CF800 2 Service Manual

FOREWORD INDEX
This manual introduces CF800-2 maintenance

General Information 1
information, removal&installation procedure, check &
adjustment methods, troubleshooting and technical Body and Muffler 2
specifications in detail. There are illustrations to guide
Inspection and Adjustment 3
your operations.
Cooling System 4
Chapter 1 mainly introduces general operation
Engine Removal and Installation 5
information, service tools, vehicle structure and basic
specifications. Air Intake System 6
Chapter 2 mainly introduces check & adjustment
Intake Manifold,Cylinder Head and Cylinder 7
methods and how to do vehicle maintenance.
Chapter 3 and further chapters mainly introduce Crankcase,Crankshaft,Gearbox 8
removal, installation, adjustment, maintenance and
CVT and Clutch 9
troubleshooting information.
Engine Lubrication System 10
Magneto System 11
CFMOTO reserves right to make improvements
and modifications to the products without prior Front Wheels,Brake,Suspension,Steering 12
notice. Overhaul and maintenance should be
Rear Wheels,Brake,Suspension 13
done according to actual condition of vehicle.
Front Differential,Rear Gearcase 14
Electrical System 15
All rights reserved Lights,Instrument,Switches 16

Zhejiang CFMOTO Power Co., Ltd.
Troubleshooting 17
June. 2011
Unit Conversion Table
Item Example Conversion

2
Pressure 200kPa(2.00kgf/cm²)33kPa(250mmHg) 1 kgf/cm =98.0665kPa 1kPa=1000Pa
1mmHg=133.322Pa=0.133322kPs
Torque 18N·m(1.8kgf·m) 1 kgf·m=9.80665N·m
3 3 3
Volume 419ml(419cm ,419cc) 419ml(0.419l) 1 ml=1 cm =1 cc 1l=1000 cm
Force 12N(1.2kgf) 1 kgf=9.80665N
1 GENERAL INFORMATION
Maintenance information………….…1-1 Tightening torque table……………1-13
Location of VIN/EIN …………………1-3 Lubricants and service products…1-19
General specifications………………1-4 W iring,pipes&cables ………………1-20
Maintenanc e specifications………1-6 MIL/ EVAP system…………………….24
1
MAINTENANCE INFORMATION
Operation cautions
1. Engine exhaust fumes are poisonous and can result in loss of consciousness or death. Do not run the
engine in an enclosed or poorly ventilated area.
2. Do not touch the engine or muffler with bare hands after the engine has been just stopped to avoid burns.
Wear long-sleeve work clothes and gloves for operation.
3. Battery electrolyte (dilute sulfuric acid) is highly caustic and can result in burns from contact with skin and
eyes. If you spill electrolyte on skin,flush with water and seek for medical attention immediately. If you spill
electrolyte on clothes,flush with water if to avoid burns. Keep battery and electrolyte out of reach of children.
4. Coolant is poisonous. Do not drink or spill it on skin, eyes or clothes. If you spill coolant on skin,immediately
wash with soap and water. If you spill coolant on eyes, flush with water and seek prompt mediacal attention.
If you swallow coolant, induce vomit and see the doctor. Keep coolant out of reach of children.
5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask.
6. Gasoline is highly flammable. No smoking or fire. Also keep gasoline away from sparks. Vaporized gasoline
is also explosive. Operate in a well-ventilated area.
7. When the battery is being charged, it produces explosive gases. Charge the battery in a well-ventilated area.
8. Be careful not to get pinched by the turning parts like wheels and clutch.
9. When more than two people are operating, keep reminding each other for safety purpose.
Cautions for removal and installation
1. Use genuine CFMOTO parts, lubricants and service products.
3. Clean mud, dust before servicing.
2. Store the removed components separately in order for correct installation.
4. Replace the removed washers, o-rings, piston pin retainers, cotter pins with new ones.
5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers.
6. Clean and blow off the detergent after removal. Apply lubricants on the surface of moving parts. Measure the
data during removal for correct installation.
7. If you do not know the length of screws, install the screws one by one and make sure they are screwed in
with the same depth.
8. Check if the removed rubber parts are aged and replace if necessary. Keep the rubber parts away from
grease.
9. Pre-tighten the bolts, nuts and screws, then torque to specification.The basic sequence is from big to small,
from inner side to outer side and criss-cross.
10.Replace aged rubber parts when assembling. Do not splash gasoline,grease onto the surface,as this
could cause damage.
1-1
11. Apply or inject recommended lubricant to the specified lubrication points.
12. Use special tools when necessary.
13. When ball bearing is removed by pressing steel balls, it can not be reused.
14. Finger turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly.
Replace if the axial or radial play is too big.
If the surface is uneven, clean with oil and replace if the cleaning does not work.
When pressing the bearing into the machine or onto the shaft,if the bearing can not be securely seated,
replace it.
15. Install the one-side dust-proof bearing in the right direction. When assembling the open type or double-side
dust-proof bearing, install with manufacturer’s mark outward.
16. Keep the bearing block still when blowing dry the bearing after washing clean. Apply oil or lubricant before
installation.
17. Install the elastic circlip properly. Turn the circlip after assembling to make sure is has been installed into
the slot.
18. After assembling, check if all the tightened parts are properly tightened and can move smoothly.
19. Brake fluid and coolant may damage painting, plastic and rubber parts. Flush with water if splashed on
thses parts.
20. Install oil seal with the side of manufacturer’s mark outward.
Do not fold or scratch the oil seal lip.
Apply grease to the oil seal lip before assembling
21. When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if any, into the groove. Replace
the pipes or hoses that cannot be tightened.
22. Do not mix mud or dust into engine and/or the hydraulic brake system.
23. Clean the gaskets and washers of the engine casing before assembling. Remove the scratches on the joint
faces by polishing evenly with an oilstone.
24. Do not twist or bend the cables too much. Distorted or damaged cables may cause poor
25. When assembling the parts of protection caps, insert the caps to the grooves, if any.
ENGINE BREAK-IN
There are many movable components inside the engine, such as piston, piston ring, cylinder, crankshaft,
gears and so on.During initial use period, proper run-in for every critical component is necessary.Break-in can
help engine components match each other better and adjust working condition.Careful treatment of a new
engine will result in more efficient performance and a longer service life.
Recommended break-in period: First 20 hours
Operation guide:
0~10 Hours
Do not operate continously at more than 50% throttle position.
Cool down the engine for every 5~10 minutes after every 1 hour operation.
Avoid sudden acceleration.Vary the throttle position slowly and smoothly.Do not vary the throttle position
rapidly.
10~20 Hours
Avoid long-time run at more than 75% throttle position. Do not open throttle completely during the period.
ATTENTION:
1.Maintain and repair as regular procedures during break-in period.
2.After break-in, do not forget to check and maintain the engine before normal use.
1-2
LOCATION OF VIN/EIN
Model Number CF800-2
1. Vehicle identification number(VIN): LCELVYZ3~
2. Name plate (Vehicle identification number label)
3. Engine identification number(EIN): 2V91W~
1-3
Item Specifications
Model type CF800-2
Overall length 2310mm
Overall width 1180mm
Overall height 1340mm
Wheelbase 1480mm
Engine type 2V91W
Displacement 800ml
Fuel type and Octane No. RQ-93 or higher unleaded gasoline
Dry weight 400 kg
Passengers 2 persons (including driver)
Total vehicle load allowed 2persons +105 kg =255 kg
AT26×9—12 49J
Front
AT26×9—14 48J
Tire
AT26×11—12 55J
Rear
AT26×11—14 54J
Min. ground clearance 270mm
Min. turning radius 8000mm
Starting Electric start
Type V-twin cylinder,4-stroke,liquid-cooled,8 valves,SOHC
Valves SOHC /Timing chain drive
Bore×Stroke 91mm×61. 5mm
Compression ratio 10.3:1
Engine Lubrication Wet sump, replaceable oil filter
Oil pump Rotor drive
Oil filter Paper type, replaceable
Engine oil type SAE15W-40/SG or higher
Cooling system Liquid-cooled/close-loop cooling
Coolant type -30℃anti-corrosion and anti-freezing
1-4
Item Specifications
Air filter type Paper filter element
Air intake
Type 0800-173000
devices Throttle body
Diameter of throttle body 48mm
Fuel tank capacity 23 L
Clutch type Wet shoes and auto centrifugal
Transmission type CVT+ Gearshift
Gearshift High, Low and Reverse
Gearshift
Manual operation /L-H-N-R-P
methods/orders
CVT ratio range 2.88~0.70
“H” gear “L” gear “R” gear
Drive train Final ratio 1.333
Gearshi
Secondary ratio 1.952
ft ratio
Single gear ratio 1.143 2.529 2.231
Total ratio 2.975 6.585 5.807
Front 33 / 9 = 3.667
Ratio of drive gear
Rear 33 / 9 = 3.667
Output type Front/Rear shaft drive
Rotation of engine output When forward, clockwise (rear view)
Left 31º
Steering Turn angle
Right 31º
Front Hydraulic Disc
Brakes
Rear Hydraulic Disc
Suspension Double A-arm and independent
Frame type Steel tube and plate
1-11
MAINTENANCE SPECIFICATIONS
Lubrication System
Item Standards Service Limit
Oi l C hange 3400ml(wi thout oi l fi lter replacement) -
Oi l C hange 3500ml(wi th oi l fi lter replacement)

Engi ne Oi L
C apaci ty Oi l C apaci ty 3600ml -
Oi l Insi de the Oi l Radi ator

600ml(Note:fi ll after fi rst start)
and Hoses
20W-50 Recommended engine oil:SAE 15w40 API SG.If it’s not

15W-40,15W-50
available,select alternative according to the following
Grade 10W-40,10W-50
specifications.
10W-30
API classifications: SG or higher
5W-30
Viscosity rating: according to the left chart
-30 -20 -10 0 10 20 30 40
-22 -4 14 32 50 68 86 104
C learance Between Inner

0.06-0.14mm 0.25mm
and Outer Rotor
C learance Between Outer

0.09-0.15mm 0.25mm
Rotor and Bore
Oi l Pump Rotor
Rotor End C learance 0.023-0.109mm 0.20mm
1500rpm:70-300kPa(90 ),Typi cal:180kPa

Oi l Pressure
6000rpm:350-550kPa(90),Typi cal:420kPa
Air Intake System
Item Standards and Specifications
Fuel Tank Total C apaci ty 23L
Throttle Body Part NO. 0800-173000
T-MAP Sensor Part No. 0800-175000
Fuel Injector Part No. 0800-171000
Idle Speed 1300 100rpm
1-6
Item Sta nd a rd s S e r v i c e l im i t
Full capac ity 3000ml

Capacity of reservoir
380 ～6 0 0 m l
Coolant capac ity
ta n k
Sta n d a rd d e n s i t y 50%
2
Opening pressure 1 0 8 k p a (1 . 1 k g f /c m )
Opening 6 5 ±2 ℃
t e m p e r a tu r e
Fully opening 85 ℃
Th e r m o s ta t
Tr a v e l wh e n f u l l y
W h e n 85 ℃，＞5mm
opening
Wa te r Resistant of B Resistant of A,C

t e m p e r a tu r e（℃） terminal（Ω） terminal（kΩ）
R e l a t i o n sb e t we e n
wa t e r t e m p .an d r e s i s ta n -20 ---- 2 8 .5 8 2 ±0 .0 0 4
t o f wa te r t e m p . s e n s o r
25 ----- 2 . 7 9 5 ±0 . 0 0 2 5
50 216.0-216.4 0.98±0 . 0 0 2 2 7
80 74.6-90.6 0 . 3 3 4 ±0 . 0 0 2 0 4
110 32-36 0 . 1 3 3 ±0 . 0 0 2 5 2
O F F - ON Around 88℃ Around 88℃

W o rk i n g te m p . o f
t h e rm o s wi tc h Around 82℃ Around 82℃
ON - O F F
Coolant type - 30 ℃ a n t i -f r e e z i n g , a n ti -c o r r o s i ve a n d h i g h b o i l i n g p o i n t
1-7
Item Standard value Service limit

Longitude 1.0mm 2.0mm
Rim jump
Transverse 1.0mm 2.0mm
Front wheel Remaining 3.0mm
Front tire groove
2
Pressure 45kPa（ 0.45kgf／ cm ）
Service
Item Standard value limit
Longitude 1.0mm 2.0mm
Rim jump
Transverse 1.0mm 2.0mm
Rear wheel Remaining 3.0mm
Rear tire groove
2
Pressure 45kPa（ 0.45kgf／ cm ）
Item Standard value Service limit

Free play of brake lever 0mm
Front brake
Thickness of brake disc 3.5mm 2.5mm
Free play of brake le ver 10-20 mm
Rear brake Free play of brake pedal 0mm
Thickness of brake disc 7.5mm 6.5mm
1-8
Item Standards
Type Magneto 3-phase AC generator
Output 3-phase AC output
Resistance of coil（ 20℃） 0.2Ω-0.3Ω
Resistance of pick-up coil 250Ω-300Ω
AC Flywheel Voltage without load(cold engine) ＞ 100V（ AC）， 5000r/min
Max. output power 350W ， 5000r/min
Stable voltage 13.5V-15.0V, 5000r/min
Peak voltage of pick -up ≥1.5V，200 r/min
3-phase supply power of
Regulator type
thyristor trigger circuit
Capacity 12V 30Ah
Voltage Fully recharged 14.4V
between
Battery Not-fully recharged ≤11.8V
terminals
Recharging Standard 1A／ 5～ 10H
current/time Quick 5A／ 1H
Item Standards
Ignition type ECU
Type Resistant-type
Standard DCPR8E (NGK)
Spark plug
Gap of spark plug 0.8-0.9mm
Characteristic ＞ 8mm， under 1Kpa
Ignition time BTDC10º 1500r/min
Resistance of Primary 0.70Ω-0.75Ω
ignition coil Secondly 6.0kΩ-7.0 kΩ
Peak voltage Primary ＞ 150V
Pulse voltage 2V
Resistance of starter relay coil 3Ω-5Ω
Resistance of auxiliary relay coil 90Ω-100Ω
Item Standards
Main 30A
Fuse
Auxiliary 10A×1 15A×5
Headlight（ Hi／ Lo） 12V—35W /35W ×2
Front position light 12V—5W ×2
Brake light/Tail light 12V—21W /5W ×2
Turn signal light 12V—10W ×4
Light & Bulb
Dashboard indicator light LED
Water temperature, fuel level,2x4 drive indicator
LCD
light
MIL LED
1-8
Valves & Cylinder Head

Item Standard value Service limit Remarks
Intake valve φ33 ——
Dia. Of valve neck
Exhaust valve φ29 ——
Thickness of valve neck Intake/Exhaust 1 0.5
Intake 0.06-0.14 ——
Valve clearance(cold engine)
Exhaust 0.11-0.19 ——
Inner dia. Of valve guide Intake/Exhaust 5.000-5.012 5.045
Gap between valve guide and Intake 0.020-0.047
stem Exhaust 0.030-0.057
Intake 90.1
Valve length
Exhaust 88.7
Intake valve 1.2±0.1 1.7
Width of valve seat seal
Exhaust valve 1.3±0.1 1.8
Valve spring free length Intake/Exhaust 40 38.2
33: 200-235N
Elasticity of valve spring Intake/Exhaust
23: 530-587N
Axial clearance of camshaft 0.12-0.28
Camshaft run-out 0.10
Bore diameter of rocker arm Intake/Exhaust 12.000-12.018 12.03
Flatness of cylinder head bottom 0.03 0.05
surface
1-10
Cylinder, Piston, Piston Ring & Crankshaft

Item Standards Service limit Remarks
Cylinder compression 1000kPa
Piston/Cylinder clearance 0.03-0.05 0.10
Flatness of cylinder top and bottom 0.03 0.05
surface
1st ring 0.25-0.40 1.5
Gap of piston ring
2nd ring 0.35-0.45 1.5
Oil ring 0.2-0.7 1.5
1st ring 1.17-1.19
Height of piston ring
2nd ring 1.47-1.49
Oil ring 2.37-2.47
1st ring 1.21-1.23
Height of piston groove
2nd ring 1.51-1.53
Oil ring 2.50-2.52
1st ring 0.02-0.06 0.15
Ring/Piston groove clearance
2nd ring 0.02-0.06 0.15
Oil ring 0.03-0.15 0.25
Piston bore 22.004-22.010
Inner diameter of small end of 22.01-22.02 22.06
connecting rod
Diameter of piston pin 21.995-22.000 21.980
Gap of piston/piston pin 0.004-0.015 0.08
Gap of piston pin/small end hole of 0.010-0.025 0.08
connecting rod
Side gap of big end of connecting 0.3-0.56 0.8
rod
Gap of connecting rod bearing 0.022-0.049 0.09
Gap of main bearing 0.02-0.05 0.09
Gap of crankshaft axial direction 0.05-0.35 0.6
1-11
Clutch + CVT + Gearbox

Item Standard value Service limit Remarks
Inner dia. of clutch friction disc 140.00-140.15 140.5
Clutch engagement RPM 1800-2400r/min
Clutch locking RPM 3300-3900r/min
Belt width 34.5（Cord layer） 33.5
Free length of driven pulley spring 238.5
Hole dia. of driven pulley collar 38.10-38.14 38.30
Groove width of gearshift 6.10-6.20 6.30
Output gear width of driven shaft 6.10-6.20 6.30
Thickness of left and right gearshift fork 5.80-5.90 5.70
Clearance between gearshift fork and 0.20-0.40 0.50
engagement groove
Groove width of gearshift drum 8.05-8.10
Dia. of gearshift pawl pin 7.90-7.95 7.83
1-12
Tightening Torque
Items TorqueN·m(kgf·m) Items TorqueN·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 20(2.0) 6mmSH Flanged bolt 10(1.0)
10mm Bolt,Nut 34(3.5) 6mm Flanged bolt, nut 12(1.2)
12mm Bolt,Nut 54(5.5) 8mm Flanged bolt, nut 20(2.0)
10mm Flanged bolt, nut 39(4.0)
Fasteners not included in below table should also be torqued to specification. Note: Threads and contact area should
be applied by engine oil.
Ref. No. Items Part number Qty Torque（N·m）
1 Mount bolt, upper part of engine GB5789 M8×35 2 35～45
2 Bolt, upper bracket of engine GB5789 M10×1.5×20 2 40～50
3 Mount bolt, front and left side of engine GB5789 M10×1.25×125 1 40～50
4 Mount bolt, front and right side of engine GB5789 M10×1.25×100 1 40～50
5 Mount bolt, front bracket of engine GB5789 M8×20 6 35～45
6 Mount bolt, rear part of engine GB5789 M10×1.25×170 1 40～50
7 Bolt, rear bracket of engine GB5789 M8×20 6 35～45
8 Bolt, rocker arm GB5789 M10×1.25×70 16 40～50
GB5789 M10×1.25×50 2
9 Bolt, front shock absorber 40～50
GB5789 M10×1.25×70 2
GB5789 M10×1.25×50 2
10 Bolt, rear shock absorber 40～50
GB5789 M10×1.25×70 2
11 Bolt, bracket of rear wheel axle GB5789 M10×1.25×140 4 40～50
12 Mount nut, rim 901B-070002 16 70～80
13 Nut, rim shaft 901-07.00.03 4 110～130
14 Bolt, rear brake caliper GB70 M10×1.25×20 2 30～40
15 Bolt, front brake disc 901-08.00.03 8 25～30
16 Bolt, front brake caliper GB5789 M8×16 4 15～25
17 Bolt, cover of handlebar GB5789 M8×55 4 15～25
18 Mount bolt, muffler GB5789 M10×1.25×70 1 40～50
29 Lower bolt, muffler body GB5789 M8×68 1 15～25
20 Bolt, muffler clamp GB5789 M8×35 1 15～25
21 Bolt, rear axle GB5787 M10×1.25×110 2 40～50
22 Bolt, front axle GB5787 M10×1.25×90 1 40～50
23 Bolt, front axle GB5787 M10×1.25×25 2 40～50
24 Bolt, bracket of front axle GB5789 M8×14 2 15～25
25 Bolt, rear end of rear drive shaft 9010-300001 6 40～50
26 Bolt, front end of rear drive shaft 9010-290001 4 30～40
27 Bolt, front drive shaft 9010-290001 8 30～40
28 Bolt, output coupler GB5789 M10×1.5×30 1 40～50

1-13
29 Thermoswitch CF250T-420500 1 9～12
30 Nut, tie rod GB9457 M10×1.25 4 30～40

Item Qty Dia. Of thread(mm) Torque (N.m) Remarks

Bolt M14X1.5 2 M14×1.5 25
Plug screw, oil passage of left crankcase 1 ZM14 20 Apply glues
Oil drain boltM12×1.5 1 M12×1.5 20
Flange bolt M8×12.5 (left crankcase) 1 M8×12.5 20
Screw R21/8 (oil passage) 2 R21/8 20 Apply glues
Nut M6(right crankcase) 4 M6 10
Stud AM6×35-8.8 (right crankcase) 4 AM6×35 10 Threadlocker
Screw M6×12（CVT cover） 1 M6×12 8
Bolt of wiring clamper(left crankcase cover) 2 M5×10 6 Threadlocker
Screw of oil seal plate(left crankcase cover) 3 M6×8 8
Bolt M12×1.25(Magneto rotor) 1 M12×1.25 105 Threadlocker
Adjust nut, valve clearance 8 M6 12
Bolt, timing sprocket 2 M8 30 Threadlocker
Plunger, tensioner 2 M16×1.5 0.1
Plug screw, tensioner 2 M18×1 4.5
Bolt, cylinder 8 M10 20,60
Thrust nut M8（exhaust pipe） 4 M8 13
Spark plug 2 M12×1.25 20
Stud M8x42（exhaust pipe） 4 M8×42 10 Threadlocker
Plug screw M12×1.5（head of cylinder 1） 1 M12×1.5 20
Tapping screw ST5.5×13(thermostat cap) 1 ST5.5×13 5
Screw, tensioner plate 2 M6×15.5 10 Threadlocker
Bolt M8, intake manifold 4 M8 20
Bolt, connecting rod 4 M9×1 10,20,50
Nut M18x1.5(left)（right crankcase） 1 M18×1.5 70 Left thread
1-14
To be continued
Item Qty Thread Dia. (mm) Torque (N.m) Remarks
Nut, drive shaft（CVT drive pulley） 1 M20×1.5 115 Threadlocker
Nut,main shaft（CVT driven pulley） 1 M20×1.5 115 Threadlocker
Lock nut, bevel gear 1 M22×1 145
Bolt M8x28(bearing seat, drive bevel gear) 4 M8×28 32
Screw M8x5（bearing holder, drive bevel gear） 4 M8×5 15
Stopper nut,M65X1.5(driven bevel gear) 1 M65×1.5 110 Threadlocker
Nut M8X28(bearing housing, driven bevel

4 M8×28 25
gear)
Screw T25(shift fork drum) 1 M5×8 6
Spring seat, Limit 1 M12×1 20
Screw M5×16（oil pump） 3 M5×16 7 Threadlocker
Screw M8X20（overriding clutch） 6 M8×20 30 Threadlocker
Bolt M6×30（Magneto stator） 3 M6×30 10 Threadlocker
Bolt, valve cap 8 M6 7
Bolt M6×45(thermostat cap, cylinder 1) 2 M6×45 6
Bolt M6×25 (Tensioner, thermostat cap of

6 M6×25 6
cylinder 2）
Water temperature sensor 1 M12×1.5 16
Switch of oil pressure 1 M10×1 12 Threadlocker
Retainer, bearing (left) Threadlocker,l

1 M55×1.5 80
eft thread
M5 4.5-5.5
Other bolts M6 8-12
M8 25
1-15
Engine Service Tools
Item Tool name Specifications Purposes
1 Vernier caliper 0-150mm Measure length and thickness
2 Micrometer 0-25mm Measure outer diameter of rocker arm shaft, valve stem, camshaft
3 Dial gauge 25-50mm Measure Max. travel of camshaft
4 Dial gauge 75-100mm Measure size of piston skirt
Inner dia. of cylinder Measure cylinder size & pressure

5
meter
Inside caliper Measure inner diameter of rocker and piston pin hole, connecting
6 10-34mm
micrometer rod hole
7 Dial indicator 1/100 Measure jump
8 Knife straight edge Measure flatness
9 Feeler gauge Measure flatness and adjust valve clearance
10 Oil guage Measure fuel level of carburetor
11 Plastigauge Measure fit clearance
12 Spring balance Measure elasticity of spring
13 RPM meter Measure RPM
Compression tester Measure cylinder compression

14
and adapter
15 Oil pressure meter Measure oil pressure
16 Air pressure meter Measure opening pressure of radiator cover
17 Ohmmeter Measure resistance and voltage
18 Amperometer Measure current of switch
19 Thermometer Measure coolant temp.
20 Timing light Measure ignition timing
21 Torque wrench One set Measure tightening torque
22 Alcohol light Warm up or increase temp.
23 Magnetic meter seat Mounting dial indicator
24 Plate Auxiliary measurement
25 V-shaped bluff Auxiliary measurement for jump
26 Nipper Mounting valve lock-clip
27 Double clip reed Disassembly and assembly of double clip
28 Pinching tools Disassembly and assembly of retainer
29 Impact driver Disassembly of crosshead bolt
30 Screw driver
31 Plus driver
1-16
Service Tools
Part number Tool name Purposes
0800-000000-871-001 Joint, oil hose Measure oil pressure
0800-014001-922-003 Remover, bearing 60/28 of left crankcase Remove bearing 60/28
0800-014001-921-002 Press tool, bearing of left crankcase Press bearing
0800-041000-922-001 Screw, locking crankshaft Lock crankshaft
0800-031000-922-001 Remover, magneto rotor Remove magneto rotor
0800-013201-922-001 Remover, bearing 6003 of CVT case Remove bearing 6003
0800-013201-921-001 Damper, CVT case cover Support CVT case cover when
pressing bearing
0800-052000-922-003 Split tool, drive & driven pulley Split driven fixing and moving
sheave to install belt
0800-051204-923-001 Installation tool, drive pulley oil seal Install drive pulley oil seal 35×42×4
0800-052000-922-002 Remover, driven pulley
0800-052000-922-001 Wrench, CVT driven pulley Fix nut of driven pulley when
installation
0800-013101-922-001 Remover, bearing 6208 of CVT case Remove bearing
0800-013101-921-001 Damper, CVT case Support CVT case when pressing
bearing
0800-013104-923-001 Installation tool, clutch housing oil seal Install oil seal of CVT clutch
housing34×55×9
9010-180100-922-001 Radiator test cap Measure cooling system pressure
0800-014001-922-002 Puller, oil seal Remove oil seal
0800-014001-922-001 Puller, bearing Remove bearing
0800-014001-921-003 Press tool, bearing Press bearing
0800-022800-922-001 Sleeve, spark plug Disassemble/install spark plug
0800-024001-922-001 Locking tool, camshaft Lock up and fix camshaft
0800-000000-871-002 Joint, cylinder pressure meter Measure cylinder pressure
0800-022102-922-001 Remover, valve guide Remove valve guide
0800-022102-922-002 Installer, valve guide Install valve guide
0800-040003-922-001 Compressor, piston ring Compress piston ring when
installation
0800-040005-922-001 Installer, circlip Install circlip of piston pin
0800-011201-923-001 Oil seal installer, breather Install oil seal of breather
0800-011201-921-003 Installation jig, breather gear shaft Support breather gear shaft
0800-011201-921-001 Press tool, breather gear shaft Press breather gear shaft
0800-011101-922-001 Support tool, left crankcase plain bearing Support left crankcase when
removing removing plain bearing
0800-012101-922-001 Support tool, right crankcase plain bearing Support right crankcase when
removing removing plain bearing
0800-011102-922-001 Remove/install tool, roller bearing Remove/install bearing
0800-060000-923-001 Press tool, front output shaft oil seal Install oil seal35×61×9 of front output
shaft
1-17
0800-062301-923-001 Installer, front output shaft Install front output shaft

0800-062206-922-001 Nut sleeve, driven bevel gear bearing Install/remove nut of driven bevel
gear
0800-062204-923-001 Press tool, oil seal of driven bevel gear Install oil seal of driven bevel gear
34×50×7
0800-062000-922-001 Backlash measurement tool Measure backlash between drive
bevel gear and driven bevel gear
0800-060002-922-001 Remover, shaft of reverse immediate gear Remove shaft of reverse immediate
gear
0800-011000-922-001 Remover, left crankcase bearing Remove bearing of left crankcase
0800-012000-922-001 Remover, right crankcase bearing 5206 Remove bearing 5206
0800-012101-921-001 Damper, right crankcase Support right crankcase
0800-011101-921-001 Damper, left crankcase Support left crankcase
0800-060000-922-001 Press tool, reverse immediate gear shaft Press reverse immediate gear shaft
0180-014001-921-001 Press tool, left crankcase cover bearing 60/28 Press bearing 60/28
0180-013201-921-001 Press tool, CVT case cover bearing 6003 Press bearing 6003
0180-013207-923-001 Press tool, oil seal of CVT case cover Press oil seal
0180-051000-922-001 Holding Wrench, CVT drive pulley Stop rotation of drive pulley
0180-013101-921-002 Press tool, CVT case bearing 6207 Press bearing
0180-053100-921-002 Press tool, clutch housing Press clutch housing
0180-053100-921-001 Damper, clutch housing Support clutch housing when
pressing clutch
0180-054000-922-001 Holding wrench, clutch Stop clutch rotation
0110-080005-923-001 Press tool, oil seal of water pump Install oil seal 10×20×5 of water
pump
0010-081004-921-001 Press tool, water seal Press water seal
0180-022006-922-001 Valve spring compressor clamp Compress, remove valve spring
0180-060008-922-001 Wrench, circlip of front output shaft bearing Install/Remove front output shaft
bearing circlip
0180-062201-921-003 Press tool, driven bevel gear shaft bearing Press bearing
（6207C3）
0180-062103-921-002 Press tool, drive bevel gear shaft bearing Press bearing
（6305）
0010-060002-921-002 Installer, bearing 6203 Press bearing
0180-012100-921-004 Installer, bearing 3206A Press bearing
0180-011100-921-004 Press tool, gearshift shaft bearing 6303 Press bearing
0040-012001-921-002 Press tool, bearing 6203 Press bearing
1-18
Lubricants and Service Products
Item Type Lubrication points Remarks
SAE15W-40
Engine oil Cylinder,Crankcase,Cylinder
API : SG or higher
head,see page（10-3）
(Alternative please see page 1-6)
Molybdenum Piston pin, valve stem, valve
disulfide grease oil seal, camshaft
Oil seal, O-ring and other
rubber seals. Sealed

Grease No. 3 MoS2 grease
bearing, CVT bearing and
bushing
Coolant Coolant capacity

-30℃Anti-freezing, anti-corrosive,
Engine cooling system depends on
high-boiling coolant
radiator pipes
Silicone sealant Loctite5699 Crankcase splitting
surfaces,contact surface
between crankcase and
cylinder,contact surface
between cylinder head and
valve cover
Threadlocker KB243 Some threads
Retaining compound KB648 Oil seal
1-19
WIRING,PIPES& CABLES LOCATION
1.Fuse box 2.Negative cable, battery 3.Battery case 4.Positive cable,battery 5.Starter relay 6.PDA connector
7.Radiator cap 8.Relay of headlight 9.Fan relay 10. 2x4 drive relay 11. 4x4 drive lock relay 12. Relay of
brake light 13. Relay of fuel pump 14. Starter auxiliary relay (1) 15. Starter auxiliary relay(2) 16. Flasher relay
17. Cap,reservoir tank
NOTE:Before check or repair above items, front top cover shoud be removed, but when check starter relay,
it can be operated from upper part of front left wheel.
1.Dashboard connector 2.Connector of ignition switch 3.Connector,cigeratte lighter 4.Connector,left handle-

bar switch
5.Winch control unit 6.Connector,right headlight 7.ECU connector 8.ECU 9.Connector, right handlebar switch
10.Connector, winch motor switch
Before checking above items, seat, front rack, left and right side panel, cover of air filter and front fender should
be removed.
1-20
1.Connector, auxiliary cable 2.Connector1, oxygen sensor 3. Starter relay 4.Connector, horn
1.Connector, fuel pump 2.Connector, fuel sensor 3.Connector, gear sensor 4.Connector, rear brake switch 5.
Connector 2, oxygen sensor 6. Fuel filter
Before checking and repair above items, left and right side panel, seat should be removed.
1-21
1.Connector,tail light/brake light/rear turn light 2.Connector, rear licence light 3.Breather hose, fuel evaporated
system(Note:For Euro standard, ATV is without fuel evaporated system, so the breather hose is only for
balancing pressure of fuel tank. It’s important to avoid hose blocked, otherwise fuel pump will be damaged. At
the same time, avoid to overfill fuel. 4.Connector, trailer power socket 5.Trailer power socket
Attention: Voltage of trailer power socket (DC12V) Max. current is less than 10A. The socket is only used for
power supply for rear turn light of trailer, tail light and rear licence light.
1.Throttle cable 2.Connector, pick-up coil 3.Throttle body 4. TPS 5. Air by-pass valve6. Injector 7. Water temp.
sensor 8. Water pipe 9. Air intake temp. sensor 10. Ignition coil
1-22
1.Water outlet pipe 2. Connector, differential gear motor 3. Brake hose 4. Water inlet pipe 5. Differential gear
motor 6. Regulator 7. Oil inlet pipe 8. Oil outlet pipe 9.Exhaust gas pipe between crankcase and air filter 10. Oil
pressure switch
1. Main cable 2.Waste fuel collection hose 3. Connector, cooling fan 4.Limit cable, gearshift
5.Rear brake cable
1-23
MIL
MIL is located at position
When the light flashes, it will indicate there’s some-
thing wrong in vehicle.The flash code consists of 4
digits.
Example 0650
“0” means flash 10 times;
“0” means flash 10 times.
Detailes please refer to page (15-27).
Also PDA can be used for diagnosis. please see page
(1-19) and (15-26) to know “How to use PDA”.
EVAP(Evaporative Emission Control System)

The system is only assembled for specified regions (such as USA california state). For European countries
and other regions, it’s not available.
If there is something wrong for EVAP, please contact local dealer for service. Do not modify the system without
approval, otherwise it will not in accordance with related laws and regulations. After disassembling the system,
check if fuel hoses are good, if any air or fuel leakage, if any blocked, if any damaged.Evaporative fuel goes into
canister through disorption hose. When engine stops, carbon inside canister can adsorp evaporative fuel.
When engine starts, fuel inside canister will go to combustion chamber through disorption hose to avoid going
out to pollute air. Meanwhile adsorption hose can balance air pressure inside fuel tank to protect fuel tank and
fuel pump.
Working Flow Layout
Fuel
Tank
Engine Throttle Body Air Filter
1. Clamp 2.Vacuum pipe of canister 3. Two way valve 4. Vaccum pipe (2) 5.Evaporative fuel pipe(2) 6.Evapo-
rative fuel pipe(1) 7.Clamp 8.Water pipe joint 9.Evaporative fuel pipe (3) 10.Clamp 11.Canister
1-24
2 BODY AND MUFFLER
Maintenanc e Information... ........ ........ ...... 2-1 Rear Fender...........................................2-10
Troubleshooting..................... ... .................2-1 LH Footboard,LH Headlight Protector..2-11
Front Rack,Battery Cover.......... .. .............2-2 Rear LH Bumper Guard,Rear Bumper, Bumper
Rear Rack..................................................2-3 Prot ector…… ………………………………2-12
2
Pa sseng er Seat ,Driver Sea t.. .. ... ... .. ... .2-4 Front Bumper,Headlight trim.... ..... ..... .2-1 3
Air Filter Cover,Dashboard Cover............2-5 Taillight Trim,Rear Fascia......................2-14
Gearshift Lever Knob, Lever Indicator, Front LH Suspension Protector,
LH Side Panel............................................2-6 Rear LH Suspension Prot ector......... ...2-15
RH Side Panel,Front Fender Extension,LH..2-7 Fuel Tank...............................................2-16
Front Fender Exte nsion,RH, Muff ler. ... .......................... .. ....................2-17
Rear Fender Extension,LH........................2-8 Body and Accessories............................2-18
Center Front Fascia,Front Fender........... 2-9
Operation Cautions
WARNING:
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special atten-
tion 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.
zThis chapter is on the disassembly and installation of rack, visible parts, exhaust pipe, muffler and fuel tank.
zHoses, cables and wires should be routed properly.
zReplace the gasket with a new one after muffler is removed.
zAfter 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
zBroken muffler
zExhaust leakage
Insufficient power
zDeformed muffler
zExhaust leakage
zMuffler clogged
2-1
BATTERY COVER
Removal
Pull strap no.1 toward dashboard cover to disengage
the latch to remove battery cover no.2.
FRONT RACK
Removal
Remove battery cover;
Remove the 4 bolts no.4;
Remove front rack no.5.
Installation
Reverse the removal procedure for installation.
Tightening Torque
Front rack mounting bolt no.4:
35 N m- 45N m
2-2
2 BODY AND MUFFLER
TOOL BOX COVER
Removal
Pull strap no.2 toward passenger seat to disengage
the latch to remove tool box cover no.1.
REAR RACK
Removal
Remove the 4 bolts no.3;
Remove rear rack no.4.
Installation
Tightening Torque
Rear rack mounting bolt no.3:
35 N m-45 N m
2-3
PASSENGER SEAT
Removal
Pull upward strap no.2 and lift passenger seat back
to remove passenger seat no.1.
Installation
DRIVER SEAT
Removal
Remove passenger seat;
Disengage driver seat latch no.4;
Remove driver seat no.3.
Installation
Check if the driver seat is secured and in place after
installation.
2-4
2 BODY AND MUFFLER
AIR FILTER COVER
Removal
Remove passenger seat( 2-4);
Remove driver seat( 2-4);
Lift the rear of air filter cover no.1 to disengage plastic
latches then pull the air filter cover backward to re-
move it.
Installation
DASHBOARD COVER
Remove passenger seat set( 2-4);
Remove air filter cover( 2-5);

