscillograp Spark Plug Frame Peak Voltage Oscillograph Ad W Ignition Coil 9 4 Pickup Coil Note gt Measure after all the wires are correctly connected gt Inspect with compression pressure in the cylinder spark plug and spark plug cap are properly installed If the spark plug is removed and then do the measurement the peak voltage will rise Remove left side panel 2 3 Disconnect CDI unit connector Connect peak voltage oscillograph terminal with the following terminal of main cable Special tools Peak voltage oscillograph 07HGJ 0020100 Use together with digital multimeter available from the market with input impedance over 10MQ DCV Connecting termi
125. r chain tensioner is installed turn the screwdriver counter clockwise The tensioner rod will be advanced under spring force and push tensioner against chain 15 67 12 Engine Removal Inspection and Installation Install the new gasket 3 Install chain tensioner screw tighten it to the specifiedTorque Chain tensioner screw tightening torque 8 N m Valve Adjuster Cover Refer to 11 3 for valve clearance Use new rubber gasket and apply grease Install Valve Inspection Cap Install valve inspection cap bolt Spark Plug Install spark plug with special tool and tighten to the specified torque Note To avoid damage to the cylinder head thread screw in the spark plug with hand first then tighten it to the specified torque with spark plug wrench Spark plug tightening torque 18N m Tool Spark Plug Wrench Engine Periphery Recoil Starter Install recoil starter Apply thread locker to the bolts and then tighten Valve Inspection Cap Install valve inspection cap Left Plastic Cover Install left plastic cover 6 Water Pipe and Hose Install water hose 5 Install bolt 4 Install water hose 3 Install clamp 1 and 2 12 Engine Removal Inspection and Installation 15 69 16 Carburetor Carburetor Removal Inspection Measurement and Adjustment Carburetor Assembly Carburetor Installation Carburetor Parameters 16 1 16 Carburetor 1 Carburetor
126. r damage Wear or Damage Replace Use special tool to remove oil seal Tool Oil seal remover Use special tool to assemble oil seal Tool Oil seal installer set Check the turning of bearing Abnormal damage Replace Oil Seal Assembly Apply lubricant grease to oil seal when assembling 15 28 15 Engine Removal Inspection amp Installation Primary and Secondary Sheave 14 Cam Oil Seal 2 pcs 2 Damper 4 pcs ip secondary Sliding Nut Secondary Sheave Ring Nut Secondary Sheave Roller 8 pcs 13 Spacer 4 pcs Oil Seal 2 pcs 14 O ring 2 pcs Primary Sliding Sheave 15 Spring Seat 7 Drive Belt 16 Spring Primary Fixed Sheave 17 Spring Plate Secondary Fixed Sheave 15 29 Primary Sliding Sheave Disassembly Remove spacer Remove Cam Qand Roller Roller Check each roller and sliding face for wear and damage Wear and damage Replace Note rollers should be replaced as a set Oil Seal Check oil seal lip for wear and damage Wear and damage Replace Remove the oil seal 15 Engine Removal Inspection amp Installation 15 30 15 Engine Removal Inspection amp Installation Primary Sliding Sheave and Fixed Sheave Check the drive face for any abnormal conditions such as damage or stepped wearing Damage or wearing Replace Install oil seal with special tool Tool Bearing
127. r gasket Replace Wear valve guide or improper valve Repair or Replace seating 4 Loose spark plug Tighten 5 Slow cranking of starting motor Check electrical part 6 Faulty valve timing Adjust 7 Improper valve clearance Adjust Engine will not No Sparking from Spark Plug start of is hard to 1 Fouled spark plug Clean or Replace start 2 Wet spark plug Clean and dry or replace 3 Defective ignition coil Replace 4 Open or short circuit with pickup coil Replace 5 Faulty generator Replace 6 Faulty CDI Replace No Fuel Reach Into Carburetor Clogged fuel tank vent tube Clogged or faulty fuel valve Faulty carburetor needle valve Clogged fuel hose Clogged fuel filter Transfer is not in Neutral position Oe On a Clean or Replace Clean or Replace Replace Replace Clean or Replace Set to Neutral position Engine stalls easily or has unstable idle speed 00 Od OT RT Or NS Improper valve clearance Improper valve seating Faulty valve guide Worn rocker arm or rocker arm shaft Fouled spark plug Improper spark plug gap Faulty ignition coil Faulty CDI Faulty generator Improper fuel level in float chamber Clogged carburetor jet Faulty fuel valve Improper adjustment or idle screw Adjust Replace or Correct Replace Replace Replace Replace or Adjust Replace Replace Replace Adjust Fuel level Clean Replace Adjust 19 1 19 Troubleshooting Complaint Symptom and P
128. r positioning bolt tightening torque 18M m Engine Right Timing Chain Put on timing chain 2 Clutch Install clutch 1 and nut 2 Tighten the nut to the specified torque left thread Clutch nut tightening torque 70N m 15 56 12 Engine Removal Inspection and Installation Install new o ring in spacer Install spacer onto the clutch housing shaft then install into CVT case Note align oil nick on spacer with oil hole on the shaft CVT Case Install dowel pin gasket and gasket to the right crankcase Install CVT case assembly to right crankcase Install bolt 2 and nut Note Tighten bolt nut diagonally Use a new gasket Install air guide plate and screw4 Primary Sheave Secondary Sheave Drive Belt Install primary fixed sheave as illustrated on the right Install drive belt between secondary sliding fixed sheave and tap with a plastic hammer to keep the belt as low as possible Note Install the drive belt with the arrow on the belt turn in the clockwise direction Drive belt contact surface should be free from any stains i 15 57 12 Engine Removal Inspection and Installation Install secondary sheave Install primary sliding sheave Tighten primary sheave nut with special tool to the specified torque Primary sheave nut tightening torque 115 N m Tool Rotor Holder Tighten secondary sheave nut with special tool to the
