Manual Servicio Papio125

PAPIO-III
CF125-3A
http://www.cfmoto.com
Edition Date: 20190311
Edition Item: CF125-3A(6FIA-WX-01-2)SM-20190311.pdf
Website: www.cfmoto.com
INTRODUCTION INDEX
This manual introduces CF125-3A
General Information 1
maintenance information, including
Maintenance Information 2
disassembly procedure checking
Technical Information 3
&adjustment methods, troubleshooting and
Seat 4
technical specifications. There are some
Fuel Tank Assy 5
illustrations, drawing to guide your operation.
Lights, Dashboard and Switches 6
The first three chapters mainly introduce
general operation information, special Air Filter Assy 7
tool, vehicle structure, basic specification, Electrical System 8
inspection&maintenance methods etc,. Muffler Assy 9
The rest chapters introduce vehicle part Wheels and Brake System 10
removal, installation, adjustment, service, Shock Absorbers and Rear Fork 11
fault diagnosis and etc,. Engine Assy 12
CFMOTO has the copyright and final Handlebar Assy 13
interpretation of this manual. Do not copy, Triple Clamps 14
translation without CFMOTO permit. Any Ignition System 15
transmission or recording is prohibited. Cleaning and Conservation 16
This manual has been improved by using Storage 17
many ways to make it accuracy. But we are Start Diagram Appendix A
no response for any difference and missing. EFI Diagram Appendix B
CFMOTO reserves right to make Electrical Diagram Appendix C
improvements and modifications to the
products without prior notice. Overhaul and
maintenance should be done according to
actual condition of vehicle. And CFMOTO is
not responsible for production improvements
and modifications. This manual is only for
reference. If any objections, please ask the
nearest dealer to get the latest information.
The information in this manual are the latest
depends on latest productions on coming out.
The images in this manual may not stand for
real model assy and parts.
Production CF125-3A is accordance with
standard: Q/CFD 013.
The manual standard: GB/T9969-2008 and
GB/T19678-2005.
C F M O TO r e s e r v e s r i g h t t o m a k e
improvements and modifications to
the products without prior notice.
Overhaul and maintenance should be
done according to actual condition of
vehicle.
CFMOTO CO.LTD
R&D
Conversion table
A Ampere lb Pound
ABDC After bottom dead m Meter
center
AC Alternating current min Minute
ATDC After top dead center N Newton
BBDC Before bottom dead Pa Pascal
center
BDC Bottom dead center PS Metric horse power
BTDC B T D C B e f o r e t o p Psi Pound/Square Inch
dead center
°C Centigrade r Revolutions
DC Direct current rpm Revolutions per
minute
F Farad TDC Top dead center
°F Fahrenheit TIR To t a l i n d i c a t o r
reading
ft Feet V Volt
g Gram W Watt
h Hour Ω Ohm
L Litre in Inch
US gal Gallon(US) US qt Quart(US)
oz Ounce HP British horsepower
cm Hg C e n t i m e t e r o f pint Pint
mercury
cu in Cubic inch mL Milliliter
Forward
This service manual is not only specially designed for professional machinist, but also
it is used to instruct the vehicle’s user how to do maintenance work. It is necessary to
know mechanical knowledge, tools proper usage and have a well understanding of
service procedure Conversion before you perfectly solve all service problems. If no,
you should get the service support by professional machinist. Please read this service
manual and understand it before operate for high efficiency work. And working in clean
area. For vehicle mechanical performance and safety works. No tools replaced or
use temporary tools since that we have been appointed the special service tools and
equipment. All service and scheduled maintenance should be executed base on the
instructions of service manual. Any consequences are responsible by the vehicle’s
owner resulted from any rule-breaking operations.
How to get Long Service Life:

●Follow scheduled maintenance and service operations base on service manual.
●Non-periodical maintenance in special situations.
●Use tools properly and use CFMOTO genuine parts.
●Special tools, dashboard and tester have been listed into this service manual for
necessary genuine parts.
●Strictly operated bas on the correct service procedures.
●Keep fully service records and specify the date of new parts replacement.
How to use this manual:

In this manual, the production will be separated as several systems. All the systems are
shows up in the contents. That will help you to lock the chapter. And each chapter has its
own contents. For example, If you wanna see ignition coil information, use the contents
to find our the electrical system and find the ignition coil in electrical system chapter.
Whenever you see the warning or warning symbol, you must keep attention and
comply with the safety operation and maintenance method
Danger: This symbol means it will cause serious injuries even death if you
don't follow the procedure.
Warning: This symbol means the special steps. It may cause the vehicle
damage if you don't follow the procedure.
Note: This symbol means the special steps for higher efficiency and easier
working.
The other three symbol as following in order to distinguish the different levels of warning
information in service manual.
●Procedure or operation should be acted.
○One step of procedure or how to operate after procedure finished. Probably it is the
guidance before attention matters.
★ To take actions based on the front steps or test results from the front procedures. It
shows detail illustration including torque, lubrication oil, and lubrication grease or tighten
glue during assembling instruction.
01 General Information
1.1 Operation Caution�� 1-1
1.2 Disassembly&Assembly Attentions�� 1-3
1.3 Location of VIN/EIN�� 1-7
1.4 Wire, Pipe and Cable Diagram�� 1-8
1.1 Operation Caution
Note: Exhaust contains toxic Note: When the engine just stops,
ingredients. Never run the engine in the temperature of engine, muffler is
enclosed or poorly-ventilated areas. still high. Never touch them with bare
hands to avoid getting burnt. Wear a
uniform with long sleeves and gloves
during operation.
Note: The liquor (dilute sulfuric acid)

in Battery is strongly corrosive. It may
burn the skin and blind the eyes. If you
contact the liquor, wash it with plenty Note: The coolant is poisonous,
of clean water immediately, and seek Never drink it. Neither let it contact
for medical treatment. Besides, wash the skin, eyes or clothes. If it contacts
it with plenty of clean water when it skin or clothes, rinse it immediately.
contacts the clothes to avoid skin If it contacts eyes, wash it with plenty
burnt. The battery and battery liquor of clean water immediately and seek
must be stored strictly out of the reach for medical treatment. If accidental
of children. drinking of the coolant, attempt to spit
it out/gargle it, and seek for medical
treatment immediately. The coolant
must be stored strictly out of the reach
of children.
1-1
CFMOTO
Note: Must wear uniform (pilot Note: No smoking or naked fire
uniform etc), cap, safety boots during at the operation site, because the
operation. Wear safety articles such gasoline is combustible. Not only
as dust-proof goggles, dust proof flames, but electric sparks shall be
respirator and gloves when necessary. avoided. Besides, the vapored gasoline
is explosive. Operate in the place with
nice ventilation.
Note: The battery may produce

combustible and explosive hydrogen
when being charged. It may explode Note: The operators shall remind
if there is a flame or electric spark. each other from time to time for safety
Charge it in the place with nice purpose during operation.
ventilation.
Note: Never touch the rotating or

movable pieces such as wheels, clutch,
etc. Pay attention not to get pinched
during operation.
1-2
1.2 Disassembly&Assembly
Attentions ■ Clean the mud, dust before
■ Use CFMOTO genuine or overhauling.
recommended parts, lubricants and
grease.
■ Replace t he removed washer s,

o-rings, piston pin circlips, cotter pins
■ Place and store the disassembled with new ones.
parts separately for correct assembly. ■ Elastic circlips might get distorted
after disassembly. Do not use the
loosened circlips.
■ Clean and blow off the detergent

after disassembling the parts. Apply
lubricant on the surface of moving ■ Measure the data during disassembly
parts. for correct assembly.
1-3
CFMOTO
■ If not know the length of screws, ■ Pre-tighten bolts, nuts and screws,
install the screws one by one and then tighten them according to the
tighten with same torque. specified torque, from big to small and
from inner side to outer side.
■ Check if the disassembled rubber

parts are aged. Replace it if necessary. ■ Apply or inject recommended
Keep the rubber parts away from the lubricant to the specified parts.
grease.
■ If remove the ball bearing by pressing

■ Use special tools when necessary. the balls, the removed bearings should
not be used again.
1-4
■ Turn the ball bearing with hands ■ Install the one-side dust-proof
to make sure the bearing will turn bearing in the right direction. When
smoothly. assembling the open type or double-
Replace if the axial or radial play is too side dust-proof bearing, the side with
big. manufacturer ’s mark should face
If the surface is uneven, clean with oil outside.
and replace if the cleaning does not o n e - s i d e d d u s t Tw o - s i d e d d u s t
work. proof proof
When pressing the bearing into the
machine or to the shaft, replace the
bearing if it could not be pressed
tightly.
one- type
■ The circlip with chamfering side

should be towards force direction.
Loosened circlips can not be used.
Turn the circlip after installation to
■ Keep the bearing block still when make sure it is has been installed into
blowing the bearing after washing. the slot.
Apply oil or lubricant before assembly.
circlip
chamfer
■ After assembly, check if all the ■ Brake fluid and coolant may damage
tightened pats are properly tightened coating, plastic and rubber parts. Flush
and can move smoothly. these parts with water if splashed.
1-5
CFMOTO
■ Install oil seal with the side of ■ When installing pipes, insert the pipe
manufacturer’s mark facing outside. till the end. Fit the pipe clip, into the
·Do not fold or scratch the oil seal lip. rove. Replace the pipes or hoses that
·Apply grease to the oil seal lip before cannot be tightened.
assembly.
dent
manufacturer
identification grease
clip
joint
■ Clean the gaskets and washers of the

■ Do not mix mud or dust into engine engine cases before assembly. Remove
or the hydraulic brake system. the scratches on the contact surfaces
by polishing evenly with an oil stone.
■ Do not twist or bend the cables too

much. Distorted or damaged cables ■ When assembling the parts like
may cause poor operation. protection caps, insert the caps to the
grooves.
cap
1-6
1.3 Location of VIN/EIN
Model: CF125-3A
VIN: ★ LCEPBJL4 ××××××××× ★
EIN: 157FMI-2B
010701
EIN VIN
010702 010703
1-7
CFMOTO
1.4 Wire, Pipe and Cable Diagram
2
4
010801
Wire harness, Wire harness, Wire harness Switch
1 2 3 4
ignition lock dashboard joint, headlight connector
5
6
13
8
12
11 9
10
010802
5 Fuel tank 8 Ignition coil 11 Throttle body
6 Fuel level sensor 9 Spark Plug 12 Canister adsorption tube
Canister magnetic Canister desorption
7 10 13 Canister
valve tube
1-8
1
3
2
6 4
5
010901
High pressure
1 3 Main cable 5 Regulator
fuel hose
2 Starter relay 4 ECU 6 Starter motor
8 9
010902
7 Auxiliary relay 8 Diagnostic connector 9 Fuse box
1-9
CFMOTO
1 2
011001
1 Sensor connector, air temp.&pressure
2 Stepping motor
3 Sensor connector, throttle position
6 5
011002
Negative cable, Positive cable,
4 Battery 5 6
battery battery
1-10
011101
1 Fuel pump 2 Fuel filter 3 Flasher
011102
4 Cable connector, fuel injector
1-11
CFMOTO
011201 011202
4 5
011205 011204
6
8
011205 011206
Cylinder head
1 Gear sensor 3 Roll-over sensor 5 7 Ignition lock
temp. sensor
2 Speed sensor 4 Oxygen sensor 6 Dashboard 8 Rear brake switch
1-12
Fuel evaporation system diagram
Fuel tank assy

Canister desorption pipe
Anti-rollover valve
Canister
Canister adsorption pipe
Exhaust pipe, fuel tank Canister magnetic valve
Adsorption pipe II, engine
Engine
Adsorption pipe I, engine 011301
Attention: To fixed the anti roll-over valve as horizontal position. Don’t change
the fuel evaporation system. Tube connection should be well connected after
maintenance by disassembling without air leakage, blocking, squeezing, broken
and damage etc. Fuel steam will be released into carbon tank by absorption tube
from fuel tank. Absorbing fuel steam by active carbon when engine stop; Fuel
steam of carbon tank will follow into combustor for burning when engine working
in order to avoid environment pollution if fuel stem released into air directly.
Meanwhile, Air pressure of fuel tank should be balanced by absorption tube.
If inner pressure of fuel tank is lower than outside, it is available to replenish
air pressure by air tube of carbon tank or absorption tube. So, All tube system
should be smooth running without blocking and squeezing, otherwise fuel pump
will be damaged, fuel tank will be deformed or broken
1-13
02 Maintenance Information
2.1 Maintenance before Operation�� 2-1
2.2 Break-in Maintenance Schedule�� 2-2
2.3 Periodic Maintenance Schedule�� 2-3
Cautions:
► = Severe Use Item. Reduce interval by 50% on vehicles subjected to severe use.
■ = Have an authorized dealer perform repairs that involve this component or system.
2.1 Maintenance before Operation

Maintenance before operation
Item
Hour Calendar km Remarks
Fuel system
Fuel hose - Daily - Inspect for aging
Electrical system
Switches - Daily -
Inspect
Lights and horns - Daily -
2-1
CFMOTO
2.2 Break-in Maintenance Schedule
Break-in Maintenance Interval
Item (Service whichever interval comes first)
Engine
■ Engine oil and oil filter - - 1000 Replace。
■ Oil strainer - - 1000 Clean
Idle - - 1000
Throttle system - - 1000 Inspect
Valve clearance 20h - 1000
Electrical system
■ Functions of electrical parts - - 1000
Battery - - 1000 Inspect
Fuses or circuit breakers - - 1000
Brake system
Brake discs - - 1000
Brake pads - - 1000 Inspect
Brake fluid level - - 1000
Inspect for free
Brake lever - - 1000
play
Inspect for damage
■ Brake hoses - - 1000
and sealing
Wheels
Tire condition - - 1000
Inspect
Tire pressure - - 1000
Suspension system
Inspect for leaking
Rear shock absorber and (maintain parts
■ - - 1000
front forks according to the
requirement)
Cooling system
■ Radiator fan function - - 1000 Inspect
Steering system
■ Steering bearings - - 1000 Inspect
Other parts
■ Diagnosis connector - - 1000 Read with PDA
Lubricate; inspect
■ Mobile parts - - 1000
for flexibility
■ Bolts and nuts - - 1000 Inspect for fastness
Inspect for damage,
■ Cables and wires - - 1000
bending and routing
2-2
02 Maintenance Information
2.3 Periodic Maintenance Schedule
Periodic Maintenance Interval
Engine
Engine oil and oil filter - 6M 5000 Replace
Oil strainer - 6M 5000 Clean
■ Clutch - - 5000
Inspect
Idle - - 10000
Throttle system - - 5000 Inspect
- - 5000 Inspect and clean
► ■ Air filter element
- 24M 20000 Replace
- - 5000 Inspect
■ Spark plug
- - 10000 Replace
■ Valve clearance - - 2500 Inspect
Electrical system
■ Functions of electrical parts - 12M 10000
Battery - 6M 5000 Inspect
Fuses or circuit breakers - 6M 5000
Inspect for damage,
■ Wires - 12M 10000
bending and routing
Brake system
- 12M 5000
Front and rear brake system
- 24M 15000
- 12M 5000
Brake discs
- 24M 15000
Inspect
- 12M 5000
► Brake pads
- 24M 15000
- 12M 5000
Brake fluid level
- - 15000
- 12M 5000 Inspect for free
Brake lever
- 24M 15000 play
- 12M 5000 Inspect for damage
■ Brake hoses
- 24M 15000 and sealing
■ Brake fluid 24M - Replace
Wheels
- 12M 5000
Tire condition
- 24M 15000
- 12M 5000 Inspect
Tire pressure
- 24M 15000
■ Wheel bearings - - 5000
2-3
CFMOTO
Periodic Maintenance Interval
Suspension system
- - 5000
■ Suspension system Inspect
- - 15000
Inspect for leaking
12M 5000
Rear shock absorber and (maintain parts
■
front forks according to the
- 24M 15000
requirement)
- - 5000
■ Swing arms Inspect
- - 15000
Cooling system
- 12M 5000
■ Radiator fan function Inspect
- 24M 15000
Frame system
Frame - - 30000 Inspect
Steering system
- - 5000
■ Steering bearings Inspect
- - 15000
Chain
Chain, rear sprocket and - - 5000
► Inspect
engine sprocket - - 15000
Other parts
- 12M 5000
■ Diagnosis connector Read with PDA
- 24M 15000
- 12M 5000 Lubricate; inspect
■ Mobile parts
- 48M 15000 for flexibility
- 12M 5000
■ Bolts and nuts Inspect for fastness
- 48M 15000
- 12M 5000 Inspect for damage,
■ Cables and wires
- 24M 15000 bending and routing
Pipes, ducts, hoses and - 12M 5000 Inspect for cracks,
■
sleeves - 48M 15000 sealing and routing
2-4
03 Technical Information
3.1 General Specifications�� 3-1 3.4 Service Specification�� 3-4
3.2 Engine Specification Chart� 3-2 3.5 Tighten Torque �� 3-7
3.3 Maintenance Specifications 3.6 Consumption Materials &
Chart�� 3-3 Assembling Materials�� 3-9
3.1 General Specifications