Remove push rivets no.4;
Remove tapping screws no.3;
Remove dashboard cover no.2;
Unplug dashboard connectors no.5;
Unplug cigarette lighter connector no.6;
Unplug ignition switch connector no.7.
Installation
Reverse the removal procedure and direction for
installation.
2-5
GEARSHIFT LEVER KNOB
Removal
Loosen locking nut no.2;
Remove gearshift lever knob by turning it
counterclockwise.
Installation
installation.
GEARSHIFT LEVER INDICATOR

Removal
Remove gearshift lever knob;
Remove screw no.4;
Remove lever indicator no.3.
Installation
installation.
LH SIDE PANEL
Removal
Remove air filter cover( 2-5
Remove gearshift lever knob ;
Remove lever indicator;
Remove bolts no.6;
Remove tapping screws no.8 retaining front and rear
fender;
Remove latch no.9;
Remove side panel.
Installation
installation.
2-6
2 BODY AND MUFFLER
RH SIDE PANEL
Removal
Remove bolts no.2;
Remove RH side panel.
Installation
installation.
FRONT FENDER EXTENSION,LH

Removal
Remove bolts&nuts no.8;
Remove push rivet no.7;
Disengage plastic latches;
Remove front LH fender extension no.6.
Installation
installation.
2-7
FRONT FENDER EXTENSION,RH
Removal
Remove push rivet no.2;
Remove front RH fender extension no.1.
Installation
installation.
REAR FENDER EXTENSION,LH

Removal
Remove tapping screw no.7;
Remove rear fender extension,LH no.4.
Installation
Reverse the removal procedure and direction
for installation.
REAR FENDER EXTENSION,RH
Refer to rear LH Fender Extension
Removal&Installation.
2-8
2 BODY AND MUFFLER
CENTER FRONT FASCIA
Removal
Remove the 2 tapping screws no.2;
Remove push rivets no 3;
Remove center front fascia.
Installation
FRONT FENDER
Removal
Remove front rack( 2-2);
Remove operator seat( 2-4);
Remove dashboard front cover( 2-5);
Remove gearshift lever knob( 2-6);
Remove lever indicator( 2-6);
Remove front LH&RH fender extension( 2-7);
Remove L&R side panel( 2-7);
Remove front center fascia;
Remove push rivets no.5&7;
Remove bolts no.4;
Remove bolts no.8;
Remove bolts no.9;
Remove bolts no.10;
Remove bolts no.12;
Remove fuse box;
Remove front fender no.11.
Installation
2-9
Rear Fender
Removal
Remove rear rack( 2-3);
Remove air filter cover( 2-5
Remove rear LH&RH side panel( 2-8);
Remove LH&RH side panel( 2-6);
Remove bolt no.4;
Remove bolt no.6;
Remove bolt no.7;
Remove bolts no.8;
Remove rear fender no.3.
Installation
2-10
2 BODY AND MUFFLER
LH FOOTBOARD
Removal
Remove side panel( 2-6);
Remove the bolts,nuts retaining front and rear
mudguard;
Remove bolts no.1;
Remove screws no.1;
Remove LH footboard no.2.
Installation
RH FOOTBOARD
Removal
Remove lever indicator( 2-6);
Refer to LH Footboard Removal&Installation.
HEADLIGHT PROTECTOR,LH
Removal
Remove bolts no.4;
Remove headlight protector,LH.
Installation
HEADLIGHT PROTECTOR,RH
Removal&Installation
Refer to LH Headlight Protector
2-11
REAR BUMPER GUARD,LH
Removal
Remove bolt no.2;
Removal rear LH bumper guard no.2.
Installation
REAR BUMPER GUARD,RH
Removal&Installation
Refer to Rear LH Bumper
Guard Removal&Installation.
REAR BUMPER
Removal
Remove rear LH&RH bumper guard.
Remove bolt no.4;
Remove rear bumper no.3.
Installation
FRONT BUMPER PROTECTOR

Removal
Remove bolt no.5;
Remove front bumper protector no.6.
Installation
2-12
2 BODY AND MUFFLER
FRONT BUMPER
Removal
Remove front bumper protector( 2-12);
Remove bolt no.2;
Remove front bumper no.1.1
Installation
HEADLIGHT TRIM
Removal
Remove front rack( 2-2);
Remove dashboard cover( 2-5);
Remove font LH&RH fender extension( 2-7);
Remove center front fascia( 2-9);
Remove front fender( 2-9);
Remove bolts no.4;
Remove bolts no.5;
Disconnect headlight connectors;
Remove headlight trim no.3.
Installation
2-13
TAILLIGHT TRIM
Removal
Remove rear rack( 2-3);
Remove rear LH&RH fender extension( 2-8);
Remove rear mudguard( 2-10);
Remove rear LH&RH bumper guard( 2-12);
Remove rear bumper( 2-12);
Remove bolts no.2;
Disconnect tail light,license plate light,rear turn lights
connectors;
Remove taillight trim no.1.
Installation
REAR FASCIA
Removal
Remove rear LH&RH bumper guard( 2-12);
Remove rear bumper( 2-12);
Remove bolts of taillight trim;
Remove bolts no.4;
Remove rear fascia no.3.
Installation
2-14
2 BODY AND MUFFLER
LH PROTECTOR,FRONT SUSPENSION
Removal
Remove bolt no.1;
Remove LH protector no.2.
Installation
RH PROTECTOR,FRONT SUSPENSION
Refer to LH Protector,Front Suspension
4 5
3
RH PROTECTOR,REAR SUSPENSION
Removal
Remove bolt no.3;
Remove bolt no.4;
Remove LH protector no.5.
Installation
LH PROTECTOR,FRONT SUSPENSION
Refer to RH Protector,Rear Suspension
2-15
FUEL TANK
Removal
WARNING:
Gasoline is highly flammable, therefore smoke and
fire are strictly forbidden in the work place.
Special attention should also be paid to sparks. Gaso-
line may also be explosive when it is vaporized, so
operation should be done in a well-ventilated place.

Remove bolts no.4;
Remove bolts no.2;
Remove bolts no.6;
Remove bolts no.7;
Remove rear plastic parts;

Disconnect fuel pump connector;
Unplug high pressure fuel line connector;
Remove fuel tank breather hose and hoses of fuel
evaporation control system;
Disconnect fuel pump connector;
Remove bolts no.5;
Remove bolts no.9;
Remove fuel tank no.8.
2-16
2 BODY AND MUFFLER
MUFFLER
WARNING:
Remove and Install muffler after it is fully cold.
Removal
Remove RH side panel( 2-7);
Remove LH side panel( 2-6);
Remove heat shield no.1;
Remove bolts no.7;
Remove heat shield no.6.
Remove bolts no.9;

Remove bolt no.10 and the clamp;
Installation
NOTE:
Replace the gasket on the exhaust port when installing.
2-17
Remove exhaust pipe bolts no.2;
Remove the exhaust pipe comp.no.1 of the front
cylinder;
Remove exhaust pipe bolts no.3;

Remove “Y” exhaust pipe comp. no.4;
Remove spring no.5;

Remove bolt no.6;
Remove muffler no.7.
Installation
NOTE:
When installing,replace the gasket on exhaust port
and graphite collar in front exhaust pipe comp..
2-18
2 BODY AND MUFFLER
BODY AND ACCESSORIES
7 8 9 10 11 12
6
3 13
2 14
15
1
16
17
21 20 19 18
22
1.Protector,Front Bumper 2.Front Bumper 3.Headlight Trim 4.Front Fender Extension,LH

5.Front Rack 6.Dashboard Cover 7.LH Handguard 8.LH Mirror
9.Air Filter Cover 10.Driver Seat 11.Passenger Seat 12.Rear Rack
13.Rear Fender Extension,LH 14.Taillight Trim 15.Rear Bumper 16.Rear Fascia
17.Spark Arrester 18.LH Footboard 19.LH Side Panel 20.Oil Check Access Cover
21.Gearshift Lever Indicator 22.Gearshift Lever Knob
2-19
3 INSPECTION AND ADJUSTMENT
Maintenance Information………………3-1 Suspension System…………………..3-11
Maintenance Interval…………………3-2 Gearshift Linkage, Fuel System…….3-12
Maintenance Procedure……………..3-3 Throttle Lever…………………………3-13
Steering C ol umn, Brake S ys tem….3-6 Cooling System…………………………3-14
Wheel……………………………………...3-9 Lighting System………………………3-16 3
Operation Cautions
WARNING:
zEngine exhaust contains poisonous carbon monoxide and can cause loss of consciousness result-
ing in severe injury or death.Never run an engine in an enclosed area.
zDon’t perform the maintenance immediately after the engine stops,as the exhaust system and en-
gine become very hot.Serious burns could result from the contact with the exhaust system or
engine.Wear long-sleeved uniform and gloves to operate when necessary.
zGasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Spe-
cial 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.
zDon’t get pinched by the drive system and other rotational parts.
ATTENTION:
Always position the vehicle on level ground.
3-1
Maintenance Intervals
Careful periodic maintenance will assure your vehicle good performance, reliability, economy and durability.
Inspection, adjustment, lubrication and other details are explained in below periodic maintenance chart.
ATTENTION：Maintenance intervals in the following chart are based upon average riding conditions.
Vehicles subjected to severe use must be inspected and serviced more frequently.
A：Adjust 10 hours or 300km

C：Clean Every 25 hours or 750km
I： Inspect Every 50 hours or 1500km
L：Lubricate Every 100 hours or 3000km or 1year
R：Replace Every 200 hours or 6000km or 2 years
Remark
Engine
Engine Oil and Filter R R
Valve Clearance I，A I，A
Condition of Engine Seals I I
Engine Mounting Fasteners I I
Air Filter C R
Coolant I I I R
Radiator Cap, Cooling System I I
Pressure Test
Spark Plug I R
Fuel System
Throttle Body I I，L
CVT
CVT Belt I R
Primary Pulley, Driven pulley I，C
Clutch I
3-2
O ： Maintenance Interval
Maintenance Interval
Task Inspection Item Every 6 Criteria
Daily Yearly
Months
Handlebar Agility O
Damage O
Steering
Installing condition O
System
Free play of ball joint pin O
Front brake lever:0mm
Free play O O
Brake Lever Main brake(FR&RR) lever: 0mm
Braking performance O O
Brake
Looseness&damage O O
lines&fittings
Brake fluid should be between
FR&RR brake fluid level O O
“LOWER” and “UPPER”
Brake System If front brake disc thickness is less

Brakedisc&pads than 2.5mm or rear brake disc
O O
wear&damage. thickness is less than
6.5mm,replace the disc.
2
Front tire:45kP（0.450kgf/cm ）
Tire pressure O O 2
Rear tire:45kPa（0.45kgf/cm ）
Crack&damage O O
Tread depth&abnormal Tread depth should be more than
O O
wear 3.0mm.
Wheel
Looseness of wheel
O O
nuts&axle
FR wheel bearing free
O O
play
RR wheel bearing free
O O
play
A-arm Free play&damage O O
Shock Leaks or damages O O
FR Diff Leaks&lubrication O O
RR Gearcase Leaks&lubrication O O
Keep the oil level even with the

Gearcase/Diff Leaks&oil level O O
bottom threads of fill plug hole.
3-3
Maintenance Maintenance Interval

Item Criteria
Daily Every 6 Yearly
Task Inspection Item
Months
Looseness of connection O O
Propshaft
Free play of splines O
Spark plug clearance：0.8－
Spark plug condition O
Ignition 0.9mm
Timing O
Battery Connections of terminals O
Electric Looseness&damages of
O
Routing connections
Fuel leakage O
Fuel
Throttle lever free play:
System Throttle condition O
3－5mm
Coolant level O O
Cooling
Leaks O
3-4
Maintenance Item Maintenance Interval

Every 6 Criteria
Task Inspection Item Daily Yearly
Months
Lights&Turn Signal Indicators Function O O
Alarming&locking Components Function O
Meters Function O
Looseness&damages O
Exhaust Pipe&Muffler
Muffler function O
Frame Looseness&damages O
Lubrication O
Others Abnormal conditions O
3-5
STEERING COLUMN
Position the vehicle on level ground.Put your hands
on the grips and shake the handlebar in the direction
illustrated in the right figure to check for free play.
If there is a free play,determine the source of it.
If the free play comes from steering column,tighten

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

bars slowly to left or right to check for agility.
If the handlebars feel rough when turning somewhere,
inspect the wiring,cables or tie-rod ends for
interference.If no interference,check the steering bear-
ing for damages.
WARNING:
Inspect the agility of handlebars before every
ride.Steering failure may result in severe injury
or death.
BRAKE SYSTEM
Front Brake Lever Free Play
Check the free play of front brake lever and the perfor-
mance of front brake.
Free play of front brake lever:0mm
3-6
MASTER CYLINDER,FRONT BRAKE
<Brake Fluid Level>
Check brake fluid level.
If the brake fluid level is below the mark”Lower”,check
master cylinder,brake lines and connections for leaks.
Remove the 2 retaining screws no.3 to open the res-
ervoir cap.
Add DOT 3 or DOT 4 brake fluid only.Never exceed
the mark no.1.
zWhen adding brake fluid,always avoid dirt or water.

zAlways use specified brake fluid.
zDon’t spill brake fluid on plastic or rubber parts,as
it would damage them.
zTurn handlebar to left or right to keep the master
cylinder level before the reservoir cap removal.
FRONT BRAKE DISC&BRAKE PADS

<Brake Pad Wear>
Inspect brake pads from the marked place.
Replace brake pads if they are worn to service limit
groove.
CAUTION:
Pads should be replaced as an assembly.
Brake Disc Inspection&Replacement

Inspect brake disc for excessive wear or damage.Re-
place brake disc when its thickness is less than 2.
5mm.
Brake Disc
Front brake disc service limit thickness:2.5mm
Brake Fluid Replacement

<Brake Fluid Replacement>
Replace brake fluid every year.
3-7
MASTER CYLINDER ASEEMBLY,4-
WHEEL BRAKE
<Brake Fluid Level>
Check brake fluid level.
If brake fluid level is below the mark no.2,inspect master
cylinder,brake lines and connections for leaks.
Unscrew reservoir cap no.1 to remove it.
Add DOT 3 or DOT 4 brake fluid only.Never exceed
the mark “UPPER”.
zWhen adding brake fluid,always avoid dirt or water.

zAlways use specified brake fluid.
zDon’t spill brake fluid on plastic or rubber parts,as
it would damage them.
zTurn handlebar to left or right to keep the master
cylinder level before the reservoir cap removal.
REAR BRAKE DISC& REAR BRAKE

PADS
<Brake Pad Wear>
Inspect rear brake pads from the marked place.
Replace rear brake pads if they are worn to service
limit groove.
CAUTION:
Pads should be replaced as an assembly.
Brake Disc Inspection&Replacement

Inspect brake disc for excessive wear or damage.Re-
place brake disc when its thickness is less than 2.
5mm.
Front brake disc service limit thickness:2.5mm
Brake Fluid Replacement

<Brake Fluid Replacement>
Replace brake fluid every year.
3-8
WHEEL
Position the vehicle on level ground.Elevate the ap-
propriate side of the vehicle by plaing a suitable stand
or other tool under the footrest frame.Shake the wheel
to check for free play or looseness.If any free play or
looseness is found,inspect A-arms,axle,rim bolts and
nuts and tighten them if necessary.
If free play or looseness still remains,inspect bearing,
A-arm bushings and ball joint pin and replace if needed.
FRONT Wheel TOE-IN

Position the vehicle on level ground to measure the
front wheel toe-in.
Toe-in:B-A=0-10mm
If the measurement is out of specification,adjust the

tie rod(no.1) locking nuts no.2.
CAUTION:
Drive the vehicle slowly after the adjustment is
completed.Ensure that handlebar works properly.
3-9
TIRE PRESSURE
Use tire pressure gauge to measure tire pressure.
CAUTION:
Test tire pressure when the tire is cold.
Maintain proper tire pressure.Improper inflation
may affect ATV maneuverability,comfort,or uneven
Tire Pressure Gauge
wear to different tires.
Specified Tire Pressure/Tire
Front Rear
2
Pressure 45kPa(0.45kgf/cm ) 45kPa(0.45kgf/cm2)
Size See chapter 1 See chapter 1
TIRE TREAD DEPTH

Replace tires when tire depth is worn to 1/8”(3mm) or
less.
3mm
CAUTION:
When tire depth is worn to 3mm or less,replace
tires immediately.
3-10
AXLE NUTS AND AXLE
Check front&rear axle nuts for looseness.
If axle nuts are loose,torque them to specified values.
Torque Specification:
Front:110-130N m(11.2kgf m-13.3kgf m)
Rear:110-130N m(11.2kgf m-13.3kgf m)
Wheel Bearing Free Play

Elevate the appropriate side of vehicle by placing a suit-
able stand under the footrest frame.Shake the wheel to
check for free play.
If there is a free play,inspect the wheel bearing.
SUSPENSION
Position the vehicle on level ground,push and release
the vehicle as illustrated.If the vehicle found unstable or
abnormal sound,check shocks for leaks,damages or
looseness to fasteners.
3-11
Shock Absorber Adjustment
The front and rear shock springs are adjustable.Ro-
tate the adjuster cam no.2 clockwise to decrease
the spring tension or counter-clockwise to increase
the spring tension.Always adjust two sides equally.
GEARSHIFT LINKAGE
Shift to check gearshift for smoothness.If not,attempt
to adjust the length of gearshift rod by turning the
locking nuts no.3.
FUEL SYSTEM
Fuel System Condition
Remove seat( 2-3);
Check fuel lines for aging,damage;
Replace fuel line if aging,damage found.
Inspect fuel tank breather hose and the hose of fuel
evaporation control system(if appliable) for damages,
bending.Replace the hoses if any damage found.
3-12
Throttle Lever no.1 Inspection
Inspect throttle lever no.1 for free play.

Free Play:3 5mm
3-5mm
Adjust throttle lever if free play is out of specification,
Slide sleeve no.3 out of place.loosen throttle cable

locking nut no.2.Turn adjuster to change the throttle
lever free play.
Reinstall locking nut no.2 and throttle cable
sleeve no.3.
If adjuster fails to change throttle lever free play to
specified value,replace throttle cable.
Speed Limiter
Speed limiter is designed to adjust throttle lever travel,
so as to limit the max speed.
Inspect the max length of limiter screw threads
Max limiter screw threads:a=12mm
Adjustment
Loose the locking nut.
Use a cross screw driver to turn the limiter screw
clockwise or counter-clockwise to adjust throttle le-
ver travel.
CAUTION:For beginners,keep the adjuster screw
clockwise turned to the max. For experienced
riders,turn the adjuster screw counter-clockwise
to change the throttle lever travel according to
speed requirements.
3-13
COOLING SYSTEM
CAUTION:
zFor safety,check the coolant level in the reser-
voir tank,not radiator.Never open the pressure
cap when the engine is hot(more than 100 ),
Escaping steam can cause severe burns.The
engine must be cool before removing pressure
cap.
zCoolant is toxic.Don’t drink nor spill on skin,eyes,
clothing.
If you spill coolant on your skin or clothing,
immediately wash it off with soap.
If you get coolant in your eyes,immediately
wash it off before medical attention.
If you swallow coolant,immediately spit it out
and gargle before medical attention.
zCoolant must be kept out of reach of children.
Coolant Level
Coolant would decrease due to evaporation,etc.In-
spect coolant level periodically.
CAUTION:
zCoolant is anti-rust and anti-freezing.Using tap water
will rust the engine,and may crack the engine
when it’s freezing. Always use specified coolant.
zPosition the vehicle on level ground before cooling
system inspection.
zStart the engine and warm it up before inspecting
the cooling system.
Start the engine and warm it up.

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

tween “LOWER” and “UPPER”.
3-14
When the coolant level is below the mark no.1-
”LOWER”,remove the reservoir tank cap and add cool-
ant to the mark no.2-”UPPER”.
Recommended Coolant:CFMOTO coolant.
Standard Mixture Ratio:50%(The freezing tem-
perature varies according to the mixture ratio.
Adjust the mixture ratio according to freeze
protection required in your area.)
When coolant is reduced significantly,inspect the
cooling system for leaks.If no coolant remains in the
reservoir tank no.3,there may be air in the cooling
system.Purge the cooling system of air.
Coolant Leakage
Inspect radiator hoses,water pump,and connections
for leaks.
If any leaks found,repair the cooling system.(
Chapter 4)
Inspect radiator hoses for aging,damages and cracks.
Hoses ages over time due to special working condi-
tions and may crack.Bend a hose to inspect for
cracks. If any damages or cracks found,replace it
with a new hose.
Inspect coolant hose clamps and tighten the loose

ones.
Inspect radiator fins for damages or mud.

Correct the fin bending.Use tap water or compressed
air to clean off the mud.
The radiator should be replaced when 20% fins are

damaged.
4.Coolant Radiator 5.Oil Radiator
3-15
Coolant Gauge Inspection
The indicator should point at 0 when the engine is not
working.Start the engine to check coolant gauge for
response.If the indicator doesn’t move,determine the
cause and take a repair.
LIGHTING
Headlight Beam Adjustment
Remove headlight protector( 2-11)
In order to adjust headlight beam,adjust bolt no.4 with
a cross screw driver or adjust nut no.3. with a wrench.
3-16
04 COOLING SYSTEM
COOLING SYSTEM
SERVICE TOOLS
4
Description P/N Page
Test Cap 9010-180100-922-001 04

Special Puller 0800-014001-922-002 15
Bearing Puller 0800-014001-922-001 15
Press Tool,Oil seal 0110-080005-923-001 16
Press Tool,Bearing 0800-014001-921-003 17
SERVICE PRODUCTS
Retaining Compound 03
Coolant 05
Engine Oil 16
Loctite 5699 17
04-1
RADIATOR
7 N.m
(62 lbf.in)
7 N.m
(62 lbf.in)
7 N.m
(62 lbf.in)
7 N.m
(62 lbf.in)
7 N.m
(62 lbf.in)
04-2
04 COOLING SYSTEM
WATER PUMP
Engine Oil
Retaining Compound
Loctite 5699
Engine Oil
10 N.m(89 lbf.in)
04-3
GENERAL
WARNING
Never start engine without coolant.Some engine
parts such as the rotary seal on water pump shaft
can be damaged.
During installation,use the torque values and

service products as in the exploded views.
Clean threads before applying a threadlocker.Refer to
LUBRICANTS AND SERVICE PRODUCTS at the be-
ginning of this manual for complete procedure.
WARNING
Torque wrench tightening specifications must
strictly be adhered to.
Locking devices(e.g.:locking tabs,elastic stop
nuts,self-locking fasteners,etc.) must be installed
or replaced with new ones where specified.If the
efficiency of a locking device is impaired,it must
be replaced.
INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns,don’t remove the radia-
tor cap or loosen the cooling drain plug if the
engine is hot.
Remove battery cover to access and remove radiator

cap.
Install the test cap(P/N 901-18.01.00-922-001 ) on
the filler neck.
Use a pressure/vaccum pump to pressurize system
to 103kpa(15PSI).
Check all hoses,radiator and cylinder(s)/base for cool-
ant leaks or air bubbles.
1.Special Radiator Cap.
04-4
04 COOLING SYSTEM
Inspection
Check general condition of hoses and clamps
tighteness.
Check the leak indicator hole if there is oil or coolant.
NOTE:Leaking coolant indicates a defective rotary
seal.Leaking oil indicates a defective inner oil seal.If
either seal is leaking,both seals must be replaced at 1
the same time.Refer to WATER PUMP SHAFT AND
SEALS in this section.
Another leak indicator hole is visible on the PTO side.

It indicates if the PTO gasket is in good condition.If a 1.leak Indicator Hole
liquid leaks by this hole,the PTO gasket replacement
is necessary.
MAINTENANCE
COOLANT REPLACEMENT
WARNING
tor cap or loosen the cooling drain plug if the
engine is hot.
Use CFMOTO premixed coolant or a blend of 50% 1

antifreeze with 50% water.
To avoid antifreeze deterioration,always use the same
brand.Never mix different brands unless cooling sys-
tem is completely flushed and refilled.
CAUTION:To prevent rust formation or freez- 1.leak Indicator Hole

ing condition,always fill the system with the
CFMOTO premixed coolant or with 50% anti-
freeze and 50% water.Don’t use tap water ,
straight antifreeze or straight water in the
system.Tap water contains minerals and impu-
rities which build up in the system.During cold
weather,straight water causes the system to
freeze while straight antifreeze thickens and
does not have the same efficiency.Always use
ethylene glycol antifreeze containing crrosion
inhibitors specifically recommended for alumi-
num engines.
Draining the System

WARNING
Never drain or refill cooling system when engine is hot.
Remove the radiator cap.
04-5
Partially unscrew cooling drain plug located below
water pump housing.
When cooling system is drained completely,remove
cooling drain plug completely and install a new washer.
Screw the cooling drain plug and torque it to 10N.m
(89Ibf.in)
Under LH Footrest
1.Cooling Drain Plug
Refilling the System

Remove related parts. 1
Unscrew bleeding screws on top of thermostat housing.
NOTE:Both two cylinders must be bled
1.Bleeding Screws
04-6
04 COOLING SYSTEM
With vehicle on a flat surface,engine cold,refill radiator.

When the coolant comes out by the thermostat hous-
2
ing hole,install the bleeding screw with its washer and
torque to 5 N.m(44 Ibf.in).
Fill up the radiator and intall radiator cap. 1

Fill the reservoir tank and keep the coolant level even at
“LOWER” mark,then install reservoir tank cap.
Run the engine until thermostat opens,then shut off the
engine.
Recheck the coolant level in reservoir tank after the egine
is completely cooled down.Refill coolant if necessary.
Maintain coolant level between “LOWER” and “UPPER”.
1.Washer
2.Bleed ing Screw
NOTE:Each year or every 100 hours or when vehicle
reaches 3000km(1865mi),check coolant concentration
(freezing point) with proper tester.
PROCEDURES
THERMOSTAT 1
The thermostat is a single action type.
3
Thermostat Removal
NOTE:Thermostat is located on the top of cylinder
head,on intake side(front cylinder).
Install a hoe pincher on both radiator hoses.

Remove:
thermostat housing screws and pull thermostat
cover.
1.Thermostat Cover
2.Screws
thermostat with seal ring out of the hole.
1.Thermostat with Seal Ring
04-7
Thermostat Test
To check thermostat,put it in water and heat water.
Thermostat should open when water temperature
reaches 65 (149 ).
Check if the seal ring is brittle,hard or damaged.If so,
replace the seal ring.
Thermostat Installation
For installation,reverse the removal procedure,pay atten-
tion to the following details.
Install the thermostat cover then torque screws to 6N.m
(53Ibf.in).
Check coolant level in radiator and reservoir tank and top
up if necessary.
CAUTION:
Don’t forget to bleed the cooling system.Refer to
COOLANT REPLACEMENT.
RADIATOR CAP
Using a pressure cap tester,check the efficiency of
radiator cap.If the efficiency is feeble,install a new
110kPa(16PSI) cap(don’t exceed this pressure).
1
RADIATOR
Radiator Inspection
Check radiator fins for clogging or damage.Remove
insects,mud or other obstructions with compressed
air or low pressure water.
Radiator Removal
Drain cooling system
Remove front facia and radiator shroud,refer to VE-
HICLE BODY AND MUFFLER.
Remove:
RH inner fender
radiator mounting bolts
overflow hose
support and reservoir tank 1.Radiator Mounting Bolts
Unplug radiator fan.
Remove radiator.
04-8
04 COOLING SYSTEM
Radiator Installation
Reverse the removal procedure for installation.Pay at-
tention to the following details.
RESERVOIR TANK
The coolant expands as the temperature (up to 100 to 2
110 212 to 230 )) and pressure rise in the system.
If the limiting system working pressure cap is reached
110kPa(16PSI),the pressure relief valve in the tempera- 1
ture cap is lifted from its seat and allows coolant to
flow through the overflow hose into the reservoir tank.
Ensure ventilation holes are not obstructed.
Removal
Remove: 1.Reservoir Tank
2.Overflow Hose
RH inner fender(refer to VEHICLE BODY AND
MUFFLER).
coolant support bolt
overflow hose
support and reservoir tank

Empty coolant tank.
Installation 1
COOLANT TEMPERATURE SENSOR 2

(CTS) 1.Bolt
Refer to ELECTRICAL SYSTEM for inspection and 2.Reservoir Tank
renewal process of CTS.
04-9
RADIATOR FAN RELAY
Installation
NOTE:Relay may be inverted by 180 at installation
and it will work correctly.Ensure to align tabs of relay
with terminals of fuse holder at installation.
1.Radiator Fan Relay
Relay Operation Test

The easiest way to check the relay is to remove it and
bypass it with a jumper.If the radiator fan is activated,
replace the relay.See illustration to find where to by-
pass the relay.
2. Bypass the Relay
Relay Continuity Test

Remove relay.
Use multimeter and select the position.
Probe relay as follows.
Terminals Resistance
Open circuit
30 87 (0L)
3.Probe Relay
04-10
04 COOLING SYSTEM
Connect battery as follows.
Terminals Resistance
0.5 max.
30 87
(continuous)
If relay fails any test,replace it.
RADIATOR FAN
Operation
The thermal switch controls the radiator operation.
Radiator fan should turn on when coolant tempera-
ture reaches 88 (190.4 ) and should turn off when 4.Connect Battery
the coolant cools down at 84 (183.2 ).
Radiator Fan Test
If radiator fan doesn’t turn on when the coolant tem-

perature exceeds 88 (190.4 ),use the following
troubleshooting chart to resolve the problem.
04-11
Is fan working? Yes Everything is ok
No
Check accessories fuse(30A) and Yes

fan fuse(20A).Is fuse burned? Replace fuse(s)
No
Bypass the relay Check relay 1
Yes
Fan turns? Replace relay
No
Apply 12 volts on fan connector Check fan
No
Fan turns? Replace fan
Yes
Check thermal switch
No
Thermal switch works? Replace CTS
Yes
Check wiring harness

and connectors
No
All work well? Repair or replace de-
Yes fective part(s)
Removal
Remove radiator shroud.
Remove the bolts.
Remove the radiator fan.
Installation
WATER PUMP HOUSING

It’s located on the engine MAG side.
04-12
04 COOLING SYSTEM
Removal
WARNING
tor cap or loosen the cooling drain plug if the 3
engine is hot.
Drain the cooling system. 3

Remove outlet hose from water pump housing.
Remove screws retaining water pump housing.
Pull water pump to remove it.
4
2
1.Cooling Drain Plug

2.Sealing ring
3.Screws
4.Water Pump Housing
Inspection
Check if gasket is brittle,hard or damaged and replace
as necessary.
1
Installation
CAUTION:To prevent leaking,take care that

the gasket is exactly in groove when you
reinstall the water pump housing.
Tighten screws of water pump housing in a
criss cross sequence. 1.Gasket
WATER PUMP IMPELLER,GEARS,

SEALS,SHAFT 2
Removal
Drain cooling system.Refer to this chapter.
Empty engine oil.Refer to LUBRICATION SYSTEM.
Remove water pump housing.Refer to this chapter.
Remove the crankcase cover,MAG side.Refer to
crankcase. 1
Remove the water pump intermediate gear and breather
shaft.
1.Intermediate Gear,Water Pump
2.Breather Shaft
04-13
Using appropriate pliers,remove and discard the re-
taining ring securing water pump gear on water pump
shaft.
Remove water pump gear. 3
Remove needle pin and gasket of water pump shaft.
2
1
1.Water Pump Impeller Assembly

2.Gasket
3.Needle Pin
To remove water pump impeller assembly from left

crankcase cover, briskly tap the water pump shaft end. 1
CAUTION: Take care not to damage impeller
wings during installation.
Using an appropriate slotted screwdriver,pry out the
rotary seal.
1.Slotted Screwdriver
2.Rotary Seal
Using 2 slotted screwdrivers ,remove outer part of wa-

ter pump stationary seal.
2
1.Stationary Seal,Water Pump

2.Slotted Screwdrivers
04-14
04 COOLING SYSTEM
Using an puller,remove outer part of rotary seal.

Install puller snugly against outer part and pull rotary
seal out.
2
1.Inner Part,Stationary Seal

2.Seal Puller
Using a bearing puller(P/N:0800-014001-922-001 ),re-

move water pump bearing(If it’s necessary to replace
the water pump bearing).
1
2
1.Bearing
2.Bearing Puller
Remove oil seal.
1.Oil seal
2.Stationary Seal Surface
04-15
CAUTION:
Be careful not to damage the rotary seal surface.
Inspection
Check impeller for cracks or other damages.Replace
1
impeller if damaged.
Inspect water pump intermediate gear and water pump
gear for cracks,wear and other damages(especially
on the snap mechanism to the needle pin).Replace if
necessary.
Turn the bearing inner ring by hand. The bearing should

run smoothly,peacefully.If it’s stuck or has noise or
other defects,replace it.
Installation 1.Bearing
For installation,reverse the removal procedure.However,
pay attention to the following.
NOTE:For installation,use the torque values in the
exploded view.Ensure to apply engine oil on
intermeadiate shaft,water pump shaft and oil seal in-
ner surface.Don’t use oil in the press fit area of the oil
seal abd rotary seal.
CAUTION:Always replace rotary seal and

stationary seal at the same time.Meanwhile,
install a new oil seal(behind the rotary seal).
Use the oil seal pusher(P/N 0110-080005-923-001) to Seal Pusher

install oil seal.
Apply oil on oil seal lip.
When installing the oil seal on the pusher,make sure
sealing lip poits outside.
Using oil seal pusher,install the oil seal in place.
1.Oil seal
2.Seal Pusher
04-16
04 COOLING SYSTEM
Place appropriate cushion blocks under the crankcase

cover to keep it level.
Using bearing pusher to push the bearing into left crank-
case press fit area.
NOTE:The left crankcase cover may be damaged if 3

no appropriate cushion bolks placed under it.
2
1
1.Bearing
2.Crankcase Cover,MAG Side
3.Bearing Pusher
Apply loctite(silicone sealant) on stationary seal
surface.
Gently tap the seal pusher to install stationary seal in
place.
3
2
1.Stationary Seal,Water Pump

2.Crankcase Cover,MAG Side
3.Seal Pusher
04-17
Install the water pump impeller assembly with rotary
seal into left crankcase cover.
NOTE:Before water pump impeller installation,

clean the rotary seal and stationary seal surface,or
2
water may enter the crankcase.
1.Water pump Impeller Assembly

2.Left(MAG Side) Crankcase Cover
Install thrust washer on water pump shaft.