129. r sensor Install reverse gear sensor 9 and tighten to the specified torque Reverse gear sensor tightening torque 20N m Install speed sensor 24 Install oil pipe and tighten the link bolt to the specified torque Link bolt tightening torque 18M m Install washer 26 and oil drainage bolt 27 and tighten to the specified torque Drain bolt tightening torque 30N m Tool Bearing Remover Bearing Installer Multimeter Ill Engine Assembly Reverse the engine removal procedure for installation Caution Clean all the parts before assembly Make sure that the parts are in good condition without any damage Apply engine oil to the moving parts before assembly Apply grease to oil seal lip and O ring Caution Make sure that drive belt primary and secondary sheaves are not stained with grease Engine Center Oil Pump and Relief Valve Install oil pump and relief valve to left crankcase as E M ea illustrated on the right Tighten to the specified 3 Oi Pump Washer torque 4 Pressure Strip Relief Valve 5 Relief Valve Oil pump bolt 10N m Relief valve bolt 10N m 15 53 15 Engine Removal Inspection amp Installation Connecting Rod Install connecting rod to left crankcase with special tool Note Do not hammer the conrod into crankcase with plastic mallet Use special tool to avoid affect of conrod precision Tool Conrod Installer Balancer Shaft Install balancer shaft Caution
130. re Clip 3 Cable Parking 4 Breather Hose Reservoir Tank 5 Connector Starting Switch 5 Vacuum Tube 6 Wire Clip 6 Connector Dashboard 7 Connector for Magneto Gear Sensor and Pickup Coil 7 Connector Handlebar Switch L amp H 8 Fuel Pipe Carburetor 8 Connector Ignition Switch 9 Wire Starting Motor 9 Wire Clip 10 Steel Wire Clip 1 Overhaul Information Left Handlebar Switch Right Handlebar Switch Cable Choke Headlight Air Inlet Duct A TS Radiator Fan Motor i S Gear Shift Rod Main Cable Steel Water Pipe Engine Gear Motor Harness Gear Motor for 2WD 4WD 4WD Diff lock 2WD 4WD 4WD Diff lock 1 Overhaul Information Brake Hose Horn Headlight Snorkel Air Filter Rear Brake Hose Cable Gearshift Connector Headlight Rear Brake Switch Cable Hand Brake Brake Hose Wire Clip Harness Handlebar Switch R Wire Clip Harness Fuel Sensor Harness Dashboard ire Clip Harness Ignition Switch 1 Overhaul Information Harness Tail Light Connector Tail Light Harness Rear Left Turning Indicator Harness Rear Right Turning Indicator Rear Branching Main Cable Connector Rectifier Regulator Shunt Relay j PP Baer ssp i ectifier Re ctmier Regulator Auxiliary Relay Starting Starting Relay Control Relay 2WD 4WD and 4WD Diff lock 2 Vehicle Body Muffler Overhaul InfO cccccceeee ceeeeeeeeaeeeeeas 2 1 Rear Fender Engine Skid Plate Fro
131. rse the removal procedure for installation Socket 10 4 10 Lighting Instruments Switches Dashboard Lighter Bulb Dashboard Lighter Remove dashboard 10 9 Remove bulb socket and replace with a new bulb Bulb specification 12V 1 7W Note Main cable and wires should be routed properly gt Dashboard chapter 1 Reverse the removal procedure for installation Dashboard Indicator Dashboard Indicator Bulb Remove dashboard 10 9 Remove dashboard indicator socket l Dashboard Remove indicating light bulb and replace with new one Bulb specification 12V 3 4W Reverse the removal procedure for installation Headlight Remove Front fender 2 8 3 fixing bolts of headlight cover Headlight cover Bolt Fixing bolt of headlight headlight connector Headlight Headlight Connector Headlight 10 5 Disconnect headlight connector Reverse the removal procedure for installation Note Be careful assembling not to damage main cable when After replacing adjust the headlight beam 3 14 Note Main cables and wires should be routed properly Ignition Switch Inspection Remove front top cover Disconnect 4P connector of ignition switch 10 Lighting Instruments Switches Connector Ignition Switch Connector Ignition Switch 10 6 Check according to the following table if the connector terminals are in continuity means pro
132. ry 8 Battery Charging System Battery Positive Pole Negative Pole 8 5 Remove fuse box from inside of rear fender Connect amperemeter between battery negative pole and negative lead Measure current leakage with ignition switch at the OFF position Note gt If the measured current is higher than the maximum limit the multimeter will be burnt Therefore measure the current by shifting from the high to the low range gt Do not turn on the ignition switch when measuring the current Current Leakage less than 1mA When current leakage is higher than specified limit there is fault with the return circuit Disconnect terminals and connectors while measuring current to check out the faults Rectifier Regulator System inspection Note Inspection can be done without removing the AC magneto from engine Remove Seat 2 3 Right amp left side panels 2 6 Rear top cover 2 5 Battery cover and battery 8 4 Rear fender 2 10 Disconnect the 2 connectors of rectifier Regulator 8 Battery Charging System Fuse Box Multimeter Battery 3P Connector Redtifier Regulator 4P Connector Rectifier Regulator Rectifier Regulator 8 Battery Charging System Check the connector terminals for loosening Rectifier Regulator bending rust or come off Check the following items of the main cable terminals of the two rectifier connectors