Item Specifications
Model CF125-3A
Length 1724mm
Width 750mm
Height 995mm
Wheel base 1214mm
Engine model 157FMI-2B
Displacement 126mL
Fuel grade 95# or above
Gross weight 114kg
Passengers Persons (including driver )
Load 150kg
Front 120/70-12 51L
Tire
Rear 130/70-12 56L
Min. ground clearance 145mm
Turning circle diameter 3.95m
Right 40°
Steering Steering angle
Left 40°
Front Hydraulic Disc
Brake system
Rear Hydraulic Disc
Front wheel Telescopic
Shock absorber Suspension
Rear wheel Cantilever type
Frame Steel tube
Item Standard
Fuel capacity 7L
Injector Type: 25335288
Voltage: DC13.5V±0.3
Fuel supplier Pressure: 0.25MPa±0.01MPa
Fuel pump
Flow: ≥40L/h
Current: ≤2.5A
Idle speed 1500r/min±150r/min
3-1
CFMOTO
3.2 Engine Specification Chart
NO. Item Type/Specification
Single cylinder/4-stroke/wind-cooled/2
1 Type
Valves/OHC
2 Bore × Stroke 57mm×58.6mm
3 Displacement 126mL
4 Compression ratio 9:1
5 Low idling speed(Idling) 1500r/min±150r/min
6 Starting Electric
Ignition type CID
7 Electrical system Spark plug/Electrode gap CR8E/0.7mm~0.9mm
Magneto type Out rotor, flywheel
Combustion chamber Triangular
Combustion
8 Air filter type Sponge, paper filter
system
Gasoline RQ-95 and above
9 Valves system Valves type SOHC/chain drive
Lubrication type Pressure and splash
Oil pump type Rotor drive
10 Lubrication system
Oil filter type Paper type, replaceable
Engine oil type SAE15W-40/SG
Clutch Wet and multi plate manual clutch
Transmission type 6-gear, constant mesh, step transmission
Reducer gear 6 gears
Mechanical reciprocating /1-0-2-3-4-5-
Gearshift methods/orders
6-5-4-3-2-0-1
Drive Primary ratio 3.5
Gear ratio
11 trai n 1st 3
Secondary ratio
system
2nd 1.857
3rd 1.368
4th 1.143
5th 0.957
6th 0.875
L(mm)×W(mm)×H(mm):
12 Overall size
441mm×325mm×440mm
13 Dry weight 32.5kg
14 Output type Chain
15 Rotation of engine output When forward, counter clockwise(left view)
3-2
3.3 Maintenance Specifications Chart
Front wheel
Item Standard Service limit
Front wheel shaft bending - 0.2mm
Longitudinal 0.8mm 2.0mm
Rim run-out
Horizontal 0.8mm 2.0mm
Front Remaining groove - 1.6mm
wheel 1 passenger: 175kPa(1.75kgf/
Tire cm2)
Tire pressure -
2 passengers: 175kPa(1.75kgf/
cm2)
Rear wheel
Longitudinal 0.8mm 2.0mm
Rim run-out
Horizontal 0.8mm 2.0mm
Rear Remaining groove - 1.6mm
wheel 1 passenger: 200kPa(2.0kgf/cm2)
Tire
Tire pressure 2 passengers: 225kPa(2.25kgf/ -
cm2)
Brake system
Front (hand brake) free travel 10mm~20mm -
Front brake
Brake disc abrasion 4mm 3mm
Rear (foot brake) free travel 10mm~20mm -
Rear brake
Brake disc abrasion 4mm 3mm
Lighting/Dashboard/Switch
Item Standard
Primary 30A
Fuse
Subsidiary 10A×1 15A×4
Front headlight(Hi/Lo) 12V 35W/35W
Brake light/Tail light LED
Front&Rear turn signal light LED
Dashboard light LED
Light, bulb Turning Indicator light LED
High-beam indicator light LED
Gear indicator light LCD
Neutral gear indicator light LED
EFI trouble indicator light LED
3-3
CFMOTO
3.4 Service Specification
Valve Train / Cylinder Head
Item Standard Limit Remark
IN 25.5mm -
Dia. of valve head
EX 22.5mm
Valve clearance(cold IN 0.08mm~0.10mm -
engine) EX 0.15mm~0.19mm
Clearance, valve guide IN 0.01mm~0.037mm -
bush and valve stem EX 0.03mm~0.057mm -
I.D of valve guide bush IN&EX 5mm~5.012mm -
IN 4.975mm~4.990mm -
O.D of valve stem
EX 4.955mm~4.970mm
Run-out of valve stem IN&EX 0.03mm 0.05mm
Length, valve stem end IN&EX 2.7mm~3.3mm 2.2mm
Thickness, valve head IN&EX 0.7mm -
Seal run-out, valve head IN&EX 0.03mm -
Width, valve seat IN&EX 0.9mm~1.1mm -
Inner 32.54mm 31mm
Free length, valve spring
Outer 34.98mm 32.5mm
When compress to
Inner 26.78mm, elasticity is
33.733.7N~44.3N.
Valve spring force
When compress to
Outer 29.78mm, elasticity is -
88.6N~104N.
IN 33.67mm
Camshaft lift
EX 33.314mm -
Camshaft to hole clearance Φ22 0.032mm~0.066mm 0.150mm
O.D of camshaft Φ22 21.959mm~21.980mm -
I.D of camshaft mating
Φ22 22.012mm~22.025mm -
hole
Camshaft run-out 0.008mm
Dia., rocker arm shaft IN&EX 11.977mm~11.995mm -
I.D, rocker arm shaft hole IN&EX 12mm~12.018mm
Cylinder head warpage 0.03mm
Cylinder head cover
0.03mm
warpage
3-4
Cylinder/Piston/Piston Ring/Connecting Rod
Item Standard Service limit Remark
Cylinder pressure 1100kPa -
Piston-to-cylinder clearance 0.03mm~0.05mm
56.955mm~56.97mm
Dia. of piston at skirt -
(Measured at 7mm to skirt end)
I.D, cylinder 57mm~57.01mm -
Cylinder warpage 0.06mm -
1 Ring R About 7mm -
Piston ring free gap
2 Ring R About 7mm -
1 Ring 0.15mm~0.25mm -
Piston ring end gap
2 Ring 0.15mm~0.25mm -
P i s t o n r i n g t o g r o o v e 1 Ring 0.02mm~0.06mm
clearance 2 Ring 0.02mm~0.06mm -
1 Ring 0.97mm~0.99mm -
Thickness, piston ring
2 Ring 0.97mm~0.99mm -
1 Ring 1.01mm~1.03mm -
Width, piston ring groove 2 Ring 1.01mm~1.03mm -
Oil ring 2.01mm~2.03mm
I.D, piston pin hole 14.002mm~14.008mm -
O.D, piston pin 13.994mm~14.000mm -
I.D, connecting rod small end 14.006mm~14.014mm -
Connecting rod big end
0.15mm~0.40mm -
side clearance
Connecting rod big end
15.95mm~16.00mm -
thickness
Crankshaft run-out 0.04mm -
Lubrication System
Outer rotor to inner rotor
0.08mm~0.15mm -
clearance
Outer rotor to pump body
0.15mm~0.193mm -
clearance
Oil pressure 3000r/min 10kPa~30kPa -
Oil type SAE15W-40, API SG or above -
Change oil 1200mL -
Change filter 1250mL -
Oil capacity
At engine
1400mL -
overhaul
3-5
CFMOTO
Clutch/Transmission
Drive plate 2.9mm~3.1mm 2.8mm
Quantity of drive plate 5
Driven plate 1.5mm~1.6mm -
Driven plate warpage 0.10mm
Quantity of driven plate 4
Free length, clutch spring 30.4mm~31.6mm 29.5mm
Quantity of spring 5
Thickness, gear NO.1 & NO.2 5mm~5.15mm -
groove N O.3 5.5mm~5.65mm -
Thickness, gear NO.1 & NO.2 4.8mm~4.9mm -
shift fork N O.3 5.3mm~5.4mm -
Air Inlet System

Item Specification Remark
Throttle model 0KIA-173000 DELPHI
Mouth size Φ28mm
Idle 1500r/min±150r/min
Electrical System
Item Specification Remark
Model CR8E
Spark plug
Gap 0.7mm~0.9mm
Spark >8mm, 1MPa
Primary
0.7Ω~0.75Ω
I g n i t i o n c o i l Coil
resistance Secondary
6.0kΩ~7.0kΩ
Coil
Magneto coil
Trigger 100Ω~160Ω
resistance
Magneto Voltage, unloading
>50V(AC),5000r/min
state (cold engine)
Max power 180Q,500r/min
Stabilized voltage 13.5V~15.0V,5000r/min
Primary peak voltage, ignition coil ≥27kV
Peak voltage, exciter coil >1.5V
Resistance, starter relay coil 3Ω~5Ω
3-6
3.5 Tighten Torque
Tighten Torque Table for Vehicle
Item Torque N•m(kgf•m) Category Torque N•m(kgf•m)
5mm screw 4(0.4)
5mm bolt, nut 5(0.5)
6mm screw 9(0.9)
6mmSH Flange bolt 10(1.0)
6mm Flange bolt, nut 12(1.2)
Please use standard torque, if without torque value mentioned below table.
Note: 1. Lubrication oil should be created on screw thread and contact surface
2. Replace when self-locking bolts disassembled.
Thread dia. Torque

Item Qty. Remark
(mm) N·m(kgf·m)
Engine
Engine lifting bracket bolt 8 8 30(3.1)
Engine lifting shaft nut 1 14 65(6.6)
Front wheel, front suspension, steering
Steering column lock nut 1 22 100(10.1)
Handlebar fastening screw 4 8 20(2.1)
Front wheel shaft 1 12 65(6.6)
Upper fastening bolt, shock absorber 2 8 34(3.5)
Lower fastening bolt, shock absorber 2 10 40(4.1)
Rear wheel, rear suspension
Rear wheel shaft nut 1 14 65(6.6)
Upper fastening bolt, shock absorber 1 10 40(4.1)
Lower fastening bolt, shock absorber 1 10 40(4.1)
Brake system
Front brake disc mounting bolt 3 8 30(3.1)
Front brake caliper mounting bolt 2 8 30(3.1)
Muffler
Mounting nut, Muffler front exhaust
2 8 26(2.7)
pipe
Muffle r body mounting bolt 1 8 20(2.1)
3-7
CFMOTO
Tighten Torque Table for Engine
Thread dia. Torque
Item Qty. Remark
(mm) (N•m)
Bolt, Crankcase 17 M6 10~12
Bolt, Oil pump 3 M6 10~12
Screw cap, front left side cover 1 M26×1.5 12~15
Bolt, tensioner plate 1 M8 18~25
Bolt, overrunning clutch 3 M8 28~32 Apply thread locker
Bolt, flywheel 1 M12 65~70 Apply thread locker
Bolt, magneto stator 3 M5 10~12 Apply thread locker
Bolt, trigger 2 M5 8~10 Apply thread locker
Nut, clutch 1 M16 47~53 Apply thread locker
Nut, balance shaft 1 M14×1.5 47~53
Bolt, clutch 5 M5 4.5~6 Apply thread locker
Bolt, primary drive gear 1 M16×1.5-L 87~93
Crankcase drain bolt 1 M14×1.25 25~30
Bolt, oil pass 1 M14×1.25 25~30
Two-end bolt (match with left
2 YM8 7~11
crankcase)
Two-end bolt (match with right
2 YM8 7~11
crankcase)
Bolt, cylinder cover (top end) 4 M8 28~32
Spark plug 1 M10 10~15
Bolt, timing chain 2 M6-10.9 15~18 Apply thread locker
Adjusting nut, valve clearance 4 M6×0.75 12~14
M5 4.5~6
Other screws, bolts and nuts M6 10~12
M8 18~25
3-8
3.6 Consumption Materials & Assembling Materials
Consumption materials include lubricant oil (engine oil), lubricant grease (butter) and
coolant. Assembling materials include flange sealants, thread locker.
Vehicle Consumption Materials
Application areas Notes Type
Vehicle’s head pipe, bearing
races wheel dust-proof seal
lip
Rear brake, cam joint, cam
joint, dashboard flexible
shaft joint, throttle cable
Multi-purpose lithium base
Throttle handlebar part
lubrication oil
Pivot, rear pedal(LH),
Pivot, rear pedal(RH),
Pivot, side stand
Oil seal lip, rear fork
Gear surface and running
part, counter gear/small gear
Thread of rear wheel axle
Engine oil
nut and joint
Lower dust-proof seal lip of
Absorber oil 5#
front shock absorber
Engine Consumption Materials & Assembling Materials

Item Specification Using parts Remark
Rotation and moving
section in cylinder
Oil Capacity
Rotation and moving
1200mL(at oil change)
For 4-stroke motorcycle section in crankcase
1250mL(at oil change
Lubricant oil SAE 15W-40 API SG Rotation and moving
and filter change)
or above section in cylinder
1400mL(at engine
head
overhaul)
Details in Lubrication
System Page
Piston pin, valve
Lubricant oil with
stem, valve oil seal,
molybdenum
camshaft
Oil seal, o-ring and
#3 MoS 2 lithium
Lubricant grease rubber seal face,
grease
bearing with sealant
Crankcase faying
face , Crankcase
and cylinder joint
Flange sealant
Cylinder head and
cylinder head cover
joint
Tread locker Parts of thread
3-9
04 Seat
4.1 Seat�� 4-1
4.1 Seat
Removal
Insert the key into seat lock 1 . 2
Turn the key clockwise.
Remove seat 2 .
Remove the key.
040101
Installation
Insert the seat into the seat groove 3 .
Press the front of the seat to slide into the
seat clasp 4 and seat lock slot 5 . 3
4
Note: Shake the seat after installation,
to ensure it is well installed.
5
040102
4-1
05 Fuel Tank Assy
5.1 LH&RH Panel �� 5-1
5.2 Fuel Tank Guard�� 5-1
5.2.1 Inner Side Plate�� 5-1
5.2.2 Fuel Tank Guard Assy�� 5-2
5.3 Fuel Tank�� 5-3
Danger:
In some situations, the gasoline is highly flammable and explosive.
Do not overfill the fuel tank. When the fuel reaches the neck of the oil filler, it is the
maximum capacity.
The engine must be stopped when refueling and must be refueled in a well-
ventilated area or outdoors
No smoking, open fire or sparkle in the refueling area or gasoline storage area.
If gasoline spills onto the skin or clothing, wash immediately with soap and water
or change the clothes.
Seek medical attention immediately if accidentally contact your eyes or swallow
gasoline.
5.1 LH&RH Panel
Removal
Remove two inner hex screws 1 .
Remove self-tapping screw 2 .
Remove LH penal 3 .
RH penal refers to LH removal procedures. 1
Installation 2
Reverse the removal procedures for 3

installation. 050101
5.2 Fuel Tank Guard
5.2.1 Inner Side Plate

Removal
Remove eight self-tapping screws 1 .
Remove two M6 bolts 2 on front inner side 1
plate.
Remove front inner side plate 3 . 3
Installation
installation.
050102
5-1
CFMOTO
5.2.2 Fuel Tank Guard Assy
Removal
Remove bolt 1 .
Remove bolt 2 .
050201
Remove two self-tapping screws 3 .
050202
Lift fuel tank cap.