Push impeller by hand to fully expose shaft hole that
needle pin can be installed.
Install pin and position it at equal distance out of shaft 3
hole so water pump gear can be installed.
22
1
1.Water Pump Impeller Assembly

2.Gasket
3.Needle Pin
Align the water pump gear groove with needle pin,then

install water pump gear on the shaft.
Make sure gear properly snaps on pin. 2
Install a new retaining ring on pump shaft end. 1
1.Needle Pin
2.Water Pump Gear
04-18
04 COOLING SYSTEM
Install water pump intermediate shaft and ensure its

end with chamfer points outside.
Install water pump intermediate gear on shaft. 1
For remaining parts installation,reverse their removal
procedure.
Assemble the other parts base on reverse sequence
of removal.
Refill all fluids,including coolant and engine oil.
2
1.Breather Shaft
2.Intermediate Gear,Water Pump
04-19
5 ENGINE REMOVAL AND INSTALLATION
Maintenance Information ......................5-1 Differential and gearcase removal and installation...5-6
Engine removal and installation ............5-2 Gearshift linkage removal and installation..............5-8
Operation Cautions:
zWhen performing engine removal and installation,use jack or other appropriate tools to securely support the
vehicle.Take care not to damage the engine,bolts and cables.
zWrap the frame in appropriate areas where might be scratched to avoid damage during removal and installation.
zIt’s not necessary to remove the engine when servicing the following parts:
-oil pump. 5
-throttle body,air filter.
-valve cover,cylinder head ,cylinder,camshaft.
-CVT system,CVT cover.
-magneto cover,AC magneto,water pump
-piston,piston ring ,piston pin
-front differential,rear gearcase
zIt’s necessary to remove engine when servicing the following parts:

-crankshaft
-transmission.
Tightening Torque:
Engine mounting bolts (upper) GB5789 M8X35 (35-45)Nzm
Engine mounting bracket bolts (upper) GB5789 M10X1.5X20 (40-50)Nzm
Engine mounting bolts (front left) GB5789 M10X1.25X125 (40-50)Nzm
Engine mounting bolts (front right) GB5789 M10X1.25X100 (40-50)Nzm
Engine mounting bracket bolts (rear) GB5789 M8X20 (35-45)Nzm
Engine mounting bolts (rear) GB5789 M10X1.25X170 (40-50)Nzm
Engine mounting bracket bolts (rear) GB5789 M8X20 (35-45)Nzm
5-1
ENGINE REMOVAL
Remove plastics ( VEHICLE BODY AND
MUFFLER,Chapter 2);
Remove air filter ( AIR INTAKE system);
Remove throttle body( ELECTRICAL SYSTEM);
Drain coolant;
Drain engine oil;
Remove hose clamp no.2;
Remove coolant inlet hose no.1;
Remove hose clamp no. 4;

Remove coolant outlet hose no.3;
Remove hose clamp no.5;

Remove engine external oil pipe no.6;
Disconnect magneto connector,CPS connector,cool-

ant temperature sensor connector,gear position sen-
sor connector,TPS connector,idle air control valve
connector,high pressure fuel line and throttle cable,
etc;
Remove muffler( VEHICLE BODY AND
MUFFLER,Chapter 2);
5-2
Remove spark plug cap no.1 from cylinder 1(front);
5
Remove spark plug cap no.2 from cylinder 2(rear);
Take starter motor positive terminal sleeve off.Remove

the nut and starter motor positive cable no.3;
Remove the bolt and negative cable no.4 of starter

motor;
5-3
Remove the 4 bolts no.1 to disconnect front propshaft
from engine;
Remove the 4 bolts no.3 to disconnect rear propshaft

from engine;
Remove CVT inlet hose clamp no.5;

Remove CVT inlet hose no.6;
Remove CVT outlet hose clamp no.7;

Remove CVT outlet hose no.8;
5-4
Remove bolt no.1 to disconnect shifting plate no.2 from

engine;
Remove engine mounting bolts (front left)&(front right) 5

no.4;
Remove engine mounting bolts(rear) no.3;
Remove engine mounting bolts(upper) no.5;
5-5
ENGINE INSTALLATION
After placing engine on the vehicle,install engine mount-
ing bolts and nuts (front left) first,then (front right) and
(rear).
Install engine inlet/outlet coolant hoses/oil pipes by

clamps onto the engine.Connect starter motor posi-
tive/negative cables.
Connect all connectors.Install CVT breather duct,spark
plus cap.Install shifting plate,air filter,throttle body and
other removed parts.
FRONT/REAR GEARCASE REMOVAL

AND INSTALLATION
Removal
Raise the vehicle off ground with jack.Ensure the ve-
hicle would not tip or fall.
Remove plastics ( VEHICLE BODY AND
MUFFLER,Chapter 2);
Remove front/rear wheels and A-arms.
1.Nut 2.Bolt#1 3.Blt#2 4.Front Differential 5.Bolt#3 6.Front Propshaft 7.Clamp

8 . Front Differential Breather Hose 9.Bolt#4 10.Rear Gearcase 11.Rear Gearcase Breather Hose
12.Rear Brake Disc 13.Bolt#5 14.Rear Propshaft
5-6
Remove front differential mounting bolts & nuts;

①
③ ②
1.Front Differential 2.Bolts 3.Front Propshaft
① 5
②
1.Front Differential 2.Bolts 3.Front Propshaft
Remove rear gearcase mounting bolts & nuts ;
② ③
3
Rear Gearcase 2.Bolts 3.Rear Propshaft
③ ②
5-7
Remove the 18 bolts which connect propshafts and
gearcases(see 5,bolt 3);
Remove propshafts,gearcases,and brake discs.
Installation
Tightening Torque:
Front differential mounting bolt :40-50Nzm
Rear gearcase mounting bolt :40-50Nzm

①
1
Front and rear propshaft bolt :40-50Nzm 1.Propshaft Bolts
GEARSHIFT LINKAGE
Removal
Remove left side panel ( 2-6);
Remove gearshift lever indicator( 2-6);
Remove bolt no.2 and shifting plate;
Loosen gearshift rod adjustment nuts no.1,remove
gearshift rod;
Remove gearshift locking cable no.5;
Remove the 3 bolts of gearshift bracket and then re-

move the linkage.
Installation
After installation,check gearshift linkage for smooth-

ness and agility.If gearshifting sticks,adjust nuts no.1
to change the length of gearshift rod.
5-8
06 AIR INTAKE SYESTEM
AIR INTAKE SYSTEM
SERVICE PRODUCTS
6
Description Part Number Page
Air Filter Cleaning Solution 03
06-1
AIR FILTER HOUSING
2.5 N.m(22 lbf.in)
10 N.m(89 lbf.in)
2.5 N.m(22 lbf.in)
6 N.m(53 lbf.in)
06-2
GENERAL
During assembly/installation, use the torque values
and service products as in the exploded views.Clean
threads before applying a threadlocker.Refer to LU-
BRICANTS AND SERVICE PRODUCTS at the be-
WARNING
Torque wrench must be used when tightening.
Locking devices(e.g.:locking tabs,elastic
stop nuts, cotter pin,etc.) must be replaced
with new ones.
1
PROCEDURES
2
AIR FILTER
Air Filter Removal
CAUTION: Never remove or modify any compo-
nent in the air filter housing. The engine manage-
ment system is calibrated to operate specifically
with these components. Otherwise, engine perfor-
mance degradation or damage can occur.
Remove passenger seat,driver seat. Refer to VEHICLE
BODY AND MUFFLER.
Release clamps and remove air filter cover.
1
Loosen clamps and remove air filter housing(upper). 1.Clamps

2.Air Filter Housing
NOTE: If vehicle is used in dusty area,inspect more
frequently than specified in MAINTENANCE CHART.
If lilquid/deposits are found, squeeze and dry the foam
filter. Replace filter element if damaged.
CAUTION: Do not start engine if liquid or deposit

are found. If there is oil in the air filter housing,
check engine oil level. Oil level may be too high.
Pour air filter cleaning solution or an equivalent into a

bucket. Put the foam filter in to soak. Do not wash
filter element.
While filter soaks, clean inside of air filter housing. 2
1
1.Clamp
2.Air Filter
06-3
Rinse foam filter with warm water and let it dry
completely.
Blow low pressure compressed air on filter element to
clean it.
Air Filter Installation
Properly reinstall removed parts in the reverse order of

their removal.
AIR FILTER HOUSING

Air Filter Housing Removal
Remove seat, side panels;
Refer to VEHICLE BODY AND MUFFLER;
Loosen clamp and hose tie; 2
Disconnect breather hose;
3
1
1.Clamp
2.Hose Tie
3.Breather Hose
Remove air filter housing mounting bolts;
1.Bolt
06-4
Pull air filter housing out.
Air Filter Housing Installation

Reverse the removal procedure for installation. 1
WARNING
Depress throttle lever several times to ensure
it properly returns.
1.Bolt
1.Bolt
06-5
07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER
INTAKE MANIFOLD,CYLINDER HEAD AND CYLINDER
7
SERVICE TOOLS
Spark plug spacer 0800-022800-922-001 07

Camshaft locking tool 0800-024001-922-001 09
Crankshaft locking bolt 0800-041000-922-001 27
Valve spring compressor clamp 0180-022006-922-001 32
Valve guide remover 0800-022102-922-001 37
Valve guide installer 0800-022102-922-002 38
Piston ring compressor 0800-040003-922-001 41
Piston pin circlip installer 0800-040005-922-001 45
SERVICE PRODUCTS
Coolant
Engine oil
Loctite 38
07-1
INTAKE MANIFOLD
0.5 N.m(5 lbf.in)
6 N.m(53 lbf.in)
Threadlocker
6 N.m(53 lbf.in)
Engine Oil
Threadlocker
0.5 N.m(5 lbf.in)
6 N.m(53 lbf.in)
Engine Oil
Threadlocker
Engine Oil
20 N.m(15 lbf.ft)
07-2
CYLINDER HEAD I
T8
T4
Threadlocker
Engine Oil T9
T6
Engine Oil
Engine Oil T3
T1See
T2 Procedure T11
T7
Inside
T5 T7 Threadlocker
T5 Threadlocker
Engine Oil
Engine Oil T3
Engine Oil
T4
Threadlocker
T5
Engine Oil
T1 60N.m (44 lbf.ft) T7 6N.m (53 lbf.in)

T2 30N.m (22 lbf.ft) T8 4.5N.m (40 lbf.in)
T3 20N.m (15 lbf.ft) T9 0.1N.m (0.89 lbf.in)
T4 12N.m (106 lbf.in) T10 16N.m (141 lbf.in)
T6 7N.m (62 lbf.in)
07-3
CYLINDER HEAD II
T6
T8
T4
T9
Engine T 1 S e e
T4 T7
Oil Procedure
Inside
T5
T2
Engine Oil
Engine Oil
Engine Oil Threadlocker
Threadlocker
T3 T5
Threadlocker
T10
T11 T7
Threadlocker
Engine Oil
T1 60N.m (44 lbf.ft) T7 6N.m (53 lbf.in)

T2 30N.m (22 lbf.ft) T8 4.5N.m (40 lbf.in)
T3 20N.m (15 lbf.ft) T9 0.1N.m (0.89 lbf.in)
T6 7N.m (62 lbf.in)
07-4
CYLINDERS AND PISTONS
Engine Oil
Engine Oil
Engine Oil
Engine Oil
Engine Oil
07-5
GENERAL
Components which are identical for both cylinders/
cylinder heads are identified in the two exploded views
by the same number. Components which are different
or which are, for instance, present of one of the cylin-
ders/cylinder heads but not on the other, have differ-
ent numbers. The information given below always re-
lates as a genaral rule.
Special reference is made in the text to work instruc- 1
2
tions which are not the same for cylinder no. 1 and
cylinder no.2.
When diagnosing an engine problem, always diagnose
cylinder 1 and 2 respectively.
Always place the vehicle on a level surface.
NOTE: For a better understanding, the many illus-
trations are taken with engine out of vehicle. To per-
form the following instructions if it is not necessary to
remove engine from vehicle.
Always disconnect BLACK(-) cable from the battery,
then RED(+) cable before working on the engine.
Even if the removal of many parts is not necessary to
reach another part, it is recommended to remove these
1.Cylinder 1 (Front)
parts in order to check them.
2.Cylinder 2 (Rear)
During assembly/installation, use the torque values
and service products as in exploded views.
Clean threads before applying a threadlocker.Refer to
LUBRICANTS AND SERVICE PRODUCTS at the be-
WARNING
Locking devices(e.g.: locking tabs, elastic stop
nuts,cotter pin,etc.)must be replaced with new
ones.
When disassembling parts that are duplicated in the
engine,(e.g.: values), it is strongly recommended to
note their position(PTO/MAG side, front/rear cylinder)
and to keep them as a “group”. If you find a defective
component, it would be much easier to find the cause
of the failure among its group of parts(e.g.: you found
a worn valve guide. A bent spring could be the cause
and it will be easy to know which one among the
springs is the cause to replace it if you grouped them
at disassembly). Also, since used parts have matched
together during the engine operation, they will keep
their matched fit when you reassemble them together
within their “group”.
07-6
MAINTENANCE
VALVE ADJUSTMENT
NOTE: Check and adjust valve clearance only when

engine is cold.
Remove valve cover.
Before checking or adjusting the valve clearance, turn
crankshaft to TDC ignition of the respective cylinder,
see CAMSHAFT.
Use feeler gauge to check the valve clearance.
Valve Clearance
Exhaust 0.11-0.19mm(0.0043-0.0075in)
Intake 0.06-0.14mm(0.0024-0.0055in)
2
1
If the valve clearance is out of specification, adjust
valves as folows.
NOTE: Use mean valve of exhaust/intake to ensure a

proper valve adjustment.
Hold the adjustment screw at the proper position and

torque the locking nut.
Repeat the procedure for each valve.
Before installing valve cover, recheck valve clearance
INSPECTION 3
LEAK TEST
Before performing the cylinder leak test, verify the
1.Adjustment Screw
following:
2.Locking Nut
-clamp(s) tightness
3.Feeler Gauge
-radiator and hoses
NOTE: For best accuracy, the leak test should be
done with the engine at normal operating temperature.
WARNING
Prevent burning yourself on hot engine parts.
Preparation
Disconnect battery
WARNING
Always respect this order for disassembly;
disconnect BLACK(-)cable first.
Remove radiactor cap.
07-7
WARNING
To prevent burning yourself only remove the 1
radicator cap by wearing the appropriate safety
equipment.
Remove any parts to have access to engine cylinder
heads.
2
Unplug spark plug cable.
Clean spark plug area and remove spark plug from

cylinder head.
1.Spark Plug Cable

2.Spark Plug
Remove valve cover. 1
1.Valve Cover Screws

Rotate crankshaft until piston is at ignition TDC(Refer
2.Valve Cover
to CAMSHAFT TIMING in this chapter).
Using the dial gauge, turn the crankshaft and set the
piston to precisely ignition TDC.
1.Dial Gauge
07-8
NOTE: If a dial gauge is not available, use a screw- 3

driver or another similar suitable tool.
CAUTION: Do not scratch or damage piston/

cylinder surface.
NOTE: At ignition TDC the marks on the camshaft

timing gear have to be parallel to cylinder head base
as per following illustration.
2
1.Marks on Camshaft Timing Gear

2.Cylinder Head Base
3.Camshaft Locking Tool
Lock camshaft at TDC by using camshaft locking tool

(0800-024001-922-001).
Camshaft Locking Tool
07-9
LEAK TEST
Connect to adequate air supply.
Set needle of measuring gauge to zero.
NOTE: All testers have specific instructions on gauge
operation and required pressure. 1
Install gauge adapter into previously cleaned spark

plug hole.
Supply combustion chamber with air pressure.
Note the amount or percentage of leakage(depending

on tester). 2
Leaka g e Pe rce ntag e E n gi ne Co n diti on

0% -15% Ex c ellent co ndition
16% -25% G ood c on dit ion
26% -40% F air Co nditio n
Po or co nditio n, diagn ose 1.Leak Tester
41%
an d repair eng ine 2.Air Supply Hose
Diagnosis
Listen for air leaks:

-air escaping on intake port/throttle body means leak-
ing intake valve(s)
- air escaping on exhaust port means leaking exhaust
valve(s)
-air bubbles out of radiator means leaking cylinder head
gascket
-air/oil escaping from crankcase means damaged
gascket and/or loosened screws.
-air/coolant escaping from cylinder/head means dam-
aged gascket(s) and/or loosened screws(refer to IN-
TA K E M A N I F O L D , C Y L I N D E R H E A D A N D
CYLINDER)
-air escaping into crankcase area means excessively
worn cylinder and/or broken piston rings(refer to IN-
TAKE MINIFOLD, CYLINDER HEAD AND
CYLINDER).
NOTE: For all the checkpoints mentioned above,

see the appropriate engine section to diagnose and
repair the engine.
Reassembly
Reverse the preparation procedure. Ensure to respect
torque values and use of appropriate products/
lubricants. Refer to exploded views in other sections
of this manual as required.
07-10
PROCEDURES
INTAKE MANIFOLD
Intake Manifold Removal

3
Disconnect fuel pump control plug.
Release fuel pressure by running engine until it runs
out of gas.
Remove seat, both side panels and fender. Refer to
VEHICLE BODY AND MUFFLER.
1
WARNING
The fuel hose may be under pressure. Cover the
fuel line connection with an absorbent rag. Slowly 2
disconnect the fuel hose to release the pressure.
Wipe off any fuel spillage.
1.Manifold Adapter
Remove the cover of air filter housing.
2.Throttle Body
Remove air filter. 3.Air Filter Housing
Unscrew bolts securing the air filter housing to frame.
Unscrew the lower clamp retaining the manifold

adapter between throttle body and intake manifold. 2
1
Remove teh manifold adapter.

Unplug fuel lines from injectors.
Disconnect both injectors. 1
Disconnect the manifold air pressure temperature
sensor(T-MAP Sensor).
Unscrew intake manifold from cylinders. 1.Injector Connector

Remove intake manifold from vehicle. 2.Fuel Line
Intake Manifold Inspection
Check intake manifold for cracks, warping at flanges

or any other damage. Replace if necessary.
Intake Manifold Installation
The installation is the reverse of the removal procedure.
1
However, pay attention to the following.
Torque manifold screws to 20N.m(15 lbf.ft)one cylin-
der at a time.
1.T-MAP Sensor
Re-enable fuel pump control plug.
07-11
VALVE COVER 1
Cover Removal
2
Remove distance screws of valve cover.
1.Distance Screws
2.Valve Cover
Remove valve cover and gasket.

Repeat the procedure for the other valve cover if
required.
2
Cover Inspection
Check the gasket on the valve cover if it is brittle,
cracked or hard. If so, replace the gasket.
Cover Installation 1
For installation, reverse the removal procedure. Torque
the cylinder screws in a crisscross sequence.
1.Valve Cover
2.Gasket
07-12
TIMING CHAIN TENSIONER
NOTE: Before removal and installation, make sure

that the respective cylinder is set to TDC ignition. Refer
to CAMSHAFT.
3 2
1
Tensioner Removal
WARNING
Timing chain tensioner is spring loaded. Never
perform this operation immediately after the en-
gine has been run because the exhaust system
can be very hot. Wait until exhaust system is
warm or cold.
1.Chain Tensioner Screw

Remove chain tensioner plug. 2.O-ring
Unscrew chain tensioner plug. 3.Spring
Remove O-ring and spring.
Unscrew screws retaining chain tensioner housing.

Remove chain tensioner housing with O-ring.
Screw tensioner plunger into housing several turns.
4
2 1
Tensioner Inspection
Check the housing for cracks or other damages. Re-

place if any.
Check chain tencioner plunger for free movement and/
or scoring.
Check if O-ring are brittle, cracked or hard. Replace if
any. 3
Check spring condition. Replace if broken or worn.
1.Chain Tnesioner Screws
2.Chain Tnesioner Housing
3.O-ring
4.Chain Tnesioner Plunger
07-13
Tensioner Installation
For installation, reverse the removal procedure.

However, pay attention to the following.
NOTE: Before installing the chain tensioner, make

sure that the camshaft timing gear can be moved back
and forth.
Apply engine oil on the plunger before installing.
NOTE: Slightly screw in the plunger until the timing

chain allows no more back and forth movement of the
camshaft timing gear. then screw in the plunger an Move Gear Back and Forth
additional 1/8 turn to reach the required torque of 0.
1N.m(0.9 lbf.in).
CAUTION:Improper adjustment of the timing

chain will lead to severe engine damage.
Fit spring on one side into the slot of the plug screw
and on the other side into the plunger. Turn spring
only clockwise in order to fit the spring end into the
notch of the plunger and to avoid loosening the plunger
during spring installation. Do not preload the spring.
NOTE: Do not forget to place the O-ring on chain

tensioner plug.
Then compress the spring and screw in the plug screw.

Finally, tighten the plug screw to 4.5N.m(40 lbf.in).
07-14
CAMSHAFT TIMING GEAR

Gear Removal
Remove valve cover.
Turn crankshaft to TDC ignition of the respective
cylinder, see CAMSHAFT.
Unscrew timing chain tensioner.
Remove camshaft timing gear screw.
To prevent timing chain stretching during removal of
camshaft timing gear screw, use the camshaft lock-
ing tool(0800-024001-922-001).
Remove camshaft timing gear.

NOTE: Secure timing chain with a retaining wire.
Camshaft Locking Tool
Gear Inspection 1
Check camshft timing gear for wear or deterioration.
If gear is worn or damaged, replace it as a set(camshaft
timing gear and timing chain). 2
For crankshaft gear, refer to Chapter 8, see
CRANKSHAFT.

2.Camshaft Timing Gear Screw
3.Camshaft Timing Gear
07-15
Gear Installation
For installation, reverse the removal procedure. Pay

attention to the following details.
1
Clean mating surface and threads of camshaft prior to

assembling camshaft timing gear.
1.Mating Surface on Camshaft

2.Threads for Camshaft Screw
07-16
Camshaft timing gear and crankshaft must be at TDC

ignition before installing the timing chain.
CAUTION: Crankshaft and camshaft must be

locked on TDC ignition position to place cam-
shaft timing gear and timing chain in the
proper position.
2
The printed marks on the camshaft timing gear must 3
be parallel to the cylinder head base. See the follow- 1
ing illustration for a proper positioning.

When the camshaft timing gear and the timing chain 2.Cylinder Head Base
are installed, remove the crankshaft locking bolt as 3.Camshaft Timing Gear
well as the camshaft locking tool.
NOTE: Before installing the camshaft screw adjust 2

the chain tensioner(see CHAIN TENSIONER below)
and check again if marks on the timing gear are par-
allel to cylinder head base.
Reinstall all other removed parts.

3

2.Camshaft Screw
3.Camshaft Timing Gear
07-17
ROCKER ARM
Rocker Arm Removal
Remove valve cover.
Remove chain tensioner and camshaft timing gear. 2
Remove screw and camshaft retaining plate. 3
1.Cylinder Head
2.Screw
3.Camshaft Retaining Plate
Remove rocker arm shafts.
4
Remove rocker arm assembly(exhaust side and in- 5 3
take side) with adjustment screws and nuts.
1 2
1.Rocker Arm Shaft

2.Rocker Arm,Exhaust
3.Rocker Arm,Intake
4.Adjustment Screw
5.Locking Nut
07-18
Remove thrust washers.

1 2 1
CAUTION: Pay attention not to lose thrust
washers or drop them into the timing chain
compartment.
3
1.2 Thrust Washers

3.Cylinder Head Spark Plug Side
4.Big Taper to Spark Plug Side
Rocker Arm Inspection
1
Inspect each rocker arm for cracks and scored fric- 2
tion surfaces. If any, replace rocker arm assembly.
Check the rocker arm rollers for freee movement, wear
and excessive radial play. Replace rocker arm assem-
bly if necessary.
Check rocker arm bore diameter. If diameter is out of

specification, change rocker arm assembly.
2.Roller
Rocker Arm Bore Diameter A.Bore for Rocker Arm Shaft
12.000-12.018mm
New
(0.4724-0.4731in)
12.030mm
Service Limit
(0.4736in)
Check adjustment screws for free movement, cracks

and/or excessive play. 1
1.Free Movement of Adjustment Screw Top
07-19
Rocker Arm Shaft
Check for scored friction surfaces; if any, replace parts.
Measure rocker arm shaft diameter.
Rocker Arm Shaft Diameter

New 11.973-11.984mm
(0.4714-0.4718in)
Service Limit 11.960mm(0.4709in)
A
Any area worn excessively will require parts

replacement. A.Measure rocker arm shaft diameter here
Rocker Arm Installation

NOTE: Use the same procedure for exhaust and
intake rocker arm.
Apply engine oil on rocker arm shaft.
Install the rocker arm shaft with the chamfered edge
first and use following procedure.
Insert a rocker arm pin through rocker arm pin bore.
Install a thrust washer then proper rocker arm(exhaust
side)or (intake side).
Push in rocker arm shaft until its chamfer reaches the
end of rocker arm bore.
1 2 3
1.Rocker Arm
2.Thrust Washer(Timing Chain Side)
3.Thrust Washer(Spark Plug Side)
Place the other thrust washer and push rocker arm

shaft to end position.
TIMING CHAIN
Refer to Chapter 8, see TIMING CHAIN.
07-20
CYLINDER HEAD
Cylinder Head Removal
The removal procedure is the same for both cylinder

heads.
Drain coolant(refer to COOLING SYSTEM).
NOTE: Before removing cylinder head, blow out re-

maining coolant by air pressure.During cylinder head
removal, the remianing coolant in cylinder head could
overflow into the engine and a little quantity of coolant
could drop into engine. In this case, the engine oil will
be contaminated.
Disconnect spark plug wire.

Disconnect temperature sensor connector, located at 1 1
2
rear cylinder head.
Remove both side panels and both inner fenders(refer
to VEHICLE BODY AND MUFFLER).
Remove exhaust pipe springs or exhaust pipe clamp.
Unscrew exhaust pipe nuts
Unplug radiator inlet hose.
Remove air filter.
Remove throttle body.
Remove the intake manifold(see INTAKE MANIFOLD 1.Cylinder Head Screws M10
above). 2.Cylinder Head Screws M6
Remove the chain tensioner(see CHAIN TENSIONER
above). 1
Remove the valve cover and its gasket(see VALVE
COVER above).
Remove thecamshaft timing gear. 2
Unscrew cylinder head screws M6 and M10 retaining
cylinder head and cylinder to cylinder base.
4
Pull up cylinder head.

Remove chain guide.
3
Remove the cylinder head gasket and scrap it.
1.Cylinder Head
2.Timing Chain
3.Chain Guide
4.Cylinder Head Gasket
07-21
Cylinder Head Inspection
Inspect timing chain guide for wear, cracks or other
damages, Replace if any.
Check for cracks between valve seats, if any, replace
cylinder head.
Check mating surface between cylinder and cylinder
head for contamination, if any, clean both surfaces.
Clean oil support through the cylinder head from
contamination. 2 1
3
1.Oil Port to lubricate Camshaft Lobes Intake/Exhaust

Cylinder Head Installation
2.Oil Supply to Camshaft Bearing Journal Timing
NOTE: The cylinder heads are not identical in design. Chain Side
Do not invert the cylinder heads at assembly. 3.Oil Supply to Camshaft Journal Spark Plug Side

Ensure dowel pin are in place.
CAUTION: Chain guide has to be fixed between 1
cylinder and cylinder head.
1.Chain Guide(fiexed between cylinder and cylinder

head)
2.Chain Tensioner Guide(mounted in Crankcase)
07-22
Install a NEW cylinder head gasket.

First, torque cylinder head screws M10 in crisscross
sequence to 20N.m(15 lbf.ft), then finish by tightening
to 60N.m(44 lbf.ft).
Install cylinder head screws M6.
1 1
2
Check chain guide for movement.
1.Cylinder Head Screws M10

2.Cylinder Head Screws M6
CAMSHAFT
NOTE: The engine is equipped with two different

camshafts.
1 2
1.Camshaft of Cylinder 1
2.Camshaft of Cylinder 2
07-23
Camshaft Timing
NOTE: If a piston(of cylinder 1 or 2) is set to

TDCignition, the camshaft timing gear of the opposite
cylinder must be in the following position.
1.Marks on Timing Gear of Opposite Cylinder

Camshaft Timing Cylinder 2
Turn crankshaft until piston is at TDC ignition as fol-

lows 2
1
Remove spark plug of both cylinders.
Remove valve cover of both cylinders.
Remove plug screw cover.
1.Gasket
2.Cover
3.Screws
07-24
Remove the crankshaft position sensor (CPS).
1.Crankshaft Position Sensor(CPS)

2.Screw
Use a 18mm socket to turn crankshaft until pistion 2

(rear) is at TDC ignition.
1
1.18mm Socket
07-25
When rear piston is at TDC ignition, marks on mag-
neto flywheel” 2 “and on the left crankcase cover(centre
of bore) are aligned. 1
2
1.Mark “2” on MAG Flywheel

2.Notch on MAG Cover
3.CPS Location
At TDC ignition, the printed marks on the camshaft

timing gear have to be parallel to cylinder head base.

07-26
To lock crankshaft at TDC ignition, proceed as follows.

Remove from crankcase plug screw with sealing ring.
2 3
1
1.Plug Screw
2.Sealing Ring
3.Crankcase PTO Side,Front Side
Lock crankshaft with the crankshaft locking bolt ( 0800-

041000-922-001).
NOTE: Make sure the locking bolt engages in the

groove of the crankshaft.
1.Crankshaft Locking Bolt
07-27
Camshaft Timing Cylinder 1
Turn cylinder 2 to TDC ignition, see Camshaft Timing, 1
Cylinder 2.
NOTE: Do not lock crankshaft.
1.18mm Socket
2.Turn Crankshaft 280 Counterclockwise
Use a 18mm socket, turn crankshaft 280
counterclockwise, until marks on magneto flywheel
and left crankcase cover are aligned.
1
2
1.Mark “1” on MAG Flywheel

2.Notch on MAG Cover
3.CPS Location
07-28
NOTE: At TDC ignition, the printed marks on the

camshaft timing gear have to be parallel to cylinder
head base as per following illustration.
CAUTION: Crankshaft can not be locked at

cylinder 1 TDC ignition.
2
Camshaft Removal
The removal procedure is the same for both camshafts.
Each camshaft is different in design. Thus, it is impor- 1
tant not to mix up any parts of the camshaft assem-
bly with that of ths other cylinder. Keep parts as a
group. 1.Marks on Camshaft Timing Gear
Remove valve cover(see VALVE COVER above). 2.Cylinder Head Base
Remove chain tensioner(see CHAIN TENSIONER
above).
Remove camshaft timing gear(see CAMSHAFT TIM-
ING GEAR above).
Remove camshaft retaining plate.
2
3
1.Cylinder Head
2.Screw
Remove rocker arms(see ROCKER ARM above). 3.Camshaft Retaining Plate
Remove camshaft.
1
NOTE: For removal, rotate camshaft so that intake/ 2
exhaust lobe shows to upper side of cylinder head.
1.Area for Cranshaft Lobes

2.Camshaft
3.Camshaft Retaining Plate
07-29
Camshaft Inspection
Check each lobe and bearing journal of camshaft for Replace parts that are not within specifications.
scoring, scuffing,cracks or other signs of wear.
Measure camshaft journal diameter and lobee height
C B
using a micrometer. A D
Camshaft Cylinder1
Camshaft Lobe(exhaust)
New 31.98-32.1mm
(1.2591-1.2638in)
Camshaft Lobe(Intake)
New 32.129-32.249mm
(1.2649-1.2696in)
Service Limit 32.03mm(1.2610in) A.Camshaft Lobe(Exhaust Valves)
B.Camshaft Lobe(Intake Valves)
Camshaft Cylinder2 C.Camshaft Journal(Timing Chain Side)
Camshaft Lobe(exhaust) D.Camshaft Journal(Spark Plug Side)
New 31.966-32.086mm
(1.2585-1.2632in)
Camshaft Lobe(Intake)
New 32.163-32.283mm
(1.2663-1.2710in)
Camshaft Journal(Timing Chain Side)

New 34.959-34.975mm
(1.3763-1.3770in)
Camshaft Journal(Spark Plug Side)
New 21.959-21.980mm
(0.8645-0.9654in)
Measure matching clearance between two ends of

camshaft and cylinder head.
Camshaft Bearing(Timing Chain Side)

New 35.007-35.025mm
(1.3782-1.3789in)
Camshaft Bearing(Spark Plug Side)
New 22.012-22.025mm
(0.8666-0.8671in)
Service Limit 22.040mm(0.8677in) A.Camshaft Bearing(Timing Chain Side)
B.Camshaft Bearing(Spark Plug Side)
07-30
CAMSHAFT INSTALLATION 1

3
CAUTION: The camshafts are not identical in
design. Do not invert the camshafts during
assembly. Any mis-up of the components will
lead to engine damage.
2
Place the camshaft retaining plate in the slot of the 1.Camshaft Retaining Plate Position
camshaft. 2.Slot Retaining Shaft
3.Direction of Movement
For other parts, refer to proper installation procedure.
07-31
VALVE SPRING
Valve Spring Removal
Remove rocker arm(see ROCKER ARM above).Re-
move cylinder head(see CYLINDER HEAD above).
Use valve spring compressor clamp(0180-022 006-922-
001)to compress valve spring.
WARNING
Always wear safety glasses when disassembling
valve springs. Be careful when unlocking valves.
Components could fly away because of the strong
spring preload. Valve Spring Compressor Clamp
Valve Spring Compressor Cup
Align valve spring compressor clamp with the center

of Valve
07-32
Remove valve cotters.

Withdraw valve spring compressor, valve spring retainer
and valve spring.
2
3
1
1.Valve Spring Compressor Clamp

2.Valve Spring Compressor Cup
3.Valve Cotter
Valve Spring Inspection

Check valve spring for visible damages, If any, replace
valve spring.
Check valve spring for free length and straightness.
Valve Spring Free Length

Normal New 40mm(1.575in)
A
Replace valves springs if not within specifications. A.Valve Spring Length
Valve Spring Installation

Colored area of the valve spring must be placed on 2
top.
To ease installation of cotters, apply oil or grease on
them so that they remain in place while releasing the
spring.
NOTE: Valve cotter must be properly engaged in valve

stem grooves. 1
After spring is installed, ensure it is properly locked
by tapping on valve stem end with a soft hammer so
that valve opens and closes a few times.
1.Position of the Valve Spring
2.Valve Cotter
CAUTION: An improper locked valve spring
will cause engine damage.
07-33
VALVE
Valve Removal
Remove valve spring, see VALVE SPRING above.
Push valve stem, then pull valves(intake and exhaust)
out of valve guide.
1 2
1.Intake Valve 33mm

2.Exhaust Valve 29mm
Remove valve stem seal with Snap-on pliers and dis-

card it.
Plier
1.Plier
2.Valve Stem Seal
07-34
Valve Inspection
Valve Stem Seal
Always install new seals whenever valves are removed.
Valve
Inspect valve surface, check for abnormal stem wear
and bending. If out of specification, replace by a new
one.
Valve Out of Round
(Intake and Exhaust Valves)
New 0.005mm(0.0002in)
Service Limit 0.06mm(0.0024in) A

Valve Stem and Valve Guide Clearance
Measure valve stem and valve guide in three places

using a micrometer and a small bore gauge.
A.Valve Stem Diameter
NOTE: Clean valve guide to remove carbon deposit

before measuring.
Change valve if valve stem is out of specification or

has other damages such as wear or friction surface.
Valve Stem Diameter

Exhaust Valve
New 4.955-4.970mm
2
(0.1951-0.1957in)
3
Intake Valve
1
New 4.965-4.980mm
(0.1955-0.1960)
Replace valve guide if valve guide is out of specifica-

1.Valve Seat
tion or has other damages, such as wear or friction
2.Exhaust Valve Contaminated Area
surface.
3.Valve Face(Contact Surface to Valve Seat)
Valve Guide Diameter

New 5.000-5.012mm
(0.1969-0.1973in)

07-35
Valve Face and Seat
Check valve face and seat for burning or pittings and

replace valve or cylinder head if there are signs of
damage.
Ensure to seat valves properly. Apply some lapping A B

compound to valve face and work valve on its seat
with a lapping tool(see Valve Guide Procedure below).
Measure valve face contact width.
NOTE: The location of contact area should be in

center of valve seat.
Measure valve seat width using a caliper. A.Valve Contact Surface Width
Valve Seat Contact Width B.Valve Seat Contact Width
Exhaust Valve
New 1.20-1.40mm
(0.047-0.055in)
Intake Valve
New 1.10-1.30mm
(0.043-0.051)
Service Limit 1.70mm(0.067in) 1
If valve seat contact width is too wide or has dark spots,
replace the cylinder head.
Valve Installation
attention to the following details. 2
Install a NEW valve stem seal. Make sure thrust
washer is installed before installing seal.
Apply engine oil on valve stem and install it.
1.Valve Spring Lower Seat
2.Sealing Lips of Valve Stem Seal
CAUTION: Be careful when valve stem is
passed through sealing lips of valve stem seal.
To ease installation of cotters, apply oil or grease on

them so that they remain in place while releasing the
spring.
After spring is installed, ensure it is properly locked
by tapping on valve stem end with a soft hammer so
that valve opens and closes a few times.
CAUTION: An improper locked valve spring will

cause engine damage.
07-36
VALVE GUIDE
Valve Guide Removal
Remove cylinder head(see CYLINDER HEAD above).