133. sen tool handle and remove the special tool 15 32 15 Engine Removal Inspection amp Installation Remove spring Remove spring seat Guide Pin amp Spacer Remove guide pin and spacer Remove secondary sliding sheave Oil Seal O ring and Oil Seal Check the O ring and oil seal for wear and damage Wear and Damage Replace Remove Oil Seal 15 33 15 Engine Removal Inspection amp Installation Install oil seal with special tool Tool Bearing install set Secondary Sheave Spring Use vernier caliper to check the spring free length If the length is shorter than the service limit replace with a new one Service Limit 145 4mm Secondary Sliding and Fixed Sheave Check drive face for any abnormal condition such as stepped wear or damage Wear or damage Replace Assembly Install a new O ring Apply lubricant grease to O ring oil seal lip and guide pin groove Material lubricant grease 15 34 15 Engine Removal Inspection amp Installation Install guide pin and spacer Note To avoid damage to the oil seal lip during assembly slide the lip with a 0 1mm steel sheet as guide Install spring seat Align hole A with hole B Install spring and spring plate Insert spring end into the hole Compress spring with special tool Align the secondary sheave end with spring plate hole Tool Secondary sheave
134. sive splash to clothes skin or eyes will cause burn or loss of sight Wash with plenty of water if splashed In case of splash into eyes wash with plenty of water and consult the doctor The electrolyte on the clothes may contact the skin as well it will cause damage to the clothes if stained for a long time Change a clothes and wash away the electrolyte Note Spark arc may be generated when removing or joining the electrical parts with switch on and will damage the electrical parts such as rectifier Operation should be done with ignition switch OFF Remove battery from vehicle for charging and do not open the electrolyte cover Note Replace if the battery service life expired Keep the ignition switch OFF when removing electrical parts Disconnect the negative connection of battery if it is stored on the vehicle Fast charging is not recommended as it may reduce the battery life VVVV If battery is repeatedly charged and discharged fully fully charged and fully discharged it may cause damage to the battery or shorten the service life or lower the capacity of battery In addition the capacity of battery will also lower in 2 3 years even under normal use So the battery should also be replaced up to 12 4V Refer to troubleshooting table 8 3 for inspection of charging system Refer to Engine Maintenance for removal and installation of AC magneto Inspection of battery should be done following the owner s manual o
135. sone ing eplace 4 Worn or slipping drive belt REplace 19 3 19 Troubleshooting Complaint Symptom and Possible Causes Remedy Difficulty or locked 1 Broken drive or driven bevel gear teeth Replace gearshift 2 Distorted shift fork Replace 3 Worn shift cam Replace 4 Improper gearshift rod Adjust 2 Carburetor Complaint Symptom and Possible Causes Remedy 1 Clogged starter jet Clean 2 Clogged starter jet passage Clean Starting Difficulty 3 Air leakage from joint between starter body Clean adjust or replace gasket and carburetor 4 Faulty starting plunger Adjust 1 Clogged slow jet Clean 2 Clogged slow jet passage Clean Idling or 3 Clogged air intake Clean low speed 4 Clogged bypass port Cicer trouble 5 Starter plunger not fully closed Adjust 6 Improper set of idle screw Adjust 7 Improper float height Adjust 1 Clogged main jet Clean 2 Clogged main air jet Clean Medium or high 3 Clogged needle jet Cee speed trouble 4 Faulty throttle Nalve Adjust 5 Clogged fuel filter Clean 6 Improper float height Adjust 7 Starter plunger not fully closed Adjust Overflow and fuel 1 Worn or damaged needle valve Replace level fluctuation 2 Damaged needle valve spring Replace 3 Improper working float Adjust or Replace 4 Foreign matter in needle valve Clean 19 4 3 Cooling System Radiator 19 Troubleshooting Complaint Symptom and Possible Causes Remedy
136. spection Check main shaft gear and sprocket surface for any damage or over wear Damage or over wear Replace Check reverse gear chain for any damage or over weer Damage or over wear Replace Disassemble driven shaft as illustrated Check each gear surface for any damage or over wear Check bearing and collar for any wear or damage Damage or over wear Replace 15 38 15 Engine Removal Inspection amp Installation Check the shift fork clearance with a thickness gauge in the groove of its gear Clearance exceeds the limit Replace Shift fork to Groove clearance Standard clearance 0 10 0 30mm Service Limit 0 50mm Measure shift fork groove width with vernier caliper Standard shift fork groove width 6 05 6 15mm Measure shift fork thickness with vernier calipers Standard fork thickness 5 08 5 90mm Check shift fork and for damage or bend Damage bend Replace Install shift fork to guide bar and move left and right In case of any unsmooth moving replace with a new one 15 39 15 Engine Removal Inspection amp Installation Put the guide bar on a flat plate and roll it In case of any bend replace with a new one NOTE DON NOT attempt to correct a bent guide bar Check shift fork spring for breakage damage Broken or damaged Replace Check shift cam groove for scratches damage Scratch or damage gt Replace Ass