Insert the key. 4
Rotate the key clockwise.
Remove fuel tank cap 4 .
When installing, fuel tank lock returns
automatically.
050203
Remove three inner hex bolts 5 .

Remove fuel tank protection panel assy 6 . 5
050204
5-2
05 Fuel Tank Assy
Remove six self-tapping screws 7 .
Disassemble fuel tank LH panel 8 , RH
panel 9 and middle guard 10 . 8
7
10
Installation
Reverse the removal procedures for
installation.
9
Note: After removing fuel tank guard 050301
assy, close fuel tank cover.
5.3 Fuel Tank 2

Removal
Remove four mounting bolts 1 .
Lift fuel tank 2 . 1
Note: Fuel tank inversion is forbidden.

Otherwise, the fuel will leak from fuel
050302
tank cover.
Fold and pull out the adsorption hose 3 .

Pull out high-pressure hose quick joint 4 .
Warning: Do not spill fuel on high

temperature parts of the vehicle. Wipe 3
the fuel immediately when it spills. 4
050303
Loose fuel pump connector 5 .

Loose fuel level sensor connector 6 .
Installation
installation.
Note: When installing fuel tank, all 6
hoses, pipes and cables can not be
extruded. 5
050304
5-3
06 Lights, Dashboard and Switches
6.1 Maintenance Information�� 6-1 6.8 Front Brake Switch�� 6-5
6.2 Trouble Shooting�� 6-2 6.9 Rear Brake Switch�� 6-5
6.3 Dashboard and Headlight Assy 6.10 Left Handlebar Switch�� 6-6
�� 6-2 6.11 RH Handlebar Switch�� 6-6
6.4 Turning light�� 6-3 6.12 Horn�� 6-6
6.5 Rear Fender Bracket and Rear 6.13 Fuel Level Sensor�� 6-7
License Light�� 6-3 6.14 Auxiliary Starter Relay and
6.6 Tail Light/Brake Light�� 6-4 Fuel Pump Relay�� 6-8
6.7 Ignition Switch�� 6-5 6.15 Battery�� 6-9
6.1 Maintenance Information

Operation Caution
Warning:
·Headlight bulb has big power and 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 cause oil stains on the glass face which may form hot
spot and cause deformation of glass face and damage to bulb.
·Pay attention to the followings 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 stains on the glass
surface.
-Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of
any oil stains on the glass surface.
·If the Inspection has to be done check if the battery is normal.
·Inspection of switch continuity can be done without removing the switches from
the vehicle.
·After the inspecting and overhauling of each part, cables and wires should be
routed properly.
Inspection Standard
Item Standard
Main fuse 30A
Fuse
Auxiliary fuse 10A×1 15A×4
Headlight(Hi/Lo) 12V 35W / 35W
Brake light/tail light LED
Front and rear turning light LED
Speedometer light LED
Turning indicator light LED
Light&Bulb
High-beam indicator light LED
Gear indicator light LCD
Neutral indicator light LED
EFI malfunction indicator
LED
light
6-1
CFMOTO
6.2 Trouble Shooting
Head light cannot turn on, Hi/Lo switch
doesn't work:
Fuse is blown
Switch is damaged
Bulb is burnt
Battery bad connection or no electricity
Wire connector loosen
6.3 Dashboard and Headlight

Assy
Removal
Remove dashboard and the headlight at
the same time. 060201
Remove two expansion screws 1 on
dashboard deco cover. 2
Remove dashboard deco cover.
Remove three screws 3 .

3
060202
Remove three headlight mounting bolts 4 .

Pull out connectors of headlight and
dashboard.
Remove headlight assy.
Remove two nuts 2 .
Remove dashboard connectors.
Remove dashboard. 4
Installation
installation.
6-2
Headlight Body
2
Removal
Remove four mounting screws 1 .
Remove headlight body 2 .
Note: When headlight damages,
replace the whole set. 1 1
Installation
installation.
6.4 Turning light

(Four turning lights adopt the same
removal and installation procedures.)
Removal
Remove nut 1 . 1
Loose turning light connector.
Note: The turning light is consisted
of LED lights. When the turning light
damages, replace the whole set. 060302
Installation
installation.
6.5 Rear Fender Bracket and Rear

License Light
Rear Fender Bracket
Removal
Remove rear seat and pull out all the
harness wires. 060303
Remove four mounting screws 1 on rear
fender inner plate.
3
Remove three bolts 3 and fender bracket
2
2.
After rear fender and fender bracket 2
removal, then remove two bolts 4 .
4
Installation
installation.
060304
6-3
CFMOTO
Rear License Light
Removal
Remove rear license light upper&lower 1
seat bolts 3 .
Pull out license light wire harness.
2
Remove rear license light upper&lower
seat.
Remove three self-tapping screws 2 on
rear license light upper&lower seat. 3
060401
Remove rear license light 1 .
Installation
installation.
Note: The license light is consisted
of LED lights. When the license light
damages, replace the whole set.
6.6 Tail Light/Brake Light
Tail Cover
Removal
1
Disconnect tail harness connectors.
Remove two hex bolts 1 on top of the rear
protection panel .
Remove two inner hex bolts 2 on the two

060402
sides.
Remove four expansion screws 3 .
Pull back tail cover assy (including tail
cover) until the fit point separates.
Installation 3
installation.
2
Tail Light/Brake Light
Removal 060403
Remove two self-tapping screws 4 and
tail cover.
4
Remove connectors between tail light
and main cable. Remove four self-tapping 5
screws 5 .
Check tail light for damage. Replace if
necessary. 060404
Note: The tail light is consisted
of LED lights. When the tail light
damages, replace the whole set.
Installation
installation.
6-4
6.7 Ignition Switch
Removal
Remove two mounting bolts 2 .
Remove ignition switch cable connector.
Remove power lock 1 .
1
Inspection
Inspect the connection of each circuit.
Power function chart

Lock column 2
Color
Red Black can extend 060501
Gear
or not
● ● NO
NO
YES
Cable AVSS AVSS
specification 1.5MM2 1.5MM2
6.8 Front Brake Switch
Remove connector of front brake switch 1
. 1
Front brake switch inspection:
Grip front brake lever, the brake light is on.
060502
Loosen front brake lever, the brake light is
off.
6.9 Rear Brake Switch 1

Remove rear brake switch 1 cable to
check the switch cable connector.
Rear brake switch inspection:
Press rear brake pedal, the rear brake light
is on.
Loosen rear brake light is off.
060503
6-5
CFMOTO
6.10 Left Handlebar Switch

Remove connectors between left
handlebar switch and main cable to check
1
switch performance.
Tu r n i n g s w i t c h Dimmer switch
warning switch Color 2
L WL W
Color Action
O Gr Sb
Action ● ● 3
● ● ● ●
● ●
● ● ●
Clutch switch Horn switch 4

5
Color Color 060601
RG G Lg B Br
Action Action Override Warning Dimmer
1 2 3
Pull ● ● ● ● switch switch switch
Turning H o r n
4 5
switch switch
Override switch
Color
B Br L
Action
● ●
1
6.11 RH Handlebar Switch
Remove the connectors between right
handlebar switch and main cable to check
switch performance.
Illumination switch 2
Color
W G Br W L
Action
● ● ●
3
● ●
● 060602
Stop switch Start switch 1 Stop switch 3 Start switch
Color Color 2 Position light/headlight switch
W B B Br WB YR
Action Action
● ● 1
● ●
6.12 Horn 2
Removal
Remove horn connector 2 and loose bolt
1 to remove it.
Installation
6-6
6.13 Fuel Level Sensor
Removal
Remove seat and fuel tank.
Remove four mounting nuts and fuel tank
sensor 1 .
Note: Remove fuel level sensor
slowly, in case it deforms. 1
060701
Inspection
Inspect fuel level sensor seal ring 2
for deformation, damage or hardening.
Replace if it does.
Check the electrical resistance of the oil
level sensor at high and low poles.
Resistance: 2
High: 4Ω~10Ω
Low: 90Ω~100Ω
060702
Connect fuel level sensor and main cable.

Turn on ignition switch, the floater of fuel 3
level sensor swings up and down slowly.
See the fuel gauge pointer on dashboard.
If the pointer can not reach F or E, it
means the fuel gauge is not qualified,
replace a new one.
If the pointer swings unsteadily, it means
the fuel gauge is not qualified, replace a
060703
new one.
Installation
installation.
Note: Check leakage after fuel level

sensor installation.
6-7
CFMOTO
6.14 Auxiliary Starter Relay and
Fuel Pump Relay
A
Use multimeter to measure the resistance
between coils of starter relay
If the resistance is beyond specification,
replace a new one.
Turn multimeter to 1×10Ω
Auxiliary starter relay coil resistance:
3Ω~5Ω
B
060801
060802
Connect battery
1 Connect ground 2
positive pole
6-8
6.15 Battery
Warning:
1. Battery acid and gas will produce serious corrosion, avoid contacting with
battery acid and gas.
2. Keep batteries out of reach of children.
3. When battery acid contacts skin, wash with plenty of water. If battery acid
enters the eye, flush with water for at least 15 minutes and seek for medical help.
Note:
1. Please wear protective clothing and goggles. Keep the battery away from
sparks and open fire. Only charge the battery in a well-ventilated room.
2. Do not mis-connect the positive and negative pole of battery. Remove the
negative wire first if disassembling battery, in case it damages electrical elements.
The system of this vehicle uses negative earth mode.
3. Battery wires are not allowed to be removed while the engine is working.
4. Battery positive/negative wires and electrical control units have to be removed
before welding on the vehicle.
5. It is forbidden to puncture the wire to test the input/output electrical signals.
6. Establish the awareness of environmental protection and effective disposal of
waste generated during maintenance.
Removal
Remove seat.
Remove battery tie band 3 .
Remove battery negative wire fixing bolt.
Remove negative wire 1 from battery.
Remove battery positive wire fixing bolt.
Remove positive wire 2 from battery.
Remove battery 4 . 2
1
Installation
installation.
080901
6-9
CFMOTO
Note:
1. Even if the battery is not used, it also loses power every day.
2. Charging condition and charging mode are very important for the service life
of the battery. Using high charging current will have a negative impact on the
service life.
3. If the charging current, charging voltage and charging time are exceeded, the
battery will be damaged.
4. If the battery becomes empty due to repeated start of the vehicle, it needs to be
charged immediately.
5. When the battery is stored in the discharge condition for a long time, deep
discharge and sulfuric acid salination will occur, which damages the battery.
6. The battery does not need to be maintained, which means the acid level does
not need to be checked.
Charge
Shut down all the electrical devices and

engine.
Remove battery.
Connect charger and battery.
After charging, remove the charger from
the battery.
If the vehicle is not used, recharge

3 months
the battery periodically.
Charging Voltage Inspection

The battery has proper performance and is
fully charged.
Start the vehicle and measure the voltage.
Measuring point is positive pole (+), the
other measuring point connects ground (-).
Charging Voltage
5000rpm 13.5V~15.0V
If less than specification:

Inspect the connectors between engine
and regulator.
Inspect the connectors between regulator
and cables.
Inspect engine electronic winding.
If more than specification:
Replace regulator.
6-10
07 Air Filter Assy
7.1 Air Filter�� 7-1
7.1 Air Filter
Note: Check air filter every 5000km,.

Clean or replace it if necessary. The
Air filter maintenance should be more
frequent when in severe environment.
Removal
Loose clamp 1. 1
Loose clamp 2.
Remove bolt 3.
4
2
Remove bolt 4.
3
070101
Note：Do not use brake hose to hang

rear brake fluid reservoir. Otherwise, the
air will get into the system.
Remove bolt 5 .
Remove four screws 6 . 5 6 7
Remove filter element cover 7 .
070102
Remove air filter 8 .
8
070103
7-1
CFMOTO
Inspection 5
If air filter jams, less air input, lower power, 1
increase fuel consumption, inspect and 1

clean air filter as follows:
•Loose four screws 1 and remove filter
element cover 2 . 2
•Remove filter element assy 3 from air
filter.
•If there is too much dirty in filter element 4 4
3
, use high-pressure air to clean it.
•Inspect air filter element for damage.
Replace if necessary.
Note: Keep filter element clean during

operation. Engine quicken damaged, if
working without, or with dirty or broken
filter. Frequently clean filter, if working
in dirty situation.
•Check the air intake pipe 5 . If dust in it,
6
clean it by detergent.
7
•Check oil storage hose 7 if engine oil
remains. If it does, remove clamp 6 and oil
storage hose 7 and clean up the engine oil
in hose. 070201
Installation
installation.
Note: Ensure all parts be fixed and

sealed reliably.
7-2
08 Electrical System
8.1 EFI Servicing Precautions�� 8-2
8.2 EFI Malfunction Excluded�� 8-4
8.2.1 Outline�� 8-4
8.2.2 EFI Malfunction Excluded�� 8-5
8.3 Charging System�� 8-8
8.3.1 Charging Diagram�� 8-8
8.3.2 Magneto Coil Resistance�� 8-8
8.3.3 MAG Non-loaded Performance�� 8-8
8.3.4 Regulator�� 8-9
8.4 EFI�� 8-10
8.4.1 EFI Structure�� 8-10
8.4.2 EFI system composed of three subsystems�� 8-10
8.4.2.1 Sensors�� 8-10
8.4.2.2 ECU�� 8-10
8.4.2.3 Actuators�� 8-10
8.4.3 EFI System Maintenance Notice�� 8-11
8.4.4 Service Tool�� 8-12
8.4.5 Structure and Performance of EFI Parts�� 8-14
8.4.5.1 ECU�� 8-14
8.4.5.2 Throttle Body�� 8-15
8.4.5.3 T-MAP�� 8-16
8.4.5.4 Idle Air Control vale�� 8-17
8.4.5.5 Cylinder Head Temp. Sensor�� 8-18
8.4.5.6 Oxygen Sensor�� 8-19
8.4.5.7 Trigger �� 8-20
8.4.5.8 Fuel Injector�� 8-21
8.4.5.9 Ignition coil�� 8-22
8.4.5.10 Speed Sensor�� 8-23
8.4.5.11 Roll-over Sensor�� 8-24
8.4.5.12 Fuel Pump�� 8-25
8.4.5.13 Gear Sensor�� 8-26
8.5 Self-diagnosis�� 8-27
8.5.1 Engine Body�� 8-28
8.5.2 Trouble Diagnosis In Accordance With Engine Error�� 8-31
8.5.3 Fault Code Table�� 8-32
8-1
CFMOTO
8.1 EFI Servicing Precautions
There are a number of important
precautions that should be followed
servicing the EFI system.
●This EFI system is designed to be used