Remove valves(see VALVE above)
NOTE: Clean valve guide area from contamina-

tion before removal.
Use valve guide remover(0800-022102-922-001)and a

hammer, drive the valve guide out of cylinder head.
Valve Guide Remover
1.Valve Guide Remover

2.Valve Guide
07-37
Valve Guide Inspection
Always replace valve stem seals whenever valve guides

are removed.
Clean the valve guide bore before reinstalling the valve
guide into cylinder head.
Valve Guide Inspection
Reverse the removal procedure for installation.Pay
Use valve guide installer(0800-022102-922-002)to in-
stall valve guide.
NOTE: Apply loctite(antiseize lubricant) on valve Valve Guide Installer
guide prior to install it into the cylinder head.
CAUTION: Push valve guide in the cold cylinder 1
head as per following illustration.
Valve Guide
(Measurement “A”)
New 14.70-15.30mm(0.5787-0.6024)
1.Valve Guide Installer

2.Valve Guide
1.Thrust Surface of Cylinder Head

2.Valve Guide
A.Measurement from Thrust Surface to Valve Guide
Top
07-38
Valve guide to be adjusted in diameter by using a

reamer. 1
Valve Guide Diameter

New 5.000-5.012mm(0.1969-0.1973in)
A
NOTE: Ensure to turn reamer in the right direction.

Use cutting oil and make brakes to clean reamer/
valve guide from metal shavings.
1.Valve Guide
A.Valve Guide Diameter
Apply some lapping compound to valve face and work

valve on its seat with a lapping tool. 3 A
NOTE: Ensure to seat valves properly. Apply mark- 2

ing paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits 1
together.
1.Valve Seat
2.Valve Face(contact surface to valve seat)
3.Turn valve while pushing against cylinder head
A.Valve Seat Angle 45
CYLINDER 1
3
Cylinder Removal 2
Remvoe chain tensioner(see CHAIN TENSIONER). 4
Remove the camshaft timing gear(see CAMSHAFT
TIMING GEAR).
Remove cylinder head(see CYLINDER HEAD).
Pull cylinder.
Discard cylinder base gasckets.
1.Cylinder
2.Piston Assembly
3.Cylinder Base Gasket
4.Camshaft Timing Chain
07-39
Cylinder Inspection
Check cylinder for cracks, scoring and wear ridges on 3
the top and bottom of the cylinder.If so, replace
C
cylinder.
Cylinder Taper 1
Measure cylinder bore and if it is out of specifications,

B A
replace cylinder and piston rings.
Measure cylinder bore at 3 recommended positions.
2
See the following illustration.
Cylinder Taper IN Diameter
New（maximum） 0.038mm(0.0015in) 1.First Measuring of Diameter
Service Limit 0.090mm(0.0035in) 2.Second Measuring of Diameter
Distance between measurements should not exceed 3.Third Measuring of Diameter
the service limit mentioned above. A.7mm(0.276 in)from Cylinder Bottom
Cylinder Out of Round B.68mm(2.68 in)
Measure cylinder diameter in piston axis direction from C.32mm(1.260 in)
top of cylinder. Take another measurement 90 from
first one and compare.
NOTE: Take the same measuring points like de-

scribed in Cylinder Taper above.
Cylinder Out Of Round B
(Intake and Exhaust Valves) A

New（maximum） 0.015mm(0.0006in)
A.Perpendicular to Crankshaft Axis

B.Parallel to Crankshaft Axis
07-40
Cylinder Installation
Reverse removal procedure for installation. Pay atten-
tion to the following details.
CAUTION: Always replace cylinder base gasket

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

ing bolt(P/N 529 035 617). Turn engine to piston 1 at
TDC, mount cylinder 1.Cylinder can not be pushed
fully over the piston unless the piston is located at
TDC.
pply engine oil in the bottom area of the cylinder
Piston Ring Compressor Tool
bore and also on the brand of the piston ring compres-
sor tool(0800-040003-922-001).
NOTE: Put timing chain through the chain pit then

put the cylinder in place.
CAUTION: Chain guide has to be fixed between

cylinder and cylinder head.
3
NOTE: After both cylinders are installed, turn crank- 1
shaft until piston of cylinder 2 is at TDC ignition and
lock crankshaft. Refer to CAMSHAFT. 2
Install cylinder head and the other parts in ac-

cordance with the proper installation procedures.
PISTON
Piston Removal
1.Piston Ring Compressor Tool
Remove cylinder head(see CYLINDER HEAD above) 2.Piston
Remove cylinder(see CYLINDER above). 3.Cylinder
Place a rag under piston and in the area of timing
chain compartment.
WARNING
Piston circlips are spring loaded.
Remove one piston circlip and discard it.
NOTE: Removal of both piston circlips is not neces-

1
sary to remove piston pin.
1.Piston Circlip
07-41
Push piston pin out of piston.
Detach piston from connecting rod.
1.Piston
2.Piston Pin
Piston Inspection
Inspect piston for scoring, cracking or other damages.

Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 8mm(0.315 1
in)perpendicularly(90 )to piston pin.
The measuring dimension should be as described in

the following tables. If not, replace piston.
1.Measuring perpendicularly (90¡ã) to pston pin

A.8 mm(0.315 in)
1
Piston Measurement
New 90.950-90.970mm
(3.5807-3.5815in)
1.Micrometer set to the piston dimension
07-42
Piston/Cylinder Clearance
Adjust and lock micrometer to the piston dimension. 2
With the micrometer set to the dimension, adjust a
cylinder bore gauge to the micrometer dimension and
set the indicator to 0(zero).
Position the dial bore gauge 20mm(0.787 in)above

cylinder base, measuring perpendicularly(90 )to pis-
1
ton pin axis.
Read the measurement on the cylinder bore gauge.
The result is the exact piston/cylinder wall clearance.
Piston/Cylinder Clearance 1.Use the micrometer to set the cylinder bore gauge
New 0.030-0.050mm 2.Dial Bore Gauge
(0.0012-0.0020in)
NOTE: Make sure used piston is not worn.

if clearance exceeds specified tolerance, replace pis-
ton by a new one and measure piston/cylinder clear-
ance again.
NOTE: Make sure the cylinder bore gauge indicator

is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
1.Indiacator set to 0(zero)
07-43
Connecting Rod/Piston Clearance
Using synthetic abrasive woven, clean piston pin from
deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measuring piston pin. See the following illustration for
the proper measurement positions.
Piston Pin Diameter
New 21.995-22.000mm
(0.8659-0.8661in)
Service Limit 21.980mm(0.7866in) A
Replace piston pin if diameter is out of specifications.
Measure inside diameter of connecting rod small end
bushing. A.Piston Pin Diameter
Connecting Rod Small En d Diameter
New 22.010-22.020mm
(0.8665-0.8669in)
1
Replace connecting rod if diameter of connecting rod
small end is out of specifications. Refer to BOTTOM
END for removal procedure.
Compare measurement to obtain teh connecting 2
rodpiston clearance.
Connecting Rod/Piston Pin Clearance

Piston Installation 1.Bore Gauge

2.Connecting Rod
Reverse the removal procedure for installation. Pay
Apply engine oil on the piston pin.
4
Insert piston pin into piston and connecting rod. 3
CAUTION: Make sure the mounting direction of

the piston is correct.
For each cylinder, install piston with the punched ar-
row on piston dome pointing toward the rear side of
the engine.
2
Front Cylinder: Mark on top of piston must show to
intake side. 1
Rear cylinder: Mark on top of piston must show to

exhaust side.
1.Piston of Cylinder 1
2.Mark on piston must show to exhaust side of cylinder 1
3.Piston of Cylinder 2
4.Mark on piston must show to exhaust side of cylinder 2
07-44
Use the piston appropriate circlip installer (0800-

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

piston circlip(s) by new ones. Place a rag on
cylinder base to avoid dropping the circlip
inside the engine.
Circlip Installer
Place circlip in sleeve as per following illustration.
1.Piston Pin Circlip

2.Sleeve
3.Assembly Jig from Piston Clip Installer
Push taper side of assembly jig until circlip reaches

middle of sleeve.
2 3
Align sleeve with piston pin axis and push push as-
sembly jig until engages in piston.
1.Hold piston while pushing circlip in place

2.Sleeve
3.Assembly Jig
4.Direction to push circlip
07-45
NOTE: Take care that the hook of the piston circlip Using a feeler gauge, check ring end gap.Replace ring
is positioned properly. if gap exceeds above described specified tolerance.
PISTON RINGS
Ring Removal
Remove the piston(see PISTON above).
Ring Inspection
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston groove
clearance. If the clearance is too large, the piston and
piston rings should be replaced.
Ring/Piston Groove Clearance

Piston Ring(1)
New 0.020-0.060mm
(0.0008-0.0024in)
Piston Ring(2)
New 0.020-0.060mm
CORRECT POSITION OF THE PISTON CIRCLIP
(0.0008-0.0024in)
Oil Scraper Ring
New 0.030-0.150mm 2
(0.0012-0.0059in) 1
Ring End Cap

Piston Ring(1)
New 0.25-0.40mm
(0.010-0.016in)
Service Limit 1. 50mm(0.059in)
Piston Ring(2)
New 0.30-0.45mm 1.Feeler Gauge
(0.012-0.018in) 2.Piston
Oil Scraper Ring
New 0.20-0.70mm
(0.008-0.028in)
To measure the ring end gap, place the ring in the

cylinder in the area of 8 16mm(5/16 5/8in) from top
of cylinder.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
07-46
Ring Installation
NOTE: First install spring and then rings of oil scraper 1

ring.
2
Install oil scraper ring first, then piston ring(2) with the
word “N and TOP” facing up, then piston ring(1) with 3
the word “N and TOP” facing up.
CAUTION: Ensure that top and second rings

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

A
Space the piston ring end gaps apart and do
A A
not align the gaps with the piston pin bore or the thrust
side exis.
1.Don’t align ring gap with piston thrust side axis

2.Don’t align ring gap with piston pin bore axis
A.120
07-47
08 CRANKCASE,CRANKSHAFT,GEARBOX
CRANKCASE,CRANKSHAFT,TRANSMISSION
SERVICE TOOLS
Description P/N Page 8
Breather Oil Seal Installer 0800-011201-923-001 06
Installation Jig,Breather Gear Shaft 0800-011201-921-003 06
Press Tool,Breather Gear Shaft 0800-011201-921-001 06
Left Crankcse Support Sleeve 0800-011101-922-001 09
Right Crankcse Support Sleeve 0800-012101-922-001 09
Plain Bearing Remover/Installer 0800-011102-922-001 09
Crankshaft Locking Bolt 0800-041000-922-001 14
Wrench,Front Output Shaft Circlip 0180-060008-922-001 18
Press Tool,Front Output Shaft Oil Seal 0800-060000-923-001 18
Installer,Front Output Shaft 0800-062301-923-001 18
Install Handle 0800-062206-922-001 20
Drive Pinion Gear Oil Seal Installer 0800-062204-923-001 20
Ring Gear Needle Bearing Installer 0180-062201-921-003 20
Drive Pinion Gear Needle Bearing Installer 0180-062103-921-002 20/21
Backlash Measurement Tool 0800-062000-922-001 21
Remover,Reverse Intermediate Gear Shaft 0800-060002-922-001 25
Remover,Left Crankcase Bearing 0800-011000-922-001 26
Remover,Right Crankcase Bearing 5206 0800-012000-922-001 26
Damper,Right Crankcase 0800-012101-921-001 32
Installer,Bearing 6203 0010-060002-921-002 32
Installer,Bearing 3206A 0180-012100-921-004 32
Damper,Left Crankcase 0800-011101-921-001 32
Press Tool,Reverse Intermediate Gear Shaft 0800-060000-922-001 32
Press Tool,Gearshift Shaft Bearing 6303 0180-011100-921-004 32
Press Tool,Bearing 6203 0040-012001-921-002 32
SERVICE PRODUCTS
Threadlocker 18
Engine coolant 35
Enigne oil
08-1
CRANKSHAFT
10 N.m(89 lbf.in)
Engine oil
Threadlocker
Engine oil
See procedure inside
Engine oil
Threadlocker
Engine oil
Engine oil
See procedure inside
Engine oil
Engine oil
10 N.m(89 lbf.in)
08-2
CRANKCASE
25 N.m
(18 lbf.ft)
Engine oil
10 N.m
(89 lbf.in)
Engine oil
10 N.m
(89 lbf.in)
25N.m
(18 lbf.ft)
10 N.m
(89 lbf.in)
Engine oil Engine oil
20 N.m Engine oil

10 N.m
(15 lbf.ft) (89 lbf.in)
08-3
GEARBOX
25 N.m
(18 lbf.ft)
110 N.m
(81 lbf.ft)
Threadlocker
145 N.m Engine oil

(107 lbf.ft)
32 N.m
(24 lbf.ft)
15 N.m
(11 lbf.ft) 10 N.m
(89 lbf.in)
80 N.m
(59 lbf.ft)
Threadlocker
Engine oil
Engine oil
08-4
GENERAL
During assembly/installation,use the torque value and
serivce products as shown in the exploded view(s).
WARNING
Torque Wrench Tightening specifications must
strictly be adhered to .Locking devices (e.g.:lock
ing tabs ,elastic stop nuts ,self-locking fasteners,
cotter pin,etc.)must be replaced with new ones
where specified .
NOTE:Before disassembly ,drain engin oil and en-

gine coolant.
DRIVE GEARS
The drive gears are located on the MAG side behind
the magneto cover.
4
Removal
Remove :
-Magneto cover(refer to Magneto Cover Removal,
Chapter 11 ) 3
-Retainer ring no.10
-Magneto,driven gear
-Oil pump intermediate gear
-Breather intermediate gear
-Oil pump gear (refer to LUBRICATION SYSTEM) 2
-water pump gear
1
-Breather gear
1.Oil Pump Gear
Inspection
2.Oil Pump Intermediate Gear
Oil Pump Intermediate Gear/Breather Interme-
3.Breather Intermediate Gear
diate Gear/Oil Pump Gear
4.Breather Gear
Inspect gears for wear or damage,replace if damaged.
Breather Gear
The engine is equipped with a breather gear which
prevents engine oil coming out though the breathing
system into the air box.
Inspect gear for wear or damage .
Check ball bearing for excessive play and smooth

operation .Replace breather gear assembly if necessay
Installation
The installation essentially the reverse of the removal
procedure ,but pay attention to the follow details:
08-5
1.Replace the oil seal of the breather gear. Inspection
2.Adequately oil the ball bearing of the breather gear. Inspection is the same for both timing chains.
3.All drive gears on the same plane. Check timing chain on camshaft timing gear for ex-
4.Replace the retainer ring no.10. cessive radial play.
Check chain condition for wear and teeth condition.
Service Tools: If chain is excessively worn or damaged,replace it as
Breather Oil Seal Installer a set(camshaft timing gear and timing chain)
0800-011201-923-001
Installation
Installation Jig,Breather Gear Shaft
Installation is the same for both timing chains.
0800-011201-921-003
Press Tool,Breather Gear Shaft
0800-011201-921-001
TIMING CHAIN
The engine is equipped with two chains .one is lo-
cated on the magneto side .the second is loacted on
the CVT side.
Removal(MAG side)
Remove:
-valve cover chain tensioner,camshaft timing gear(refer
to INTAKE MANIFOLD,CYLINDER HEAD AND
CYLINDER) 3
-Magneto,driven gear,oil pump intermediate gear,
breather intermediate gear.
-Timing chain guide and lower timing chain guide.
Carefully pull the timing chain sideward and down from
the crankcase. 2
1
NOTE:Mark the operation direction of the timing chain
before removal.
1.Timing Chain Guide
2.Timing Chain
Removal(CVT side)
3.Chain Tensioner
Remove:
-valve cover chain tensioner and camshaft timing gear
(refer to INTAKE MANIFOLD,CYLINDER HEAD AND 1
CYLINDER)
-CVT cover CVT drive gear CVT driven gear£¬Belt
Note Mark operation direction of the belt .
-CVT case Clutch
-Timing chain guide and lower timing chain guide.

Carefully pull the timing chain sideward and down from
the crankcase.
Note:Mark the operation direction of the timing chain
before removal.
1.Timing Chain
08-6
The installation essentially the reverse of the remove

procedure ,but pay attention to the follow details:
Note:Ensure to perform proper valve timing .lock crank-
shaft (see crankshaft )and camshaft at TDC ignition
(refer to intake manifold ,cylinder head and cylinder
section).Install timing chain with camshaft timing gear
then ,adjust chain tension (refer to intake manifold ,
cylinder head and cylinder section).Loosen crankshaft
,turn 440 degree on clockwise direction (from CVT side)
and camshaft at TDC ignition,Install timing chain with
camshaft timing gear then ,adjust chain tension,to
perform proper valve timingrefer to intake manifold ,
cylinder head and cylinder section).
CAUTION:Improper valve timing will damage en-

2
gine components.
TIMING CHAIN TENSIONER

Removal
Refer to TIMING CHAIN above.
Inspection
Check timing chain tensioner for wear ,cracks or other
damage ,replace if necessary. 1
Installation
The installaiton is the reverse of the removal proce- 1.Chain Tensioner
2.Screw
dure .
CRANKCASE
NOTE:Before disassembly ,drain engin oil and en-
gine coolant.
Crankcase Disassembly
NOTE:Before splitting the crankcase,measure crank-
shaft axial play (refer to CRANKSHAFT).
Remove:
-Front drive shaft,ring gear
-CVT cover,CVT,belt,CVT air guide and clutch(refer to
CVT AND CLUTCH)
-Drive gears(refer to DRIVE GEARS)
NOTE:Oil pump removal from crankcase is not nec-

essary ,but recommended to see condition of oil pump.
-Left crankcase cover and electric starter(refer to
MAGNETO SYSTEM )
-electric starter drive gear(refer to STARTING
SYSTEM)
-oil filter(refer to LUBRICATION SYSTEM)
08-7
-Cylinder head and cylingder( refer to INTAKE 2
MANIFOLD,CYLINDER HEAD AND CYLINDER)
-Timing chain,tensioner and guide.(refer to TIMING 1
CHAIN,TENSIONER AND GUIDE). 1
Remove all bolts of crankcase. 5
4
3
1.11 bolt M6X45

2.4 bolt M8X60
3.4 bolt M8X50
4.2 bolt M6X50
5.1 bolt M6X80
Carefully split crankcase halves by using a soft ham-
mer .
NOTE:During disassembly ,do not damage the seal-
ing surface of the crankcase halves.
Pull crankshaft out of crankcase.

Crankcase Cleaning
WARNING
Use safety goggles to avoid eye injuries.
1
Clean crankcase using a part cleaner;

Dry crankcase using compressed air; 1.Soft Hammer
Clean oil passage.
08-8
Crankcase inspection
Check crankcase halves for cracks or other damage.
replace if necessary.
Check plain bearing for scoring or other damages. 2 1
NOTE:Measure plain bearing inside diameter and
compare to magneto and CVT side journal diameter
of crankshaft(refer to CRANKSHAFT).Replace if the A
measurements are out of specification.
plain bearing inside diameter(CVT/MAG)

service Limit: 42.100mm(1.6575in)
Plain Bearing Replacement
plain bearing removal
1.Oil bore
Caution:Alway support crankcase halves properly when
2.Plain bearing
ball bearings or plain bearings are removed .Damages
3.Measure plain bearing inside diameter
to crankcase halves may occur if this procedure is not
performed correctly .
NOTE:Always use a press for removal of plain bearing.
Remove plain bearing with the proper plain bearing re-
move/installer. 3
Carefully push the plain bearings out from the crank-
case half inside towards the outside.
NOTE:Place the proper crankcase support sleeve
under crankcase halves before removing plain bear-
ings .
NOTE:During disassembly ,do not damage the seal-

ing surface of the crankcase halves.
Service Tools: 2
1
Left crankcse support sleeve
0800-011101-922-001
Right crankcse support sleeve 1.Crankcase half
0800-012101-922-001 2.Crankcase support sleeve
Plain bearing remover/installer 3.Plain bearing remover/installer
0800-011102-922-001
Plain Bearing Installation

NOTE:Crankcase and plain bearing must be installed
as a pair as shown in the following table:
Crankcase Plain Bearing
Red (A) Red
Blue(B) Blue
CAUTION:Unless otherwise instructed,never use
hammer to install ball bearings or plain bearings,
use press only.
Install plain bearings with the proper plain bearing re-
mover/installer in a cool crankcase.Do not lubricate
plain bearing and /or crankcase for installation.
08-9
NOTE:Place proper crankcase support sleeve un-
der the crankcase halves before installing the plain
bearings(refer to bearing removal procedure).
Carefully press-in the plain bearings in the same di-

2
rection as during disassembly,from then crankcase
inside towards the outside.
During disassembly ,make sure not to damage the
sealing surface of the crankcase halves.
1
CAUTION:Mark position of oil bore on crankcase

half and on plain bearing remover/installer .Align 1.Oil positon marked on crankcase
mark on plain bearing remover/installer with 2.Plain bearing remover/installer
mark on crackcase half.
NOTE:Wrong oil bore will stop supply to plain bear-

ing and will cause engine damaged. 3
2
CAUTION:The partition of the palin bearing in
left crankcase must be positoned near to oil bore 1
in clockwise direction.(refer to No.2 in next
installation)
CAUTION:The partition of the palin bearing in

right crankcase must be positoned near to oil bore
in clockwise direction.(refer to No.2 in next 1.Oil bore
installation) 2.The partition of the plain bearing
NOTE:Use an o-ring ( 42x1-1.5mm 0.04-0.05in)) 3.Left crankcase
to hold plain bearing in place during installation,the o-
ring will disappear in the groove of the palin bearing
3
remover/installer. 2
Service Tools:
Left crankcse support sleeve
0800-011101-922-001 1.Oil bore
Right crankcse support sleeve 2.The partition of the plain bearing
0800-012101-922-001 3.Right crankcase
Plain bearing remover/installer
0800-011102-922-001
08-10
Crankcase Assembly
The assembly procedure of crankcase is the reverse 3
of disassembly procedure.However,pay attention to the 21 22
21
following details. 8 1
2
2
1. Clean oil passages and make sure they are not
20
clogged. 7
18
2. Clean all metal components. 19
3. Carefully clean contact surface between left and 6 17
right crankcase. 5
4. Install a new crankcase gasket. 11 12 13 14 15
5. Apply engine oil when install crankshaft bearing.
ATTENTION:Correctly reinstall crankshaft (refer 4
to CRANKSHAFT ).
Tighten screws on crankcase in sequence as shown

in right picture.
9
16 10
CRANKSHAFT
2
1.Crankshaft
2.Right Crankcase
08-11
Crankshaft Locking Procedure
NOTE: When crankshaft is locked, rear cylinder

(cylinder No.2 ) is at TDC ignition, crankshaft cannot 2
1
locked at TDC of front cylinder (Cylinder No.1)
Remove:
-Spark plug cable and spark plugs of both cylinders
-Valve covers of both cylinders
-Plug cover and gasket of plug cover
1.Gasket
2.Plug Cover
3.Screws
-Crankshaft position sensor(CPS)
1.Crankshaft position sensor

2.Screw
08-12
-Screw and gasket washer
2 3
1
1.Screw
2.Washer
3.Left crankcase
Use 18mm socket to rotate crankshaft until

piston of cylinder No.2 is at TDC ignition.
1
1.18mm Socket
08-13
When piston of rear cylinder is at TDC, Marks on
magneto flywheel and magneto cover are aligned.
1
2
1. Mark “2” on magneto flywheel

2.Notch on magneto cover
3.CPS Location
Use screwdriver to check if V-type groove of crank-
shaft balancer is aligned with the hole.
1.Screwdriver
Lock crankshaft with crankshaft locking bolt (P/N:0800-
041000-922-001).
1.Crankshaft locking screw
08-14
Crankshaft Removal
Refer to CRANKCASE.
Crankshaft Inspection
NOTE:Check each bearing journal of crankshaft for
scoring,scuffing,cracks and other signs of wear.
NOTE:Replace the crankshaft if the gears are worn
or otherwise damaged.
CAUTION: Components with less than the ser-
vice limit always have to be replaced. Other-
wise servere damage may be caused to the
engine. 1
Crankshaft Axial Play
NOTE: Axial play of crankshaft needs to be mea-
sured before splitting the crankcase.
1.Timing sprokcet (gear) of crankshaft
Use dial gauge to measure crankshaft axial play at
MAG side.
Crankshaft Axial Play
0.050-0.350
New 2
(0.002-0.014in)
Service Limit 0.6mm(0.024in) 3
If play is out of specification, replace crankcase and/ 1
or crankshaft.
Connecting Rod Big End Axial Play

Using a feeler gauge,measure the distance between
butting face of connecting rods and crankshaft
counterweight.
1.Crankshaft
Connecting Rod Big End Axial Play
2.Connecting Rod
0.300-0.560
New 3.Gauge
(0.012-0.022in)
3
Connecting Rod/Piston Pin Clearance
Refer to INTAKE MANIFOLD,CYLINDER HEAD AND
CYLINDER. 1
2
Connecting Rod Big End Radial Play
Remove connecting rod from crankshaft.
NOTE: Make sure the same marking of connecting
rod to assemble together, do not mix it and exchange
between cylinder 1 and cylinder 2.
CAUTION:Always replace connecting rod 1.Connecting Rod Screws
screws no.1 if removing connecting rod. 2.Plain Bearing
3.Connecting Rod
08-15
Measure the diameter of crankpin and compare to in-
ner diameter of connecting rod big end.
A
1
Install screws of connecting rod and measure inner

1.Crankshaft
diameter of connecting rod big end.
A.Diameter of connecting shaft neck
Install bearing of connecting rod as original condition.
Use below-mentioned methods and torque to tighten.
Crankpin A
43.946-43.960mm
Standard
(1.7302-1.7307 in)
Service Limit 43.93mm(1.7295 in)
Inner Diameter of Connecting Rod Big End

Clearance between Connecting Rod Big End 1.Inner Diameter of Connecting Rod Bid End
and Crankpin
Crankshaft Radial Play,MAG/PTO Side

Measure crankshaft on MAG/PTO side and compare
to innner diameter of MAG/PTO plain bearing(see
A
CRANKCASE).
Diameter of Crankshaft MAG/PTO Side
41.960-41.970mm
Standard
(1.652-1.6524 in)
1
1.Crankshaft
A.Diameter of PTO Side Crankshaft
B.Diameter of MAG Side CrankshaftMAG
Clearance between Crankshaft and Crankcase Hole
08-16
Crankshaft Assembly
NOTE: Follow the table below to assemble
crankshaft,connecting rod and connecting rod plain
bearing.
Inner Diameter of
Bearing of Con-
Connecting Rod Crankpin
necting Rod 1
Big End
A Black
B Blue
A Red
3
A Black 2
Cranksahft assembly procedure is the reverse of 1.Half Plain Bearing of Connecting Rod Big End
disassembly procedure.However,the following details 2.Split Surface of the Connecting Rod
should be noted. 3.Nose of Plain Bearing in Line with Connecting Rod
Groove
1.When inner diameter of connecting rod big end is
less than service limit, replace and use new
connecting rod bearing.
2
After installing bearing into big end of connecting
rod,use compressed air to clean connecting rod
1
split surface.
3
NOTE: Oil on inner surface of connecting rod plain
bearing and crankshaft pin surface before installation.
There are oil passage plug at CFMOTO logo side of

cylinder 1 and cylinder 2 connecting rod.
1.CFMOTO Logo
Screw of connecting rod should be tightened by fol- 2.Plug of Oil Passage
lowing methods. 3.Mark A or B on connecting shaft
-Firstly torque to 10Nzm(7.5Ibfzft).
DO NOT apply threadlocker.
-Then, torque to 20Nzm(15 Ibfzft).
-Finally torque to 50Nzm(35.25 Ibfzft).
1.Torque Wrench
08-17
CAUTION: Improper installation will cause
1
screw looseness and engine damage.
ATTENTION: Bearing of connecting rod big end and
piston pin rotation cannot be changed. 2
Crankshaft Installation
The procedure of crankshaft installation is the reverse
of removal, but following detailes should be cared.
Do not mix connecting rod of cylinder No. 1 and No.2
ATTENTION: Do not damage plain bearing of
crankcase when installing crankshaft (together
with connecting rod).
3
ATTENTION:Before installation of camshaft and

valve rocker arm, do not forget to install locking
1.Crankcase
bolt to make sure crankshaft on top dead position.
2.Connecting rod of cylinder No.1
3.Connecting rod of cylinder No.2
Engine Front Output Shaft Removal
Remove shaft collar, O-ring, oil seal and bearing
retainer.
Remove front output shaft.
Inspection
Inspect if bearing turns freely and smoothly,or has
abnormal wear.Replace if necessary.
Installation
Reverse the removal procedure for installation.Pay
5 3
Before installation, Oil bearing. Meanwhile,use a new 4 2
1
oil seal and grease should be applied on lip of oil seal.
1.Oil Seal
Use service tool to tighten bearing retainer (left thread) 2.Shaft Collar
by applying threadlocker. 3.O-ring
Tightening Torque: 80Nzm 4.Bearing Retainer
5.Front Output Shaft
Service Tool:
Bearing retainer socket: 0180-060008-922-001
Oil seal installer: 0800-060000-923-001
Installer,front output shaft: 0800-062301-923-001
08-18
Ring Gear Removal

Remove ring gear bearing carrier screws;
Remove ring gear and adjustment shimshaft; Remove

output shaft collar, O-ring, and oil seal;
3 2 1
6 5
1.Shaft Collar
2.O-ring
3.Oil seal
4.Screws
5.Ring Gear Comp.
6.Adjustment Shim
Use protector to avoid ring gear damage,
fasten bearing carrier and press ring gear out;
1
2
3
1.Ring Gear Protector

2.Bearing Carrier
3.Ring Gear
08-19
Use bench vice to fix bearing carrier, then remove bear-
ing and use special wrench (0800-062206-922-001)to
remove thrust nut, finally remove bearing.
Ring Gear Inspection

Inspect gear for any surface damage,wear. Replcae if
1
necessary.
Inspect bearing for operation condition.

2
Ring Gear Installation

Installation procedure is the reverse of removal
procedure.Pay attention to the details
Use oil seal installer (0800-062204-923-001) to install

NEW oil seal and O-ring.
1.Special Tool
When replacement of right crankcase,ring gear or bear- 2.Bearing Carrier of Ring Gear
ing seat, adjustment shim should be chekced and
adjusted.
Service Tool:
Drive pinion gear bearing(6305) installer:
0180-062103-921-002
Ring gear bearing(6207C3) installer:
0180-062201-921-003
When installation, apply oil on bearing, oil seal, o-

ring; apply threadlocker on bearing thrust nut and 1
tighten to below torque.
Tightening Torque:110Nzm
Drive Pinion Gear Removal 2
Separate left and right crankcase(see CRANKCASE);

1. Screws
Remove drive pinion gear bearing carrier screws;
2.Drive Pinion Gear
Remove drive pinion gear;
Remove circlip of drive pinion gear and output driven

gear;
Use a clean rag to protect drive pinion gear shaft and

fix it on bench vice;
Loosen drive pinion gear nut and remove drive pinion

gear and adjustment shim;
1.Nut
08-20
Drive Pinion Gear Inspection 5

4
Inspect drive pinion gear and output driven gear teeth 3
for rusting,scratches,wear.Replace if necessary.
Inspect if bearing turns freely and smoothly.Replace if

necessary.
When replacing any of crankcase,drive pinion gear, 6
and drive pinion gear carrier,the adjustment shim should
7
be readjusted.Refer to the content further.
2
Drive Pinion Gear Installation

1
Reverse the removal procedure for installation.Oil bear-
8
ing and tighten nut to sepecified torque.
7
Tightening Torque:145N m.
Shim Adjustment Procedure

1.Drive Pinion Gear Carrier 5.Adjustment Shim
When crankcase and/or drive pinion gear and/or ring
2.Output Driven Gear 6.Drive Pinion Gear Shaft
gear and/or bearing carrier are replaced,the shim must
3.Drive Pinion Gear Nut 7.Bearing Retaining Plate
be adjusted.
4.Drive Pinion Gear 8.Ball Bearing
WARNING
Both gear backlash and tooth contact should
be in specification.
Gear Backlash
Install drive pinion gear and ring gear then install crank-
case gasket;
Close crankcase and install some screws;
To lock drive pinion gear,using a clean screwdriver,
reach the hole of drive pinion gear seat through speed
sensor hole,then pry output driven gear out of place in
its axial direction;
Install gear backlash measurement tools and dial 2
gauge;
Rotate ring gear shaft from engagement to engage-
ment to measure gear backlash.
NOTE:Measure the gear backlash at 4 positions.