137. spring compressor Tighten ring nut temporarily Remove the special tool from secondary sheave 15 35 15 Engine Removal Inspection amp Installation Tighten the ring nut with special tool to the specified torque Ring Nut Tightening Torque 100N m Tool Ring nut wrench Sheave Holder Drive belt Check belt for any greasy substance Check contact surface of belt for any cracks and damage Check belt width with vernier caliper Damage width out of range Replace Belt width service limit 33 5mm Tool vernier caliper Caution If belt surface is stained with grease or oil degrease the belt thoroughly 15 36 Transmission 15 Engine Removal Inspection amp Installation Z O Description Qty MAIN SHAFT GEARSHIFT SHIFT CAM RIGHT CRANKCASE LEFT CRANKCASE DRIVEN SECTOR GEAR SPROCKET REVERSE GEAR CHAIN REVERSE GEAR DRIVEN OUTPUT GEAR O OINI OD a BR Ww rho gt DRIVE SECTOR GEAR oee oS S eS Oo No Description Qty 10 DRIVEN GEAR HIGH RANGE 11 DRIVEN GEAR LOW RANGE 12 SPRING SHIFT FORK 13 RIGHT SHIFT FORK 14 GUIDE BAR 15 DRIVEN SHAFT 16 SPRING SHIFT FORK 17 LEFT SHIFT FORK 18 SHIFT FORK ASSEMBLY 93 a oa S S oo 15 37 15 Engine Removal Inspection amp Installation In
138. t 5K 2 Check CDI if it is out of service 3 Check ignition circuit Usually the voltage between black wire and earth wire green should be 12V If there is no voltage check from the battery positive terminal to the end of black wire 4 Check the cable check if there are any faults from the input of trigger signal output of magneto pickup to output CDI terminal and ignition output wire black yellow 5 Check stop switch When switch is at the ignition position black white wire should be cut with green wire In case of weak spark check the following 1 Check CDI 2 Check ignition coil and secondary coil whether there is short circuit or fault with the damp resistance 9 3 Inspection of Ignition System Note gt Ifthe spark plug generates no spark check first if there is come off loosening or poor contact with the wiring then measure the peak voltage gt Different multimeter has different input resistance and shows different readings Measure with digital multimeter with input impedance over10MQ DCV Connect peak voltage oscillograph with digital multimeter Special tools Peak voltage oscillograph 519 922 150000 Use together with digital multimeter available from the market with input impedance over 10MQ DCV Ignition Coil Primary Voltage Note gt Measure after all the wires are correctly connected gt Inspection should be done when the spark plug and spark plug cap are pro
139. t as illustrated on the right Valve head Radial Run out out of range Replace Service Limit 0 03mm Tool Dial Gauge 1 100 Magnetic Stand V Block Valve Face Wear Check each valve face for wear or damage Replace valve with a new one if it is found to have abnormal wear Measure valve head thickness T Valve head thickness T out of range Replace Service Limit 0 5mm Tool Vernier Caliper Valve Stem End AN Check valve stem end for pitting or wear In case of any pitting or wear resurface the valve stem end If the length T is less than service limit replace valve with a new one Valve Stem End Length Service Limit 2 4mm Tool Vernier Caliper 15 18 15 Engine Removal Inspection amp Installation Valve Spring Valve Spring keeps valve and valve seat tight Weakened spring results in reduced engine power output and chattering noise from valve mechanism Measure the spring free length Spring free length out of range Replace Service Limit 38 8mm Tool Vernier Caliper Measure the force to compress the spring to the specified length Valve spring tension out of range Replace Service Limit IN EX 182N 210N 31 5mm Tool Spring Scale Measure valve spring incline Spring incline out of range Replace Valve Spring Incline Limit 2 5 1 7mm Assembly of Cylinder Head Install each valve spring seat Apply moly oil to valve stem seal and fit into position Material Moly
140. t side panel and footrest board Remove left side panel in the direction as illustrated on the right Footrest Board LH Screw Left Side Panel Installation Reverse the removal procedure of installation 2 Vehicle Body Muffler Right Side Panel J op Cover Fuel Tank Remove ee p Seat 2 3 i Remove Bolt 1 for right side panel and fuel tank top cover Right Side Pane Bolt 1 Remove Bolt 2 for right side panel and front fender Front Fender Bolt 2 Remove screw for right side panel and right footrest board Footrest Board RH Remove right side panel in the direction as illustrated on the right Installation Reverse the removal procedure of installation 2 Vehicle Body Muffler Top Cover Fuel Tank Remove Seat 2 3 Front rack 2 2 Front top cover 2 4 Left side panel 2 6 Right side panel 2 7 Bolt 1 Bolt 2 Bolt 1 Bolt 2 Bolt 3 Bolt 4 Top cover fuel tank Installation Reverse the removal procedure of installation Front Fender Remove Front rack 2 2 Front top cover 2 4 Left side panel 2 6 Right side panel 2 7 Top cover fuel tank 2 8 Disconnect wiring connectors from front fender Remove electrical components from front fender Remove 3 bolts from frame Remove 6 screws and nuts from left and right footrest board Screw Nut Remove front fender 2 8 Left Footrest Board Remove
141. tall water pump and tighten the bolts to the specified torque Water pump bolts tightening torque 10N m Note Set the water pump shaft slot end B to oil pump shaft flat side A Connect water hoses Add coolant Install left side cover 17 Cooling and Lubrication System Illustration of CF 188 Engine Lubrication System Oil Drain Bolt Washer Oil Drain Bolt 11 Oil Pump Oil Bypass Valve External Oil Pipe Oil Filter Clutch Crankshaft Cylinder Body 10 Piston 11 Camshaft 12 One way Clutch 13 0il Dip Rod Oo ON DOA FF WN 17 14 17 Cooling and Lubrication System Inspection of Lubrication System 11 8 Inspection of Oil Pump and Relief Valve 12 41 17 15 18 Electrical System Charging System 18 1 Electric Starting Ignition System 18 1 Charging System Magneto Resistance of Generator Coil Measure resistance between the three lead wires Replace a new stator coil if resistance not within specified value Check that the generator core is insulated Set multimeter at 1x100 Generator Coil Resistance 0 9 1 50 Yellow Yellow Insulate Resistance Q Yellow Earthing wire Generator Non load Performance Start engine run it at 5000r min Measure AC voltage between three lead wires of generator with multimeter Replace the generator if the voltage is lower than the s