with a 12 V sealed battery as its power
source. Do not use any other battery
except for a 12 V sealed battery as a
power source.
●Do not reverse the battery cable
connections. This will damage the ECU.
●To prevent damage to the EFI parts, do
not disconnect the battery cables or any
other electrical connections when the
ignition switch is on or while the engine is
running.
●Take care not to short the leads that are
directly connected to the battery positive (+)
terminal to the chassis ground.
●When charging, remove the battery from
the motorcycle. This is to prevent ECU 1
damage by excessive voltage.
●Do not turn the ignition switch ON while
any of the EFI electrical connectors are
d i s c o n n e c t ed. T h e E C U me mor izes
service codes.
●Do not spray water on the electrical parts,
EFI parts, connectors, leads, and wiring. 080201
●Whenever the EFI electrical connections
are to be disconnected, first turn off the
ignition switch, and disconnect the battery
(-) terminal. Do not pull the lead, only the
connector. Conversely, make sure that all
the EFI electrical connections are firmly
reconnected before starting the engine.
●Connect these connectors until they click
(1).
8-2
●If a transceiver is installed on the
motorcycle, make sure that the operation
of the EFI system i s not influenced by
electric wave radiated from the antenna.
Check operation of the system with the
engine at idle. Locate the antenna as far
as possible away from the ECU.
●When any fuel hose is disconnected, fuel
may spout out by residual pressure in the
fuel line. Cover the hose joint with a piece
of clean cloth to prevent fuel spillage.
●When any fuel hose is disconnected, do
not turn on the ignition switch. Otherwise,
the fuel pump will operate and fuel will
spout from the fuel hose.
●Do not operate the fuel pump if the pump
is completely dry.
●Before removing the fuel system parts,
blow the outer surfaces of these parts
clean with compressed air. A
●To prevent corrosion and deposits in the
fuel system, do not add to fuel any fuel
antifreeze chemicals.
To maintain the correct fuel/air mixture,
there must be no inlet air leaks in the B
EFI system. Be sure to install the oil filler
plug A and clutch cover B after filling the
engine oil.
080301
8-3
CFMOTO
8.2 EFI Malfunction Excluded
8.2.1 Outline
A
When an abnormality in the system occurs,
the MIL (LED) goes on to alert the rider on
the meter panel. In addition, the condition B
of the problem is stored in the memory
of the ECU (electronic control unit). With
the engine stopped and turned in the self
diagnosis mode, the service code [A] is
indicated by the number of times the MIL
(LED) blinks. 080401
When due to a malfunction, the MIL
(LED) remains lit, ask the rider about the
conditions [B] under which the problem
occurred and try to determine the cause
[C]. First, conduct a self-diagnosis
inspection and then a non-self-diagnosis
inspection. The non self-diagnosis items
are not indicated by the MIL (LED). Don’t
rely solely on the EFI self-diagnosis
function, use common sense.
Even when the EFI system is operating
normally, the MIL (LED) [A] may light up
under strong electrical interference.
No repair needed. Turn the ignition switch
OFF to stop the indicator light.
When the MIL (LED) goes on and the C
080402
motorcycle is brought in for repair, check
the service codes. When the repair has
been done, the light (LED) doesn’t go on.
But the service codes stored in memory
are not erased to preserve the problem
history, and the light (LED) can display
the codes in the self-diagnosis mode. The
problem history is referred when solving
unstable problems.
When the motorcycle is down, the vehicle
down sensor is turned OFF and the ECU
shuts off the fuel injectors and ignition
system.
The MIL (LED) blinks but the service code
cannot be displayed. The ignition switch is
left ON. If the starter button is pushed, the 080403
electric starter turns but the engine doesn't
start.
To start the engine again, raise the
motorcycle, turn the ignition switch OFF,
and then ON. The vehicle down sensor is
turned
8-4
8.2.2 EFI Malfunction Excluded
●The DFI part connectors A have seals B

, including the ECU.
●Join the connector and insert the needle
adapters C inside the seals B from behind
the connector until the adapter reaches the
terminal.
C B D
Note: Insert the needle adapter
straight along the terminal in the
connector to prevent short-circuit
between terminals.
A
●Make sure that measuring points are

correct in the connector, noting the position
of the lock D and the lead color before 080501
measurement. Do not reverse connections
of the hand tester or a digital meter.
●Be careful not to short-circuit the leads
of the EFI or electrical system parts by
contact between adapters.
●Turn the ignition switch ON and measure
the voltage with the connector joined.
A
Note: Insert the needle adapter
straight along the terminal in the
connector to prevent short-circuit
between terminals.
B
●After measurement, remove the needle

adapters and apply silicone sealant to the
seals A of the connector B . 080502
●Always check battery condition before
replacing the EFI parts. A fully charged
battery is a must for conducting accurate
tests of the EFI system.
●Trouble may involve one or in some
cases all items. Never replace a defective
part without determining what causes
the problem. If the problem was caused
by some other item or items, they must
be repaired or replaced, or the new
replacement part will soon fail again.
8-5
CFMOTO
●Measure the electrical resistance of the A

coil after the EFI parts cool down.
●Make sure the electric connection
clean and tight. And check the wire if it
got burned, abrasion,too short and etc.
Damaged cable and bad connection can
cause the trouble comes out again and
again and make the EFI system running A
unstable.
●If the cable is damaged or aging. Please 080601
replace the cable.
●Disconnect each connectors A . And
check if there is any corrosion, dust or
damaged.
●If connectors getting corrosions or
dusted. Please clean up carefully if the E A C
connectors get damaged. Please replace
the connectors. Connectors should be well
connected. D
●Check the wiring continuity. Use the
wiring diagram to find the trouble wire B
F
termination.
● C o n n e c t t h e AV O m e t e r o n w i r e
termination. 080602
●Set the AVO meter on X1Ω range. And
read the data showing on AVO meter.
●If the data is not 0¦ø. Means the problem
should be cable. Replace the main cable
or secondary cable.
●If the cable A is far. Use a Cable D to C A B
Connect C to the ground[B] and check
another connector E and F to make sure
it is OK. That can check the connection
of the long cable. If connection is poor,
replace the cable. D
080603
8-6
●When check the cable A shortcut or not.

Open B side and check the connection
between side C to D . If OK, the cable has
short cut and needs repairing.
●Check the ECU connection again and
again. To make the trouble easier point
out.
●If the wire and connector has no trouble,
EFI parts may be next point. Use input and
out put voltage checking way. But it cannot
check the ECU itself.
●If you find trouble, replace the trouble
parts. If the wire, connector and EFI parts
has no trouble. Replace the ECU.
Color Codes:
B: Black L: Blue Gr: Grey
Lg: Light
Br: Brown G: Green
green
Sb: Sky blue O: Orange R: Red
P: Purple W: White Y: Yellow
8-7
CFMOTO
8.3 Charging System
8.3.1 Charging Diagram
1
4 5
080801
1 Magneto 3 Fuse 5 Load
2 Stable Voltage 4 Battery 6 Regulator
8.3.2 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.
MAG Coil Resistance:
0.1Ω~0.5Ω (Yellow-Yellow) 080802
Resistance between Stator Coil and Core:
∞Ω (Yellow-Ground)
8.3.3 MAG Non-loaded Performance

● Start the engine and allow it run at
5000r/min. Use multimeter to measure the
voltage between 3 output lines.
● If the reading is below specification,
replace with a new magneto.
Turn Multimeter to V(AC).
Voltage between Output Lines When MAG
Non-loaded:
>50V(AC) at 5000r/min 080803
8-8
8.3.4 Regulator
080901
After engine running and at the state of battery full charged, if the voltage between
positive and negative terminal exceeds 15V or is lower 13.5V, replace with a new
regulator.(Engine RPM is about 5000r/min.)
8-9
CFMOTO
8.4 EFI
8.4.1 EFI Structure
10 4 8
1 7 9
2 5
3
11
6
12
13
081001
1 Air filter 6 Roll-over sensor 11 Trigger
2 T-MAP 7 Injector 12 Fuel pump assy
Cylinder head
3 ECU 8 Ignition coil 13
temp. sensor
4 Idle air control valve 9 Oxygen sensor
5 Throttle body 10 TPS
8.4.2 EFI system composed of three 8.4.2.2 ECU
subsystems Electronic Control Unit, the brain of EFI
8.4.2.1 Sensors system,which determines the amount of
A sensor is a device that measures a fuel injection, ignition timing and other
physical quantity and converts it into a parameters a engine needs to keep
signal which can be read by an observer or running by calculating and analyzing
by an instrument. Sensors in EFI system values provided by sensors.
include: 8.4.2.3 Actuators
Air pressure sensor (Air density and Actuators execute the EFI instruction. Main
pressure information) actuators include:
Air temp. sensor (Air density information) ●Fuel Pump
TPS (Load, load range, speed information) ●Fuel Injector
Trigger (crankshaft information) ●Ignition Coil
Cylinder head Temp. Sensor (engine ●Idle Air Control Valve
temp.)
Speedometer sensor (Output shaft RPM
information)
Oxygen Sensor (Air factor= λ >1 or <1)
Roll-over Gear Sensor (Output vehicle
gradient information)
8-10
8.4.3 EFI System Maintenance Notice ●If possible, don’t do the spark test. If
●Always use genuine CFMOTO parts for spark test is done unavoidably, try to
maintenance. Otherwise it can not assure complete the test as soon as possible.
a normal performance to EFI system. Besides, don’t open the throttle, otherwise,
●During the maintenance procedure, never a large quantity of unburnt fuel would enter
try to break down the EFI components. muffler, causing the catalytic converter
●In the course of maintenance, EFI parts damage.
must be handled carefully. ●Idle speed is controlled by ECU, so it’s
●Ignition switch must be shut off before unadjustable. The throttle limiter screw
connecting or disconnecting connectors. has been adjusted by manufacturer before
Otherwise, it may cause the EFI parts sale. Therefore, it’s not recommended to
damage. adjust it by the user.
●When removing fuel pump from fuel tank, ●Don’t reverse the battery cable
do not energize the fuel pump. Otherwise, connections. This may damage electrical
a spark can cause a fire. components.
●Fuel pump is not allowed to operate ●Never remove the battery cables When
in a dry environment or under water. the engine is running.
Otherwise, its life would be shortened. ●Always remove cables and electrical
Besides, reverse connections between control units which are connected with
positive and negative terminal of fuel pump battery terminals.
is not permitted. ●Never test the component input and
●The fuel pressure in EFI fuel supply output electric signal by piercing the cable
system is very high (about 330kPa), plastic jacket.
accordingly, all fuel lines are high pressure ●Respect the environment and dispose of
resisting. Even if the engine is not running, the left during maintenance.
the fuel pressure is high. Therefore, do
not 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 replacement
should be practiced by a professional
person in a well-ventilated place.
8-11
CFMOTO
8.4.4 Service Tool
Tool: PDA
Function:
Read erase trouble code of EFI system,
observe data flow and accessories test
etc.
081201
Tool: Digital multimeter
Function:
Inspect the parameter of EFI system like
voltage, current and resistant etc.
081202
Tool : Vacuum Gauge
Function:
Inspect the pressure of air inlet hose.
081203
8-12
Tool: Ignition timing light
Function:
Inspect ignition timing of the engine.
081301
Tool: Cylinder compression gauge
Function:
Inspect the cylinder pressure of the engine.
081302
Tool: Oil pressure gauge
Function :
Check the pressure of fuel system and
judge the working condition of fuel pump
and oil pressure regulating valve in fuel
system.
081303
Tool: Fuel injector cleaning analyzer
Function:
Analyze the cleaning of fuel injector.
081304
8-13
CFMOTO
8.4.5 Structure and Performance of EFI ECU
Parts
8.4.5.1 ECU
Electronic control unit , is the brain of EFI
system. It analyzes and cope with the
information provided by sensors, and send
the conclusion in the form of instruction to
actuator, then make the engine run in the
optimal condition.
Note: 081401
Do not allow to increase the load on ECU pin position
the cover or cap of ECU.
Handle with care. Do not drop it on the
ground.
ECU Pin Function:

081402
J1-1 Stepper motor A high J2-1 Ignition coil drive A
J1-2 Canister magnetic valve J2-2 Power to ground
J1-3 MIL J2-3 KW2000 (K-line output)
J1-4 Null J2-4 Trigger signal high
J1-5 Null J2-5 Fuel injector signal
J1-6 RPM output J2-6 Null
J1-7 Can signal low J2-7 Oxygen sensor heated
Intake air temperature
J1-8 Can signal high J2-8
signal
J1-9 Power to ground J2-9 Fuel tank signal
J1-10 Null J2-10 5V (signal ground)
J1-11 Stepper motor A low J2-11 Instake air pressure signal
J1-12 Stepper motor B high J2-12 TPS signal
J1-13 Stepper motor B low J2-13 Trigger signal low
Cylinder head temperature
J1-14 Roll-over switch J2-14
signal
J1-15 Speed sensor signal J2-15 Ignition switch power
J1-16 Null J2-16 5V
J1-17 Null J2-17 Oxygen sensor signal
J1-18 Neutral gear switch J2-18 Battery
Limit Data
Value
Item Unit
Min. Typical Max.
Normal working 9 14±0.1 16 V
Battery voltage
Limit function 6.0~9.0 16.0~18.0 V
Limit and time
Keep part of function, can
of battery over 26.0V 5 min
diagnose the trouble
voltage
Working temperature -40 +70 °C
Storage temperature -40 +70 °C
8-14
8.4.5.2 Throttle Body
Connect with air filter and the engine, 1
control the on-off angle of throttle by

throttle cable. Send out the angle signal 2
through TPS to ECU.
Note: Do not remove or adjust the A

TPS, as it has been accurately adjusted
and set before delivery. Do not drop 081501
throttle body assembly, especially on
1 Stepping motor 2 T-MAP 3 TPS
hard surfaces.
TPS Pin Function:

C connects ECU J2-12 (output signal).
B connects ECU J2-10 (Ground).
A connects ECU J2-16 (5V power). B A
081502
The throttle limit screw 4 is not allowed

to adjust.
4
Do not adjust throttle limit screw
manually because idle speed is
adjusted by EFI system .
081503
The wiring diagram of connection with