Rotate the shaft 90 each time.
If gear backlash is out of specification,make the ad-
justment by adjusting the thickness of ring shim.
Gear Backlash:0.1-0.2mm(0.004-0.008in) A
1
Adjustment Steps
Gear Backlash Shim Adjustment 1.Backlash Measurement Tool

< 0.1mm Increase shim thickness 2.Dial Gauge
A.46mm(1.81 in)
0.1-0.2mm Correct
> 0.2mm Reduce shim thickness
08-21
Tooth Contact
After backlash adjustment is carried out,the tooth
contact must be checked.Pay attention to the follow- 1
ing procedures:
Remove ring gear from crankcase;
Clean and degrease drive pinion gear and ring gear
teeth;
Apply a coating of machinist’s layout dye or paste to
several teeth of the driven gear;
Install ring gear;
Rotate the ring gear several turns in both directions;
Remove drive pinion gear and ring gear,then inspect
the the coated teeth of the drive pinion gear.The tooth
contact pattern should be as shown below;
2
Pattern 1 Contact at tooth top Incorrect
Pattern 2 Contact at tooth middle Correct
Pattern 3 Contact at tooth root Incorrect
If gear tooth contact is found to be correct(pattern 2),

continue the next step.
If gear tooth contact is found to be incorrect(pattern 1

and pattern 3),the shim thickness between the drive
3
pinion gear and ring gear must be changed and the
tooth contact re-checked until correct.
NOTE:Clean the dye coated on the gear teeth after
the tooth contact adjustment is finished.
Adjustment Steps
Tooth Contact Shim Adjustment
Pattern 1 Reduce shim thickness
Pattern 3 Increase shim thickness
CAUTION:Make sure to check the backlash af-

ter the tooth contact has been adjusted,since it
may have changed.Adjust the tooth contact and
backlash until they are both within specification.
If the correct tooth contact cannot be maintained
when adjusting the backlash,replace the drive
gear and ring gear.
08-22
Shift Lever Assembly Removal

Remove shift lever cover screws;
Remove shift lever cover and gasket;
3
1.Screws
2.Shift Lever Cover
3.Shift Lever Gasket
Remove driven shift lever assembly;

Remove drive shift lever assembly.
3
1.Screw
2.Driven Shift Lever Assembly
3.Drive Shift Lever Assembly
Main Shaft,Driven Shaft Assembly,Shift

Drum,Shift Fork/Shaft Removal
Remove gearshift limit spring seat;

Remove limit spring and steel ball;
4 3 2
1
1.Steel Ball
2.Spring
3.Washer
4.Spring Seat
08-23
Split crankcase(see CRANKCASE);
Remove gearshift driven shaft washer,driven lo range 1
gear;
2
1.Washer
2.Driven Lo Range Gear
Remove drive pinion gear assy;

Remove gearshift main shaft by shifting to lo gear
range;
1
1.Main Shaft
08-24
Remove gearshift driven shaft assy,shift drum,shift

forks,parking lock lever;
2
1 4
3
1.Shift Drum
2.Shift Fork
3.Parking Lock Lever
4.Driven Shaft Assy
Reverse Intermediate Gear Removal

NOTE If reverse intermediate gear and needle
bearing turn freely and smoothly,and clearance of them
1
is normal,no need to remove them.
To remove reverse intermediate gear and needle

bearing,a proper service tool is required to press it out
of left crankcase.(Use care to protect reverse inter-
mediate gear and needle bearing from damage.)
1.Service Tool
08-25
Bearing Removal in Crankcase
If necessary,heat crankcase up to 100 (212 ) be-
fore bearing removal.
WARNING
Clean oil,outside and inside,from crankcase
before heating.
CAUTION:Always support crankcase properly

when bearing is removed.Crankcase damages 1
may occur if this procedure is not performed
correctly.
To remove ball bearing in crankcase,use a blind hole
bearing puller.
Inspection
2
Always verify for the following when inspecting com-
ponents in crankcase:
gear teeth damage
1.Bearing Puller
worn or scoured bearing surface
2.Ball Bearing
excessively worn ,scoured,or bent shift fork
excessively worn ,scoured,or bent shift fork shaft
rounded engagament dogs and slots
1
excessively worn ,scoured parking lock lever
worn shift fork engagement pins
worn shift track on shift drum
worn or scoured shift fork claw
worn splines on shafts and gears
excessively worn and scoured parking cam
Bearing
Check if bearing turns freely and smoothly.If any bind-
ing or abnormal noise has been found,replace it with a
1.Bearing
new one.
Shift Fork/Shaft
Check both shift forks for excessice wear.Check shift
fork claw for bending. A
Measure shift fork claw thickness.
Shift Fork Claw Thickness(both forks)
New 5.8-5.9mm(0.228-0.232in)
A.Shift Fork Claw
08-26
Measure shift fork pins.
Shift Fork Pin Diameter(both) A
New 7.9-7.95mm(0.311-0.313 in)
A.Diameter of Shift Fork Pin
Fit shift fork onto the shift fork shaft,then move the
shaft as illustrated.Check if shift fork slides smoothly.
Replace if necessary.
Place shift fork shaft on a level surface and roll it.If

any bending has been found,replace it with a new one.
CAUTION: Do not try to correct the bend shift

fork pin.
08-27
Inspect shift fork springs for damages.Replace if
necessary.
Shift Drum
Inspect shift drum tracks for excessive wear and other
damages.
Inspect parking lock cam on shift drumfor excessive
wear and other damages.Replace if necessary.
Inspect limit washer for damages.
Parking Lock Lever

Check parking lock lever for cracks or other damages. 1
08-28
Gearshift Main Shaft

Check gearshift main shaft for damages.
Check gear teeth of gearshift main shaft for pittings,
scuffing and excessive wear.Replace if necessary.
B
A
Measure main shaft neck diameter of two ends as
shown.If the meassurements are less than the ser-
vice limit,replace.
Gearshift Main Shaft Neck Diameter
Service Limit
MAG Side 16.97mm(0.666 in)

A.MAG Side
CVT Side 29.97mm(1.178 in) B.CVT Side
Gearshift Driven Shaft Assy

Disassemble gearshift driven shaft assy as shown.
Check teeth of each gear for fittings,scuffing and ex- 6
cessive wear.Check needle bearing and circlip for wear 3 1
and damages.Replace if necessary. 2
3
4
5
3
7
6 6
8
11
9
6
10
12 11
1.Washer 17.5x32x1 7.Driven Hi Range Gear

2.Driven Lo Range Gear 8.Driven Shaft
3.Needle Bearing 9.Driven Output Gear
4.Washer 24.5x33.5x1 10.Reverse Driven Gear
5.Gearshift Sliding Bushing 11.Circlip 29
6.Circlip 29 12.Parking Lock Gear
08-29
Gears
NOTE:Gears must be replaced in a pair.Always re-
place circlip after removal.
driven shaft output gear for reverse gear shifting
gearshift sliding sleeve for high and low gear shifting A
Measure the width for engegement of shift fork.If the
width is out of specification,replace the gear.
The width for engegement of shift fork on the gear should
be the same with the one on the sliding sleeve.
Width for Engagement of Shift Fork
New 6.1-6.2mm(0.240-0.244 in)

A.Groove Width
Inspect reverse driven gear,high range gear,low range

gear for damages.Measure the gear inner diameter,if
it’s out of specification,replace the gear.
A
The inner diameter of reverse driven gear,high range
gear,low range gear is the same.
Inner Diameter
New 29-29.021mm(1.1417-1.1425 in)
A.Inner Diameter
Driven Shaft
Check driven shaft for damages.
Check driven shaft for pittings,scouring and exces-
sive wear.Replace if necessary.
B
B
B
A
Measure driven shaft neck diameter,f it’s out of

specification,replace it.
Driven Shaft
Service Limit
A 16.978(0.6684 in)
B 23.970(0.9437 in)
08-30
Reverse Intermediate Gear

Check reverse intermediate gear for damages.Mea-
sure the inner diameter.If it’s out of specifiacation,re-
place it. A
1
Reverse Intermediate Gear Inner Diameter
New 29.007-29.028 mm(1.1420-1.1428 in)
Service Limit 29.032 mm(1.1430 in)
1.Reverse Intermediate Gear

A.Inner Diameter
Reverse Intermediate Gear Shaft

Check reverse intermediate gear for damages.Mea- 1
sure reverse intermediate gear shaft neck diameter If
it’s out of specification,replace it.
A
Reverse Intermediate Gear Neck Diameter
New 24.980-24.993 mm(0.9834-0.984 in)
Service Limit 24.974 mm(0.9832)

1.Reverse Intermediate Gear Shaft
A.Reverse Intermediate Gear Shaft Neck Diameter
Shift Lever Assembly
Check shift lever cover for cracks,deformation and
other damages.Replace if necessary. 1
1.Shift Lever Cover
08-31
Check drive shift lever and driven shift lever for cracks,
deformation,wear and other damages.Replace if
necessary. 1 2
Assembly
Assembly procedure is the reverse of disassembly 1.Drive Shift Lever
procedure.Pay attention to the following details: 2.Driven Shift Lever
Always use a new circlip.Pay attention to the direc-

tion when installing a new circlip.Perform the installa-
tion as illustrated.
Lightly oil gears and shafts before assembly.
CAUTION:
Once circlip is removed,it has been damaged.
Round edge facing
Therefore,never use it for a second time.When
the gear
installing a new circlip,do not open the circlip
too much.
After circlip installation is finished,make sure the circlip

is in place.
When installing shift fork shaft,ensure shift forks and
shift fork springs are in correct locations as illustrated.
1.Shift Fork Shaft 2.Circlip 12;

3.Left Shift Fork 4 Shift Fork Spring(thin)
5.Right Shift Fork 6.Shift Fork Spring(thick)
7 .Spring Seat
08-32
Installation
Crankcase installation procedure is the reverse to re-
moval installation procedure.However,pay attention to
the following details:
Do not use a hammer to install ball bearing unless its
structure is special.Only use a press tool to install a
bearing.
If necessary,heat crankcase up to 100 (212 ) be-
2
fore removing ball bearing. 3
1
WARNING
Clean oil,inside and outside,from crankcase
before heating. 1.Reverse Intermediate Gear
ut a new ball bearing in an icebox or equivalent facil- 2.Needle Bearing
3.everse Intermediate Gear Shaft
ity to chill for 10 minutes before installation.
Using sevice tool,install the ball bearings in left crank-
case and right crankcase.
CAUTION:Always support crankcase properly
when installing ball bearings.
Perform the correct procedure when installing a 2
new oil seal(Refer to Oil Seal Installation above).
3
Other Parts in Crankcase
Fit needle bearing onto reverse intermediate gear shaft,
then install them together with reverse intermediate
gear.
1
NOTE Reverse intermediate gear collar faces re- 1.Reverse Intermediate Gear
2.Left Crankcase
verse intermediate gear shaft small end.
3.Bearing
NOTE:Press bearing no.3 before installing reverse

intermediate gear
Using press machine,press reverse intermediate gear 2
in the left crankcase.
Place parking lock lever in place in crankcase.

Engage shift fork assy with gearshift driven shaft assy, 1
then fit them in place in left crankcase.
NOTE:Do not install washer 17X32X1and reverse 3

range gear into gearshift driven shaft assy.
1.Shift Fork Assy

2.Driven Shaft Assy
08-33
Install drive pinion gear assy then tighten the 4 retain-
ing screws.
1
1
1.Screws
2.Drive Pinion Gear
Place parking lock lever in parking position,then align

shift drum tracks with shift forks and fit it in left
crankcase.Shift parking lock lever to parking position, 1
then align shift drum axial track with shift fork pin and
fit it in the left crankcase.
2
Using an appropriate tool,shift to low range,then in- 1.Shift Drum

stall gearshift main shaft. 2.Axial Track
Install washer and low range gear.
Using an appropriate tool,shift to neutral range.
Turn main shaft,check if gears rotate freely and
smoothly. 3
1
Rotate the main shaft,check if the corresponding mesh-
ing gears turn freely and smoothly.
2
NOTE:When installing rotational parts,equally oil
shaft necks.
1.Washer
2.Lo Range Gear
3.Main Shaft
08-34
Install a new crankcase gasket

1
NOTE:Always use a new crankcase after splitting
crankcase.
Place the right crankcase on the left crankcase.In-
stall screws and torque to specifications.
WARNING
Do not turn shift drum before shift lever
installa tion is completed.
Install driven shift lever assy and drive shift lever assy.;
Torque driven shift lever screw to specified value;
1.Crankcase Gasket
NOTE:When installing driven shift lever assy and drive

shift lever assy,the marks on their teeth should be
1
aligned
2
4 1
3
Install shift lever cover gasket and cover; 1.Marks

Install shift lever cover screws and torque to specified 2.Screw
value; 3.Driven Shift Lever Assy
4.Drive Shift Lever Assy
3
Install other removed parts.
2
1.Screws
2.Shift Lever Cover
3.Shift Lever Cover Gasket
08-35
09 CVT AND CLUTCH
CVT AND CLUTCH

9
SERVICE TOOLS
Decription P/N Page
Split tool,drive&driven pulley 0800-052000-922-003 6

Drive pulley oil seal installer 0800-051204-923-001 8
Drive pulley holder 0180-051000-922-001 10
Driven pulley remover 0800-052000-922-002 11
Driven pulley holding wrench 0800-052000-922-001 14
Installer,clutch housing oil seal 0800-013104-923-001 16
Clutch housing damper 0180-053100-921-001 16
Clutch holding wrench 0180-054000-922-001 18
SERVICE PRODUCTS
Decription P/N Page
Engine oil
Threadlocker
Retaining Compound
09
09-1
Threadlocker Retaining
Threadlocker T3 Compound
LH Threads
Threadlocker
T2
Engine Oil Engine Oil
Threadlocker
T3
Engine Oil
T1
Threadlocker
T1
T3
T1 115N m(85lbf ft)

T2 70N m(52lbf ft)
T3 10N m(89lbf in)
09-2
09 CVT AND CLUTCH
GENERAL
NOTE: For a better understanding, the following il-
lustrations are taken with engine out of vehicle.To
perform the following instructions,it is not necessary
to remove engine.
During assembly/installation,use the torque values and
service products as in the exploded views.
Clean threads before applying a threadlocker.Refer
to LUBRICANTS AND SERVICE PRODUCTS at the
beginning of this manual for complete procedure.
WARNING
Torque wrench tightening specifications must
strictly be adhered to.Locking devices(e.g.: lock-
ing tabs, elastic stop nuts,cotter pin,etc.)must be
replaced with new ones.
WARNING
Never touch CVT while engine is running.
09
Never drive vehicle when CVT cover is removed.
WARNING
Any drive pulley repairs must be performed by
an authorized CFMOTO dealer.Subcomponent
installation and assembly tolerances require strict
adherence to procedures detailed.
CAUTION: Never use any type of impact wrench

at drive pulley removal and installation.
WARNING
The clutch assembly is a precisely balanced
unit.Never replace parts with used parts from
another clutch assembly.
CAUTION: These pulleys have metric threads.

Do not use SAE threads puller.Always tighten
ouller by hand to ensure that the drive pulley has
the same type of threads(metric vs SAE) prior to
fully tightening.
09-3
CVT COVER
CVT Cover Removal
Remove CVT cover screws;

3
Remove CVT cover comp.;
Remove gasket.
2
1
1.Screw
2.CVT Cover
3.CVT Case
3 2
1
4
1.CVT Cover 2.Screw

3.Gasket 4.Dowel Pin
CVT Cover Inspection
Remove the bolts and retaining plate, the remove oil

seal;
Inspect bearing rotating condition.If any damage has

been found,replace the bearing; 1
2
3
Apply lubricant oil on bearing outer ring.Use special 4
5
tool to instrall the bearing and check it for smoothness;
6
Apply grease inside bearing; 7
Use a new seal and apply grease on seal lips. 1.CVT Cover 2.Bearing
3.Oil Seal 4.Retaining Plate
5.Screw 6.Washer
7.Screw
09-4
09 CVT AND CLUTCH
CVT Cover Installation
Reverse the removal procedure for CVT Cover

installation.
NOTE:
Tighten bolts in criss-cross sequence;
Replace new seal;
After Installing oil seal retaining plate, apply
threadlocker on screw threads.
DRIVE BELT
Drive Belt Removal
Remove CVT cover and gasket(Refer to CVT Cover);
Remove drive pulley (refer to Drive Pulley);

Remove driven pulley (refer to Driven Pulley);
1 09
2
3
1.Drive Pulley
2.Drive Belt
3.Driven Pulley
NOTE:
If no printed arrow mark has been left on drive belt,
remark the belt during removal to avoid incorrect
installation.
09-5
Drive Belt Inspection
Check belt for cracks,fraying or abnormal wear.

1
Check drive belt width at cord level.
Replace if it is out of specification.
2
Belt Width Service Limit:33.0mm(1.181 in)
Tool:Vernire caliper
1.Drive Belt
CAUTION: If belt surface is contaminated with 2.Cord in Drive Belt
grease or oil, degrease the belt thoroughly.
2 1
3
Drive Belt Installation

Reverse the removal procedure for belt installation.
NOTE:
1.Using special tool,insert the threaded hole of driven
pulley and tighten to open the pulley.
1.Special Tool
2.Driven Pulley
2.No grease on belt and drive pulley
3.Drive Belt
3.Arrow printed on belt should point towards the front

of vehicle,viewed on top. 1 4
If no arrow on belt, install follow removal directly
remark.
4.Primary sheave should install corectly to avoid belt

against other parts and not well installed.
3 2
1.Printed Mark on Drive Belt

2.Drive Pulley(Front)
3.Driven Pulley(Rear)
4.Rotation Direction
09-6
09 CVT AND CLUTCH
DRIVE PULLEY
Drive Pulley Removal
8
7 6
Remove CVT Cover no.2 (refer to CVT Cover);
Remove drive pulley nut no.4 and drive pulley sliding 4
sheave no.6;
Remove driven pulley nut no.3 and driven pulley no.5;
Remove drive belt(refer to Drive Belt);
Remove drive pulley fixed sheave;
2
3
5 1
1.CVT Cover Screw 2.CVT Cover

3.Driven Pulley Nut 4.Drive Pulley Nut
5.Driven Pulley 6.Drive Pulley Sliding Sheave
7.Drive Belt 8.Drive Pulley Fixed Sheave
Drive Pulley Disassembly 09
Remove drive pulley shaft sleeve;

1 2
Remove cam and rollers;
4
1.Sleeve 2.Drive Pulley Sliding Sheave

3.Roller 4.Cam
2
1
1.Cam
2.Roller
09-7
Cam, Sliders and Rollers Inspection
Check Cam for wear and other damages. Replace if 2

3
necessary. 1
Check slider wear and other damages. Replace if
necesary.
Check each roller and sliding surface for wear and
other damages, if any damage has been found,replace
all rollers.
NOTE: Whenever replacing rollers and sliders,always

replace all rollers and sliders at the same time,or un- 1.Cam
balanced drive pulley will occur because of rollers or 2.Slider
sliders difference. 3.Roller
Oil Seal Inspection 1
NOTE:If no oil seal inside, It’s not necessary to per-

form this procedure.
2
Check oil seal lip for wear and other damages.Re-
place if necessary. 1.Oil Seal
2.Drive Pulley Sliding Sheave
2
Special tool is required to install the oil seal.

2.Special Tool
09-8
09 CVT AND CLUTCH
Primary sliding sheave and fixed sheave In-

spection 1
Check drive pulley faces for abnormal conditions.If any

wear and damage has been found,replace it.

Drive Pulley Sliding Sheave Installation 2.Drive Pulley Fixed Sheave
Install 8 rollers into sliding sheave;
09
2
1.Roller
Install 4 sliders on cam;

Install cam on sliding sheave;
Install shaft sleeve into sliding sheave. 2
1.Cam
NOTE: When installing shaft sleeve, hold the cam 2.Slider
to avoid rollers coming out of place. 3.Drive Pulley Shaft Sleeve
09-9
Drive Pulley Installation
Reverse the removal procedure for instrallation
NOTE:
1.If oil seal is inside the hole, apply grease inside the
hole and oil seal lip
CVT Drive Pulley Holder
2.If belt surface is stained with grease or oil, degrease
the belt thoroughly.
3.Using sepecial tool,tighten the drive pulley nut to
specified torque: 1
Drive Pulley Nut Tightening Torque:115N.m

2
Special tool:Drive Pulley Holder
1.Drive Pulley Holder

2.Locations to Place Drive Pulley Holder
DRIVEN PULLEY 8
7 6
Removal 4
Remove CVT case(refer to CVT COVER);

Remove drive pulley nut(refer to DRIVE PULLEY);
Remove driven pulley nut and driven pulley;
Remove drive belt(refer to DRIVE BELT); 2

5 3
1
Remove driven pulley;
1.CVT Cover Bolt 2.CVT Cover
3.Driven Pulley Nut 4.Driven Pulley Nut
5.Driven Pulley 6.Drive Pulley
7.Drive Belt 8.Drive pulley Fixed Sheave
09-10
09 CVT AND CLUTCH
DRIVEN PULLEY
Disassembly
1 2
NOTE:
Before disassembly, mark on the spring installation
holes and cam feet to sliders positions.
1.Cam and slider marks

2.Spring Installation Holes Marks
As the illustration shows, place driven pulley on the 1

special tool base.
Turn special tool handle to compress the cam and 09

1.Driven Pulley Remover
spring.Using a circlip remover(a plier),remove circlip.
2.Driven Pulley
1.Driven Pulley Remover

2.Circlip
3.Circlip Remover
09-11
Slowly loosen tool handle to release the spring tnesion
and remove the special tool;
Remove cam;
Remove guide pin;
Remove spring and sliding sheave of driven pulley.
3 2 1
4
1.Cam
2.Guide Pin
3.Spring
4.Sliding Sheave of Driven Pulley
Driven Pulley Inspection
Driven Pulley Fixed Sheave Inspection
Check driven pulley faces for any abnormal conditions,

such as heavy wear or visible damage. Replace if
necessary.
NOTE:Clean fixed sheave of driven pulley before

inspection.
1
NOTE:Driven pulley assembly is precisely matched. 1.Drive Face of Fixed Sheave
If only fixed sheave or sliding sheave is replaced,the

vibration may increase.It’s recommended to replace
both when necessary.
09-12
09 CVT AND CLUTCH
Driven Pulley Sliding Sheave Inspection
Inspect the drive face of sliding sheave for heavy wear

and damage.Replace if necesary.
1.Drive Face of Sliding Sheave
Inspect the 4 sliders on driven pulleyfor wear and

1 1
other damages.If the worn thickness is over the
measurement illustrated in the following figure,
replace all 4 sliders at the same time.
2
1
09
1.Slider
NOTE:Clean the sliding sheave before inspection. 2.Sliding Sleeve
A 1.5mm
09-13
Cam Inspection
2
Check spring cam sliding face for wear and other
damages. replace if necessary. 2
1.Cam
2.Sliding Face
Driven Pulley Spring Inspection
Check spring free length. If it is shorter than limit

length, replace it.
Spring free limit length A:214.0mm.
1.Spring
Driven Pulley Assembly
Reverse the disassembly procedure for driven pulley

assembly.
NOTE:Special tool is also required in driven pulley

assembly.
Driven Pulley Installation 1

Reverse the removal procedure for driven pulley
installtion.
NOTE: 2
Torque driven pulley nut to specified value.
Driven Pulley Nut Tightening Torque:115N.m.
1.CVT Driven Pulley Holder
09-14
09 CVT AND CLUTCH
CVT AIR GUIDE

3
CVT Air Guide Removal
4
Remove CVT cover(refer to CVT COVER);

5
Remove drive pulley(refer to DRIVE PULLEY)
1
6 2
Remove driven pulley(refer to DRIVEN PULLEY);
1.Screws 2.Air Guide Plate

Remove drive belt(refer to DRIVE BELT);
3.Screw 4.Clutch Housing
5.Nut 6.Air Guide
Remove air guide plate;
Remove CVT case screws and nuts;
Remove clutch housing and CVT Case;
Remove dowel pin(or not) and gaskets;
Remove one-way clutch.
2
09
1
1.Dowel Pin
2.Gasket(front)
Clutch Housing Disassembly
3.Gasket(rear)
Remove oil seal;
Remove retaining ring;
Use press machine to press clutch housing out of

CVT air guide.
NOTE: If bearing or oil seal is not suspected to be

damaged, it’s not necessary to perform the disassem-
bly procedure.
09-15
CVT Air Guide and Clutch Inspection
Check bearing for rotation condition,if any abnormal

condition has been found, remove bolt and bearing 5
plate to replace the bearing.
Check oil sea,if any damage has been found, replace

it; 2
Check one-way clutch for wear and damage.Replace 4

if necessary;
3 1
Check clutch housing innner side if color changes into
blue and for scratches, cracks or uneven wear, if 1.Screws 2.Bearing Plate
serious damage has been found, replace it. 3.Bearing 4.CVT Air Guide
5.Oil Seal
NOTE:If bearing is checked to be ok,it’s not neces-

sary to replace it.However,whenever disassembling
clutch housing,oil seal must be replaced.
1
CVT Air Guide and Clutch Housing Assembly 2
1.One-way Clutch
Apply grease on bearing and install it in place by 2.Clutch Housing
special tool.Check the rotation condition;

Install CVT bearing plate and screws;
Using hydraulic press machine and special press tool,

install the clutch housing into CVT air guide.
NOTE: When pressing clutch housing, it’s required

to put a special holding tool on clutch shaft end to
support bearing inner ring.
Apply grease on oil seal lip and install it with a special

tool;
Install one-way clutch into clutch housing;
NOTE:The marked side of one-way clutch should

point outside.
09-16
09 CVT AND CLUTCH
CVT Air Guide and Clutch Housing Installa-

tion
Reverse the removal procedure for CVT air guide and
clutch housing installation.
NOTE:
1.Use new front and rear gasket.Keep them even on
bases .
2.Fasten screws/nuts in criss-cross sequence.
CLUTCH
Removal
Remove CVT cover (refer to CVT COVER);
Remove drive pulley(refer to DRIVE PULLEY);
Remove driven pulley(refer to DRIVEN PULLEY);
Remove drive belt(refer to DRIVE BELT);

Remove CVT air guide and clutch housing (refer to
CVT AIR GUIDE and CLUTCH HOUSING);
2 1 09
Use special tool to remove clutch nut and remove
clutch. 1.Clutch Nut
2.Clutch
NOTE: Clutch nut threads is left hand oriented.
09-17
Clutch Inspection
1
Check clutch for debris,scratches, uneven wear and
discolouration.Meanwhile,check clutch shoe depth, if
no groove remains on any brake shoe, replace the
clutch.
Check one-way clutch for wear, if any damage has been
found,replace it.
NOTE:Clutch must be replaced as an assembly. 2
1.Clutch Shoe
2.Clutch Collar
Clutch Installation
Reverse the removal procedure for clutch installation.
Use special tool to hold clutch and then tighten nut. 1 2
NOTE: Apply threadlocker on nut threads.Torque it

to specified torque value.The threads are left hand
oriented.
1.Clutch Holding Tool

Nut tightenning Torque Value:105N m. 2.Clutch
09-18
10 ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
SERVICE TOOLS 10

Oil Pressure Gauge 6
Adapter Hose 6
SERVICE PRODUCTS

Engine Oil
Threadlocker
10-1
COMPONENTS
NEW Engine Oil
T2
Threadlocker
T3 Threadlocker
T4
Engine Oil Engine Oil
Engine Oil
M12X1.5
T1
Threadlocker
NEW
T4
Threadlocker
T3
T1 20N m(15lbf in)

T2 12N m(107lbf in)
T3 10N m(89lbf in)
T4 6N m(15lbf in)
10-2
ENGINE LUBRICATION
1 1
8
2
7
6
5
1
1 2
4
6
1.Camshaft Bearings 5.Oil Strainer

2.Oil Pressure Switch 6.Oil Pump
3.Oil Filter 7.Crankshaft Main Bearings
4.Oil Pressure Regulator Valve 8.Connecting Rod Bearing
10-3
GENERAL
Lubrication is employed to reduce the wear of some

components,such as piston,crankshaft,camshaft,etc,
which moves relative against other parts.Proper lubri-
cation is the basis for engine normal operation.
Recommended engine oil is required for this engine.
Engine oil has cleaning,anti-rust,sealing,cooling and
other functions besides lubrication.
WARNING
Locking devices(e.g.: locking tabs, elastic stop
nuts,cotter pin,etc.)must be replaced with new
ones.
Engine Oil Level Check

Start the engine and allow it to idle for a few minutes,
then shut it off.Wait a few minutes to allow oil flow
down to crankcase then check oil level; 1
2
Ensure vehicle is on a level surface;
Unscrew dipstick and wipe the oil residue off,then put

dipstick in the hole.Don’t screw in dipstick to read oil
Oil Level Mark:1.Upper 2.Lower
level,just make dipstick threads contact the hole
surface;
Remove dipstick and read oil level;

Engine oil level must be between “upper” and “lower”
marks;
If oil level is below “lower”,refill.
NOTE:
Strictly follow the procedure above,otherwise wrong
oil level may be indicated;
Vehicle must be placed on a level surface;
Don’t screw in dipstick to read oil level.
10-4
Engine Oil Change
Replace engine oil and filter element at the same

time when engine is warm.
WARNING
The engine oil can be very hot.Wait until engine
oil is warm.
Place a drain pan under the engine oil drain plug

area;
Clean the drain plug area;

1 2
Unscrew oil dipstick,drain plug and discard the

gasket ring;
Allow oil to drain completely from crankcase;
Intall washer and drain plug; 1.Drain Plug

2.Washer
Drain plug tightening torque:20N m

Replace oil filter element,refer to OIL FILTER further
in this section;
Refill engine with about 3.4 L recommended engine

oil through dipstick hole;
Install dipstick.Run the engine to ensure oil filter and

drain plug areas are not leaking;
After filling,check engine oil level with dipstick.

Refer to Engine Oil Level Check above.
NOTE:
Oil condition gives information about the engine
condition.See TROUBLESHOOTING section.
Check the drained engine oil for engine shavings
and residue.Presence of debris indicates a failure
inside the engine.Check engine to correct the
proplem.
10-5
ENGINE OIL PRESSURE
The engine oil pressure test should be done with a

warm engine 90 ( 194 ) and the recommended
engine oil.
Remove engine oil pressure switch;
Install engine oil pressure gauge and adapter hose.
The engine oil pressure should be within the follow-

ing values:
Engine Oil Pressure Gauge
O il Pr ess ur e 12 50 RP M 6 000 RP M
Min im a l 70 KP a 350 KPa
No mina l 18 0 KP a 420 KPa
M axi ma l 30 0 KP a 550 KPa
If the engine oil is out of specifications,check the

points described in THROUBLESHOOTING section.
Remove engine oil pressure gauge and adapter
hose.
Reinstall the engine oil pressure switch.
Adapter Hose
NOTE:To remove adapter hose from engine oil

pressure gauge,use the service tool.
10-6
OIL FILTER ELEMENT
Removal
Remove oil filter cover screws; 2
Remove oil filter cover;

1
Remove o-ring;
Remove oil filter element.

4
3
1.Screw
2.Oil Filter Cover
3.O-ring
4.Oil Filter Element
Oil Filter Element Inspection
Check and clean the engine oil filter inlet and outlet
area for dirt and other contaminations.
1 2
1.Inlet bore from the oil pump to the oil pump

2.Outlet to the engine oil providing system
10-7
Oil Filter Element Installation
Install a NEW o-ring on oil filter cover; 2
Apply engine oil on o-ring and the end of filter;
Install the element into oil filter bore;

1
Install the oil filter cover on the engine.
1.Apply a light coating of oil here

Torque screws to 10N m(89Ibf in). 2.Apply a light coating of oil here
OIL PRESSURE REGULATOR VALVE

Engine oil pressure valve is located on engine PTO
side(under CVT air guide).
The oil pressure regulator valve works when the oil
pressure exceeds 450kPa(65PSI).
Removal
Remove screws no.1 and the holding strip; 1
Remove oil pressure regulator valve.
1.Engine Oil Pressure Regulator Valve

Inspection
Inspect oil pressure regulator valve no.4,spring seat
no.5,plunger no.7,o-ring no.8 for damages.Replace if
3
necessary.Circlip no.3 must be replaced.Check
2
spring no.6 for free length.If the length is out of the
following values,replace it. 1
7 8
6
5
4
Spring F ree Length
New Nom inal 17mm

1.Bolt 2.Holding Strip 3.Circlip
Service Limi t 16mm 4.Oil Pressure Regulator Valve
5.Spring Seat 6.Spring
7.Oil Plunger 8.O-ring
Installation
10-8
OIL PUMP
Oil pump is located on the engine MAG side(under

magneto cover).
1.Oil Pump
Removal
2
Remove magneto cover and related parts(see 4 3
Magneto Cover Removal);
Remove magneto rotor(see Rotor Removal);
Remove circlip,oil pump gear,needle pin,thrust

washer in turn;
1.Circlip 2.Oil Pump Gear

3.Needle Pin 4.Thrust Washer
Remove oil pump cover screws and oil pump cover; 2
Remove pump shaft with inner rotor and outer rotor.

1
1.Screws 2.Oil Pump Cover
10-9
Inspection
Inspect oil pump for marks or other damages.Check

for scratches in crankcase between outer rotor and
oil pump bore.If so,replace damaged parts; 4
1
2 3 5
1.Oil Pump Bore 2.Outer Rotor

3.Oil Pump Shaft 4.Needle Pin
5.Inner Rotor
Check inner rotor for corrosion pin holes or other

damages.If so,replace oil pump shaft assembly.
1.Pittings on the teeth

Using a feeler gauge,measure the clearance of inner
and outer rotors plus the clearance between outer
rotor and oil pump bore as shown.
1
If clearance between inner rotor and outer rotor
exceeds the tolerance,replace the inner and outer A
rotor. A
Ensure to also check oil pump cover,if damaged,
replace the oil pump cover.
1.Inner Rotor 2.Outer Rotor
A.Service Limit:0.25mm
10-10
If clearance between outer rotor and its bore in

crankcase exceeds the tolerance,replace outer rotor
assembly and/or crankcase.
Using a depth gauge,measure the axial clearance of

the oil pump as shown.Difference between measure-
ments should not exceed 0.1mm(0.008in).If so,
replace the inner and outer rotor.
Measurement ”A”
Using a depth gauge,measure the axial depth of the

part that extends to oil pump bore as shown.
A-B 0.2mm
NOTE:When the axial clearance of the oil pump

shaft assembly increases,the oil pressure
decreases. Measurement ”B”
Installation
NOTE:No marks on inner and outer rotor.When

installating outer rotor,no secified direction for outer
rotor.
After installation,check for smooth operation of
the oil pump assembly.
Final Test
After engine is completely reassembled,start engine

and make sure oil pressure is within specifications
(refer to Engine Oil Pressure above.)
10-11
ENGINE OIL STRAINER
The engine oil strainer no.7 is located on the bottom

of left crankcase half.
Removal
Refer to Chapter 8.
Cleaning and Inspection 2

3
Clean engine oil strainer with a part cleaner then
use an air gun to dry it.
1.Oil Strainer
2.Retaining Plate
WARNING 3.Screws
Always wear eye protector.Chemicals can
cause a rash break out and injure your eyes.
Installation
OIL DELIVERY PIPE AND OIL RADIATOR 1
4
2
4
3
1. Inlet Oil Delivery Pipe

2.Outlet oil Delivery Pipe
3.Oil Radiator
4.Oil Delivery Pipe Holding Screw
10-12
Removal
1
Remove engine inlet and outlet oil delivery pipe
retaining screws;
Remove engine inlet and outlet oil delivery pipes.
3
1.Inlet Oil Delivery Pipe

2.Outlet Oil Delivery Pipe
3.Holding Screw
Remove the 4 mounting bolts then oil radiator;
CAUTION:Drain the oil in the oil delivery 1

pipe and oil radiator before removal.
1.Oil Radiator Mounting Bolts
Remove engine inlet and outlet union bolts no.1;

Remove inlet and outlet oil delivery pipes.
1
1.Union Bolt
10-13
1
Oil Delivery Pipe Inspection

1.Engine Oil Outlet Union Bolt
Inspect oil delivery pipe for leaks,cracks and other
damages.If so,replace it;
Always replace oil pipe clamp after removal.
Oil Radiator Inspection and Cleaning
Inspect radiator for deformation and bulge.If so,replace 1

it;
Use an air gun to clean the dirt on radiator fins; 2
1.Oil Radiator
2.Air Gun
Inspect radiator fins for deformation.If so,use a small

screw driver to repair the fins.
1
Oil Delivery Pipe and Oil Radiator Installa-
tion 2
1.Screw Driver
Reverse the removal procedure for installation. 2.Oil Radiator
Union bolt tightening torque 25N m
10-14
11 MAGNETO SYSTEM
MAGNETO SYSTEM
11
Magneto Rotor Remover 0800-031000-922-001 6
Engine Oil
Threadlocker
Loctite 5699(Silicone Sealant) 11
11-1
Engine Oil
T3
Loctite 5699
T4
Engine Oil
Threadlocker
T3
T2
T1
Engine Oil T3
T1 105N m(78lbf ft)

T2 30N m(22lbf ft)
T3 10N m(89lbf in)
T4 4N m(36lbf in)
11-2
11 MAGNETO SYSTEM
GENERAL
Always perform the electric tests before removing or
installing whatever component.
During assembly/installation,use the torque values and
service products as in the exploded view. Clean
threads before applying threadlocker.Refer to LUBRI-
CANTS AND SERVICE PRODUCTS at the begining
of this manual for complete procedure.
WARNING
Torque wrench tightening specification must
strictly be adhered to.Locking devices.(e. g .:
locking tabs ,elastic stop nuts,cotter pins , etc.)
must be installed or replaced with new ones
where specified.If the efficiency of a locking
device is impaired ,it must be renewed.
MAGENTO COVER
Removal 3 1
Drain engine oil (refer to LUBRICATION SYSTEM 2

and cooling system) and coolant; 11
2
2 2
Remove crankshaft position sensor(CPS);
Disconnect magneto connector;
2
Remove magneto cover retaining screws;
2
Remove magneto cover. 2
1.Magneto Cover
2.Retaining screws
Inspection and Cleaning 3.CPS(crankshaft position sensor)
Check magneto cover for cracks or other damages.

Check working condition of rolling bearing.Replace if

necessary.
11-3
NOTE:
Clean all metal components in a nonferrous metal
cleaner.Use suitable tool to remove gasket.
WARNING
Wear safety glasses and work in a well ventilated
area when working with strong chemical
products. Aslo wear suitable non-absorbent
gloves to protect your hands.
Installation
For installation, reverse the removal procedure.Pay

attention to the following.
1
NOTE:
At installation replace magneto cover gasket.
Apply sealing compound on startor cable grommet
as shown on the right.
apply grease on bearing
1.Apply Loctite 5699(Silicone Sealant)
17
16 1
5
Tightening sequence for screws on magneto cover is 15 6
14 4
as per following illustration.
3 7
13
12 8
Refill engine with recommended oil and coolant.
2
11 10 9
Tightening Sequence
11-4
11 MAGNETO SYSTEM
STATOR
1
Removal
3
Magneto Cover
Removal
4
Remove screws securing holding strip;

2
Remove stator retaining screws then the stator.
1.Stator
2.Stator retaining Screws
3.Holding Strip
4.Holding Strip screws
Inspection
Check stator condition, if damaged replace it.
Check if stator wires are brittle ,hard or otherwise

11
damaged.
Stator Installation 1.Stator

For installation, reverse the removal procedure.
CAUTION:
When installing the stator take care that the
cable is in place(guide for the wire).
1
NOTE:
There is only one position for the stator(notch in the 2
magneto housing cover )
1.Threads for cable holding strip

2.Notch for stator
11-5
ROTOR
Removal 1 2
Remove magneto cover.(Refer to MAGNETO

COVER above );
Remove screw and washer securing rotor to 3

crankshaft.
1.Bolt
2.Washer
3.Rotor
Install magneto puller and then remove rotor.
1.Magneto Puller
NOTE: 1
Use grease to magneto puller end prior to install rotor
puller in order to protect crankshaft.
Screw magneto puller bolt to remove rotor.
1.Rotor
2.Magneto Puller
11-6
11 MAGNETO SYSTEM
Inspection
Check inner side of rotor for scratches or other

damages.
Check keyway of rotor for wear or damages.
Check if trigger wheel teeth are bent or otherwise

damaged.
Check woodruff key and keyway on the crankshaft 1

for wear or damages.
1.Rotor with trigger wheel
Replace parts as necessary.
Installation
For installation,reverse the removal procedure.