142. tem is correct voltage lt 15V Incorrect Inspect rectifier system 8 6 Incorrect Main cable has short open circuit Correct Faulty contact of connectors 8 3 Battery Note Keep the ignition switch at OFF before operation Remove Seat 2 3 Bolt1 amp Bolt2 Battery fixing plate Battery cover Loosen negative pole screw and disconnect negative lead Remove positive pole cap and screw Disconnect positive lead Installation Reverse the removal procedure for installation Note gt Apply clean lubricant grease to the pole after installation gt Install cap firmly on the positive pole after installation Inspection Measure voltage between battery terminals and check test status Complete test 12 8V Insufficient test lt 11 8V Insufficient charge Recharge Note When recharging after normal charging measure the voltage between terminals after 30 minutes Measuring immediately after recharging will not gain the correct test due to the sharp voltage changes between the terminals Battery Note Usually no hydrogen will be generated during charging except when overcharged Keep away from fires when charging Charge according to the current and time specified on the label of battery Remove battery from vehicle Refer to above content 8 Battery Charging System Fixing Plate Battery Bolt 1 Battery Cover Battery Positive Pole Negative Pole 8 4 Co
143. ter pump Water Hose Reservoir Tank Water Outlet Hose Radiator 4 7 5 Removal and Installation of Engine Drive Train and Gearshift Unit Overhaul InfO 0 cece eee eee ee nett eens 5 1 Removal and Installation of Front and Rear AX ICS jean ora ine a E Aa tegen ceuean sees 5 5 Engine Removal and Installation 5 2 Removal and Installation of Gearshift Unit 5 7 Overhaul info Operation cautions Securely support the ATV with bracket when removing or installing engine Take care not to damage frame engine body bolts and cables Wrap the frame to avoid any possible damage when removing or installing the engine Following operation doesn t require removal of engine from the vehicle Oil pump Carburetor air filter Cylinder head cover cylinder head cylinder body camshaft CVT system CVT cover Gearbox Right side cover AC magneto water pump FPiston piston ring piston pin Following operation require removal of engine from vehicle Crankshaft Tightening torque Engine front upper mounting bolt 35N 45N m Engine front rear mounting bolt 40 50N m Bolt engine front rear mounting bracket 35 45N m Bolt engine front upper mounting bracket 35 45N m 5 1 5 Removal and Installation of Engine Drive Train and Gearshift Unit Engine Removal Remove Plastic Chapter 2 Air Filter Engine service chapter Carburetor Engine service
144. th load 1300r min 100r min 6 Starting type Electrical starting Recoil Starting Ignition CDI Magneto ignition BTDC10 1500r min Ignition Timing 7 Electrical Spark Plug DPR7EA 9 NGK 0 8mm 0 9mm System Spark Plug Gap Magneto Permanent Magnet AC Type Combustion Chamber Triangle Combustion Chamber Combustion Carburetion Type Model Vacuum Diaphragm Type MIKUNI BSR36 89 8 System Air Filter Sponge Element Filter Gasoline RQ 90 9 Vave Valve Type SOHC Chain Drive System Lubrication Type Pressure amp Splash Lubrication Oil Pump Rotor Type 10 System Filter Type Full Flow Filter Screen Oil Type SAE10W 40 SF A Cooling Cooling Type Closed Coolant Circulation System Coolant Type 35 C Rust resistant antifreeze Clutch type Wet Auto centrifugal Operation Mode Automatic CVT Parking and Gear Shifting Gears 2 Forward Gears 1 Reverse Gear Shift Type Sequence Hand Operation L H N R P CVT Gear Ratio 2 88 0 70 12 Drive Final Ratio 1 333 24 18 bevel gear System Secondary 1 952 41 21 Transfer Ratio Gear Ratio Gears Low Gear 2 25 36 16 High Gear 1 35 27 20 Reverse Gear 1 471 25 17 Total Low Gear 5 857 High Gear 3 514 Reverse Gear 3 828 13 Overall Dimension 610x568x519mm 14 Net Weight 70kg 15 Output type Front and rear shaft output 16 Rotational Direction of Engine Output Clockwise from behind engine at forward gear 13 5 Overhaul Data 13 Engine Overhaul Information
145. thermostat pellet for cracks Test the thermostat in the following steps Pass a string between thermostat flange as illustrated on the right Immerse the thermostat in a beaker with water Make sure that the thermostat is in the suspended position without contact to the vessel Heat the water by placing the beaker above a stove and observe the temperature rise on a thermometer Take the temperature reading from thermometer when the thermostat valve opens Thermostat Valve Opening Temperature 68 74 C Keep heating the water to raise the water temperature Just when the water temperature reaches the specified value the thermostat valve should have been lifted by 3 5 4 5mm Installation Reverse the removal procedure for installation Apply coolant to the rubber seal of thermostat Install thermostat case Tighten to the specified torque Tightening Torque 10N m Water Pump Removal and Disassembly Remove engine left side cover Drain coolant 11 10 Note Before draining coolant check water pump for oil or coolant leakage In case of oil leakage check the water pump oil seal O ring In case of coolant leakage check the water seal 17 Cooling and Lubrication System A Thermostat String Valve Lift 3 Stove Thermostat Left Side Cover 17 Cooling and Lubrication System Remove clamps and water hoses Release bolts and remove water pump