ECU. See the right picture.
TPS
081504
8-15
CFMOTO
8.4.5.3 T-MAP
The pressure-sensitive diaphragm in
T-MAP connects with magnetic core in coil.
When the pressure inside air intake pipe
A B C D
gets changed, the diaphragm moves as
well as the magnetic core. At this moment,
the sensor output signal voltage changes.
According to the voltage change, the ECU
can convert the air intake volume of the
engine. Based on this signal, engine also
refers other signals to control the fuel
injection. 081601
T-MAP is a NTC thermo resistance. The
resistance becomes lower when the
air temperature becomes higher. ECU
monitors air intake temperature change by
a comparing circuit inside.
Pin function:
D connects ECU J2-10 (5V voltage
ground).
C connects ECU J2-8 (Inlet air temp.
signal).
B connects ECU J2-16 (5V voltage).
A connects ECU J2-11 (Inlet air pressure
signal).
T-MAP
081602
8-16
8.4.5.4 Idle Air Control vale
IACV is used to control the air flow of by- D C B A
pass. ECU calculates the engine load
and controls IACV through electrical
pulse duration and frequency (commonly
known as duty ratio). IACV allows
different air flows passed through under
different pressure. Therefore, it should
be connected properly. Otherwise, idle
speed may be incorrect. When there is no
electrical pulse, IACV would be closed.
081701
Pin function:
A connects with ECU J1-13 (IACV B low).
B connects with ECU J1-1 (IACV A high).
C connects with ECU J1-12(IACV B high).
D connects with ECU J1-11(IACV A low).
Idle Air Control Valve Circuit:
Idle air control valve

081702
8-17
CFMOTO
8.4.5.5 Cylinder Head Temp. Sensor Cylinder head temp. sensor
This sensor is a NTC thermo resistance.
The resistance becomes lower when the
air temperature becomes higher, but it
is not a liner relationship. ECU monitors
engine temperature condition by provided
parameters.
Pin function:
A connects ECU J2-14(cylinder head A B
temp. signal).
B connects ECU J2-10 (5V voltage
ground).
Cylinder head temp. sensor and ECU

circuit: 081801
Cylinder head temp. sensor
081802
Cylinder head temp. sensor temperature R-T chart:
Temp.(°C) MAX(Ω) NOM(Ω) MIN(Ω)

-40 354739 332776 310813
-20 102067 96481 90895
0 34227 32566 30905
25 10439 10000 9561
80** 1298 1257 1216
110 523.3 509.1 494.9
130** 306 298.4 290.8
160 150.7 146.9 143.1
180 99.14 96.1 93.06
200 67.38 65 62.62
8-18
8.4.5.6 Oxygen Sensor
This sensor is used in closed-loop
feedback controlled fuel injection to A
improve the air-to-fuel ratio accuracy and B
control the emission. It’s located in the
C
exhaust stream to measure the amount
of oxygen in exhaust and send the signal D
to ECU, which can revise the fuel injector
081901
output, so as to reduce the amounts of
unburnt fuel and make catalytic converter
convert HC, CO and NOX of Nitrogen
efficiently.
Pin function:
A connects ECU J2-10 (5V voltage
ground).
B connects ECU J2-17 (Oxygen sensor
signal of cylinder 1).
C connects ECU J2-7(Oxygen sensor
heated).
D pin (heated power).
Circuit of sensors and ECU:
Oxygen sensor
081902
8-19
CFMOTO
8.4.5.7 Trigger
The trigger transfers signal of engine 1 2
speed to ECU and by which ECU to
confirm engine speed ignition angle and
injecting phase.
Pin function:
1 connects ECU J2-4 (trigger signal high).
2 connects ECU J2-13 (trigger signal
low).
082001
The circuit of connection between trigger

and ECU.
Trigger
082002
Measure trigger resistance value
Set multimeter to 1×100Ω range.

Trigger coil resistance: 100Ω~160Ω(20°C)
Replace a new one when resistance is not
within above value range.
Measure trigger peak voltage 1
Connect multimeter and peak voltage
2
adapter as shown as right picture
+Probe: Blue/Yellow cable 082003
-Probe: Green cable 1 Magneto 2 Trigger resistance
Note: Refer to owner manual when

use peak value voltage adapter. 2
●Set multimeter to ACV range.

●Set engine to Neutral gear, turn on
ignition switch.
●Press starter button and keep engine
1
running for seconds, then measure trigger
coil peak value voltage. 3
●Repeat a few times and record the
highest value 082004
Trigger coil peak value voltage: ≥2V (300r/
1 Magneto
min)
2 Peak voltage gauge
Replace a new one when peak value 3 Trigger peak voltage
voltage is not within above value range.
8-20
8.4.5.8 Fuel Injector
One end of fuel injector mounts into fuel
injector seat, and the other end attaches 1
2
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 injector after the joint between injector
and injector cap is installed.
Pin function:
1 connects output end of fuel pump relay.
2 connects ECU J2-5 (Fuel injector
control signal).
Fuel injector resistance: 12Ω±0.6Ω (20°C)

082101
Connect with fuel pump relay
Fuel Injector Circuit:
Fuel injector 082102
Fuel Injector Installation

Install fuel injector manually. Never knock
fuel injector with a hammer.
When removing and installing fuel
injector, the O-rings on both ends must be
replaced.
Perform pressure relief before fuel injector
removal if necessary.
Te s t t h e f u e l i n j e c t o r s e a l i n g a f t e r
installation to ensure no leaks.
8-21
CFMOTO
8.4.5.9 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.
082201
Connect fuel pump relay
Ignition coil
Secondary Ignition Voltage Test:
●Connect the engine according to EFI 082202
wiring diagram.
●Connect the peak voltage tester Peak voltage measurement
according to the right diagram.
●Start the engine.
●Secondary ignition voltage should be
more than 15kV.
Battery
ECU
Spark plug
082203
Ignition coil parameter chart table:
Value
Item Unit
Standard
Nominal voltage 12 V
Primary 0.7 Ω
Resistance (20°C~25°C)
Secondary 6.9 kΩ
8-22
8.4.5.10 Speed Sensor
This sensor provides engine output shaft
speed to ECU. Then ECU can calculate
the speed according to this signal. It is
a hall switch type device, which outputs
square wave by the change of the
magnetic field.
Pin function: 1 2
1 : Battery +DC 12V
2 : Output voltage signal
3 : Connecting ground
3
082301
+12V voltage
Ground 3 2 1
Speed sensor circuit:
Hall switch
Speed sensor
082302
Speed Sensor Inspection

Ground pin 3 and pin 1 with +12V power.
Fix the gear 1 2.5mm away from the
speed sensor as the picture shows.
Turn multimeter to DCV.
Slowly turn the gear and measure the 1
voltage between pin 1 and pin 2 to

determine that if the reading varies from
0V~12V
If the reading doesn't vary, it indicates 082303
the sensor is defective and needs to be
replaced.
8-23
CFMOTO
8.4.5.11 Roll-over Sensor
Roll-over sensor is used for preventing 1
vehicle from tilting. When vehicle’s tilt 65°±10° 65°±10°
angle is larger than settled tilt angle, an
"OUT" signal will be transferred to ECU.
ECU will stop the engine.
082401
1 Tilt angle
The "UP" faces upward when installing as

picture shows.
082402
1 2
Connect the engine as EFI diagram shows:
VCC 1 connects ECU J2-16 (+5V).
OUT 3 connects ECU J1-18 pin.
GND 2 connects negative pole.
082403
8-24
8.4.5.12 Fuel Pump
The right picture shows the fuel pump assy,
fuel pump relay and ECU wiring diagram.
This fuel pump assy consists of fuel pump,
plastic bracket, fuel strainer, fuel filter element
and pressure-regulating valve. It delivers fuel
from the tank to the engine at a certain oil
pressure and flow rate.
Pin function:
1. Blue (Ground)
2. Red (Connects fuel pump relay output port)
Performance parameter:
Pressure-regulating valve open pressure:
(0.25±0.01)MPa
Flow rate: more than 40L/h 082501
This fuel pump assy is used inside the fuel
tank.
Do not run the fuel pump assy when there
is no fuel inside the fuel tank, in case of fuel
pump damage.
Handle the fuel pump gently. Do not drop it on
hard surfaces.
The battery supplies power to the fuel pump

through the relay. Only when starting or
running the engine can the circuit be switched
on.
Measure fuel pressure:
Connect oil pressure gauge and fuel pump oil
port, lock with clamp to ensure there is no leak
form the junction.
Connect the circuit as the picture shows.
Turn on ignition switch and stop switch.
The fuel pump will work for 5 seconds. When
stop working, the oil pressure should reach the
specified value. Otherwise, replace with new
fuel pump.
After stopping working, the pressure should
maintain 0.2MPa for at least 5 minutes.
Otherwise, replace fuel pump assy.
Fuel hose pressure release method:
The fuel supply pressure in EFI system is high,
all fuel hoses are high-pressure resistance.
Even the engine does not work, the pressure
in fuel passage is still high. So when in the
maintenance process, be careful not to remove
the fuel hose causally.
When servicing EFI system, release the
pressure before removing the fuel hose. The
release method is like:
Remove the fuel pump relay. Start the
engine and make it idle until the engine stops
automatically.
8-25
CFMOTO
8.4.5.13 Gear Sensor
This sensor provides the gear position
signal for meter display. It also achieves
the protection function with the cable and
ECU.
Pin function:
W/Y - First gear 082601
R/B - Second gear
G/L - Third gear
Y/L - Fourth gear
Br/R - Fifth gear
G/R - Sixth gear
L - Neutral gear
2
082602
When each pin at a certain gear position,
1~6 gear Neutral gear
there is continuity between this pin and 1 2
connector connector
engine. Otherwise, no continuity.
8-26
8.5 Self-diagnosis
Self-diagnosis Outline
ECU constantly monitor sensors, actuators
and circuits, MIL and battery voltage,
etc, even ECU itself and inspect the
sensor output signal, actuator drive signal
and internal signal (such as close loop
control, coolant temperature, idle speed
control and battery voltage control, etc.)
for reliability. If any process or signal is
suspect, ECU records the trouble code in
the RAM memory.
Faulty information is recorded in the form
of trouble code, and in the sequence of
which trouble comes first.
When servicing, using PDA and MIL, the
defective parts can be promptly found to
improve the service efficiency and quality.
Self-diagnosis Procedures
When a problem occurs with the EFI
system and ignition system, the MIL (LED)
keeps on.
Note: Use a fully charged battery
when conducting self-diagnosis.
Otherwise, the light (LED) will
illuminate very slowly or won’t 082701
illuminate.
MIL Conditions
Turn on the ignition switch and the
engine does not work. No trouble code
appears:
●MIL keeps on for 4s, then goes off. Or
MIL keeps on until engine starts.
engine does not work. Trouble code
appears:
●MIL keeps on.
e n g i n e i s w o r k i n g . Tr o u b l e c o d e
appears:
●MIL keeps on.
8-27
CFMOTO
8.5.1 Engine Body
Troubles Possible Cause Countermeasures

Cylinder pressure too low
1. Cylinder worn Replace
2. Piston ring worn Replace
3. Air leakage of cylinder gasket Replace
4. Valve stem worn or unsuitable valve Repair or replace
seat
5. Spark plug loosen Tighten
6. Starting motor rotate too slowly Check electrical parts
7. Improper valve timing Adjust
8. Improper valve clearance Adjust
Spark plug cannot ignite or weak
Cannot start or
ignition
difficult to start
1. Improper spark plug clearance Adjust or replace
2. Spark plug dirty or wet Clean & dry or replace
3. Defect ignition coil Replace
4. Trigger short circuit or open circuit Replace
5. Magneto malfunction Replace
Insufficient fuel inside throttle body
1. Breather hole block Clean or replace
2. Injector blocked or failure Clean or replace
3. High Pressure oil pump failure Inspect or replace
4. Low pressure,oil pump Inspect or replace
5. Oil pump Filter net blocked Clean or replace
1. Improper valve clearance Adjust

2. Unsuitable valve seat Repair or replace
3. Defective valve Replace
4. Rocker or rocker arm wear Replace
No idle speed or 5. Dirty spark plug Replace
unstable speed 6. Incorrect valve clearance Replace or adjust
7. Ignition coil failure Replace
8. In & Ex a air hose blocked, idle Adjust or replace
valve
9. Magneto failure Replace
8-28
1. Valve spring getting worn Replace

2. Camshaft worn Replace
3. Spark plug dirty Clean or replace
H i g h R P M 4. Spark plug gap too narrow Adjust or replace
unstable 5. Valve timing incorrect Adjust
6. Ignition coil failure Replace
7. Low pressure,oil pump Adjust or replace
8. Air filter too dirty Clean or replace
Check oil level and

1. Engine oil too much
drain
2. Piston ring worn
Replace
Blue or black 3. Valve worn
Replace
exhaust gas 4. Cylinder worn or scraped
Replace
5. Valve stem worn
Replace
6. Oil seal of valve stem damaged
Replace
Adjust
1. Valve clearance improper
Replace
2. Valve spring getting weak
Adjust
3. Valve timing incorrect
Replace
4. Cylinder worn
Replace
5. Piston ring worn
Replace or repair
6. Improper valve seat
E n g i n e Clean or replace
7. Spark plug dirty
Power not Clean or replace
8. Improper spark plug gap
enough Clean or replace
9. Injector blocked
Adjust or replace
10. Insufficient pressure,oil pump
Clean or replace
11. Air filter too dirty
Replace
12. Rocker arm or camshaft worn
Tighten or replace
13. Air leakage of inlet pipe
Check oil level and
14. Engine oil too much
change
1. Carbon deposit on piston head

Clean
2. Engine oil too less or too much
Check and add or drain
3. Oil pump failure
E n g i n e Replace
4. Fuel hose blocked
Overheating Clean
5. Air leakage of inlet pipe
Tighten or replace
6. Unsuitable engine oil
Change oil
7. Cooling system failure(see7-5)
8-29
CFMOTO
Valve abnormal noise
1. Valve clearance too big Adjust
2. Valve spring worn or broken Replace
3. Swing arm or camshaft worn Replace
Piston abnormal noise
1. Piston worn Replace
2. Cylinder worn Replace
3. Carbon deposit inside combustion Clean
chamber
4. Piston pin or pin hole worn Replace
5. Piston ring or groove worn Replace
Timing chain abnormal noise

1. Chain stretched out Replace chain and sprocket
2. Chain sprocket worn Replace chain and sprocket
Engine abnormal
3. Tensioner failure Repair or replace
noise
Clutch abnormal noise

1. Clutch gear worn or damaged Replace clutch gear
2. Cushion rubber aging or damaged Replace clutch gear
Crankshaft abnormal noise

1. Bearing noise Replace
2. Crankshaft pin bearing down Replace
3. Clearance too big Replace
Transmission abnormal noise

1. Gear worn or damaged Replace
2. Main shaft or counter shaft worn Replace
3. Bearing worn Replace
4. Bushing worn Replace
1. Clutch drive disc worn Replace

Clutch slippery 2. Clutch driven disc worn or damaged Replace
3. Clutch spring getting weak Replace
8-30
8.5.2 Trouble Diagnosis In Accordance With Engine Error
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 are 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 the 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.
8-31
CFMOTO
8.5.3 Fault Code Table
No. Code Description(delphi)