Pay attention to the following.
Clean crankshaft taper and rotor with cleaner.
11
Oil sprag clutch in sprag clutch housing and install

sprag clutch gear.
Slide rotor onto crankshaft.The woodruff key and the

keyway must be aligned. 4
2
1
1.Sprag Clutch
2.Sprag clutch housing
3.Sprag clutch gear
4.Apply engine oil here
11-7
Slide spacer bush onto crankshaft and 4
1
torque the bolt to specified value.
Bolt tightening torque:105N m
Rotate starter double gear counterclockwise to align
5
intermediate gear teeth with clutch sprag gear teeth.
NOTE:Breather shaft end with chamfer should 3

faces outside.
1.Double Gear 2.Breather Gear Shaft
3.Intermediate Gear 4.Sprag Clutch Gear
SPRAG CLUTCH 5.Spacer Bush 6.Bolt
NOTE:It is not necessary to remove if sprag clutch

has no problem.
2
3 4
Sprag Clutch Removal
1
Remove magneto cover (refer to MAGNETO
COVER above);
Remove rotor(refer to ROTOR above);
Remove sprag clutch gear;
1.Bolt
Remove sprag clutch housing screws and sprag
2.Rotor
clutch housing.
3.Sprag Clutch
Sprag Clutch Inspection 4.Sprag Clutch Housing
Perform a functional test of the sprag clutch.To do

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

wear and damage. 1
NOTE:
Sprag clutch must look in counterclockwise direction.
Sprag clutch,housing and gear must be replaced at
the same time ,if damaged.
Sprag Clutch Functional Test
1.Lock Direction
11-8
11 MAGNETO SYSTEM
Sprag Clutch Installation

For installation,reverse the removal procedure .
3
Pay attention to the following details.

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

2 4
to 30N m.
Apply engine oil on sprag clutch and inside sprag 1
clutch gear hole.
1.Sprag Clutch 2.Sprag Clutch Housing

3.Sprag Clutch Gear 4.Apply engine oil here
SPRAG CLUTCH GEAR
Removal
Remove rotor (refer to ROTOR above);
Pull sprag clutch gear from the rotor.
11
1
2
1.Rotor
Inspection 2.Sprag Clutch Gear
Inspect gear,especially teeth and sprag clutch
collar,for wear and other damages.
3 2
Check needle bearing condition;
Replace Drive Gear if necessary.
Installation
1
NOTE:
Apply engine oil on needle bearing and collar of drive INSPECT
gear. 1.Teeth
2.Collar
3.Needle Bearing
11-9
STARTER DRIVE GEARS
4
The starter gears are located on the engine MAG
side behind the magneto cover. 4
Removal 3
Remove magneto cover (refer to MAGNETO 2

COVER above);
1
Remove breather shafts,double gear,intermediate 1.Intermediate Gear
gear. 2.Starter Double Gear
3.Starter Gear
Inspection 4.Breather Shaft
Inspect gears and shafts for wear and damage.
Installation
NOTE:
Apply engine oil on every gear shaft and teeth.
11-10
12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING
C h e ck & r e pa i r i n f o r ma t io n … …… …1 2 - 1 B ra ke sy s t e m …… …… …… …… …… 1 2 -4
Tr o u b le s h o o t in g … …… ……… …… …1 2 - 2 Fro nt su sp en sio n …… …………… ……12 -7
F ro n t wh e e l … …… …… …… …… ……1 2 - 3 St ee ri ng s yst e m………… ……………1 2- 12
12
Operation Cautions:
CAUTIONS:
Securely support the vehicle when doing check and repair

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
Radial 0.8mm 2.0mm

Wheel Runout
Axial 0.8mm 2.0mm
Front Wheel
Tread Depth - 3.0mm
Tire
Tire Pressure 4 5 kP a -
Front Brake Brake Lever Free Play 0 mm -
Tightening Torque
Nut, steering tie-rod GB9457 M10x1.25 (30~40) N m
Lock nut, steering stem GB6187 M14x1.5 (100~120) N m

Bolt, front brake disc 901-08.00.03 (25~35) N m
Bolt, front caliper GB5789 M8x16 (15~25) N m
Axle nut 901-07.00.03 (15~25) N m

Bolt, front shock absorber GB5789 M10x1.25x50,GB5789 M10x1.25x70 (15~25) N m
Wheel nut 901-07.00.02B (70~80) N m
Bolt, A-arm GB5789 M10X1.25X70 (40~50) N m
12-1
SERVICE TOOLS Wheel cannot turn freely
Rod, bearing remover Faulty wheel bearing
Head 10mm, bearing remover Wheel installed improperly
Handle A, driving tool Brake drag
Sleeve 28x30, driving tool Front suspension too shoft
Guide tool 10mm Weakened front shock absorber
Locknut spanner
Tire pressure is too low
Bearing remover set
Front suspension too hard
Rotor puller
Front shock absorber is damaged
Remover shaft
Remover hammer Tire pressure is too high
Assembling tool shaft Noise from front shock absorber
Faulty front shock absorber
Loosened tightening parts of front shock
absorber
Poor brake performance
Faulty brake adjustment
Stained brake disc
Brake pads worn
TROUBLESHOOTING
Heavy steering
Upper thread is over tightened
Steering bearing is damaged or worn
Inner&outer bearing races are damaged
or not well tightened.
Steering stem is distorted
Low tire pressure
Tire worn
Excessive handlebar free play
Steering bearing is damaged or not well tightened.
LH and RH shock absorber not matched
Deflected tires
Deformed frame
Worn tire
Shaking wheel bearing
Severe front wheel runout
Wheel rim distorted
Faulty wheel bearing
Faulty tires
mproper balance of wheels
Imporper tightening of wheel shaft
12-2
FRONT WHEEL
Removal
Securely support front wheels;
Remove wheel cap;
Remove the 4 wheel nuts no.1;
Remove front wheel.
Rim&Inspection
Check rim for damages,deformation,nicks.If any ab-

normal condition has been found,replace it.
Slowly turn wheel,use a dial gauge to measure the
rim runout
Service limit: 2.0mm (Axial)

2.0mm (Radial)
Installation
Press rim into tire with special tool;
Fix wheel on the hub;
Wheel nuts tightening torque:70-80 N m
FRONT WHEEL HUB

Removal
Remove front wheel ( 12-3);
Remove front brake caliper 5 ( 12-4);
Remove rim axle nut no.2;
Remove brake disc and hub together;
Remove the 4 brake disc bolts no.6;
Remove front wheel hub no.4.
Installation
Tightening torque of axle nut : 110-130N.m
Tightening torque of brake disc bolts no.6: 25-35N. m
(apply threadlocker)
12-3
FRONT BRAKE SYSTEM
Front Brake Caliper
Removal
Remove front wheel( 12-3);
Remove the two bolts no.2;
Remove caliper no.1.
Inspection
Check any cracks of brake calipers and oil
leaks from tightening areas.Replace if necessary.
Installation
Tightening torque of brake caliper bolt: 15-25N.m
(Apply threadlocker)
BRAKE PADS
Removal
Remove brake caliper ( 12-4);
Remove main sliding shaft of brake pads with allen
wrench;
Remove brake pads;
Measure thickness of brake pad friction surface no.4,
if it is less than 1mm, then replace both pads at the
same time.
12-4
BRAKE DISC
Removal
Remove brake calipers ( 12-4);
Remove brake disc and wheel hub from vehicle
Remove the 4 brake disc bolts shown in the right
picture, then remove brake disc.
Inspection
Thickness of brake disc:
If less than 2.50mm,replace it.
Brake Disc
Bolts
Installation
Tightening torque of brake disc bolts: 25-30N.m
FRONT BRAKE MASTER CYLINDER

Removal
Remove top cover of handlebar;
Remove right hand guard;
Remove bolt no.2;
Seperate master cylinder no.1 of front brake from
handlebar. It’s not necessary to remove it if replace-
ment is not required.
Attention:
Do not hang the master cylinder by brake line,
keep master cylinder in place (not inclined) while
installing it to avoid air entering brake line.
Keep brake line routed properly (refer to Chap-

ter 1) and ensure it is not kinked.
After installation of brake system, check brake
performance.
12-5
4-WHEEL MASTER CYLINDER
Revoval
Remove brake pedal ( 2-11);
Remove bolts no.2;
Remove bolts no.4;
Remove cotter pin no.9;
Remove master cylinder no.1 from vehicle.
Installation
Attention:
In order to avoid air entering 4-wheel master
cylinder, keep it in place while installing it.
Keep brake line routed properly (refer to Chap-
ter 1) and ensure it is not kinked.
After installation, check brake performance.
T-FITTING
Removal
Remove bolt no.6 and T-fitting.
Installation
Attention: Keep brake line routed properly (refer
to Chapter 1) and ensure it is not kinked.
After installation, check if 4-wheel brake lever or
brake pedal can control front brake.
REAR BRAKE CALIPER

Disassembly
Remove bolt 7 and then disassemble rear brake cali-
per 8
Installation
Attention: Keep brake line routed properly (refer
to Chapter 1) and ensure it is not kinked.
After installation, check if 4-wheel brake lever or
brake pedal can control front brake.
Mainten brake fluid level between “UPPER” and
“LOWER”, if necessary, add DOT 4 fluid (CFMOTO
recommended) into brake fluid reservoir. Check
brake light and switch.
12-6
FRONT SUSPENSION
Front LH Suspension
ATTENTION:Do not remove left and right suspen-
sion at the same time, otherwise vehicle may tip or
fall.
Removal
Park the vehicle on a level ground and securely sup-
port the front part of vehicle.
Remove LH front protector of suspension ( 2-15);
Remove brake caliper ( 12-4);
Remove front wheel hub ( 12-3);

Remove bolts and nuts no.2 of front LH shock ab-
sorber and LH upper A-arm;
Remove front shock absorber no.1;
Remove bolts and nuts no.3 of LH front A-arm;

Remove cotter pin and nut no.5 assembled on left steer-
ing knuckle;
Remove front LH upper A-arm 4;
Remove cotter pin and locking nut no.8 of steering tie-
rod;
Remove bolts and nuts no.6 of LH front A-arm as-
sembled on frame;
Remove locking bolt no.9 of LH front A-arm;
Remove front LH lower A-arm no.7;
Remove steering knuckle from drive shaft;
There are optional shock absorbers available for differ-
ent markets.
The procedure above is for basic configuration. As for
other optional shock absorbers,refer to the procedure
above.
12-7
1.Front shock absorber 2.Nut 3. LH protector 4.Circlip 5. Top ball pin 6.LH front lower A-arm 7.Circlip 8.
Guard,brake disc 9.Bolt 10.Hub bearing 11.Washer 12.LH steering knuckle 13. Bottom ball pin 14.Buffering
collar 15.Cap, buffering collar 16.LH front upper A-arm 17.M6 Nut clip 18. Bolt 19. Slot nut 20. Cotter pin 21.
Bolt 22. Bearing kit, fixing end 23. Small clamp 24.Front LH drive shaft assy 25.Bearing kit,motion end 26.
Front LH drive shaft
FRONT SHOCK ABSORBER

Removal
NOTE: If only replacing front shock absorber,it’s not
necessary to remove other parts.
Remove bolt no.21 and nut no.2, then finally remove

front shock absorber (LH) no.1.
Inspection
Check shock absorber for oil leaks,oil seal aging and
other damages.Replace if necessary.
12-8
Installation
As for removal, installation and check procedure of

front shock absorber (RH),refer to front shock absorber
(LH).
A-ARM
NOTE: There are totally 8 units of A-arm, procedure
of removal, disassembly, check and installation is
same, so only front upper A-arm (LH) and fron lower
A-arm(LH) are introduced.
Front LH A-arm
Removal
Remove front shock absorber(LH) ( 12-7);
Remove bolt no.18 and tightening nut no.2 mounting
front LH upper A-arm on frame;
Remove bolt 18 and tightening nut mounting front LH
lower A-arm on fram;
Remove front wheel, brake caliper and wheel hub be-
fore disassembling shock absorber;
Remove steering tie-rod before the removal of bolts;
Remove steering knuckle from drive shaft before re-
moval of front LH A-arm ;
Finally remove front LH A-arm.
12-9
Inspection of upper A-arm
Remove front Upper A-arm (LH) no.3( 12-7);
Remove circlip no.2 (Type: GB894.1 34)
Remove top ball pin no.1;
Check top ball pin no.1 if it can move freely and also
check its clearance. If it cannot move frelly or too big
clearance, replace it. At the same time, check grease
inside top ball pin if it is deteroirated. Check dust boot
of ball pin if damaged or aging;
Remove bushing no.5 of front upper A-arm(LH);
Check bushing no.5 if damaged or aging, replace if
necessary.
Inspection of Lower A-arm
Remove front Lower A-arm (LH) no.3( 12-7);
Remove circlip no.2 (Type: GB894.1 34)
Remove top ball pin no.6;
Check top ball pin no.6 if it can move freely and also
check its clearance. If it cannot move frelly or too big
gap, replace it. At the same time, check grease in-
side top ball pin if it is deteroirated. Check dust boot
of ball pin if damaged or aging.
Remove bushing no.5 of front upper A-arm(LH)
Check bushing no.5 if damaged or aging, replace it if
necessary.
Installation
Use special tool to press ball pin into A-arm;
Install as reverse procedures of disassembly.
Attention: Upper and Lower A-arms should not

vibrate after installation, otherwise replace bush-
ing no.5.
Inspection of Left Steering Knuckle

Remove left steering knuckle no.10 ( 12-7);
Remove circlip no.8 (Type: GB893.1 55);
Use special tool to remove hub bearing no.9 (Type:
DAC3055);
Check hub bearing if any damaged and move freely,
or big clearance.Replace it if necessary.
12-10
DRIVE SHAFT
NOTE:Method and procedure of removal, inspection
and installation between front and rear drive shafts
(LH &RH) are silimar,therefore only front drive shaft
(LH) is introduced.
Front LH Drive Shaft

Removal
NOTE: If only repairing front LH driveshaft, it’s not
necessary to remove front LH suspension from vehicle.
Remove front wheel(LH)( 12-3);
Remove front caliper (LH)( 12-4);
Remove front wheel hub (LH)( 12-3);

Remove front LH drive shaft no.3 from left side of front
differential;
Check dust boot if any damaged. If damaged, replace
it.
Check bearing kit of fixed and motion end if it can
move flexibly. Also check there is any clearance be-
tween universal joint and splines. If it cannot move
freely and there is noise, replace it.
CAUTION:Universal joint must move freely, oth-

erwise it can damage drive shaft and cause out
of control of tire and accident.
Installation
12-11
STEERING
Handlebar
Master cylinderof front brake ( 12-15);
Top cover of handlebar
Removal
Remove tapping screw no.1;
Remove top cover of handlebar.
Installation
4-WHEEL HAND BRAKE LEVER

Removal
Remove bolts no.3;
Remove 4-wheel hand brake lever;
Installation
WINCH CONTROL SWITCH

Removal
Remove bolt no.5;
Remove winch control switch no.6.
Installation
LH HANDLEBAR SWITCHES
Removal
Remove bolts no.8;
Remove left handlebar switches no.7.
Installation
12-12
RH HANDLEBAR SWITCHES
Removal
Remove bolts no.2;
Remove right handlebar switches no.1;
Unplug connector no.3 of left handlebar switches,
Unplug connector no.4 of right handlebar switches.
Installation
REAR VIEW MIRROR

Removal
Slide sleeve no.6 out place and unscrew no.nut 7,
then remove rear view mirror no.5 in anti-clockwise
direction.
NOTE: As for rear view mirror (LH), the threads are
right hand, so remove it by turning it counter-clockwise.
Unscrew nut in clockwise direction and unscrew rear
view mirror (RH) to remove.
NOTE: As for rear view mirror (RH),the threads are
left hand, so remove it by turning it counter-clockwise.
Installation
12-13
HANDLEBAR
Removal
Remove top cover of handlebar ( 12-12);
Remove left and right handlebar switch ( 12-12);
Remove left and right brake pump from handlebar;
Remove left and right hand protector;
Remove bolt 1 of handlebar cover;
Remove handlebar no.2.
Installation
Handlebar cover bolt: GB5789 M8x55
Tightening torque: 15-25N m (1.5-2.5kgf m)
ATTENTION:
Keep Main cable, throttle cable, brake line
properly routed.
Screws RH Handlebar
Cover
Throttle Cable Installation
Remove the 3 screws illustrated in the right picture
and remove top cover of right handlebar;
Install throttle cable;
Install top cover of right handlebar.
Throttle Cable
12-14
STEERING EXPLODED VIEW
1.Bolt 2.Alum. cover, handlebar 3. Seal ring 4. Bolt 5.Lock clip 6.Adapter plate 7.Bush 8.Support bush,
steering bearing 9.Steering stem 10. Flange bolt M6x17 11. Steering bearing seat 12. Nut 13. Cotter pin
14.Nut 15. Washer 16. Steering tie-rod
12-15
STEERING COLUMN
Removal
Remove plastics( Chapter 2);
Remove upper cover of handlebar ( 8-12);
Remove handlebar ( 8-14);
Remove 4-wheel hand brake lever( 8-12);
Remove connector of handlebar switches;
Remove nut of steering tie-rod and steering column;
Use slotted screw driver and hammer to fix lock clip;
Remove bolt no.1;
Remove cotter pin;
Remove steering tie-rod nut and washer;
Press steering tie-rod away from steering column;
Remove bolt no.14;
Lift steering bearing away from steering stem;
Installation
NOTE: After installation, be sure to check steering

agility.
12-16
STEERING BEARING & OIL SEAL
Removal
Remove steering bearing ( 8-16);
Steering bearing and oil seal are pressed onto steer-
ing column, check if any damaged. If damaged, please
replace it.
Installation
NOTE: After installation, it is necessary to check
steering agility.
12-17
13 REAR WHEELS,BRAKE,SUSPENSION
Maintenance Information..........13-1 Rear Brake System...............13-4
Troubleshooting......................13-2 Rear Suspension...................13-5
Rear Wheels..........................13-3
MAINTENANCE INFORMATION 13
Operation Cautions 13
CAUTION:
zWhen performing rim,suspension maintenance,jack or other suitable stand is required to raise the
vehicle body off the ground.
zRim,suspension mounting bolts,nuts should be genuine parts.
zNever exert an excess force on the wheels.Be careful not to damage wheels.
zwhen removing tires from wheels,use special tools,such as tire removal rod and tire protector to
avoid damages to rims.
Maintenance Specifications:
Radial - 2.0mm
Wheel Runout
Axial - 2.0mm
Rear Wheel
Tread Depth - 3.0mm
Tire
Tire Pressure 4 5 kP a -
Rear Brake Brake Lever Free Play 10-20mm -
Tightening Torque:
Axle Nuts: 110-130N m
Wheel Nuts: 70-80N m
Upper Shock Mounting Bolts&Nuts: 40-50 N m
Lower Shock Mounting Bolts&Nuts: 40-50 N m
13-1
Troubleshooting
Rear wheel runout
Wheel deformation
Defective tire
Tire pressure is excessively low
Wheel is unbalanced
Axle nut is loose
Wheel nuts are loose
Too soft rear shock

Weakened spring tension
Rear shock leak
Too stiff rear shock

Rear shock bending
Too high tire pressure
Poor braking performance

Improperly adjusted braking
Brake pads or disc is damaged or stained
Brake pads is worn
13-2
REAR WHEEL
Removal
See the front wheel removal.( 12-3)
RIM&CHECK
Check rim for damages,deformation,nicks.If any abnormal condition has been found,replce it.
Slowly turn wheel,use a dial gauge to measure the rim runout
Service Limit:
Radial:2.0mm
Axle:2.0mm
Installation
See front wheel installation( 12-3).
WHEEL HUB
Removal
Remove rear wheel( 13-3);
Remove rear axle nut;
Remove wheel hub.
Installation
Axle Nut Tightening Torque:110-130N m
Hub
Axle Nut
13-3
REAR BRAKE SYSTEM
Rear Brake Caliper
Removal
Remove rear wheel,LH( );
Remove the 2 bolts fitted on A-arm;
Remove brake caliper.
Bolts
Inspection
Visually inspect caliper for cracks and brake fluid leaks.
Replace the part if any damage has been found.
Installation
NOTE:Refer to Chapter 1 for brake line routing.
Rear Brake Disc

Brake Disc
Chapter 1
Remove the drive shaft;
Remove rear caliper( 3-4);
Remove the 6 rear brake disc mounting 6 bolts ;
Bolts
Remove brake disc( 13-3 .
Rear Propshaft
Inspection
Replace the brake disc if it’s thickness is less than 6.
5mm.
Measuring Rear Brake Pads no.1

If the brake pad friction surface no.2 1mm,replace
the 2 brake pads no.1 as an assembly.
Installation
NOTE:Refer to Chapter 1 for brake line routing.
A whole brake system replacement:( Chapter 12,
Brake System)
13-4
REAR SUSPENSION
Rear Suspension,LH
NOTE:When servicing suspension,don’t remove LH suspension and RH suspension at the same time.
Otherwise,vehicle may tip or fall.
1.Bolts 2.Gland Cover 3.Rubber Support 4.Bolt 5.Self-locking Nut 6.Bolt 7.Rear Shock,LH 8.Stabilizer
Bar 9.Rear LH Ball Pin 10.Real LH A-arm 11.Rear Upper A-arm,LH 12.Rear Lower A-arm,LH 13.Bolt
14.Bushing 15.Bearing 16.Circlip 17.Grease Fittings 18.Bearing Carrier 19.Rear RH Ball Pin 20.Rear LH
Suspension protector 21.Buffering Collar 22.Cap,Buffering Collar 23.Bolt 24.Bearing Kit,Fixed End
25.Small Clamp,Fixed End 26.Rear LH Axle 27.Rear Bell Boot,Motion End,LH 28.Front Axle,LH
Disassembly
STABILIZER BAR
Removal
Remove bolt no.1;Remove gland cover no.2 and rub-
ber support no.3;Remove self-locking nut no.2;Remove
LH ball pin no.9 and RH ball pin no.26;Remove stabi-
lizer bar.
Installation
13-5
REAR LH SHOCK ABSORBER
NOTE When removing LH&RH shock,use appro-
priate tool to support and raise the vehicle body.
If only shock requires maintenance,it’s not necessary
to remove the complete suspension system before
service.
Remove rear LH shock mounting bolt and nut;
Remove rear LH shock.
Installation
REAR A-ARMS,LH
See Front LH Upper/Lower A-arm Removal,
Inspection,Installation in Chapter 8.
REAR SUSPENSION,RH
See rear LH Suspension Removal,Inspection,and
Installation.
13-6
14 FRONT DIFFERENTIAL/REAR GEARCASE
Standards
Lubricating Period
Interval 14
Item Type Capacity
Initial Next
Front Differential SAE15W/40 SG Initial:0.33L /Replace:0.28L

350km 5000km
or
Rear Gearcase SAE80W/90 GL-4 Initial:0.30L/Replace:0.25L
Item Qty Specification Toque(N.m) Remark
Bolt,F/D 6 M8X28 25
Motor Screw,F/D 4 M8X20 13
Bolt,Shift Fork Rack Stopper 1 M8X10 13 Apply threadlocker
Nut,F/D 1 M14X1.5 62
Bolt,R/G 6 M10X1.25X22 45
Fill Bolt,F/D 1 M10X1.25X12 25
Drain Bolt,F/D 1 M10X1.25 25
Retainer,F/D 1 M64X1.5X7 80
Bolt,R/G 2 M10X1.25X25 40
Bolt,R/G 6 M8X25 25
Nut,Drive Pinion Gear Shaft,R/G 1 M12X1.25 70
Bolt,Bearing Carrier,R/G 4 M8X30 25
Retainer,R/G 1 M65X1.5X10 70
Nut 1 M8 16
Fill Bolt,R/G 1 M20X1.5X12 25
Drain Bolt,R/G 1 M14X1.25X12 25
F=Front,D=Differential,G=Gearcase,R=Rear
14-1
Inspection & Maintenance
Inspection and maintenance is required if any of problems below happened to front differential and rear gearcase.
Problem Description Possible Causes
1.A pronounced hesitation or “jerky” movement during A.Bearing damage;

acceleration,deceleration,or sustained speed. B.Improper gear lash;
C.Gear severely worn;
2. Abnormal noise in front differential and/or rear D.Gear blocked
gearcase. E.Drive shaft broken
F.lack of lubrication
3.No power transmitted from the engine to the front and/ G.Foreiggn objects in the front differential and/or rear
or rear wheel. gearcase
NOTE: Problems A,B and C above may be difficult to diagnose.The symptoms are quite subtle and
difficult to distinguish from normal machine operating noise.If there is reason to believe these components
are damaged,remove the components and inspect them.
Obsernvation and Judgement
1.Investigate any unusual noises:
a. Unstable noise during acceleration or deceleration.The noise increases with front and/or rear
wheel speed,but it does not increase with higher engine or transmission speed.
Diagnosis:Possible wheel bearing damage.

b. Constant abnormal noise during acceleration or deceleration might be caused by improper gear lash
during assembly.
NOTE:Improper assembly or adjustment of the front differential and/or rear gearcase will aggravate gear
wear and block;
c.Slight noise would be noticed during low-speed driving, while may not be heard during high-speed driving.
This symptom might be caused by gear block.
WARNING:In case of above mentioned itmes, stop riding immediately for inspection and fix the
problem before successive use.otherwise it will cause loss of control of the machine and possible
injury to the rider.
2.Check lubrication condition;
Often check if the consumption of lubricant is normal and the metal particles in lubricant is normal.
3.Chcek lubricant leakage;
a.Check front differential and rear gearcase housing for oil residue throughly;
b.Oil residue on ground on the parking lot;
c.Lubricant splash inspection.Check if there is gear case or oil seal leakage. Replace broken parts if
necessary.
14-2
FRONT DIFFERENTIAL EXPLODED VIEW
24
23
22
21
7
25
12
Item Part Name QTY Item Part Name QTY

1 Bolt M8X28 6 17 Bearing F1512 1
2 Differential Gear Case,LH 1 18 Drive Pinion Gear 1
3 O-ring 141X2.4 1 19 Bearing 6007 1
4 Bearing 16007 1 20 Oil Seal 48X65X9 1
5 Circlip 62 1 21 Coupler 1
6 Drive Clutch Cover 1 22 O-ring 14X6.8 1
7 Drive Clutch 1 23 Nut Washer 1
8 Shimφ83X71 1-2 24 Nut M14X1.5 1
9 Differential Gear Assembly 1 25 Screw M8X20 4
10 Shim φ61X48 2-4 26 Gear Motor 1
11 Drain Bolt M10X1.25 1 27 O-ring 81.2X1.9 1
12 Washer 10,Drain Bolt 1 28 Shift Fork Rack 1
13 Washer 14,Fill Bolt 1 29 Stopper Shaft 1
14 Bolt M14X1.25 1 30 Screw M8X10 1
15 Oil Seal 24X38X8 2 31 Retainer M64x1.5X7 1
16 Differential Gear Case,RH 1 32
14-3
Inspection After Front Differential Disassembly
Check if there is damage or cracks on the front diffrential gear case and the condition of bearing seats.
Check front differential bearing free play,rotation,bearing cage,steel balls,needles conditions. Replace if
necessary(Using special tools).
Check if oil seal lips and O-ring shape are normal. Replace if necessary.
Check cylndrical surface that contacts oil seal lips condition.Replace if necessary.
Check teeth of front differential drive pinion gear and ring gear. Replace if necessary.
Check differential spider gears teeth,gear carrier for wears. Replace if necessary.
Check differential inside and outside splines for wears. Replace if necessary.
Check rack face, inspect worn surface. Replace broken parts if necessary.
Check gear motor working status. Replace with new parts if necessary.
Gear motor inspection must be carried out with special equipment or acted on the vehicle.
Check other parts. Replace broken parts if necessary.
14-4
Front Differential Assembly and Adjust-

ment
Front RH Differential Gear Case Assembly 16
Item “31” tightening torque: 80N m
Item “24” tightening torque 62N m
NOTE: Apply engine oil on oil seal, bearing and drive

clutch assembly;
10 23 24
Apply threadlocker on item “24” .
Front LH Differential Gear Case Assembly
NOTE: Use engine oil for oil seal or bearing

assembly.
Differential Gear Assembly

Spider Gear Pin
Spider Gear Locking Pin
Bolt M10 X 1.25 X 22 tightening torque 45N m
Bearing 61912 Adjustment Shim
Gear Carrier Washer

NOTE: Use engine oil for bearing and differential gear;
Use proper shim to make gear work freely; Washer
Driven Gear
Drive Gear Bearing 6007
Upper Gear Carrier

Washer
Shim 0.1 0.2 0.3 0.4 Bolt M10X1.25X22 Ring Gear

thickness 0.5 1.0
14-5
Front Differential Assembly and Adjustment
1
3
8
Assemble front differential as illustrated:
7 10
Tightening Torque
Item “1” 25N m 28

Item “25” 13N m 29
30
Item “30” 13N m
27
Fill Bolt 25N m
25
Drain Bolt 25N m
26
Use threadlocker for item “30” assembly.
a Use proper shim no.8 and no.10 to adjust gear lash

between drive pinion gear and ring gear. 1
2
Measure the lash between drive bevel gear and driven

bevel gear as inllutrated: Install gear lash measure-
ment tool no.1,locking bolt(M10X1.25X60) no.2.Using
a dial gauge, make sure the measuring point is 21mm
(0.83 in).Rotate gear lash measurement tool from en-
gagement to engagement.
Standard: 0.10 ~ 0.25
Shim 0.1 0.2 0.3 0.4

thickness 0.5 1.0
b When assembling front differential gear motor,shift

fork rack and drive clutch should be against tightly as
the arrow points.
14-6
c Using special equipment or vehicle control circuit,

1
switch diff. motor to 2WD before assembly.
d Make sure b and c is assembled properly and use

illustrated position screw M8X100 no.1 to assemble
differential gear motor and front differential.
14-7
FRONT DIFFERENTIAL EXPLODED VIEW
24
23
22
21
7
25
12
Item P/N Qty Item P/N Qty
1 Bolt M8X28 6 17 Beari ng F1512 1
2 D i fferenti al Gear C ase,LH 1 18 D ri ve Pi ni on Gear 1
3 O-ri ng 141X24 1 19 Beari ng 6007 1
4 Beari ng 16007 1 20 Oi l Seal 48X65X9 1
5 C i rcli p 62 1 21 C oupler 1
6 D ri ver C lutch C over 1 22 O-ri ng 14X6.8 1
7 D ri ver C lutch 1 23 Nut Washer 1
8 Shi m 83X 71 1-2 24 Nut M14X1.5 1
9 D i fferenti al Gear Assy 1 25 Screw M8X20 4
10 Shi m 61X 48 2-4 26 Gear Motor 1
11 D rai n Bolt M10X1.25 1 27 O-ri ng 81.2X1.9 1
12 Washer 10,D rai n Bolt 1 28 Shi ft Fork Rack 1
13 Washer 14,Fi ll Bolt 1 29 Stopper Shaft 1
14 Bolt M14X1.25 1 30 Screw M8X10 1
15 Oi l Seal 24X38X8 2 31 Retai ner M64X1.5X7 1
16 D i fferenti al Gear C ase,RH 1 32
14-3
Bearing Disassembly
a Disassemble needle bearing 55BTM6720 as shown
when necessary.
b When replacing needle bearing NA5903, rear

gearcase should be heated to 150 before
replacement.
Rear Gearcase Inspection after Disas-

sembly
Check if there is damage or cracks on the rear gear case and the condition of bearing seats.Replace if
necessary.
Check rear gearcase bearing free play,rotation,bearing cage,steel balls,needles conditions. Replace if
necessary(Using special tools).
Check teeth of gearcase drive pinion gear and ring gear. Replace if necessary.
Check if oil seal lips and O-ring shape are normal. Replace if necessary.
Check cylndrical surface that contacts oil seal lips.Replace if necessary.
Check gearcase inside and outside splines for wears. Replace if necessary.
Check other parts. Replace if necessary.
14-9
Rear Gearcase Assembly and Adjustment
Illustration
Tightening Torque
Item “1” 40N m

Item “2” 25N m
Item “12” 70N m
Item “15” 25N m
Item “20” 70N m
Item “31” 16N m
Bolt 25N m
Bolt 25N m
Use threadlocker for Item “29” assembly.

Assembly and gear lash adjustment between drive
pinion gear and ring gear of rear gearcase.
a Adjust installation gear lash by choosing “24”washer.
b Adjust gear lash by choosing “6” washer.
c Check tooth contact between drive pinion gear and

1
ring gear by coloring.
d Measure installation gear lash between drive pinion
gear and ring gear as illustrated: Install gear lash
measurement tool no.1,locking bolt(M14X1.25X60) no.
2.Using a dial gauge,make sure the measuring point
is 22mm.Turn gear lash measurement tool from en-
gagement to engagement.
Standard: 0.1~0.2
2
e Keep the axial gear lash within 0.1~0.2 by choosing

washer “8” .
Washer
0.2 0.3 0.4
“6”
Washer 1.0 1.2 1.4 1.6 1.8

“8”
Washer
0.4 0.5 0.6
“24”
14-10
f Adjust item “29” as illustrated, and make sure the

Ring Gear
distance between its end and back of the ring gear is
0.3~0.6. Tighten item “31”.
0.3-0.6
Apply threadlocker here
14-11
15 ELECTRICAL SYSTEM
Charging System……………………………………………………………………………..........15-2
Starting System……………………………………………………………………………………15-4
Electronic Fuel Injection (EFI) System………………………………………………………......15-8
1. EFI Structure…………………………………………………………………………………15-8
2. EFI Maintenance N otice……………………………………………………………………15-9 15
3. EFI Service Tools……………………………………………………………………………15-10
4. EFI Components and Function………………………………………………………….....15-12
ECU..........................................................................................................................15-12
Throttle Body............................................................................................................15-13
T -MAP Sensor..........................................................................................15- 14
Coolant Temperature Sensor....................................................................................15-16
Oxygen Sensor.........................................................................................................15-17
CPS..........................................................................................................................15-18
Speed Sensor...........................................................................................................15-19
Gear Position Sensor................................................................................................15-20
Fuel Pump................................................................................................................15-21
Fuel Injector..............................................................................................................15-22
Idle Air Control Valve................................................................................................15-23
Ignition Coil...............................................................................................................15-24
5. EFI Self-diagnosis.......................................................................................................15-25
MIL...........................................................................................................................15-25
PDA.........................................................................................................................15-26
Trouble Code............................................................................................................15-27
Appendix: EFI wiring diagram, starting wiring diagram, CF800-2 wiring diagram
15
15-1
CHARGING SYSTEM
Charging Circuit
5
6
3
1
1.Magneto 2.Voltage Regulator/Rectifier 3.Voltage Stablizing 4.Fuse 5.Battery 6.Load
Magneto Coil Resistance

Measure 3-phase magneto stator coil resistance;
If the resistance is out of specification,replace with
a new stator;
Check for the insulation between stator coil and
core.
Turn multimeter to 1X10
MAG Coil Resistance 0.5-1.5

(Yellow-Yellow)
Resistance between Stator Coil and Core:
(Yellow-Ground)
MAG Non-loaded Performance

Start the engine and allow it run at 5000r/min;
Use multimeter to measure the voltage
between 3 output lines.
Ifthe reading is below specification,replace with
a new magneto.
Turn Multimeter to V(AC)
Voltage between Output Lines When MAG

Non-loaded:
>200V(AC) at 5000r/min
15-2
VOLTAGE REGULATOR/RECTIFIER
1
2
3
After engine running and at the state of battery

Connect multimeter between terminals; full charged,if the voltage between positive and
Read resistance; negative terminal exceeds 15v or is lower 12v,
If any reading is out of specification, replace with a new MAG.
replace with a new regulator.
Turn multimeter to DIODE.
NOTE:
If multimeter reads below 1.4v when
15
probes unconnected,replace its battery.
(+)
1 2 3 (-) (+)
1 ∞ ∞ 400-500 ∞
2 ∞ ∞ 400-500 ∞
(-) 3 ∞ ∞ 400-500 ∞
(-) ∞ ∞ ∞ ∞
(+) 400-500 400-500 400-501 750-850
15-3
STARTING SYSTEM
Starting Circuit Diagram
1
3 1.Outer Cover
2 2.Brush Holder
5 3.Brush Spring
4 4.O-ring
5.Brush Terminal
6
6.Main Housing(yoke)
4 7.Washer
8.Armature
9.Washer
10.Cover Inner
11.O-ring
9
7
8 11
10
Starter Motor
15-4
BRUSH
Check brush for damages,cracks.