146. ting mace of water pump body with bearing and mechanical seal Damage Replace Impeller Check the impeller and shaft for damage Damage Replace Assembly and Installation of Water Pump Install oil seal with special tool Tool Oil Seal Installer Note The stamped mark on the oil seal faces outside Apply alittle grease to the oil seal lip 17 Cooling and Lubrication System 17 10 17 Cooling and Lubrication System Install mechanical seal with a suitable socket wrench Note Apply sealant to side A of mechanical seal Install bearing with special tool Tool Bearing Installer Note The stamped mark on the bearing faces outside gt Tool Install seal ring to impeller Clean off the oil and grease from mechanical seal and install it into the impeller Note A side of mechanical seal faces impeller Apply grease to impeller shaft Install impeller shaft to water pump body ener pply Grease 17 11 17 Cooling and Lubrication System Install E ring to water pump shaft Install new gasket to water pump body Install water pump cover and tighten the bolts and bleed bolt Water Pump Cover Bolts Tightening Torque 6N m Check impeller for smooth turning Install the new O ring Note Use the new O ring to prevent oil leakage Apply grease to O ring Overflow Tube 17 12 17 Cooling and Lubrication System Ins
147. tion and adjust or replace if necessary R Replace C Clean 14 2 Procedures of Maintenance amp Adjustment This section describes the maintenance procedures for each item mentioned in the Periodic Maintenance Chart VALVE CLEARANCE Inspect initially at 20 hour break in and every 40 hours or every 1000km thereafter Inspect the clearance after removing cylinder head Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power Check the valve clearance at the period indicated above and adjust the valve clearance to specification if necessary gt Remove cover plate recoil starter gt Remove inspection cap on left crankcase gt Remove 2 valve adjusting cover gt Turn the crankshaft until the line of T D C on rotor is aligned with mark of inspection hole on left crankcase gt Insert feeler gauge to check the clearance between the valve stem end and the adjust bolt on the rocker arm Valve Clearance When cold IN 0 05 0 10mm EX 0 17 0 22mm Note The valve clearance must be adjusted when the engine is cold Adjust the valve clearance when the piston is at the Top Dead Center T D C on the compression stroke If the clearance is incorrect bring it into the specified range using the special tool Loosen valve adjust bolt and nut insert a feeler gauge between the valve stem end and valve adjusting bolt tighten valve
148. tortion 13 6 Cylinder Piston Piston Ring Connecting Rod 13 Engine Overhaul Information Item Standard Service Limit Remark Cylinder Pressure 1000KPa Cylinder Piston Clearance 0 030 0 051 0 15 Piston Skirt Diameter 87 460 87 480 87 380 10mm form skirt end Inner Diameter of Cylinder 87 500 87 522 Cylinder Joint Face Distortion 0 015 0 05 Top IR About 11 7 8 9 Piston Ring Free Gap an 2 R About 12 9 5 Ring Piston Ring Gap In Bore Top Ring 0 15 0 30 0 60 2P Ring 0 15 0 30 0 60 Piston Ring Groove Top Ring 0 04 0 08 0 180 Clearance 2 Ring 0 03 0 07 0 150 r Top Ring 0 97 0 99 Piston Ring Thickness ND Z 2 Ring 1 17 1 19 Top Ring 1 03 1 05 Piston Ring Groove Width 2ND Ring 1 22 1 24 Oil Ring 2 51 2 53 Inner Diameter of Piston Pin 23 002 23 008 23 030 Hole Outer Diameter of Piston Pin 22 995 23 000 22 980 Inner Diameter of Connecting 23 006 23 014 23 040 Rod Small End Clearance of Connecting Rod 0 10 0 55 1 0 Big End Thickness of Connecting Rod 24 95 25 00 Big End Crankshaft Play 0 03 0 08 Lubrication Item Standard Service Limit Remark Clearance between Inner 0 03mm 0 10mm 0 15mm and Outer Rotors Clearance between Outer 0 03mm 0 10mm 0 12mm Rotor and Oil Pump Body Oil Pressure 130Kpa 170Kpa 3000r min
149. uffler is removed After muffler is installed check if there is any exhaust leakage Tightening torque Muffler Rear Fixing Bolt 35 45N m Muffler Exhaust Pipe Bolt 35 45N m Muffler Body Fixing Bolt 35 45N m Troubleshooting Loud exhaust noise Broken muffler Exhaust leakage Insufficient power Distorted muffler Exhaust leakage Muffler clogged 2 1 2 Vehicle Body Muffler Front Rack Bolt Cap Front Fender Bottom Remove Remove 2 nuts from the bottom of front fender Exert upward and remove bolt cap a Front Top Cover Remove 7 P Fixing Bolt 1 Bolt 2 Fixing Bolt 3 Bolt 4 Front rack Front Rack Installation Reverse the removal procedure for installation Tightening Torque Fixing Bolt 1 Bolt 2 35 N m 45N m Fixing Bolt 3 Bolt 4 25 N m 30N m 2 2 Seat Remove Pull upward seat buckle Lift and push seat backward Installation Press upward seat buckle Press seat forward and down Note Make sure that the seat is firmly installed Seat Support Rear Rack Remove Seat 2 3 Bolt 1 bolt 2 Remove seat support Remove the 2 nuts for rear rack and rear fender from rear fender bottom Disconnect connectors of rear turning indicator 2 Vehicle Body Muffler Seat Buckle Seat Support Bolt 1 Bolt 2 Rear Fender Bottom Nut one each on left amp right Ornament Panel Rear Rack Connector Rear Turning Indicator 2 3 Re