1 P0031 O2 Heater Circuit Low Voltage
2 P0032 O2 Heater Circuit High Voltage
3 P0107 MAP Circuit Low/Open Voltage
4 P0108 MAP Circuit High Voltage
5 P0112 IAT Circuit Low Voltage
6 P0113 IAT Circuit High Voltage
7 P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage
8 P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open"
9 P0122 TPS Short to low diagnostic
10 P0123 TPS Short to high /open diagnostic
11 P0131 O2 sensor Short to low diagnostic
12 P0132 O2 sensor Short to high diagnostic
13 P0201 Injector (INJ) Circuit Malfunction
14 P0230 Fuel Pump (FPP) Coil Circuit Low Voltage or Open
15 P0232 Fuel Pump (FPP) Coil Circuit High Voltage
16 P0351 Electronic Spark Timing (EST) Ignition Coil Malfunction
17 P0444 Canister Control Purge (CCP) short to low/open
18 P0445 Canister Control Purge (CCP) short to high
19 P0650 Malfunction Indicator Lamp (MIL) short Diagnostic
8-32
(1)Starting Failure/Hard Starting
General failure part: 1. Battery; 2. Starter motor; 3. Wirings harness or ignition switch; 4.
Engine mechanism part.
General diagnosis procedures:
Item Procedures Results Next
Use multi-meter to check battery voltage if YES Next step
1 voltage is between 8V~14V or not when engine
NO Replace battery
starts.
Turn on ignition switch, stop switch side stand YES Next step
2 switch and check if voltage of ECU pin J2-15 is Repair switches or
NO
around 12V. change harness
Keep ignition switch “on”, use multi-meter to YES Next step
3 check if voltage of starting motor anode is over Repair switches or
NO
8V. change harness
Disassemble starting motor and check its Repair or replace
YES
4 working status, especially whether there was starting motor
broken circuit or jammed by bad lubrication. NO Next step
If error only occur in Winter, check if starting Change to proper
YES
5 motor resistance is too big caused by improper lubricant
oil used. NO Next step
Check if mechanical resistance is too big inside Check engine inside
YES
engine. resistance
6
Repeat above
NO
procedures
(2)When starting, engine can rotate but cannot start

General failure part: 1. No fuel; 2. Fuel pump; 3. Trigger; 4. Ignition coil; 5. Mechanical
parts of engine
Connect fuel pressure gauge, turn on ignition YES Next step
1 switch or start engine, check if fuel pressure is Check and repair fuel
around 250kPa. NO
supply system
YES Next step
Connect PDA, check if there's signal of RPM
2 Check and repair RPM
data after starting engine. NO
sensor circuit
Disconnect high-tension cable, connect spark YES Next step
plug and set its electrode 5mm to engine body,
3 Check and repair
then start engine to check if blue and white NO
spark appears. ignition system
Eliminate engine
Test cylinder pressure and check if pressure is YES
4 mechanical failures
enough.
NO Next step
Use PDA to test, turn on ignition switch, check YES Use PDA to check
if power supply of ECU pin J2-18 and pin J2-15
5
is normal; check if pin J2-2 and pin J1-9 works NO Repair related circuit
normally.
8-33
CFMOTO
(3)Difficult to start hot engine

General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Water temp. sensor; 4.
Ignition coil.
NO
around 250kPa. supply system
2 Check and repair
spark appears. ignition system
Check whether the failure happens right after YES Change fuel
3
fueling. NO Next step
4
normally.
(4)Difficult to start cold engine

General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Engine temp. sensor; 4.
Injector; 5. Ignition coil; 6. Throttle body and by-pass; 7. Mechanical parts of engine
YES Next step
Connect fuel pump gauge ,start engine, check if
1 Check and repair fuel
pressure is around 330kPa. NO
supply system
2 Check and repair
ignition system
spark appears.
Clean throttle body
Slightly draw throttle cable and check if engine YES
3 and by-pass
could start easily.
NO Next step
Disassemble injector and use special tool to YES Replace injector
4
check if there is leakage or block. NO Next step
5
filling fuel. NO Next step
Eliminate engine
YES
6 Check if cylinder pressure is insufficient. mechanical failures
NO Next step
7
normally.
8-34
(5)Difficult to start in any conditions
General failure part: 1. Water in fuel tank; 2. Fuel pump; 3. Water temp. sensor; 4.
Injector; 5. Ignition coil; 6. Throttle body and by-pass; 7. Air intake pipe; 8. Ignition timing;
9. Spark plug; 10. Mechanical part of engine
Check and repair air
YES
1 Check if air filter is blocked or air intake pipe leaks. intake system
NO Next step
YES Next step
Connect fuel pump gauge, start engine, check if
2 Check and repair
pressure is around 250kPa. NO
fuel supply system
Disconnect high-tension cable, connect spark plug YES Next step
3 and set its electrode 5mm to engine body, then start Check and repair
NO
engine to check if blue and white spark appears. ignition system
Check if spark plug is suitable for requirement YES Next step
4
including its type and clearance. NO Adjust or replace
Clean throttle body
Slightly draw throttle cable and check if engine YES
5 and by-pass
could start easily.
NO Next step
Disassemble injector and use special tool to check YES Replace
6
if there is leakage or block. NO Next step
Check whether the failure happens right after filling YES Change fuel
7
fuel. NO Next step
Eliminate engine
YES
NO Next step
YES Next step
Check if ignition timing complies with standard
9 Check and repair
regulation. NO
ignition timing
10
normally.
8-35
CFMOTO
(6)Normal starting, but unstable idle speed
General failure part: 1. Water in fuel tank; 2. Injector; 3. Spark plug; 4. Throttle body
and by-pass; 5. Air intake pipe; 6. Air control valve; 7. Ignition timing; 8. Spark plug; 9.
Mechanical part of engine
Check if air filter is blocked or air intake pipe YES
1 intake system
leaks.
NO Next step
YES Clean or replace
2 Check if air control valve is blocked.
NO Next step
3
Check if there is carbon deposit inside throttle YES Clean
4
body and air control valve. NO Next step
Disassemble injector and use special tool to YES Replace
5
6
Eliminate engine
YES
NO Next step
YES Next step
8 Check and repair
regulation. NO
ignition timing
9
normally.
8-36
(7)Normal starting, but unstable idle speed during engine warming
General failure part: 1. Water in fuel tank; 2. Injector; 3. Spark plug; 4. Throttle body and
by-pass; 5. Air intake pipe; 6. Air control valve; 7. Mechanical part of engine
1 intake system
leaks.
NO Next step
2
3
Repair circuit or
Disconnect water temp. sensor connector and YES
4 replace sensor
start engine to check idle speed is stable or not.
NO Next step
5
6
Eliminate engine
YES
NO Next step
Use PDA to test, turn on ignition switch, check if power YES Use PDA to check
8 supply of ECU pin J2-18 and pin J2-15 is normal;
NO Repair related circuit
check if pin J2-2 and pin J1-9 works normally.
(8)Normal starting, but unstable idle speed after engine warming
General failure part: 1. Water in fuel tank; 2. Injector; 3. Spark plug; 4. Throttle body and
by-pass; 5. Air intake pipe; 6. Air control valve; 7. Mechanical part of engine
1 intake system
leaks.
NO Next step
2
3
4
5
Eliminate engine
YES
NO Next step
7
normally.
8-37
CFMOTO
(9)Normal starting, unstable idle speed or engine stop when it is electronic loaded
(e.g. headlight is on)
General failure part: 1. Air control valve; 2. Injector
Disassemble air control valve and check if YES Clean
1 there is carbon deposit inside throttle body, idle
NO Next step
adjustment and by-pass.
Check if output power increases when lighting, YES Next step
2 by using PDA to test if ignition advance angle, NO Next step
fuel spray and air intake volume is normal. NO Repair air intake system
3 check if there is leakage or blocked or wrong
NO Next step
fuel flow.
(10)Engine starts normally, but idle speed is too high

General failure part: 1. Throttle body and by-pass; 2. Injector seat; 3. Air control valve; 4.
Water temp. sensor; 5. Ignition timing
YES Adjust
1 Check if throttle cable is jammed or too tight.
NO Next step
2 intake system
leaks.
NO Next step
3
Repair wiring or replace
Remove water temp. sensor connector, start YES
4 sensor
engine to check if idle speed is too high.
NO Next step
YES Next step
5 Check and repair
regulation. NO
ignition timing
6
normally.
8-38
(11)RPM cannot increase or engine stop when accelerating
General failure part: 1. Water in fuel tank; 2. TPS; 3. Spark plug; 4. Throttle body and by-
pass; 5. Air intake pipe; 6. Air control valve; 7. Injector; 8. Ignition timing; 9. Exhaust pipe
YES
1 Check if air filter is blocked. intake system
NO Next step
NO
around 250kPa. supply system
3
Remove air control valve and check if there is YES Clean
4 carbon deposit inside throttle body, air control
NO Next step
valve and by-pass.
YES Next step
5 Check if T PS and its circuit is normal. Repair wiring or
NO
replace sensor
6
7
YES Next step
8 Check and repair
regulation. NO
ignition timing
YES Next step
9 Check if exhaust gas exhale smoothly. Repair or replace
NO
exhaust pipe
10
normally.
8-39
CFMOTO
(12)Low acceleration
General failure part: 1. Water in fuel tank; 2. TPS; 3. Spark plug; 4. Throttle body and by-
pass; 5. Air intake pipe; 6. Air control valve; 7. Injector; 8. Ignition timing; 9. Exhaust pipe
YES
NO Next step
around 250kPa. NO
supply system
3
NO Next step
valve and by-pass.
YES Next step
5 Check if T PS and its circuit is normal. Repair wiring or replace
NO
sensor
6
7
YES Next step
8 Check and repair
regulation. NO
ignition timing
YES Next step
NO
exhaust pipe
10
normally.
8-40
(13)Difficult to accelerate and bad performance
General failure part: 1. Water in fuel tank; 2. TPS; 3. Spark plug; 4. Ignition coil; 5.
Throttle body and by-pass; 6. Air intake pipe; 7. Air control valve; 8. Injector; 9. Ignition
timing; 10. Exhaust pipe
Check if clutch sliding, low tire pressure, bad YES Repair
1
brake or wrong tire size. NO Next step
YES
NO Next step
around 250kPa. NO
supply system
4 Check and repair
then start engine to check if spark is strong NO
enough. ignition timing
5
including its type and clearance. NO Replace
NO Next step
valve and by-pass.
YES Next step
7 Check if T PS and its circuit is normal. Repair wiring or
NO
replace sensor
8
9
YES Next step
10 Check and repair
regulation. NO
ignition timing
YES Next step
NO
exhaust pipe
12
normally.
8-41
09 Muffler Assy
9.1 Muffler�� 9-1
9.1 Muffler
Warning: The exhausting system are

very hot when running the vehicle. Do
not touch high-temperature parts. Wait
until it cools down before servicing
exhausting system.
Removal 1
Remove oxygen sensor connector 1 by
rotating it counter clockwise.
090101
Remove two bolts 2 . 2
090102
Remove RH footrest bracket mounting bolt

3.
Remove muffler assy 4 . 3
Installation 4
installation.
9-1
10 Wheels and Brake System
10.1 Front Brake Assy Removal�� 10-1
10.2 Front Brake Assy Inspection�� 10-2
10.2.1 Brake Hose, Hose Damage and Installation Inspection�� 10-2
10.2.2 Brake Performance Inspection�� 10-2
10.2.3 Front Brake Fluid Level Inspection�� 10-2
10.2.4 Brake Fluid Replacement�� 10-3
10.2.5 Front Brake Lever free Play�� 10-4
10.2.6 Front Brake Pad Inspection�� 10-4
10.3 Front Brake Assy Removal�� 10-5
10.4 Rear Wheel Assy Removal�� 10-6
10.5 Front/Rear Wheel Inspection, Brake Disc�� 10-7
10.5.1 Tire Pressure Inspection�� 10-7
10.5.2 Tire Inspection�� 10-7
10.5.3 Wheel bearing Inspection�� 10-8
10.5.4 Brake Pad Inspection�� 10-8
10.6 Rear Brake Assy Removal�� 10-9
10.7 Rear Brake Assy Inspection�� 10-11
10.7.1 Rear Brake Fluid Level Inspection�� 10-11
10.7.2 Rear Brake Fluid Replacement�� 10-11
10.7.3 Rear Brake Pedal Free Play�� 10-12
10.7.4 Rear Brake Pad Inspection�� 10-12
10.1 Front Brake Assy Removal

Removal
Remove RH rear view mirror.
2
Remove two bolts 1 .
Remove front brake pump assy 2 .
Note: Do not hang brake pump on

1
brake hose. Ensure the installation
position and fix the direction in case
air enter into hydraulic system.
100101
Push the front brake hose 4 inwards to
separate it and brake hose wire clip 3 .
3
Remove front brake hose clip 5 .
Separate front brake clip 5 and front brake
hose 4 .
100102
10-1
CFMOTO
Remove two bolts 6 .
Remove front brake caliper assy 7 along
the direction of brake disc.
6
Note: After removing front brake
caliper assy, it is not allowed to hold or 7
release front brake lever.
100201
Installation
installation.
10.2 Front Brake Assy Inspection B
10.2.1 Brake Hose, Hose Damage and A

Installation Inspection C
Inspect brake hoses, connectors and pipes
for damage, crack and leakage.
The high pressure in pipes and hoses may
cause leaking A or hose cracking.
Inspect hoses by bending or twisting them.
If any crack B , bulge C or leaking is
found, replace with a new one. 100202
Tighten all brake hose mounting bolts and
brake pipe connector nuts.
Inspect brake hose pipeline. Reinstall the
brake hose if wrong.
10.2.2 Brake Performance Inspection

Inspect vehicle brake performance on the
dry and flat ground.
If the brake performance is not good,
inspect the brake system for damage or
other defects.
10.2.3 Front Brake Fluid Level

Inspection
Straighten the vehicle to make the front 1
brake fluid reservoir 1 parallel the ground.
Check if the brake fluid level is between UPPER
the UPPER and LOWER line. LOWER
If lower than LOWER line, add the brake
fluid until the level reaches the UPPER
line.
If higher than upper line, reduce the brake 100203
fluid with a injector until the level reaches
the UPPER line.
10-2
10.2.4 Brake Fluid Replacement
Straighten the vehicle to make the front
brake fluid reservoir parallel the ground. 1
Remove two cross bolts 1 .
100301
Remove brake fluid reservoir cover 3 .

Remove fluid reservoir gasket 4 and
washer 2 .
3
4
100302
Remove air-bleed bolt rubber cap 5 .
Connect a clean plastic hose with the air-
bleed bolt 6 . 5
Place the another end of the hose in a
6
container.
Add new brake fluid.

Repeatedly hold and loose brake lever
until it feels hard.
Hold the brake lever tightly. 100303
Loose air-bleed bolt a little bit.
Tighten the bolt right after the old brake
fluid sprays out.
Repeat the above procedures until the new
brake fluid sprays out.
Note: Keep the brake fluid level
between upper and lower line. Do not
spray brake fluid on plastic parts or
painted surface.
Pull out plastic hose.
Install air-bleed bolt rubber cap.
Install brake fluid reservoir. 100304
10-3
CFMOTO
10.2.5 Front Brake Lever free Play
1
Front brake lever free play 1 :
10mm~20mm
100401
10.2.6 Front Brake Pad Inspection
Removal
Remove front brake caliper.
Remove two bolt plugs 1 .
2
Remove two brake pad guide pins 2 .
Remove front outer brake pad 4 .
4
Remove front inner brake pad 3 .
3
2 100402
A
Inspection B
Inspect brake pad thickness of each
caliper.
Replace when the brake pad thickness A
reaches service limit B 3mm.
A
B
100403
A 制片磨擦层 B 1.5mm
Installation
installation.
Warning: Do not run the vehicle
right after replacing new brake discs
or pads. Do break-in on brake pads.
Operate the brake lever several times
until brake pad and brake caliper
engage well.
10-4
10.3 Front Brake Assy Removal
Removal 3
Remove front brake hose clip 1 .
Remove three bolts 2 on the right side. 1
Remove three bolts 2 on the left side.
2
Remove front fender 3 from the front side
of the vehicle.
Place a jack under the engine. Press the
rear part of the vehicle to make the front
wheel off the ground.
100501
8
Remove two nuts 5 .
Pull out front wheel shaft 7 .
Remove front wheel 8 .
Note: Do not lose front wheel shaft
6 bushing. 6
5 7
100502
Remove three front brake disc bolts 9 .