If any damages,replace with a new brush.
COMMUTATOR
Check for color change,damages,wear;

If any damages,replace with a new commutator;
If the color changes,poslish the commutator sur
face with sand paper and wipe it up with a clean,
dry cloth.
If over wear,cut a part of insulator B and main
tain the distance betwen A nd B as d.
d 1.5mm
ARMATURE
Use a multimeter to check the armature coil continu-

ity and the one between coil and the shaft.If armature
coil has no continuity or there is continuity between 15
the coil and the shaft,replace the armature with a new
one.
OIL SEAL
Check for damages or leaks.

If damages or leaks,replace with a new starter
motor.
15-5
STARTER RELAY
Put 12V between positive and negative

terminal.
Use multimeter to check if there is continuity
between 2 contacts.
If multimeter clicks,there is continuity between
contacts.
If 12V is removed,no continuity remains between
contacts.
If both above 2 items are ok,it indicates the
replay is ok.
Turn mulitimeter to DIODE.
CAUTION:
The voltage loaded between terminals can not
exceed 2 mins,otherwise,starter relay may over-
heat or burn.
Use multimeter to measure starter relay coil

resistance,if the reading is out of specification,
replace a new relay.
Turn multimeter to 1X10
Starter Relay Coil Resistance:3-5
AUXILIARY STARTER RELAY,FUEL

PUMP RELAY
Put 12V between auxiliary starter relay positive and A
negative terminal;use multimeter to cheack the
continuity between A and B.
Turn multimeter to DIODE.
If multimeter clicks,it indicates there is continuity
between A and B.
If 12V is removed,no continuity remains between B
contacts.
If both above 2 items are ok,it indicates the
replay is ok. Ground
Turn multimeter to 1X100 ;measure auxiliary
starter relay resistance.
Auxiliary starter relay resistance 90-100
NOTE:At the back of auxiliary starter relay,parallel to Battery(+)

diode,it’s the relay coil positive terminal.
15-6
ENGINE STARTING NOTICE

Poperly route according to starting schematic
diagram.
Before starting,check if all parts are fitted correct;
Regarding EFI components connection,refer to EFI
section.
Check air intake system.
Check fuel supply system;ensure there is no bolck
or leaks.
Test fuel presure with fuel pressure gauge.
Pressure in fuel pump outlet:0.33 0.01Bar.
Place the transmission in Neutral.

Check EFI with PDA for faut;if there is,eliminate
the trouble according to DTC(Diagnostic Trouble
Code).
Fuel Pressure Gauge
Close the throttle and turn the engine stop switch

to “RUN”,then push starter switch to run the engine.
After starting,warm up until idle speed is stable and
check it.
NOTE:
If idle speed is unstable or too high,shut off the 15
engine,and then start it.
Idle Speed:1250 100rpm.
15-7
EFI Structure
Idle Air Control Valve
T-MAP Senor
Air Filter
Ignition Coil Coolant Temp. Sensor
TPS
O2S(Oxygen Sensor)
CPS
ECU
Fuel Pump
EFI system is composed of three

subsystems:
Sensors:
A sensor is a device that measures a physical
(3)Actuator:
quantity and converts it into a signal which can be
Execute the EFI instruction.Main actuators include:
read by an observer or by an instrument.Sensors in
EFI system include: Fuel Pump
Fuel Injector
Throttle Position Sensor(TPS)
Ingnition Coil
Crankshaft Position Sensor(CPS)
Coolant Temp. Sensor
Speed Sensor
Gear Positon Sensor and Reverse Gear Sensor
Oxygen Sensor
4WD/LOCK
Over-ride Switch
(2)ECU:
Electronic Control Unit,the brain of EFI system,which
determines the amount of fuel injection, ignition tim-
ing and other parameters a engine needs to keep run-
ning by calculating and analysing values provided by
sensors.
15-8
EFI System Maintenance Notice

Always use genuine CFMOTO parts for maintenace, Don’t reverse the battery cable connections.This
otherwise it can not assure a normal performance may damage electrical components.
to EFI system.
During the maintenance procedure,never try to Never remove the battery cables When the engine
break down the EFI components. is running.
In the course of maintenance,EFI parts must be Always remove cables and electrical control units
handled carefully. which are connected with battery terminals.
Ignition switch must be shut off before connecting Never test the component input and output electric
or disconnecting connectors,otherwise,it may signal by piercing the cable plastic jacket.
cause the EFI parts damage.
When removing fuel pump from fuel tank,do not Respect the environment and dispose of the waste
energize the fuel pump,otherwise,a spark can left during maintenance.
cause a fire.
Fuel pump is not allowed to operate in a dry

enviroment or under water,otherwise,it’s life
would be shortened.Besides, reverse connections
between positive and negative terminal of fuel
pump is not permitted.
The fuel pressure in EFI fuel supply system is very

high(about 330kPa),accordingly,all fuel lines are
high pressure resisting.Even if the engine is not
running,the fuel pressure is high.Therefore,do not
15
disassemble the fuel line unless it’s necessary.
When the fuel line needs to be repaired,release
the fuel pressure as follow shows:
Remove fuel pump relay,start the engine and
allow it to idle until the engine stalls
automatically.
Fuel line removal and fuel filter replace ment should
be practiced by a proffessional person in a
well-ventilated place.
If possible,don’t do the spark test.If spark test
is done unavoidably,try to complete the
test as soon as possible.Besides,don’t open the
throttle,otherwise,a large quantity of unburnt fuel
would enter muffler,causing the catalytic converter
damage.
Idle speed is controlled by ECU,so it’s unadjustable.

The throttle limiter screw has been adjusted by
manufacturer before sale,therefore,it’s not
recommended to adjust it by the user.
15-9
SERVICE TOOLS
Tool Name:PDA
Function:
Read/clear EFI system trouble codes,observe
datastream.
Tool Name:Digital Multimeter
Function:
measure voltage, current and resistance
and other parameters in EFI system.
Tool Name:Vaccum Gauge
Function:
Check the manifold for air pressure.
15-10
Tool name:Timing Light
Function:
This light is used to check engine ignition timing.
Tool name:Compression Tester
Function
This tester is used to check cylinder compression,so
as to determine if the rings or valves are bad and leak-
ing pressure.
Tool Name:Fuel Pressure Gauge
15
Function
This gauge is used to test the fuel pressure,so as to
check fuel pump and fuel pressure regulator working
conditions.
Tool Name:Fuel Injector Analyser
Function:
This analyser is used to clean and analyse fuel
injectors.
15-11
EFI COMPONENTS AND FUNCTION
(1)ECU:
ECU pins and function:
PINOUT CHART
J1 CONNECTOR
PIN# Description PIN# Description
J1-1 IACVHI/IAV J1-10 COILB/ESTB
J1-2 MAGNETO CUT J1-11 IACALO
RELAY/CLTL/ESTC
J1-3 MIL J1-12 IACBHI
ECU
J1-4 DEAD BATT J1-13 IACBLO
BYPASS/O2BHTR/INJC
J1-5 SPARE ANALOG J1-14 ROLLOVER
J1-6 TACHOMETER J1-15 VSS/02B SENSOR
J1-7 CANLO J1-16 DIAG
J1-8 CANHI J1-17 FUEL PUMP RE-CIR
J1-9 GND(POWER) J1-18 PNSW
J2 CONNECTOR
Pin# Pin# Description
J2-1 COILA/ESTA J2-10 5VRTN
J2-2 GND(POWER) J2-11 MAP
J2-3 KW 2000 J2-12 TPS
J2-4 CRANK VR HI(23XHIFI) J2-13 CRANK VR LO(23XLOFI)
J2-5 INJA J2-14 CLT
J2-6 INJA J2-15 IGN
J2-7 O2A HTR J2-16 5VREF
J2-8 IAT-MAT J2-17 O2A SENSOR
J2-9 FUEL PUMP RELAY J2-18 VBATT
J2
J2 J1
J1
99 11 99 11
ECU Pin Locations: 18

18 10
10 18
18 10
10
Limit Data:
Value
Item Unit
Min Standard Max
Operation
9.0 14.0±1 16.0 V
Battery Voltage Normal
Function
6.0-9.0 16.0-18.0 V
Limited
Withstanded Limited Function Such As
26.0V 5.0 Min
Overvoltage and Time Diagnosis
Working Temp -40 +70 ?
Storage Temp -40 +70 ?
It’s not allowed to apply a heavy load on ECU housing,or it may deform and damage ECU.
Always handle ECU gentlely.Never drop it,especially on a hard surface.
15-12
(2)THROTTLE BODY ASSEMBLY:

Idle Air Control Valve Connected
Connected between air filter and engine.When throttle with Air Filter
lever is applied,the valve butterfly in throttle body would
spin at a certain angle.Tps can monitor the position of
valve butterfly and send the signal to ECU.
TPS
Pins and function:

Connected with Air
1.Connected to 5V power Intake Manifold
2.Ground
3.Outout voltage signal Throttle Body Assembly
11 22
3
3
TPS
15
TPS Circuit:
99 1 TPS
ECU
18 16
18 12 10
J2
J2
Idle speed limiter screw is not allowed to adjust.
Idle speed is regulated by ECU.
Idle Speed
Adjuster Screw
15-13
(3)T-MAP SENSOR:
This sensor integrates Inlet Air Temperature Sensor
and Manifold Absolute Sensor.It’s used to detect both
inlet air temperature and maifold absolute pressure,
providing ECU the signal of engien load. 4 3 43 2 1 21
Pins and Function:
1.Ground
2.Connected with 5V power
3.Voltage signal output
T-MAP Sensor Circuit: T-MAP Sensor
9 1
ECU 18 16 11 10
J2
J1
MAP Sensor
1 4 2
9 8 1
18 10
J2
J2
IAT Sensor
1 3
The right figure illustrates the allowed installation angle

to avoid condensated water built up in T-MAP sensor,
causing pressure sensitive elements damage.
15-14
The following figure refers to output volatge-pressure relation.
5
4.65
4.65
Output Voltage in V
0.4
0
0
0 10 115
Absolute Pressure in kPa
The following chart explains resistance-temperature relation. 15
60000
50000
40000
30000
20000
10000
0
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
-10000
Resistance( )
温度（℃）)
Temp.( 标称阻值（OHM)
Resistance(OHM)
15-15
(4)COOLANT TEMPERATURE SENSOR
(CTS):
This sensor is a negative temperature coefficient(NTC)
thermistance,whose resistance increases with the tem-
perature of coolant decreases.It outputs 2 set of
coefficients,one is for ECU to monitor the tempera-
ture of coolant,the other is for meter dispaly.
A and C consists of one group,which provids signal for
ECU.
Coolant Temperature Sensor
B and threaded portion consists of one group,which
provides sigal for coolant temperature gauge.
Coolant Temperature Sensor Circuit:
9 1
ECU
18 14 10
J2 T
T
B
A C
Connected with Meter
The right chart explains pin B and threaded portion- Meter Channel Resistance(b-Threaded Portion)
coolant temperature relation.
Temp.( ? ) Resistance(Ω)
45 265.0-323.0
80 74.6-90.6
115 25.7-31.7
The right chart explains pin A,C-coolant temperature

ECU Channel Resistance(a-c)
relation. The siganl is for ECU.
Temp.( ? ) Resistance(Ω)
-25 38,583
0 9,399
25 2,795
80 334
115 115.7
15-16
(5)OXYGEN SENSOR:
This sensor is used in closed-loop feedback-controlled
fuel injection to improve the air-to-fuel ratio accuracy
and control the emission.
It’s located in the exhaust stream to measure
the amount of oxygen in exhaust and send the signal to
ECU,which can revise the fuel injector output ,so as to
reduce the amounts of both unburnt fuel and oxides of
nitrogen entering the atmosphere.
Pins and Function:
1.Connected with positive terminal,heating power(white) D C B A
2.Connected with negative terminal,heating power(white)
3.Connected with negative terminal,signal output(grey)
4.Connected with positive terminal,signal output(black)
Oxygen Sensor Circuit:
Engine
Stop
DCBA DCBA Switch
9 7 1 9 5 4 1
1817 10 18 10 15
J2 J1
O2S 2 O2S 1 ECU
The following table explains the oxygen sensor working parameters.
Parameter New oxygen sensor After 500 hours bench test

Exhaust temp. at a 350 850 350 850
certain duty ratio
Sensor voltage (mv) 840±70 710±70 840±70 710±70
when λ=0.97(Co=1%)
Sensor voltage (mv) 20±50 55±30 20±50 40±40
when λ=1.10
Sensor inner resistance 1.0 0.1 1.5 0.3
Response 150 150 300 200
time(ms)(600mv-300mv)
Response 150 150 300 200
time(ms)(300mv-600mv
15-17
(6)CRANKSHAFT POSITION SENSOR
(CPS):
Detects the rate at which the crankshaft is spinning
and provides the signal for ECU to determine ignition
and fuel injection.
A B
(+) (-)
CPS Circuit: CPS

9 4 1
J2
18 13 10
A B
ECU
CPS Resistance:
Set multimeter to 1X2K range;
CPS resistance:950 50 (20 )
If the CPS resistance reading is out of specifi
cation above,replace.
Test CPS Peak Voltage AC Magneto
Connect multimeter and peak voltage adapter as
right wiring diagram illustrates; CPS Resistance
+Probe: Green Lead
- Probe: Blue Lead
NOTE:
When using peak voltage adapter,refer to some
CPS Peak Voltage Tester
instructions.
Set multimeter to V range;
Place the transmission in N and turn the ignition
switch to ”ON”;
Push starter switch and allow the engine to run for AC Magneto
seconds,then test CPS peak voltage;
Repeat above procedure and get the highest CPS CPS Peak Voltage
peak voltage;
CPS peak voltage : 2V (300rpm)
If the CPS peak voltage reading is out of above
specification,replace.
15-18
(7)SPEED SENSOR:
This sensor is used to detect the rotating speed of the
engine output shaft and provide the signal for ECU to
determine the vehicle speed. It belongs to Hall effect
sensor,that varies its output voltage in response to a
magnetic field.
Pins and Function: 1

2
1.Ground
3
2.Output voltage signal (>80% input power voltage)
3.Power+DC12V
Speed Sensor Exterior
+12V Power
The right figure refers to speed sensor wiring:
Ground 1 2 3
ECU
Hall Switch
15 15
Speed Sensor
1
Speed Sensor Test: 2
Ground pin 1and connect pin 3 with +12V power; 3
Fix a gear 2.5mm away from a speed sensor as

the right figure illustrates;
Turn multimeter to DCV range;
Slowly turn the gear and measure the voltage be-

tween pin 2 and pin 3 to determine that if the reading
Gear 2.5mm
varies from 0V-12V;
If the reading doesn’t vary,that indicates the sen-
sor is defective and needs to be
replaced.
15-19
(8)GEAR POSITION SENSOR:
This sensor is used to provide the gear position signal for meter display.
Pins and Function:
Yellow/Blue-L(Low Gear)
Orange/Blue-H(High Gear)
Yellow/Black-P(Park Gear)
White/Yellow-N(Neutral)
Sky Blue/White-R (Reverse Gear)
When each pin at a certain gear position,there is

continuity between this pin and engine.Otherwise,no
continuity.
Gear Position Sensor
(10)CAUTION when driving in reverse
When driving in reverse,gear position sensor sends

the reverse signal to ECU and meter.ECU would limit
the vehicle speed in response to the reverse signal.
15-20
(10)FUEL PUMP ASSEMBLY:

This fuel pump assembly includes fuel pump,plastic 1 2
support,preliminary filter,fine filter and pressure
regulator.It suppies fuel for engine under a certain pres-
sure and flow.
Fuel Outlet
Pins and Function:
1.Blue(Ground)
2.Red(Connected with fuel pump relay output terminal)
Parameters:
Pressure regulator opening pressure:0.33 0.01MPa
Flow:>35L/h
This fuel pump is located in fuel tank;

Don’t operate the fuel pump in dry condition in or-
der to prevent damage.
Always handle the fuel pump gently.Never drop the
fuel pump,especially on a hard surface.Such a shock
to pump can damage it.
Fuel Pump Assembly
Fuel Pump Wiring:

Battery supplies power for fuel pump assembly via
9 1
fuel pump relay,which connects the fuel pump circuit
J2
only with the engine started. 15
18 10
Fuel Pressure Test:
Connect the fuel pressure gauge with fuel outlet
and tighten the joint with a clamp to prevent fuel leaks;
Route according to the right circuit;
Turn both ignition switch engine stop switch on;
At this moment,fuel pump will operate for 5
seconds.After the fuel pump stops running,fuel pres- Fuel Pump Relay
sure should be in specification,otherwise replace it;
After the engine stops running,0.25MPa fuel
pressue should be kept for more than 5minutes,other-
wise replace the fuel pump;
Power
Pressure Relief in Fuel System:
In an EFI model,the pressure in fuel system is very Engine
high,so all the line is high pressure resistant.Even Stop
though the engine is not started,the pressure in fuel Switch
system remains high.Therefore,it’s not recommended
Ignition Switch
to remove fuel lines before pressure relief.
Follow the procedure below to perform pressure relief: M
Remove fuel pump relay.Start the engine and allow it

to idle until the engine stops automatically
15-21
(11)FUEL INJECTOR:
One end of fuel injector mounts into fuel injector seat, Connected with Injector Cap
and the other end attaches to the injector cap,which
connects with a fuel line.Fuel injector is controlled by
ECU to inject fuel at stated time into the engine.
This injector nozzle is a 4-hole style.Don’t turn injec-
tor after the joint between injector and injector cap is
installed.
Pins and Function: Mark”+”
Connector with the mark”+”:connected with fuel
pump relay output terminal.
Connector without mark:connected with ECU pin 14.
Connected with Injector Seat

Fuel Injector Resistance:12 1 (20 )
Fuel Injector Exterior
9 65 1
18 10
ECU
Fuel Injector Circuit:

Engine
Stop
Switch
Ignition
Switch
R/W
R/W
R/Y
W/B
W/B
1 2 1 2
Fuel Injector Installation:

Install fuel injector manually.Never knock fuel in-
jector with a hammer.
When removing and installing fuel injector,the o-
Injector 1 Injector 2
rings on both ends must be replaced;
Perform pressure relief before fuel injector removal
if necessary;
Test the fuel injector sealing after installation to
ensure no leaks.
15-22
(12)IDLE AIR CONTROL VALVE:

IACV is used to control the air flow of by-pass.ECU
calculates the engine load and controLs IACV through Idle Air Control Valve
Connected with Air Filter
electrical pulse durationand frequency(commonly
known as duty ratio).IACV allows diffrent air flows
passed through under different pressure diffrences.
Therefore,it should be connected properly,otherwise,
idle speed may be incorrect.When there is no electri-
cal pulse,IACV would be closed. TPS
Pins and Function:

1.Pin A:IACBLO-ECU J1-13;
2.Pin B:IACBHI-ECU J1-12;
3.Pin C:IACALO-ECU J1-11; Connected with Manifold
4.Pin D:IACAHI/IAV-ECU J1-1;
9 1
ECU J1
18 10
Br/W
Y/L
Y/L
Br
Idle Air Control Valve Circuit:
L
12 34 15
Idle Air Control Valve Parameters:
Value Unit
Item
Min Standard Max
Rated Voltage 13.5 V
Resistance(+20? ) 16 Ω
Rated Current 0.85 A
Control Pulse Frequency 30 Hz
Standard Control Pulse Width ≈8 ms
Air Flow(When Pressure
Difference=700mbr, 5.0 m3/h
Duty Ratio=100%)
15-23
(13)IGNITION COIL
Ignition coil transforms the low voltage of primary coil
to high voltage of secondary coil needed to spark the
spark plug and ignite the mixture of air and fuel in
cylinder.
Pins and Function:

1.Ignition coil (-) of cylinder 1 connected with pin 1,ECU J2;
1.Ignition coil (+) of cylinder 1 connected with battery(+);
3.Ignition coil (-) of cylinder 2 connected with pin 10,ECU J1;
4.Ignition coil (+) of cylinder 2 connected with battery(+);
Connected with High Tnesion Lead
J2
9
9 11
18
18 10
10
Ignition Coil Circuit: ECU Ignition Coil 1

99 11
18
18 10
10 Engine
Stop
J1 Switch
Ignition Coil 2
Secondary Ignition Voltage Test:

Connect the engine according to EFI wiring diagram; Peak Voltage Tester
V
Connect the peak voltage tester according to the
right diagram;
Start the engine;
Secondary ignition voltage should be >15000V.
Battery
ECU Spark Plug
Ignition Coil Parameters:
Item Value Unit

Min Standard Max
Stated Voltage 14 V
Operating Voltage 6 16.5 V
Resistance Primary Winding Resistance 0.74 0.76 0.78 Ω
（20-25℃） Secondary Winding Resistance 10.1 10.6 11.1 KΩ
Primary Current 7 A
15-24
(14)EFI SELF-DIAGNOSIS:
ECU constantly monitors sensors,actuators,circuits,MIL and battery voltage,etc,even itself.It also tests sen-
sors output signal,actuator drive signal and inner signal(such as closed-loop control,coolant temp. signal,idle
speed control and battery voltage control,etc for reliability ).If any malfunction or suspectable signal found,
ECU would record the fault information in RAM.
Fault information comes in form of fault codes,which are then displayed on PDA, in sequence of which fault
comes first.
Fualt can be divided into “steady fault” and “occasional fault” (such as a fault caused by harness short or loose
connection.)
PDA or MIL can be used to locate the part in trouble immediately after fault happens.
(1)MIL(or FI Indicator):
MIL is a light-emitting diode and located on instrument panel.
It indicates different fault codes through the flashes in differ-
ent frequency. Resistance
MIL Circuit:The current in pin 3,ECU J1 should be J1-3
less than0.1A. +12V Power LED
MIL Flash Principles: J1-9
(1):Turn ignition switch on and depress kill J2-2
switch.Don’t run the engine.If no malfunc-
tion happens. ECU
MIL turns on for 5 seconds,then turns off.
(2):Turn ignition switch on and depress kill
switch.Don’t run the engine.If malfunction
happens. 15
MIL turns on for 5 seconds and turns off.Then MIL
flashes to indicate a fault code:
The interval between fault codes is 3.5s,between dig-
its is 1.2s,and a flash lasts for 0.4s as well as the
interval between 2 flashes.
MIL fashes 10 times to indicate 0.From 1-9,how much
it counts,how many times MIL flashes.
Take fault codes P0117 and P0232 for example:

MIL lights up for 5 seconds turns off and lasts for 3.
5s flashes for 10 times(the frequency is 0.4s)
turns off and lasts for 1.2s flashes once turns off
and lasts for 1.2s flashes once turns off and lasts
for 1.2s flashes for 7 times turns off and lasts for
3.5s flashes for 10 times turns off and lasts for
1.2s flashes for 2 times turns off and lasts for 1.
2s flashes for 3 times turns off and lasts for 1.2s
flashes for 2 times.
(3):Turn ignition switch on and run the
engine.Malfunction happens.
MIL lights up until malfunction disappears.
15-25
(2)PDA:PDA has 3 pins-power,ground wire and data
cable K.Thses pins are connected with related ECU
pins.
The right photoe refers to operation panel of PDA.When
it comes to detailed keys function,refer to PDA in-
struction book.
Pins and Function:
1.Connected with pin 3,ECU J2;
2.Ground UP 123
3.Connected with +12V power
RH Selection
LH Selection
DOWN Key
Keys and Function:
EXIT OK Key
LH Key:Page up
Power Switch
UP Key:Scroll Up
RH Key:Page Down
9 21
Down Key:Scroll Down J2
18 10
OK Key:Entrance
EXIT Key:Exit
Connected with Battery(+)

PDA Function:
(1)Version Infomation Display
RED GRN PPL
PDA can display engine,ECU hardware and soft ware infomation.
(2)Fault Display
PDA monitors IAP sensor,IAT sensor,coolant temperature sensor,TPS,O2S,O2S heater circuit,air-to-fuel
ratio revision,fuel injector,fuel pump relay,CPS,speed signal,idle speed,idle air control valve,system voltage,
ECU,FI indicator and displays the fault code.
(3)Engine Data stream Display
PDA can display battery voltage,RPM,desired idle speed,vehicle speed,coolant temperature,coolant tem-
perature sensor signal voltage,inlet air temperature,IAT sensor signal voltage,inlet air pressure,inlet air flow,
IACV target position,TPS signal voltage,throttle body position,throttle body relative position,canister duty,
charging time,FI pulse width,park
advance angle,O2S voltage,engine relative load,cansiter load,IACV position,atmospheric pressure,altitude
multiplier,engine operation time.
(4)EFI Status Display
Starter switch,main relay,fuel pump relay,idle speed,idle speed,full load status,deceleration activation,
acceleration activation,FI close loop activation,lambda control activation,canister control valve activation,
MIL status.
(5)Actuator Test Function
MIL,fuel pump,IACV,canister control valve,ignition,fuel injection.
15-26
FAULT CODE TABLE:
P0107 MAP Circuit Low Voltage or Open MAP-Manifold Absolute Pressure

P0108 MAP Circuit High Voltage
P0112 IAT Circuit Low Voltage IAT-Inlet Air Temperature
P0113 IAT Circuit High Voltage or Open
P0117 Coolant/Oil Temperature Sensor
Circuit Low Voltage
P0118 Coolant/Oil Temperature Sensor
Circuit High Voltage or Open
P0122 TPS Circuit Low Voltage or Open TPS-Throttle Body Position
P0123 TPS Circuit High Voltage
P0131 O2S 1 Circuit Low Voltage O2S-Oxygen Sensor
P0132 O2S 1 Circuit High Voltage
P0032 O2S 1 Heater Circuit High Voltage
P0031 O2S 1 Heater Circuit Low Voltage
P0201 Injector 1 Circuit Malfunction
P0230 FPR Coil Circuit Low Voltage or Open FPR-Fuel Pump Relay
P0231 FPR Coil Circuit Low Voltage or Open
P0232 FPR Coil Circuit High Voltage
15
P0336 CKP Sensor Noisy Signal CKP-Crankshaft Position
P0337 CKP Sensor No Signal
P0351 Cylinder 1 Ignition Coil Malfunction
P0505 Idle Speed Control Error
P0562 System Voltage Low
P0563 System Voltage High
P0650 MIL Circuit Malfunction MIL-Malfunction Indicator Light
P1693 Tachometer Circuit Low Voltage
P1694 Tachometer Circuit High Voltage
P0137 O2S 2 Circuit Low Voltage
P0038 O2S Heater 2 Circuit High Voltage
P0037 O2S Heater 2 Circuit Low Voltage
P0500 VSS No Signal VSS-Vehicle Speed Sensor
P0850 Park Neutral Switch Error
P0445 CCP short to high
P0444 CCP short to low/open
15-27
16 LIGHTS,INSTRUMENT,SWITCHES
Maintenance Info...........................16-1 Handlebar Switches.........................16-7

Troubleshooting............................16-2 Brake Light Switch-Horn.................. 16-8
Bulb replacement..........................16-3 Fuel Sensor....................................16-9
Dashboard- Headlight....................16-5 Fuel pump.....................................16-10
16 16
Ignition Switch..............................16-6
Maintenance Information
Operation Cautions
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.
The temperature of headlight is quite high when turned on. Replacing with bare hand or stained glove will
leave oil residue 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 switch in the OFF position, and replace after the
bulb is cooled down.
-Replace the bulb with hands in clean gloves to avoid oil rsidue on the glass surface.
-Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil residue 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 switches from the vehicle.
After the inspecting and maintenance 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.
Maintenance Specifications
I t em S ta n d a rd
M a in 20 A
Fu se A u x ilia ry 10 A× 1 15A × 5
H e a d l i g h t（ H i ／ L o ） 1 2V-3 5/ 35 W × 2
B r a ke l i g h t ／ Ta i l l i g h t 1 2 V - 2 1 /5 W × 2
T urn Lig ht 12 V-10W × 4
L ig h t P an el Lig ht LE D
C o ola nt t e m p . ,F u e l LCD
l e v e l , 2 W D /4 W D ind ic at or
li ght
MIL LE D
16-1
Troubleshooting
Head Light Cannot Turn On
Blown fuse
Open circuit of main cable
Burnt bulb
Defective switch
16-2
Bulb Replacement
Headlight Bulb
Cautions
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 left headlight protector ( 2-11);
Remove headlight( 16-5);

Remove left position light(front) no.1;
Remove headlight bulb (left) no.2;
Remove left turn light no.3;
Unplug headlight connector;

Remove dust-proof cap, headlight connector,
circlip and replace with a new bulb.
WARNING:
Wear clean gloves when replacing bulb.
Oil residue on the glass surface may cause
the bulb break.Clean the stained surface with
alcohol or isoamyl acetate.
9
Align the three pins of the bulb with the three 7
positioning holes in the
socket when replacing the bulb. 6
4
2
5
Bulb no.7 specification:12V-35/35W 3 3
Bulb no.6 specification:12V-5W

1 2
Bulb no.5 specification :12V-10W
8
2
Reverse the removal procedure for installation
After replacing the bulb, adjust headlight beam
( 3-14).
Headlight Inspection
Turn the ignition switch to ON position,
turn light switch to the illumination
position and check if the headlight is on.
-ON: Normal
-Still off: short circuit of main cable or
broken main cable
16-3
Front Turn Light Bulbs
Remove LH headlight protector( 2-11);

Remove headlight( 16-5);
Remove front turn llight no.1;
Rmove front turn light bulbs.
Bulb Specification:12V-10W
Rear Turn Light Bulbs

Remove rear turn light cover;
Remove rear turn light bulbs;
Replace rear turn light bulbs no.4;
Bulb Specification:12V-10W
Remove tail light cover;

Remove brake light/tail light bulb no.5;
Replace brake light/tail light bulb;

Bulb Specification:12V-21/5W
NOTE:
Main cable,wiring and tube should
be routed properly( Chapter 1).
16-4
Dashboard
Remove cover of dashboard( 2-5);

Remove nuts no.1;
Remove dashboard connectors no.2;
Remove dashboard.
NOTE: If dashboard has something wrong,

it’s recommended to replace the whole dashboard.
Headlight
Remove cover of headlight (-2-11);
Remove screw no.3;
Remove screw o.4;
Disconnect headlight connector;
Disassemble headlight comp.
Reverse the removal procedure for installation

NOTE:
Be careful not to damage main cable when
assembling.
After replacment, adjust the headlight beam( 3-14);

NOTE:
Main cables and wires should be routed
properly.( 1-20)
16-5
Ignition Switch
Inspection
Disconnect 4P connector of ignition switch;
Check according to the following table if
the connector terminals are in continuity.
:Continuity
ON
OFF
RB G B/W
Removal
Disconnect 4P connector of ignition switch;
Remove bolt and remove ignition switch;
Installation
16-6
Handlebar Switches
Disconnect left handlebar switch connectors;
Check according to the following table if
the connector terminals are in continuity.
Continuity
Light Switch no.1
B/Br Br Br/W L W/L W
OFF
B=Black Br=Brown W=White L=Blue G=Green

Gr=Grey R=Red O=Orange Sb=Sky Blue
Lg=Light Green
Kill Switch no.3 Starter Switch no.2
B/W G B/Br Y Y Gr/R
16-7
Turn Switch no.1
O Gr Sb
PUSH
Horn switch no.3 Over-ride Switch no.4
OFF OFF
ON ON
Right Handlbar Switch no.5

Br/B L/G L/B Br/G Gr/W L/G Br/R Br/G Lg/Br G
2WD
4WD
LOCK
If something above wrong, replace

handlebar switches( 12-12).
Hazard Light Switch no.2
Gr/B B/Br
Brake Light Switch no.6

Disconnect brake light switch connector and
check terminals for continuity.
Brake lever applied:continuity
Brake lever released. no continuity
No continuity: Replace brake light switch
Horn no.7
Inspection
Remove front vent grille ( 2-13);
Disconnect horn;
Connect with a fully charged 12V battery
and check if the horn sounds.
Defective Horn: Replace
16-8
Fuel Sensor
Remove:
Remove passenger seat ( 2-4);
Remove driver seat ( 2-4);
Remove 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 fuelgauge.
Remove fuel sensor 2P connector;

Connect multimeter between 2P connector
terminals;
Shake float with hand and measure the resistance
of float at different positions.
Connection Terminal:
Upper: Blue/White-Green:
4-10 (20 )
Lower: Blue /White-Green: Fuel Sensor 2P Connector
90-100 (20 )
Faulty fuel sensor: Replace
Installation
Put fuel sensor into installation hole of fuel tank.
Fuel sensor should be fitted properly.
No fuel leakage is allowed.
Inspection of Fuel Gauge
Switch on power supply and check if fuel Fuel Sensor
level gauge functions normally.
If fuel gauge works normally,
Reverse the removal procedure for
installation of plastic parts and seat.
16-9
Fuel Pump
Removal
Remove rear seat( 2-4);
Remove front seat( 2-4);
Remove related plastics(see Chapter 2);
Drain fuel in fuel tank ;
Remove the 5 bolts no. 2;
Remove fuel pump no.3 from fuel tank no.1;
Disconnect fuel pump connector.
Fuel Pump Specifications
Voltage:DC13.5 0.3V,
Pressure:0.2 0.01MPa,
Rate of flow 45L/h,
Current 2A,
Regulator working pressure: 0.25 0.01MPa,
Current 2.2A.
Inspection of Fuel Pump

Turn ignition switch to ON and check if fuel
pump functions normally.
If fuel fuel works abnormally,please check if circuit
is open circuit or if EFI system has any problem.
NOTE:
If any probelm of electrical equipment and electrical
system in this chapter ,please refer to chapter of elec-
trical equipment .
16-10
17 TROUBLESHOOTING
1.Engine troubleshooting............................................................... 17-2

2.Trouble code table..................................................................... 17-6
3.EFI system troubleshooting by trouble code................................. 17-7
4.Trouble diagnosis by engine problems..........................................17-13
17
17-1
17 TROUBLESHOOTING
1.Engine troubleshooting
Trouble Possible causes Countermeasures

Engine cannot be started 1.Check electrical system
1) Fuse defective Check or replace
2) Battery low voltage Check or recharge
3)Bad wiring connection Check or replace
2.Check spark plug
1) Ignition coil bad connection or defective Check or replace
2) High-tension cable bad connection or defective Check or replace
3) Speed sensor defective Check or replace
4) Flywheel defective Check or replace
5) Gap of spark plug incorrect Adjust or replace
6) Spark plug dirty Clean or replace
7) Spark plug wet Dry it or replace
3. Check fuel supply system
1) Canister
2) Fuel pump leakage or defective Repair or replace
3) Fuel hose leakage Tighten
4) Fuel insufficient Check fuel tank
5) Injector blocked or defective Replace
4.Check cylinder pressure
1) Cylinder worn Replace
2) Piston ring worn Replace
3) Cylinder gasket broken Replace
4) Valve stem worn Replace
5) Valve seat seal unsuitable Repair or replace
6) Valve worn Replace
7) Spark plug loose Tighten
8) Starting RPM too low Check or replace
9) Valve timing incorrect Adjust
10) Valve clearance incorrect Adjust
5. Air bypass valve blocked or defective Clean or replace
6. Not shift to “N” gear Shift to “N” gear
7. Check trouble code Check
Difficult to start engine 1. Air bypass valve adjustment failure See engine control system
2. TPS not reset See engine control system
3. Adjust throttle cable
4. Cylinder pressure insufficient
5. Check spark plug Check or replace
1) Spark plug defective
2) Spark plug improper installation Replace defective part
3) Spark plug damaged
4) Spark plug dirty
6. Fuel insufficient or fuel pressure not enough
17-2
17 TROUBLESHOOTING
Trouble Possible causes Countermeasures