150. ul Information Carburetor Item Standard Remark Carburetor Type MIKUNI BSR36 89 I D Mark 07G0 Carburetor Barrel Size 36mm Engine Idle Speed 1300r min 100r min Main Jet MJ N10221 130 Main Air Jet MAJ MD13 24 35 Jet Needle JN J8 5E26 Needle Jet NJ 785 401011 P OM Pilot Jet PJ N224103 22 5 Pilot Jet Screw PS 604 16013 1A Electrical System Item Standard Remark Spark Plug Type NGK DPR7EA 9 Gap 0 8 0 9 Spark Character gt 8mm Ignition coil Primary 0 10 0 50 Resistance Secondary 120 220 Magneto Coil Pick up 1500 3000 Resistance Magneto Voltage Without load gt 100V AC 5000r min Max Magneto Output Power 300W 5000r min Regulated Voltage 13 5V 15 0V 5000r min Primary Peak Voltage of Ignition Coil gt 150W Starter Relay Coil Resistance gt 120W Starter Relay Coil Resistance 30 50 Auxiliary Starter Relay Coil Resistance 90 1000 13 9 Tightening Torques 13 Engine Overhaul Information Item Quantities Thread Size mm Tightening Torque Remark N m Reverse Gear Sensor 1 M10 1 25 20 Spark Plug 1 M12 1 25 18 Water temperature P 1 Rc1 8 8 Apply Thread Locker Sensor Adjusting Nut Pap 4 M5 10 Valve Clearance Nut Primary Sheave 1 M20 1 5 115 Nut ne meconealy 1 M20 1 5 115 Sheave Ring Nut ing Nut Secondary 1 M30 1 100 Sheave Nut Front
151. ulb gt Oil stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate gt Make sure that the three pins of the bulb should be in line with the three positioning holes in the socket when replacing the bulb Bulb specification 12V 35 35W Reverse the removal procedure for installation After replacing the bulb adjust headlight beam 3 14 Inspection of Headlight Turn the ignition switch to ON position turn light switch to the illuminating position and check if the headlight is on ON Normal Still off short circuit of main cable or broken main cable 10 Lighting Instruments Switches Headlight Dust Cover Headlight Connector Headlight Circlip Headlight 10 3 10 Lighting Instruments Switches Brake Light Tail Light Bulb Tail Light Remove 2 tapping screws Remove tail light cover Turn brake light tail light bulb counter clockwise and remove it Replace brake light tail light bulb Bulb Specification 12V 21 5W Reverse the removal procedure for installation Screw Socket Front Turning Indicator Bulb Front Turning Indicator Bulbs Remove headlight 10 5 Remove cover of front turning light Replace front turning light bulbs Bulb Specification 12V 10W Rear Turning Indicator Bulbs Remove screw Remove rear turning indicator cover Replace rear turning indicator bulbs Bulb Specification 12V 10W Reve
152. ure Gauge Adaptor 14 11 14 Checks amp Adjustment Inspection of Oil Pressure Oil Pressure 130 170kpa at 3000r min Lower or higher oil pressure may be caused by I Oil pressure is too low Clogged oil filter Leakage from oil passage Damaged O ring Oil pump failure Combination of above items II Oil pressure is too high Oil viscosity is too high Clogged oil passage Combination of above items Testing Oil Pressure Remove bolt Connect tachometer with ignition coil Install oil pressure gauge and joint seat to main oil gallery Warm up engine as per following Summer 10 minutes at 2000r min Winter 20 minutes at 2000r min To Ignition Coil After warming up increase engine speed to 3000r min and record readings of oil pressure gauge After testing apply thread locker to the thread in the hole of main oil channel Install bolt and tighten to the specified torque Tighten torque 23N m Tools Oil pressure gauge Tachometer 14 12 Inspection of Clutch Engagement and Lock up CF188 engine is equipped with a centrifugal type automatic clutch Before checking the initial engagement and clutch lock up two inspection checks must be performed to thoroughly check the operation of the drive train l Initial Engagement Inspection Connect tachometer to ignition coil Start engine Shift gear lever to High position Slowly increase throttle and note down the engine speed r min
153. urface of moving parts Measure the data during disassembly for correct assembling If you do not know the length of screws install the screws one by one and make sure they are screwed in with same depth Pre tighten the bolts nuts and screws then tighten according to the specified torque from big to small and from inner side to outer side Check if the disassembled rubber parts are aged and replace if necessary Keep the rubber parts away from grease Apply or inject recommended lubricant to the specified parts Use special tools wherever necessary Replace the disassembled ball bearings with new ones Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly Replace if the axial or radial play is too big If the surface is uneven clean with oil and replace if the cleaning does not help When pressing the bearing into the machine or to the shaft replace the bearing if it could not be pressed tight Install the one side dust proof bearing in the right direction When assembling the open type or double side dustproof bearing install with manufacturer s mark outward Keep the bearing block still when blowing dry the bearing after washing clean Apply oil or lubricant before assembling Install the elastic circlip properly Turn the circlip after assembling to make sure is has been installed into the slot After assembling check if all the tightened parts are properly tightened and can move smoothly
154. ve Shift Cam Fork Shaft Drive Bevel Gear Remove left crankcase from driven bevel gear Drive Shaft Drive Shaft Remove drive shaft and driven shaft Balancer Shaft Remove balancer shaft Balancer Shaft 15 12 15 Engine Removal Inspection amp Installation Crankshaft Separate crankshaft from left crankcase with special tool Tool Crankshaft Separator Oil bump Relief Valve Remove oil bump and relief valve 15 13 15 Engine Removal Inspection amp Installation Engine Components Inspection Cylinder Head Cover Disassembly Caution Each removed part should be identified to its location and the pars should be laid out in groups designated as Exhaust Intake so that each will be restored to the original location during assembly Remove rocker arm shaft bolts A Remove rocker arm shaft by using M6 bolts B Cylinder Head Cover Distortion Clean off sealant from the fitting surface of cylinder head cover place cylinder head cover on a surface plate and measure distortion with a thickness gauge Cylinder head Cover Distortion Limit 0 05mm Tool Thickness Gauge Distortion out of range gt Replace Note Cylinder head cover and cylinder head should be replaced together Rocker Arm Shaft Measure out diameter of rocker arm shaft with a micrometer Rocker Arm Shaft O D IN EX Limit 11 973 11 984mm Tool Micrometer 0 25mm 15 14