Remove front brake disc 10 . 10
100503
Installation
installation.
10-5
CFMOTO
10.4 Rear Wheel Assy Removal
Removal
Lift up rear wheel with bracket.
Remove nut 2 .
Remove washer 1 .
1 2
100601
Pull out bolt 3 .

Remove washer 4 .
Remove rear brake caliper.
Push the rear wheel forward.
Remove chain.
Remove rear wheel.
5
Note: when removing rear wheel, 3
lean the tire a little bit rightward, in
case the sprocket seat 5 falls down to 4
cause injury.
100602
Note: Do not lose two rear wheel

shaft sleeves 6 .
100603
Remove sprocket seat assy 7 and rear

7 8
sprocket 8 .
Remove four bolts 10 . 9
Remove two lock pads 9 .
Remove the rear sprocket 8 . 10 10
100604
10-6
Remove sprocket rubber damper 11 .
11
100701
Remove three bolts 12 .

12
Remove brake pad 13 .
13
Installation
10.5 Front/Rear Wheel Inspection,

Brake Disc
10.5.1 Tire Pressure Inspection
Remove tire inflation valve cap.
Measure the tire pressure with air gauge.
Install tire inflation valve cap.
One person Two people
Pressure kgf/ kgf/
kPa 2 psi kPa psi
cm cm2
F r o n t
175 1.75 25 175 1.75 25
wheel
R e a r
200 2.00 29 225 2.25 33 100703
wheel
Adjust the tire pressure according to the
standard if necessary.
10.5.2 Tire Inspection

Clean the embedded stone A or other
inclusions B on tires.
Inspect the tire for cracks or damages by
watching it. Replace if necessary. If tire
expands or has bulges on it, replace a new
tire.
100704
10-7
CFMOTO
When the tire thread wears to the block 1
height, replace a new tire. 1
100801
10.5.3 Wheel bearing Inspection

Front Wheel
Use jack to lift the front wheel off the
ground.
Inspect the front wheel bearing for damage
B
by pushing and pulling wheel A .
Inspect the wheel smooth play by rotating
A
it B . Inspect the wheel for noise when
rotating it.
Replace a new one if noise or the wheel
can not rotate smoothly.
100802
Rear Wheel
Use jack to lift the rear wheel off the B
ground.
Inspect the rear wheel bearing for damage A
by pushing and pulling wheel A .
Inspect the wheel smooth play by rotating
it B . Inspect the wheel for noise when
rotating it.
Replace a new one if noise or the wheel 100803
can not rotate smoothly.
10.5.4 Brake Pad Inspection

Measure the brake disc thickness A with A
micrometer. Replace a new one if beyond
service limit.
Service
Item Standard
limit
Front Brake pad
4mm 3mm
Rear wear
100804
10-8
10.6 Rear Brake Assy Removal
Removal 2
Remove two screws 1 .
3
Remove screw 2 .
Remove sprocket cover 3 .
1
100901
Remove three bolts 5 .

Remove rear inner fender 4 .
5
4
100902
8
Remove rear wheel 6 .
Remove rear brake caliper 7 . 11
Remove rear brake hose clip 10 .
Separate rear brake hose clip 10 and rear
brake hose 9 .
Remove seat 8 . 7 9
Remove RH plate 11 .
Note: After removing rear brake 6
caliper assy, it is not allowed to step 10
the rear brake pedal.
100903
Remove bolt (13).

Remove rear brake fluid reservoir (15). 13 15
Remove rear brake switch connectors.
Remove bolt (14).
Remove nut (16).
12
Remove RH footrest (12) and whole rear
brake assy.
16
Note: Do not hang brake fluid
reservoir with brake hose. Do not lean
front brake fluid reservoir, in case the
14
air gets into hydraulic system.
100904
10-9
CFMOTO
Remove rear brake return spring 17 .
Remove bolt 18 .
19
17
18
101001
Remove gasket 22 .
Remove washer 21 .
Remove rear brake assy from RH footrest.
Remove washer 20 .
22
20
21
101002
Remove cotter pin 24 .
Remove cotter pin 23 .
Remove rear brake pedal.
Note: The removed cotter pin can
not be used again.
24
23
101003
Installation
installation.
10-10
10.7 Rear Brake Assy Inspection
10.7.1 Rear Brake Fluid Level Inspection
Straighten the vehicle to make the rear
brake fluid reservoir parallel the ground.
Check if the brake fluid level is between
the UPPER and LOWER line through the
RH plate brake fluid viewer 1 . 1
If lower than LOWER line, add the brake
fluid until the level reaches the UPPER
line.
If higher than upper line, reduce the brake
fluid with a injector until the level reaches 101101
the UPPER line.
1
10.7.2 Rear Brake Fluid Replacement

Remove seat 1 .
Remove RH plate 2 .
101102
5
3
Remove reservoir cap 5 .
Remove reservoir gasket 3 .
101103
Remove air-bleed bolt rubber cap 7 . 6

Connect a clean plastic hose with the air-
bleed bolt 6 .
Place the another end of the hose in a
container.
101104
10-11
CFMOTO
Add new brake fluid.
Repeatedly step brake pedal until it feels
hard.
Step the brake pedal.
Loose air-bleed bolt a little bit.
Tighten the bolt right after the old brake
fluid sprays out.
Repeat the above procedures until the new
brake fluid sprays out.
Note: Keep the brake fluid level
between upper and lower line. Do not
spray brake fluid on plastic parts or 101201
painted surface.
Pull out plastic hose.
Install air-bleed bolt rubber cap.
Install brake fluid reservoir.
10.7.3 Rear Brake Pedal Free Play 1

Rear brake pedal free play 1 :
10mm~20mm
101202
2
10.7.4 Rear Brake Pad Inspection
Removal
Remove rear brake caliper.
1
Remove bolt plug 2 .
Remove brake pad guide pin 1 .
101203
Remove rear outer brake pad 3. 4
Remove rear inner brake pad 4. 5

Remove spring pad 5 .
101204
10-12
Inspection
Inspect brake pad thickness of each A
B
caliper.
Replace when the brake pad thickness A
reaches service limit B 3mm.
B
101205
A 制片磨擦层 B 1.5mm
Installation
installation.
Warning: Do not run the vehicle
right after replacing new brake discs
or pads. Do break-in on brake pads.
Operate the brake pedal several times
until brake pad and brake caliper
engage well.
10-13
11 Shock Absorbers and Rear Fork
11.1 LH Footrest Bracket�� 11-1
11.2 Side Stand�� 11-1
11.3 Rear Shock Absorber�� 11-1
11.4 Rear Fork�� 11-2
11.5 Chain�� 11-2
11.6 Front Shock Absorber�� 11-2
Note: Before operation, the vehicle

has to be fixed, in case it falls down to
cause injury.
11.1 LH Footrest Bracket

Removal
Remove LH footrest bracket nut 1 .
Remove bolt 2 . 1
Remove LH footrest 3 . 3
RH footrest bracket refers to 10.6 Section.
Installation
installation.
11.2 Side Stand 2

110101
Removal
Remove nut 2 .
Remove inner hex bolt 1 .
Remove side stand spring 3 .
Remove side stand 4 . 1 2
Installation
4
installation.
11.3 Rear Shock Absorber

Removal 110102
Remove bolt 1 .
Remove bolt 2 .
Remove rear shock absorber 3 .
Note: After rear shock absorber 1
removed, the rear fork can be removed.

Installation
installation. 3
Rear shock absorber nut tighten torque:
35N•m~45N•m 2
110103
11-1
CFMOTO
11.4 Rear Fork
Removal
Remove rear fork shaft 1 .
Remove rear fork 2 . 2
Installation
installation.
1
Rear fork shaft nut tighten torque: 110201
50N•m~80N•m
11.5 Chain
Removal
Remove three inner hex bolts 1.
1
Remove small sprocket guard 2.
2
Remove chain 3 . 3
110202
1
11.6 Front Shock Absorber
Removal 2
Remove four bolts 1 .
Remove front shock absorber deco cover 1
2.
110203
3
3
Remove two inner hex bolts 3 . 6

Remove two inner hex bolts 4 .
Remove two inner hex bolts 5 . 5
4
Remove front shock absorber 6 . 5
110204
11-2
11 Shock Absorbers and Rear Fork
Installation 8
7
installation.
Before installing front shock absorber, the

upper ends 7 of two front shock absorber
should be paralleled, and the upper end
should exceed the upper surface of upper
holder 8 for about 1mm~2mm. 110301
11-3
12 Engine Assy
12.1 Special Tool for Engine��12-5 12.4.4 Cylinder Head Cover Assy
12.2 Engine Removal��12-8 Assembly��12-27
12.2.1 Engine LH/RH Lower Guard 12.4.5 Camshaft Disassembly��12-28
Removal��12-8 12.4.6 Camshaft Inspection��12-28
12.2.2 Engine Removal��12-9 12.4.6.1 Cam Wear��12-28
12.3 Engine Disassembly�� 12-11 12.4.6.2 Camshaft Journal
12.3.1 Engine Oil Drain�� 12-11 Diameter ��12-28
12.3.2 Rear LH Cover Removal�� 12-11 12.4.6.3 Camshaft Bearing Wear...
12.3.3 Gearshift Lever Removal� 12-11 ��12-29
12.3.4 Timing Adjustment��12-12 12.4.7 Camshaft Assy Assembly12-29
12.3.5 Starter Motor Removal��12-12 12.4.8 Cylinder Head Disassembly...
12.3.6 Starter Dual Gear Removal... ��12-29
��12-13 12.4.9 Cylinder Head Inspection12-30
12.3.7 Magneto Rotor Removal��12-13 12.4.9.1 Tensioner Plate Inspection
12.3.8 Magneto Stator Removal�12-14 ��12-30
12.3.9 Gear Sensor Removal��12-14 12.4.9.2 Cylinder Head Inspection
12.3.10 Drive Sprocket Removal12-15 ��12-31
12.3.11 Oil Filter Removal��12-15 12.4.9.3 Valve Stem Inspection...
12.3.12 Clutch Removal��12-16 ��12-32
12.2.13 Oil Pump Removal��12-18 12.4.9.4 Valve Spring��12-33
12.3.14 Drive Gear and Primary Drive 12.4.10 Cylinder Head Assembly......
Gear Removal��12-18 ��12-34
12.3.15 Balance Shaft Nut Removal 12.4.11 Cylinder Body Inspection...
��12-19 ��12-36
12.3.16 Timing Chain Tensioner 12.4.11.1 Cylinder Body
Removal��12-19 Deformation��12-36
12.3.17 Spark Plug Removal��12-19 12.4.11.2 Cylinder Body Inner
12.3.18 Cylinder Head Cover Removal Diameter Inspection��12-36
��12-20 12.4.12 Piston Inspection��12-36
12.3.19 Cylinder Head Removal�12-20 12.4.12.1 Piston Diameter��12-36
12.3.20 Timing Chain Removal��12-21 12.4.12.2 Piston Ring Groove
12.3.21 Cylinder Body Removal�12-21 Clearance��12-37
12.3.22 Piston Removal��12-22 12.4.12.3 Free Gap and Working
12.3.23 Gearshift Assy Removal12-22 Gap of Piston Ring��12-37
12.3.24 Crankcase Disassembly12-23 12.4.13 Piston Pin and Pin Hole�12-37
12.3.25 Transmission Case Removal 12.4.14 Crankshaft Connecting Rod
��12-24 Assy Inspection��12-38
12.4 Engine Inspection��12-26 12.4.14.1 Small End Inner Diameter
12.4.1 Valve Clearance Adjustment Measurement��12-38
��12-26 12.4.14.2 Big End Clearance
12.4.2 Cylinder Head Cover Assy Inspection��12-38
Disassembly��12-26 12.4.14.3 Crankshaft Run-out
12.4.3 Cylinder Head Parts Inspection Inspection��12-38
��12-26 12.4.14.4 Crankshaft Journal
12.4.3.1 Cylinder Head Inspection Clearance��12-39
��12-26 12.4.15 Balance Shaft Assy
12.4.3.2 Rocker Arm Shaft Inspection��12-39
Inspection��12-27 12.4.15.1 Disassembly ��12-39
12.4.3.3 Rocker Arm Inspection... 12.4.15.2 Inspection��12-39
��12-27 12.4.15.3 Assembly��12-39
12-1
CFMOTO
12.4.16 Magneto Rotor Inspection... 12.5.10 Starter Motor Installation......
��12-40 ��12-55
12.4.17 Overriding Clutch��12-40 12.5.11 Cylinder Head Installation...
12.4.17.1 Overriding Clutch ��12-56
Disassembly��12-40 12.5.12 Camshaft Installation��12-56
12.4.17.2 Overriding Clutch 12.5.13 Timing Adjustment��12-57
Inspection��12-40 12.5.14 Cylinder Head Cover
12.4.17.3 Overriding Clutch Installation��12-57
Assembly��12-40 12.5.15 Tensioner Installation��12-58
12.4.18 Starter Driven Gear, Dual 12.5.16 Clutch Assy Installation�12-58
Gear and Dual Gear Shaft��12-41 12.5.17 Primary Drive Gear Assy and
12.4.19 Clutch Parts Inspection�12-41 Oil Pump Installation��12-59
12.4.19.1 Primary Driven Gear...... 12.5.18 Balance Shaft Nut Installation
��12-41 ��12-60
12.4.19.2 Primary Drive Gear�12-41 12.5.19 RH Side Cover Installation...
12.4.19.3 Clutch Friction Disc12-42 ��12-61
12.4.19.4 Clutch Driven Disc��12-42 12.5.20 Oil Filter Installation��12-61
12.4.19.5 Clutch Spring��12-42 12.5.21 Engine Drain Bolt Installation
12.4.19.6 Thrust Bearing and ��12-62
Clutch Bracket��12-42 12.5.22 Gear Sensor Installation12-62
12.4.20 Gearshift Assy��12-43 12.5.23 Drive Sprocket Installation...
12.4.21 Main Shaft Assy��12-43 ��12-62
12.4.22 Gearshift Rod Inspection...... 12.5.24 Rear LH Cover Installation...
��12-45 ��12-63
12.4.22.1 Gearshift Position Spring 12.5.25 Gearshift Pedal Lever
��12-46 Installation��12-63
12.4.22.2 Gearshift Cam Position 12.5.26 Screw Plug and Spark Plug
Mechanism��12-46 Installation��12-63
12.4.23 Crankcase Parts Inspection 12.6 Engine Installation��12-65
��12-46 12.6.1 Engine Installation��12-65
12.4.24 Tensioner Inspection��12-47 12.6.2 Engine LH/RH Lower Guard
12.4.25 Speed Sensor Inspection... Installation��12-66
��12-47 12.7 Air Intake System��12-67
12.4.26 Magneto Inspection��12-48 12.7.1 Throttle Body Removal��12-67
12.5 Engine Assembly��12-49 12.7.2 Throttle Body Inspection�12-68
12.5.1 Transmission Case Installation 12.7.3 Fuel Injector��12-68
��12-49 12.7.4 Throttle Body Installation12-69
12.5.2 Crankshaft and Balance shaft 12.8 Lubrication System��12-70
Installation��12-50 12.8.1 Engine Oil Volume Inspection
12.5.3 Crankcase Installation��12-51 ��12-70
12.5.4 Gearshift Assy Installation��12- 12.8.2 Engine Oil Replacement��12-70
51 12.8.3 Oil Strainer��12-70
12.5.5 Piston Installation��12-52 12.8.3.1 Oil Strainer Removal�12-70
12.5.6 Cylinder Body Installation...... 12.8.3.2 Oil Filter Strainer
��12-53 Inspection��12-71
12.5.7 Magneto Rotor Installation... 12.8.3.3 Oil Filter Strainer
��12-54 Installation��12-71
12.5.8 Dual Gear II Installation��12-54 12.8.3.4 Oil Pressure Inspection...
12.5.9 Magneto Stator Installation... ��12-71
��12-55
12-2
12 Engine Assy
12.1 Special Tool for Engine
Magneto rotor removing tool (to remove magneto rotor)
0800-031000-922-001
120301
V-block
0800-060000-923-001
120302
Valve stem seal ring installing tool (to help install valve stem seal ring)
152MI-022500-923-001
120303
Bearing puller
CF188-060008-922-001
120304
12-3
CFMOTO
Piston pin circlip installing tool (to install piston pin circlip)
0800-040005-922-001
120401
Feeler gauge (to measure the valve clearance)
120402
Spark plug sleeve
0800-022800-922-001
120403
Valve spring compressing tool
CF188-022006-922-001
120404
12-4
12 Engine Assy
Clutch stopping wrench (to install/remove clutch nut and nut on right crankcase)
0GR0-011102-921-001
120501
Valve clearance adjusting wrench (to adjust valve clearance)
CF188-060006-922-001
120502
12-5
CFMOTO
12.2 Engine Removal
Fix the vehicle on the operation bench.
-Remove fuel tank LH panel.
-Remove all connectors on engine.
-Remove fuel tank RH panel.
-Remove LH panel.
-Remove RH panel.
-Remove seat.
-Remove battery +/- connecting wires.
-Remove throttle body.
-Remove muffler.
Note: Remove the engine until it

cools down or wear protection clothes
to avoid burnt injury.
12.2.1 Engine LH/RH Lower Guard