Engine 1. Coolant insufficient (lower than LOWER line) Refill coolant
overheating 2. Air bubbles inside cooling system Remove air bubbles and refill
3. Water temp. sensor defective Replace sensor
4. Thermostat defective(cannot open when coolant is very Replace thermostat
hot) a. Check and replace water
5. Coolant leakage pump seal
b. Check and replace water hose
● Water hose broken or aging and clamp
● Clamp loosen Replace
6. Water impeller damaged Tighten
7. Water pump cover leaking Replace
8. Cylinder head cover/Cylinder gasket leakage Tighten or replace
9. Water pump cover washer leakage Replace
10. Water pump gear wear or damaged Replace
11. Water pump shaft defective
Troubles Possible causes Countermeasures

Engine oil 1. Check oil level and if any leakage of crankcase or oil seal Replace and reassembly
consumption ● Crankcase damaged Replace
too high or ● Tightening bolt loosen Tighten
oil pressure ● Seal ring or O-ring/washer damaged or broken Replace
too low ● Piston ring wear (blue spark can be seen)
● Piston ring damaged (compression ratio too low) Replace
● Oil seal of valve damaged or aging Replace
2. Oil filter blocked
3. Check oil drain plug screw of crankcase Replace all oil seal of valves
● Oil drain plug screw loosen Replace and change oil
● Oil drain plug screw of left crankcase loosen or washer is
missing Tighten
4. Oil seal of indicator hole is leaking Tighten or install washer
5. Oil strainer blocked Replace oil seal
6. Check oil pump Clean or replace
● Oil pump rotor over-worn Replace
● Oil pump leakage or damaged by air into oil pump Replace
● Oil pump gear damaged Replace
● Engine oil is unsuitable Use recommended oil
Engine oil 1. Coolant and oil leaking from leakage indicator hole Replace oil seal and water
whitening 2. Cylinder head cover and cylinder gasket damaged seal
3. Bolt of cylinder head cover loosen Tighten or replace
4. Engine oil impure Tighten and change oil
Replace damaged parts
(including oil filter and oil)
17-3
17 TROUBLESHOOTING
Abnormal 1. CVT belt getting narrow Replace

acceleration 2. Check drive pulley
● Rollers wear Replace
● Drive pulley track wear Replace
3. Drive/driven pulley shaft move not flexibly Clean or replace
4. Spring of driven pulley too strong Replace
5. Sliders of driven pulley wear Replace
6. Groove of drive/driven pulley damaged Replace
7. Intake&exhaust valve clearance incorrect Replace
8. Compression ratio too low Adjust
9. Ignition of spark plug abnormal Replace
Max. speed too low 1. Check point 1,2 and 3 of “abnormal acceleration”
2. CVT system polluted by water, oil and dust
3. Drive pulley blocked Clean and replace
4. Spring of driven pulley weak or damaged Clean or replace
Replace
Transmission not 1. Check bush of drive pulley
good 2. Check point 1and 2 of “abnormal acceleration”
● Bush blocked on shaft Clean and Replace
3. Check driven pulley
● Spring of driven pulley weak or damaged Replace
● Sliders wear or damaged Replace
CVT belt over-worn or 1. Check CVT inlet&outlet air pipe

burned ● CVT overheating Clean
● Drive fixing sheave impeller blocked Clean
2. Check pulley groove
● Dirty oil inside groove Clean and replace belt
● Water into CVT case Clean and replace belt
CVT belt not good 1. Belt over-worn and getting narrow Replace
2. Wrong belt Replace
3. Part of belt wear Replace
4. Belt broken or over-used Clean CVT system and
5. Dirty oil inside groove replace belt
6. Drive/driven pulley groove damaged by stone or other Clean
foreign objects Clean or replace
7. Belt aging and getting fragile Replace
17-4
17 TROUBLESHOOTING
Noise from cylinder head 1. Valve clearance incorrect Adjust or replace

2. Tensioner failure Replace
3. Chain guide wear Replace
4. Chain extended or chain sprocket wear Replace
5. Bolt of sprocket loosen Tighten
6. Valve rocker arm or camshaft wear Adjust or replace
7. Camshaft timing incorrect Adjust or replace
Noise from crankshaft and 1. Bearing damaged Replace
connecting rod 2. Plain bearing damaged Replace
3. Flywheel rotor loosen Tighten or replace
4. Bearing of left crankcase cover wear Replace
Noise from crankcase 1. Engine oil leaking Replace, tighten and add oil
2. Gear damaged or wear Replace
Noise from CVT when at idle 1. Bush of driven pulley blocked or wear Replace driven pulley
speed 2. Check drive pulley
3. Rollers wear Replace at the same times
4. Drive pulley track wear Replace
5. Drive moving sheave wear Replace
6. Nylon sliders wear Replace
7. Axial move blocked Clean or replace
8. Nut of drive pulley loosen Tighten
Noise from CVT when at 1. Check point 1~3 of idle abnormal noise
transmission 2. Drive pulley dirty and wet Clean and dry
3. Nut of drive/driven loosen Tighten
4. Driven sliders over-worn Replace
5. Belt and cone surface damaged by outside Clean or replace
materials
CVT drive pulley vibration 1. Nut of drive pulley loosen Tighten
2. Gap of bush of drive pulley too big Replace
3. Rollers missing or over-worn Replace at the same times
CVT driven pulley vibration Gap of bush of driven pulley too big Replace
17-5
17 TROUBLESHOOTING
2.Trouble code table

Trouble Code Trouble Description Remarks
P0107 MAP Circuit Low Voltage or Open MAP-Manifold Absolute Pressure
P0108 MAP Circuit High Voltage
P0112 IAT Circuit Low Voltage IAT-Inlet Air Temperature
P0113 IAT Circuit High Voltage or Open
P0117
Coolant/Oil Temperature Sensor Circuit Low Voltage
P0118
Coolant/Oil Temperature Sensor Circuit High Voltage or Open
P0122 TPS Circuit Low Voltage or Open TPS-Throttle Body Position
P0123 TPS Circuit High Voltage
P0131 O2S 1 Circuit Low Voltage O2S-Oxygen Sensor
P0032 O2S 1 Heater Circuit High Voltage
P0031 O2S 1 Heater Circuit Low Voltage
P0230 FPR Coil Circuit Low Voltage or Open FPR-Fuel Pump Relay
P0231 FPR Coil Circuit Low Voltage or Open
P0232 FPR Coil Circuit High Voltage
P0336 CKP Sensor Noisy Signal CKP-Crankshaft Position
P0337 CKP Sensor No Signal
P0505 Idle Speed Control Error
P0562 System Voltage Low
P0563 System Voltage High
P0650 MIL Circuit Malfunction MIL-Malfunction Indicator Light
P1693 Tachometer Circuit Low Voltage
P1694 Tachometer Circuit High Voltage
P0137 O2S 2 Circuit Low Voltage
P0038 O2S Heater 2 Circuit High Voltage
P0037 O2S Heater 2 Circuit Low Voltage
P0500 VSS No Signal VSS-Vehicle Speed Sensor
17-6
17 TROUBLESHOOTING
3. EFI troubleshooting by trouble code

Instructions：
1.Only after stable trouble is confirmed, then do checking and repair. Otherwise it will bring mistakes.
2.Below mentioned multimeter is only for digital multimeter, pointer multimeter is not
allowed for checking EFI circuit.
3.If trouble code means voltage too low, it is short circuit to ground or open circuit. If trouble code means
voltage toot high, it is short circuit to power. If trouble code means circuit has something wrong, then
there is open circuit or many circuits in trouble.
Diagnosis helps：
1. If trouble code cannot be removed, then it is stable trouble.
If it is temporary trouble, please check wiring connectors
2. During checking, do not neglect influences of vehicle maintenance, cylinder pressure and valve
timing.
3. Replace ECU and test.
If trouble code can be removed by replacement of ECU, thenitis a trouble originated from ECU. If
trouble code still exists, then install original ECU and check other parts step by step.
In the following, there are detailed descriptions about trouble codes and diagnosis
procedures.
17-7
17 TROUBLESHOOTING
Trouble code:P0032/P0038：Heater coil high voltage of Cylinder 1 and 2 oxygen sensor

Possible causes Checking procedures
1）Open circuit between ECU and oxygen sensor C 1 ） Measure resistance between ECU pins and oxygen
pin sensor C pin, check if it’s ok.
2 ） Open circuit between main relay and oxygen 2）Measure resistance between main relay and oxygen
sensor C pin. sensor D pin, check if it’s ok.
3) Open circuit between oxygen sensor C and D pin 3) Measure resistance (9.6KΩ) between oxygen sensor C
pin and D pin.
Trouble code P0031/P0037：Heater coil low voltage of Cylinder 1 and 2 oxygen sensor
1）Short circuit between ECU and ground. 1)Measure resistance between ECU and ground
2）Short circuit between ECU and oxygen sensor D pin 2）Measure ECU voltage and check if it's ok.
3）Short circuit between ECU and other circuits. 3）Measure resistance (9.6KΩ) between oxygen sensor D
pin and ECU
Trouble code :P0131/P0137：Oxygen sensor low voltage of cylinder 1 and 2

Tips: EFI system can judge output signal if it’s ok by measuring voltage between oxygen sensor A pin and B pin.
Oxygen sensor sometimes will be broken during cold starting.
1）Short circuit between ECU and ground 1） Measure resistance between ECU and ground and
2）Short circuit between ECU and oxygen sensor D check if it’s ok.
pin. 2）Measure ECU voltage and check if it’s ok.
3）Short circuit between ECU and other circuits. 3) Measure resistance (9.6KΩ) between oxygen sensor D
4）Oxygen sensor defective, replace it. pin and ECU
Trouble code : P0132/P0138：Oxygen sensor high voltage of cylinder 1 and 2

Possible causes: Checking procedures
1）Open circuit between ECU and oxygen sensor A 1) Replace oxygen sensor
and B pins. 2) Replace ECU
2) Open circuit between oxygen sensor A pin and B 3) Wiring checking.
pin
17-8
17 TROUBLESHOOTING
Trouble code P0107：Intake air temp. sensor low voltage or open circuit
Possible causes： Repair procedures：
1）The sensor short circuit to ground 1）Measure resistance between ECU and ground
Trouble code P0108：Intake air temp. sensor high voltage

1）The sensor short circuit to ground 1）Measure ECU pin voltage
Trouble code P0112： Intake air temp. sensor low voltage

1）The sensor connected with ECU pin short circuit 1）Measure resistance between ECU pin and ground
to ground
Trouble code P0113：Intake air temp. sensor high voltage or open circuit
1）The sensor connected with ECU pin short circuit 1）Measure sensor voltage connected with ECU pin if it’s ok.
to power
Trouble code P0117：Water temp. sensor low voltage

1)The sensor connected with ECU pin short circuit 1) Measure resistance between ECU pin and ground.
to ground
Trouble code P0118：Water temp. sensor high voltage or open circuit

1）The sensor connected with ECU pin short circuit 1) Measure voltage of ECU pin if it’s ok.
to other circuit.
17-9
17 TROUBLESHOOTING
Trouble code P0122：TPS low voltage or open circuit

1）ECU pin short circuit to ground 1）Measure resistance between ECU pin and ground
Trouble code P0123：TPS high voltage

1）Short circuit between ECU pin and other circuit 1）Measure voltage connected with ECU pin if it’s ok.
Trouble code P0201/ P0202: 1/2 cylinder injector coil defective

1） Injector coil if it’s open circuit. 1） Measure injector resistance
2） Improper connection between injector pin and 2） Check continuity of all wirings
ECU pin 3）Measure resistance between ECU pin and ground
3） Improper connection between injector pin and 4）Measure voltage connected with ECU pin.
relay
4）All drive circuit connected with ECU short to ground
5）Short circuit between ECU pin and other circuit.
Trouble code P0336： Pick-up (Crankshaft phase sensor) signal incorrect

1） Wiring continuity short circuit or open circuit from 1） Check wiring continuity if it’s ok.
time to time 2） Check flywheel rotor gear quantity.
2） Installation of crankshaft signal wheel improperly
3） RPM sensor installation improperly
Trouble code P0337：Pick-up (crankshaft phase sensor) no signal

After engine is started, ECU will monitor pick-up signal and other signals at the same time.
It will judge if pick-up signal is missing or not by signal reasonability.
1）Open circuit between RPM sensor and ECU 1） Measure resistance between pick-up and ECU
2）Short circuit between pick-up and ECU 2） Measure resistance of pick-up
3）Open circuit of pick-up coil. 3） Measure peak voltage of pick-up.
17-10
17 TROUBLESHOOTING
Trouble code P0230：Fuel pump relay coil low voltage or open circuit
Trouble code P0232：Fuel pump relay coil high voltage
1) Open circuit/short to ground/short to power 1）Measure resistance or voltage between ECU and fuel pump
between control circuit of fuel pump relay relay.
connected with ECU and fuel pump replay 2）Measure resistance between fuel pump relay and main
2）Open circuit between fuel pump relay and main relay.
relay. 3）Measure resistance between two pins of fuel pump relay.
3）Open circuit between relay coils.
Trouble code P0505：Out of idle speed when at idle condition

Engine idle speed is controlled by ECU close-loop. In case ECU gives idle instruction, but engine
idle speed still is higher than targeted idle speed set by ECU, then it’s trouble.
1） Check adjust screw of throttle, throttle cable 1）Switch off ignition more than 3 seconds and restart engine.
and throttle working condition if it’s ok.
2）Too dirty inside throttle body.
Trouble code P0562：Battery low voltage

Trouble code P0563：Battery high voltage
1）Flywheel already broken and cannot generate 1) Check flywheel power generation ( By measuring flywheel
power or battery power leakage voltage)
2）Open circuit of flywheel stator coil. 2) Measure regulator voltage
3）Regulator already damaged
Trouble code P0650：MIL light drive circuit defective

1) Open circuit/short to ground/short to power 1）Measure resistance or voltage between ECU and MIL light
between ECU and MIL light drive circuit. drive circuit.
2）Open circuit between MIL and main relay
3）MIL light burnt
Trouble code P0500: Speed sensor no signal

When vehicle is running with gear and with loose throttle body, ECU will monitor engine RPM
and speed sensor. In case engine has high RPM, but speedometer shows 0 or very low, then it’s
a trouble of speed sensor.
1）Short or open circuit between ECU and speed 1) Measure resistance between ECU pins and speed sensor.
sensor 2）Measure resistance between ECU pins and ground
17-11
17 TROUBLESHOOTING
Trouble code：P0850 Nuetral gear sensor defective

Engine cannot be started when at “N” gear position.
Possible causes: Repair procedures:
1）Open circuit between N gear sensor and ground 1) Measure resistance between ECU pin and N gear sensor
Trouble code：P0445 Starter auxiliary relay high voltage

Trouble code：P0444 Starter auxiliary relay low voltage or open circuit
1 ） Open circuit/short to ground/short to power 1）Measure resistance or voltage between ECU and auxiliary
between ECU and auxiliary relay. relay.
2）Open circuit between auxiliary relay and power. 2）Measure resistance between auxiliary relay and power.
3）Open circuit between relay coils. 3）Measure resistance between auxiliary relay two pins.
Trouble code P1693：RPM low output voltage

Trouble code P1694：RPM high output voltage
After engine is started, ECU will monitor pick-up signal and other signals.
It will judge if pick-up signal is missing or not by signal reasonability.
1） Short circuit or open circuit between wirings 1） Check wiring continuity.
from time to time. 2） Check flywheel rotor gear quantity.
2） Improper installation of crankshaft signal 3） Measure resistance between pick-up and ECU
wheel. 4） Measure resistance of pick-up
3） Improper installation of RPM sensor 5） Measure peak voltage of pick-up.
4） Open circuit between RPM sensor and ECU
5） Short circuit between pick-up and ECU
6） Open circuit between pick-up coils
Trouble code P0351/ P0352：1/2 ignition coil defective

1） Ignition coil open circuit 1） Measure resistance of ignition coil
2） Improper connection between ignition coil and 2） Check wiring continuity.
ECU pins. 3）Measure resistance between ECU pin and ground
3） Improper connection between ignition coil and 4）Measure voltage between ECU pins
relay.
4）Short circuit between drive circuit connected
with ECU and ground.
5）Short circuit between ECU pin and other circuits
17-12
17 TROUBLESHOOTING
4. Trouble diagnosis by engine problems

Before trouble diagnosis by engine problems, initial checking should be done as follows.
1. Confirm if trouble light is ok;
2. Confirm there’s no trouble code record by PDA checking.
3. Confirm there’s really trouble existing complained by end-users.
Then check the following points.
（1） Check fuel hoses if any fuel leakage；
（2） Check vacuum pipes if any broken, twist or improper connection；
（3） Check intake manifold if any blocked, air leakage or damaged；
（4） Check high-tension cable if any damaged, aging；or ignition order is correct.
（5） Check wiring close to ground if it’s clean and firm；
（6） Check connector of all sensors and actuator if any loose or improper connection.
Important note： In case there’re some problems as above-mentioned, then removal work should be done
firstly, then go to next diagnosis.
Diagnosis helps：
1. Confirm engine without any trouble record.；
2. Confirm there’s really trouble existing；
3. During checking, do not neglect vehicle periodic maintenance, cylinder pressure, valve timing, fuel supply
and so on；
4. Replace ECU to test.
In case trouble disappears, then it’s a problem of ECU. If trouble still exists, then assemble original ECU and
check other points.
Frequent troubles list：
 When starting engine, engine cannot rotate or rotate slowly.
 When starting engine, starter motor can rotate but cannot start engine.
 Difficult to start warm or hot engine
 Difficult to start cold engine
 RPM is ok, but difficult to start engine.
 Starting is ok, but idle speed is unstable at any time.
 Starting is ok, but idle speed is unstable during engine warm-up period.
 Starting is ok, but idle speed is unstable after engine warm-up.
 Starting is ok, idle speed is unstable or engine stop when switch on some lights or other electric
components.
 Starting is ok, but too high idle speed.
 RPM cannot go up or engine stop when acceleration.
 Slow acceleration.
 Insufficient power and bad performance when acceleration.
17-13
17 TROUBLESHOOTING
（1）When starting, engine cannot rotate or rotate slowly.

Possible causes：1. battery；2. starter motor；3. wiring or ignition switch；4. engine mechanical part.
General operation procedures：
Item operation procedures Result Then
No.
Use multimeter to measure voltage between positive and Yes Next step
1 negative terminals of battery, normal value should be 8-12V
No Replace battery
when starting engine.
Keep ignition switch on starting position, then use multimeter to Yes Next step
2 measure voltage of positive terminal of starter motor. Normal
No Repair or replace wiring
value should be more than 8V.
Remove starter motor and check if any open circuit or blocked Yes Repair or replace starter motor
3
by bad lubrication
No Next step
If trouble only exists in winter, then resistance of starter motor Yes Change good engine oil
4
is too big by unsuitable engine oil.
No Next step
Yes Check resistance inside engine
5 Check if mechanical resistance is too big inside engine
No Repeat above procedures
（2）When starting, starter motor can rotate but engine cannot be started.
Possible causes：1. No fuel inside fuel tank；2. Fuel pump；3. Pick-up；4. Ignition coil；
5. Engine mechanical part.
Item Operation procedures Result Then
No.
Switch on ignition switch(repeat several times if necessary)
Yes Next step
or start engine and use fuel pressure meter to measure fuel
1
pressure of fuel pump. Correct value should be around
No Check fuel supply system
330Kpa (3.30Bar)
Yes Next step
Use PDA to see RPM data, and start engine to check if any
2
RPM signal output. No Check RPM sensor wiring
Disconnect high-tension cable and connect spark plug, keep Yes Next step
3 spark plug 5mm away from engine body, then start engine to
check if any white/blue spark occurs. No Check ignition system
17-14
17 TROUBLESHOOTING
Yes Remove engine mechanical trouble

4 Check cylinder pressure if it’s enough or not
No Next step
Connect PDA and switch on ignition to check ECU-J2-15 pin Yes Use PDA to diagnose
5 and J2-18 pin if it is powered normally; Check ECU-J1-9 pin
and J2-2 pin if it is connected to ground normally. No Check and repair wiring circuit
（3）Difficult to start hot or warm-up engine

Possible causes：1. Fuel with water；2. Fuel pump；3. Water temp. sensor；4. Ignition coil.
No.
Yes Next step

Connect fuel pressure meter and start engine to measure
1
fuel pressure if it’s around 330Kpa (3.30Bar) Check and repair fuel supply
No
system
Disconnect high-tension cable and connect spark plug, keep Yes Next step
2 spark plug 5mm away from engine body, then start engine to
see if there’s blue and white spark. No Check and repair ignition system
Check and repair wiring or

Disconnect connector of water temp. sensor and start Yes
replace sensor
engine, check if engine can be started successfully. (or use a
3
300Ω resistant to connect water temp. sensor connector and No Next step
check if engine can be started successfully.
No Next step
Yes Change fuel
4 Check fuel quality and if it’s caused only after filling fuel.
No Next step
and J2-2 pin if it is connected to ground normally. No Check & repair wiring
（4）Difficult to start cold engine

Possible causes：1. Fuel with water；2. Fuel pump；3. Water temp. sensor；4. Injector；5. Ignition coil；
6.Throttle body and air by-pass valve；7. Engine mechanical part
17-15
17 TROUBLESHOOTING

no.
Yes Next step

Use fuel pressure meter and start engine to measure
1
if fuel pressure is around 330Kpa (3.30Bar)
No Check and repair fuel supply system
Disconnect high-tension cable and connect spark Yes Next step

2 plug, keep it 5mm away from engine body, then start
engine to check if there’s blue and white spark. No Check and repair ignition system
Disconnect connector of water temp. sensor, start

Yes Check and repair wiring or sensor
engine and check if it can be started successfully. (or
3
use 2500Ω resistant to connect sensor and check if
No Next step
engine can be started successfully.
Clean throttle body and air by-pass
Open throttle very slowly to check if it can be started Yes
4 valve
easily.
No Next step
Remove injector and use special cleaning equipment Yes Replace injector
5
to check if any leakage or blocked No Next step
Check fuel quality and if it is caused just after filling Yes Change fuel
6
fuel No Next step
Yes Remove engine mechanical problem
7 Check cylinder pressure if it is enough or not.
No Next step
Connect PDA and switch on ignition to check
Yes Use PDA to diagnose
ECU-J2-15 pin and J2-18 pin if it is powered normally;
8
Check ECU-J1-9 pin and J2-2 pin if it is connected to
No Check and repair wiring
ground normally.
（5）RPM is ok, but difficult to start engine at any time.
Possible causes：1. Fuel with water；2. Fuel pump；3.Water temp. sensor；4. Injector；5. Ignition coil；
6.Throttle body and air by-pass valve；7. Intake manifold；8. Ignition timing；9. Spark plug；
10. Engine mechanical part
No.
Check air filter if any blocked, or intake manifold if any Yes Check and repair intake manifold
1
blocked or leakage
No Next step
17-16
17 TROUBLESHOOTING
Yes Next step

Use fuel pressure meter and start engine to check if fuel
2
pressure is around 330Kpa (3.30Bar) Check and repair fuel supply
No
system
Disconnect spark plug cap and connect spark plug, keep it Yes Next step
3 5mm away from engine body, then start engine to check if
there’s blue and white spark. No Check and repair ignition system
Yes Next step

4 Check spark plug if it is under technical specifications.
No Adjust or replace
Check and repair wiring or replace
Disconnect water temp. sensor connector and start engine to Yes
5 sensor
check if it can be started successfully.
No Next step
Open throttle very slowly to check if engine can be started Yes Clean throttle body
6
easily. No Next step
Remove injector and use special cleaning equipment to check Yes Replace injector
7
if any leakage or blocked. No Next step
Yes Change fuel
8 Check fuel quality and if it is caused just after filling fuel.
No Next step
Yes Remove engine mechanical part
9 Check cylinder pressure if it is enough.
No Next step
Yes Next step
10 Check ignition timing if it is ok.
No Check and repair ignition timing
and J2-2 pin if it is connected to ground normally. No Check and repair wiring
（6）Starting is ok, but idle speed is unstable at any time

Possible causes：1. Fuel with water；2. Injector；3. Spark plug；4.Throttle body；5.Intake manifold；
6. Air by-pass valve；7.Ignition timing；8.Spark plug；9. Engine mechanical part
No
Check and repair intake manifold
Check air filter if any blocked, or intake manifold if any air Yes
1 system
leakage.
No Next step
17-17
17 TROUBLESHOOTING
Yes Clean or replace

2 Check if air by-pass valve is blocked
No Next step
Yes Next step
3 Check spark plug if it’s under technical specifications.
Check throttle body and by-pass air pipe if any carbon Yes Clean
4
deposit. No Next step
Remove injector and use special cleaning equipment to Yes Replace
5 check if any leakage, blocked or incorrect fuel flow and so
No Next step
on.
Yes Change fuel
6 Check fuel quality and judge it’s caused just after filling fuel.
No Next step
Yes Remove mechanical problem
7 Check cylinder pressure if it’s not enough.
No Next step
Check mechanical ignition timing if it’s under technical Yes Next step
8
specifications. No Check and repair ignition timing
and J1-2 pin if it is connected to ground normally. No Check and repair wiring
（7）Starting is ok, but idle speed is unstable during engine warming-up.

Possible causes：1. Fuel with water；2. Water temp. sensor；3. Spark plug；4. Throttle body and by-pass air
pipe；5.Intake manifold；6.Air by-pass valve；7. Engine mechanical part
Item Operation procedures Resul Then
No. t
Check air filter if any blocked or intake manifold any Yes Check air filter and intake manifold
1
leakage
No Next step
Yes Next step
Remove air by-pass valve and check throttle body, air Yes Clean it
3
by-pass valve and idle by-pass pipe if any carbon deposit. No Next step
Remove water temp. sensor and start engine to check if Yes Check wiring or replace sensor
4
engine can keep stable idle during warming-up. No Next step
Remove injector and use special cleaning equipment to Yes Replace
No Next step
on.
17-18
19 TROUBLESHOOTING
Check fuel quality and if it’s caused just after filling Yes Change fuel
6
fuel. No Next step
Yes Remove engine mechanical problem
7 Check cylinder pressure if it’s out of range.
No Next step
8
No Check and repair wiring
ground normally.
（8）Starting is ok, but idle speed is unstable after engine warming up.
Possible causes：1. Fuel with water；2. Water temp. sensor；3. Spark plug；4. Throttle body and idle by-pass
pipe；5. Intake manifold；6. Air by-pass valve；7. Engine mechanical part
Item Operation procedures Re- Then
No. sult
Check air filter if any blocked, and intake manifold if any Yes Check&repair air filter &intake manifold
1
leakage. No Next step
Yes Next step
Remove air by-pass valve, check throttle body, air Yes Clean it
3
by-pass valve and it pipe if any carbon deposit. No Next step
Disconnect connector of water temp. sensor and start Yes Check & repair wiring or replace sensor
4
engine to see if any unstable idle during warming up No Next step
Remove injector and use special cleaning equipment to Yes Replace it
5 check if any leakage, blocked or incorrect fuel flow and
No Next step
so on.
Yes Change fuel
6 Check fuel quality if it’s caused just after filling fuel.
No Next step
Yes Remove mechanical problem
7 Check cylinder pressure if it’s out of range.
No Next step
Connect PDA and switch on ignition to check Yes Use PDA to diagnose
8
No Check & repair wiring
ground normally.
Turn off ignition, and switch on ignition to restart engine Yes
9
after 3 seconds. No Check & repair wiring
（9）Starting is ok, but idle speed is unstable or killed off when lights (or other electrical components) switched
on.
17-19
17 TROUBLESHOOTING
Possible causes： 1. Air by-pass valve；2. Injector

Item Operation procedures Results Then
No.
Remove air by-pass valve, check throttle body, air by-pass Yes Clean it
1
valve and it pipe if any carbon deposit. No Next step
Check engine output power if it is too big when switching Yes Operate step 4
2 on electric components. And use PDA to check advanced
ignition angle, fuel spray width and air intake flow. No Next step

No Next step
on.
Connect PDA and switch on ignition to check ECU-J2-15
pin and J2-18 pin if it is powered normally; Check
4
ECU-J1-9 pin and J2-2 pin if it is connected to ground
No Check&repair wiring
normally.
（10）Starting is ok, but idle speed is too high.

Possible causes：1.Throttle body and idle pipe； 2.Injector seat；3. Air by-pass valve；4. Water temp. sensor；
5. Ignition timing
No.
Yes Adjust
1 Check throttle cable if it is blocked or too tight.
No Next step
Yes Check&repair air intake system

2 Check air intake system and injector seat if any leakage
No Next step
3
valve and its pipe if any carbon deposit. No Next step
Check&repair wiring or replace
Disconnect connector of water temp. sensor and start Yes
4 sensors
engine to check if idle speed is too high.
No Next step
Yes Next step
5 Check ignition timing if it is under technical specifications.
No Check & repair ignition timing
Turn off ignition, switch on ignition after 3 seconds and Yes
6
restart engine. No Check & repair wiring
17-20
17 TROUBLESHOOTING
and J2-2 pin if it is connected to ground normally. No Check &repair wiring
（11）RPM cannot go up or engine stop when acceleration

Possible causes：1. Fuel with water；；2.Air intake sensor and TPS；3. Spark plug；4.Throttle body and its idle
pipe；5.Intake manifold；6.Air by-pass valve；7. Injector；8.Ignition timing；9. Exhaust pipe
General diagnosis procedures：
No.
Check air filter if any blocked, and intake manifold if any Yes Check&repair air intake system
1
leakage.
No Next step
Use fuel pressure meter and start engine to measure fuel Yes Next step
2 pump pressure. Normal value should be around 330Kpa
(3.30Bar) No Check&repair fuel supply system
Yes Next step

4
valve and it pipe if any carbon deposit. No Next step
Yes Next step
5 Check air intake temp. sensor, TPS and its wiring if it is ok. Check&repair wiring or replace
No
sensor
No Next step
on.
Yes Change fuel
7 Check fuel quality and if it’s caused just after filling fuel.
No Next step
Check ignition order and ignition timing if it is under Yes Next step
8
technical specifications. No Check&repair ignition timing
Yes Next step

9 Check exhaust pipe if any leakage or blocked.
No Repair & replace exhaust pipe
Connect PDA and switch on ignition to check ECU-J2-15
pin and J2-18 pin if it is powered normally; Check
10
ECU-J1-9 pin and J2-2 pin if it is connected to ground
normally.
17-21
17 TROUBLESHOOTING
（12）Slow acceleration
Possible causes：1.Fuel with water；2. Air intake pressure sensor and TPS；3. Spark plug；4. Throttle body
and its idle pipe；5. Intake manifold；6. Air by-pass valve；7. Injector；8. Ignition timing；9. Exhaust pipe
No.
Check air filter if any blocked, and intake manifold if Yes Check&replace air intake system
1
any leakage.
No Next step
Use fuel pressure meter and start engine to Yes Next step
2 measure fuel pump pressure. Normal value should
be around 330Kpa (3.30Bar) No Check&repair fuel supply system
Check spark plug if it’s under technical Yes Next step

3
specifications. No Adjust or replace
Remove air by-pass valve, check throttle body, air Yes Clean it
4
by-pass valve and it pipe if any carbon deposit.。 No Next step
Yes Next step
Check air intake temp. sensor, TPS and its wiring if it
5
is ok. No Check&repair wiring or replace sensor
Remove injector and use special cleaning Yes Replace it

6 equipment to check if any leakage, blocked or
No Next step
incorrect fuel flow and so on.
Check fuel quality and if it’s caused just after filling Yes Change fuel
7
fuel. No Next step
8
Yes Next step

No Repair or replace exhaust pipe
ECU-J2-15 pin and J2-18 pin if it is powered
10
normally; Check ECU-J1-9 pin and J2-2 pin if it is
connected to ground normally.
（13）Power not enough when acceleration and bad performance

Possible causes：1.Fuel with water；2. Air intake pressure sensor and TPS；3. Spark plug；4. Ignition coil；
5. Throttle body and its idle pipe；6.Intake manifold；7.Air by-pass valve；8. Injector；9. Ignition timing；10.
Exhaust pipe
17-22
17 TROUBLESHOOTING

No.
Check if any clutch slippery, or tire pressure too low, or Yes Repair
1
brake too tight, or tire size incorrect and so on. No Next step
Check air filter if any blocked, and intake manifold if any Yes Check&repair air intake system
2
leakage.
No Next step
Use fuel pressure meter and start engine to measure fuel Yes Next step
3 pump pressure. Normal value should be around 330Kpa
(3.30Bar) No Check&repair fuel supply system
Yes Next step

Disconnect high-tension cable, and connect spark plug,
4
keep it 5mm away from engine body to check if spark is ok.
No Check&repair ignition system
Yes Next step

6
valve and it pipe if any carbon deposit.。 No Next step
Yes Next step
7 Check air intake temp. sensor, TPS and its wiring if it is ok. Check&repair wiring or replace
No
sensor
No Next step
on.
Yes Change fuel
9 Check fuel quality and if it’s caused just after filling fuel.
No Next step
10
Yes Next step

No Repair or replace exhaust pipe
Connect PDA and switch on ignition to check ECU-J2-15 Yes Use PDA to diagnose
12 pin and J2-18 pin if it is powered normally; Check ECU-J1-9
pin and J2-2 pin if it is connected to ground normally. No Check&repair wiring
17-23

CF800 2 Service Manual

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CF800 2 Service Manual

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FOREWORD INDEX

This manual introduces CF800-2 maintenance

All rights reserved Lights,Instrument,Switches 16

Item Example Conversion

engine in an enclosed or poorly ventilated area.

Wear long-sleeve work clothes and gloves for operation.

is also explosive. Operate in a well-ventilated area.

Item Standards Service Limit

Oi l C hange 3400ml(wi thout oi l fi lter replacement) -

Oi l C hange 3500ml(wi th oi l fi lter replacement)

Oi l Insi de the Oi l Radi ator

20W-50 Recommended engine oil:SAE 15w40 API SG.If it’s not

C learance Between Inner

C learance Between Outer

1500rpm:70-300kPa(90 ),Typi cal:180kPa

Air Intake System

Item Standards and Specifications

Fuel Tank Total C apaci ty 23L

Throttle Body Part NO. 0800-173000

T-MAP Sensor Part No. 0800-175000

Fuel Injector Part No. 0800-171000

Idle Speed 1300 100rpm

Full capac ity 3000ml

Wa te r Resistant of B Resistant of A,C

O F F - ON Around 88℃ Around 88℃

Item Standard value Service limit

Item Standard value Service limit

Valves & Cylinder Head

Cylinder, Piston, Piston Ring & Crankshaft

Clutch + CVT + Gearbox

Ref. No. Items Part number Qty Torque（N·m）

1 Mount bolt, upper part of engine GB5789 M8×35 2 35～45

2 Bolt, upper bracket of engine GB5789 M10×1.5×20 2 40～50

5 Mount bolt, front bracket of engine GB5789 M8×20 6 35～45

6 Mount bolt, rear part of engine GB5789 M10×1.25×170 1 40～50

7 Bolt, rear bracket of engine GB5789 M8×20 6 35～45

8 Bolt, rocker arm GB5789 M10×1.25×70 16 40～50

11 Bolt, bracket of rear wheel axle GB5789 M10×1.25×140 4 40～50

12 Mount nut, rim 901B-070002 16 70～80

13 Nut, rim shaft 901-07.00.03 4 110～130

14 Bolt, rear brake caliper GB70 M10×1.25×20 2 30～40

15 Bolt, front brake disc 901-08.00.03 8 25～30

16 Bolt, front brake caliper GB5789 M8×16 4 15～25

17 Bolt, cover of handlebar GB5789 M8×55 4 15～25

18 Mount bolt, muffler GB5789 M10×1.25×70 1 40～50

29 Lower bolt, muffler body GB5789 M8×68 1 15～25

20 Bolt, muffler clamp GB5789 M8×35 1 15～25

21 Bolt, rear axle GB5787 M10×1.25×110 2 40～50

22 Bolt, front axle GB5787 M10×1.25×90 1 40～50

23 Bolt, front axle GB5787 M10×1.25×25 2 40～50

24 Bolt, bracket of front axle GB5789 M8×14 2 15～25

25 Bolt, rear end of rear drive shaft 9010-300001 6 40～50

26 Bolt, front end of rear drive shaft 9010-290001 4 30～40

27 Bolt, front drive shaft 9010-290001 8 30～40

28 Bolt, output coupler GB5789 M10×1.5×30 1 40～50

30 Nut, tie rod GB9457 M10×1.25 4 30～40

Item Qty Dia. Of thread(mm) Torque (N.m) Remarks

Item Qty Thread Dia. (mm) Torque (N.m) Remarks