155. ve ignition coil Measure the ignition coil resistance in both primary and secondary windings using the multimeter If both the primary and secondary windings are close to the specified value the ignition coil is in good condition Ignition Coil Resistance Primary 0 1 1 5 OQ Terminal Ground Secondary 12 22KQO Terminal Spark Plug Cap Pickup Coil Peak Voltage Measure the pickup coil peak voltage in the following steps Connect multimeter and peak voltage adaptor as illustrated on the right Probe Green lead wire Probe Blue lead wire Shift the gear to neutral position and turn the ignition Pickup Coil switch to the ON position Press the starter button and crank the engine several seconds then measure the pickup coil primary peak voltage Repeat above steps several times and take the measured highest pickup coil peak voltage Set the multimeter to AC V position Pickup Coil Peak Voltage 24V If the voltage is lower than the standard value replace the pickup coil Pickup Coil Resistance Set the multimeter to 1x1000 position Peak Voltage Adaptor Magneto Magneto Pickup Coil Resistance 120 1300 Pickup Coil Replace the pickup coil if the resistance is not within the value 18 8 19 Troubleshooting 1 Engine Complaint Symptom and Possible Causes Remedy Compression is Too Low 1 Worn cylinder Replace 2 Worn piston ring Replace 3 Leakage with cylinde
156. when the vehicle starts to move forward Engagement speed 1800r min 2400r min If the engagement speed is out of the above range check the following Clutch shoes Clutch shoe wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch Il Clutch Lock up Inspection Connect the tachometer to ignition coil Start the engine Shift gear lever to High position Apply front and rear brakes as firmly as possible Fully open the throttle for a brief period and note the maximum engine speed obtained during the test cycle Lock up Speed 3300r min 3900r min Warning Do not apply full power for more than 5 seconds or damage to clutch or engine may occur If the lock up speed is out of the above range check the following Clutch shoes Clutch wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch Tool Tachometer 14 Checks amp Adjustment To Ignition Coil 14 13 A Engine Removal installation Orders and the Relative Page Numbers 15 Engine Removal Inspection amp Installation Item Description Disassembly Inspection Assembly Remarks Maintenance Engine Water Hose Pipe 15 2 15 11 15 69 Periphery Left Side Cover 15 2 15 69 Recoil Starter 15 2 15 49 15 68 Spark Plug 15 2 15 4 15 68 Cylinder Head Cover 15 3 15 14 15 66 Tensioner 15 3 15 24 15 67 Engine Camshaft 15 3 15 21 15 65
157. xing bolts of bumper and 2 center fixing bolts then pull bumper down Installation Reverse the removal procedure for installation Fuel Tank Warning Gasoline is highly flammable therefore smoke and fire are strictly forbidden in the work place Bolt3 Front Vent Grille Bolt 4 Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove Left and right side panel 2 6 Front fender 2 8 Fuel tank top cover 2 8 Bolt 1 Bolt 2 Bolt 1 Fuel Tank Disconnect 3P connectors of fuel sensor Connector Fuel Sensor Remove Bolt 3 Bolt 4 Remove Fuel hose and Clamp Fuel tank Installation Reverse the removal procedure for installation Note Be careful not to damage main cable pipes and hoses Main cable cables pipes and hoses should be routed properly according to the routing drawing Take precaution against fuel leakage when removing fuel Fuel Hose Fuel Tank Bottom Plate Remove Fuel tank 2 15 Bolt 1 Bolt 2 Fuel tank top cover Installation Reverse the removal procedure for installation Note Be careful not to damage main cable pipes and hoses Main cable cables pipes should be routed properly according to the routing drawing 2 Vehicle Body Muffler Fuel Tank Bolt 4 Bottom Plate Fuel Tank Bolt Muffler Caution Perfor
158. y sliding sheave Remove secondary sheave nut with special tools Remove secondary sheave Remove drive belt Tool Sheave Holder Remove primary fixed sheave Remove bolt for air guide plate Remove air guide plate 15 9 15 Engine Removal Inspection amp Installation CVT Case 4 a Remove bolt 1 of CVT case Remove nut 2 of CVT case Remove outer clutch face and CVT case Remove dowel pin front and rear gasket Clutch Remove one way clutch Remove clutch shoe fixing nut with special tool Remove clutch shoe Note The clutch shoe nut has left hand threads Tool Timing Chain Remove timing chain 15 10 Engine Center Gear position bolt Remove gear position bolt 1 Remove spring and steel ball Right Crankcase Remove left crankcase bolts Remove right crankcase bolts Separate right crankcase with special tool Caution The Crankcase separator plate should be parallel with the end face of crankcase Crankshaft should remain in the left crankcase half Tool Crankcase separator Driven Bevel Gear Front Output Shaft Remove bevel gear cover bolt Remove driven bevel gear Remove front output shaft nut 15 Engine Removal Inspection amp Installation 15 11 15 Engine Removal Inspection amp Installation Remove Oil seal Bearing limit nut Remove Front Output Shaft Shift Cam Fork Shaft Remo

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CF500/CF500 A

CF500/CF500-A

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