Removal
Remove bolt 1 .
Remove bolt 2 .
Remove engine LH lower guard 3 .
3
120601
Remove bolt 1 . 1
Remove bolt 2 .
Remove engine LH guard mounting
bracket 3 .
3
2
120602
12-6
12 Engine Assy
Remove bolt 1 .
Remove bolt 2 . 1
Remove engine RH lower guard 3 .
3
120701
Remove bolt 1 .
Remove bolt 2 .
Remove engine RH guard mounting
bracket 3 .
1
2
3
120702
12.2.2 Engine Removal
Support the engine with a pallet that can 1

go up and down.
Remove bolt 1.
Remove bolt 2.
Note: There are nuts behind bolt 1 2

and 2 . When removing these bolts, fix
the nut with wrench and then remove 120703
the bolts.
Remove bolt 1 .
Remove bolt 2 . 2
Remove engine front suspension bracket
3.
Note: There are nuts behind bolt 1 3
the nut with wrench and then remove
the bolts.
120704
12-7
CFMOTO
Remove engine upper hanging bolt 1 .

Note: There are nuts behind bolt 1
the nut with wrench and then remove 1
the bolts.
120801
Remove rear fork shaft 1 .

Remove bolt 2 .
1
Note: There are nuts behind bolt 1
the nut with wrench and then remove
the bolts.
120802
Decline the pallet slowly. Remove the
engine until it goes down to the proper
place.
Note: Take care when removing the

engine, in case it falls down to cause
injury or engine damage.
12-8
12 Engine Assy
12.3 Engine Disassembly
Place the engine on the operation bench.

Fix the engine firmly on the bench.
Note: Fix the engine firmly on the

bench, in case it falls down to cause
injury or engine damage.
12.3.1 Engine Oil Drain
Place a pan under the engine to store the

engine oil from the engine.
Remove the drain screw plug on LH
crankcase. Drain the oil into the pan and
then do the next step.
1
120901
12.3.2 Rear LH Cover Removal

Remove rear LH cover 2 .
1
2
120902
12.3.3 Gearshift Lever Removal

Remove bolt 1 . 1
Remove gearshift lever 2 .
120903
12-9
CFMOTO
12.3.4 Timing Adjustment

Remove Front LH side cover bolt cap 1 .
Remove O-seal ring 2 .
2
121001
Remove bolt 1 .
Remove washer 2 .
121002
Place the sleeve on bolt 1 and rotate the

crankshaft. Through the bolt hole 2 , watch 3
2
mark "I" position. When mark "I" aligns with
the mark 3 , stop rotating the crankshaft
and this is the timing position.
121003
12.3.5 Starter Motor Removal

Remove bolt 1 .
Pull out stater motor 2 by shaking it. If it is
too tight, use a rubber hammer to slightly
knock it and then shake the motor to
remove it. 2
121004
12-10
12 Engine Assy
12.3.6 Starter Dual Gear Removal

Remove bolts 1 .
Remove front LH cover gear guard 2 .
121101
Remove dual gear shaft I 1 .

Remove dual gear I 2 .
121102
12.3.7 Magneto Rotor Removal
Remove bolts 1 .
Remove front LH cover 2 .
121102
Remove dowel pins . 1
Remove gasket 2 .
Remove nut 3 . 1
Note: Clean the remaining gasket on

cover and case. If it is difficult to clean,
use knife to scrape it.
Note: Pay attention to the dowel pin
3 when removing Front LH cover, in 3
case dowel pins get lost.
Note: The removed gasket is for 1
disposal.
2
121103
12-11
CFMOTO
Install the special tool: magneto rotor

removing tool 1 on magneto rotor 2 .
Remove magneto rotor 2 .
1
121201
Remove woodruff key 1 .
Remove starter big gear 2 .
Remove dual gear II 3 . 3
Remove dual gear shaft II 4 . 4
Note: Pay attention to the woodruff

key 1 when removing magneto rotor,
in case it gets lost. 2
1
121202
4
12.3.8 Magneto Stator Removal
2
Remove bolts 1 . 2
Remove bolts 2 . 3
Remove magneto stator 3 .
Remove trigger 4 . 1
Remove wire press plate 5 .
121203
1
12.3.9 Gear Sensor Removal
Remove screws 1 . 2
Remove gear sensor 2 . 3

Remove rubber seal ring 3 . 1
121204
12-12
12 Engine Assy
12.3.10 Drive Sprocket Removal

Remove speed sensor disc 2 .
2
121301
1
Remove bolts 1 .
Rotate the sprocket guard 2 to make
woodruff key to the proper position. Then
remove sprocket guard. 1
Remove drive sprocket 3 .
3 2
121302
Remove bolts 1 . 1
Remove countershaft oil seal press plate
2. 2
121303
12.3.11 Oil Filter Removal

Remove nuts 1 .
Remove oil filter cover 2 . 2
Remove spring 3 . 4
Remove oil filter element 4 . 1
Note: Pay attention to the seal ring

when removing oil filter cover. In case 3
it gets broken or lost.
121304
12-13
CFMOTO
Remove seal ring 1 .

1
121401
12.3.12 Clutch Removal

Remove bolts 1 .
Remove engine RH cover 2 . 1
2
121402
Remove RH side cover gasket 1 .

1
Remove screws 2 . 2
121403
Grasp clutch rod 1 to pull out the rod with

clutch plate 2 . Then remove the rod 1
from the plate 2 . 1
121404
12-14
12 Engine Assy
Remove springs 1 .
Remove all clutch friction discs 2 .
Remove all clutch driven pads 3 .
2
121501
Use special tool: clutch stopping wrench 1

to fix the clutch hub. 1
Remove nut 2 .
2
121502
Remove lock retainer 1 .

Remove clutch hub 2 . 1
121503
Remove washer 1 .
Pull primary driven gear 3 up and down. 2
When the bushing 2 gets exposed a
little bit, use a nipper plier to remove the 3
bushing 2 .
Remove primary driven gear 3 .
121504
12-15
CFMOTO
Remove washer 1 .
121601
12.2.13 Oil Pump Removal

Remove circlip 1 .
Remove oil pump driven gear 2 .
1
121602
Remove pin shaft 1 .

Remove bolts 2 . 2
Remove oil pump 3 .
121603
12.3.14 Drive Gear and Primary Drive 3

Gear Removal
Chip the edge of lock washer 2 to make it
flat with a chisel. 1
Remove nut 1 (left-hand thread).
Remove washer 2 .
Remove stud 3 with a special tool.
2
121604
12-16
12 Engine Assy
Remove oil pump drive gear 1 .

Remove primary oil pump drive gear 2 .
Remove guide block 3 . 2
Note: Pay attention to the guide
block 3 when removing drive gear 1 1
and primary drive gear 2 . In case it
3
gets lost.
121701
12.3.15 Balance Shaft Nut Removal

Remove balance shaft nut 1 (left-hand 1
thread). 2
Remove washer 2 .
121702
1 2 . 3 . 1 6 T i m i n g C h a i n Te n s i o n e r 2 1
Removal 3
Remove bolts 1 .
Remove timing chain tensioner 2 .
Remove seal gasket 3 .
1
121703
12.3.17 Spark Plug Removal

Use special tool: spark plug sleeve 1 to
remove spark plug 2 . 1
121704
12-17
CFMOTO
12.3.18 Cylinder Head Cover Removal
2
Remove bolts 1 .
Knock the cylinder head cover 2 upward
to remove it.
1 1 1
121801
Remove timing sprocket.
Remove cam shaft plug 1 .
Remove cam shaft assy 2 .
Note: Pay attention to the position 3

plate 3 when removing cam shaft. In
case it gets lost.
1
2
121802
1
12.3.19 Cylinder Head Removal
Hook the timing chain 1 , in case it gets
into the engine.
Remove nuts 2 .
Remove nuts 1 and washers. 2

121803
Remove nuts 2 and washers.
Remove cylinder head 3 .
Note: Hook the timing chain when

removing cylinder head. In case it gets
into engine.
1 2
3
121804
12-18
12 Engine Assy
Remove cylinder head gasket 1 .

Remove dowel pins 2 .
Remove chain guide 3 .
3
1
2
121901
12.3.20 Timing Chain Removal

Remove timing chain 1 from the
crankshaft on the LH side. 1
121902
12.3.21 Cylinder Body Removal
Remove cylinder body 1 .
Note: Pull out the cylinder body

when removing it. In case cylinder 1
body and other parts get damaged.
121903
Remove dowel pins 1 .

Remove cylinder body gasket 1 .
121904
12-19
CFMOTO
12.3.22 Piston Removal

Use special tool: piston circlip removing
tool to remove circlip
Remove piston pin 2 . 1 2
Remove piston 3 .
3
Note: When removing piston pin,
just remove the circlip on one side. 122001
12.3.23 Gearshift Assy Removal

Pull out gearshift rod 1 .
1
Note: Pull out the gearshift rod with
the spring during removal. 2
122002
Remove bolts 1 .
Remove gearshift pawl plate 2. 3 1
Remove gearshift cam guide 3.
2
1
122003
Hold the LH pawl 1 and RH pawl 2
together with hand or plier.
Pull out the gearshift cam driven gear
when putting the LH and RH pawl into the
1
gearshift cam driven gear.
Note: When removing gearshift cam
driven gear assy, pay attention to the
pawls, pawl pins and springs, in case
2
they get lost. 3
122004
12-20
12 Engine Assy
Remove pawls 1 .
Remove pawl pins 2 .
Remove the pawl springs 3 from the 3
mounting points 4 . 2
4 4 1
122101
Remove gear switch contactor 1 .

Remove spring 2 with magnet.
1
2
3
2
1
Remove bolt 1 . 122102

Remove washer 2 .
Remove neutral gear position spring 3
with magnet.
Remove neutral gear lock pin 4 with
magnet.
4
3
2
1
122103
12.3.24 Crankcase Disassembly

1
Remove bolts 1 .
Make LH crankcase as the base and
remove RH crankcase. 1
122104
12-21
CFMOTO
Remove dowel pin 1 . 2

Rotate the balance shaft 2 to the proper
1
position as picture shows.
Remove balance shaft 3 .
Remove crankshaft 4 .
4 3
122201
12.3.25 Transmission Case Removal

Remove fork shaft 1 .
Remove fork shaft 2 . 1
2
Remove fork 3 .
Remove fork 4 .
4
3
122202
Remove washer 1 .
Remove main shaft 3 and countershaft 2
together.
Remove gearshift drum 4 .
3
2
122203
Remove pin 1 . 2
Remove washer 2 . 1
122204
12-22
12 Engine Assy
Remove bolt 1 .
Remove spring 2 .
Remove gearshift cam position assy 3 . 2 5
Remove washer 4 under the gearshift
cam position assy 3 .
1
Remove gearshift cam position plate 5 .
3
4 122301
12-23
CFMOTO
12.4 Engine Inspection
12.4.1 Valve Clearance Adjustment
Remove stainer cover and o-seal ring.
Fix the lock nut 5 with wrench. 2

Loose adjusting screw 4 with special tool:
3
valve clearance adjusting wrench 3 . 1
Insert a proper filler gauge into the gap
4
between rocker arm and spring lock 2 . 5
The filler gauge can be drawn with proper
force. 122401
Tighten valve clearance nut 5 and check
the clearance is proper.
Note: Make sure the engine is at

timing position when adjusting the
valve clearance.
Valve clearance
Intake valve 0.08mm~0.10 mm
Outlet valve 0.15mm~0.18 mm
12.4.2 Cylinder Head Cover Assy

Disassembly 1
Remove strainer cover and o-seal ring 1 .
Remove cam shaft plug 2 . 4
3 1
Remove bolts 3 .
Pull out rocker arm shafts 4 with plier.
Remove o-ring 5 .
2
Remove valve rocker arms 6 .
Remove washers 7 . 7
5
Note: After disassembly, all the parts
6 122402
should be placed in classification.
Install parts to their original positions.
12.4.3 Cylinder Head Parts Inspection

12.4.3.1 Cylinder Head Inspection
Clean sealing glue on the joint surface of
cylinder head cover. After cleaning, put it
on the bench and check its joint surface
flatness with filler gauge.
Cylinder head cover joint surface flatness
Service limit: 0.05 mm
Replace a new cylinder head cover if its
joint surface flatness is out of service limit.
(The cylinder head and cylinder head
cover are one component, replace the 122403
whole set.)
12-24
12 Engine Assy
12.4.3.2 Rocker Arm Shaft Inspection
Inspect each rocker arm shaft for 1
scratches. Replace if necessary.
Use micrometer to measure the outer

diameter 1 of the rocker arm shaft.
Micrometer standard: 0~25 mm
Rocker arm shaft outer diameter

11.977 mm~11.995 mm 122501
Replace if out of service limit. Replace with

new parts if any part is severely worn.
12.4.3.3 Rocker Arm Inspection

Inspect rocker arm for crank or scratch.
Replace if any defect occurs.
Inspect the joint surface 1 with camshaft.

Inspect valve clearance adjusting bolt
3
head 2 for wear. Replace if severely worn.
Use micrometer to measure the inner

1
diameter 3 of valve rocker arm shaft hole.
Replace if out of service limit.
Rocker arm inner diameter 2

122502
12 mm~12.018 mm
Inspect washers, seal rings and dowel

pins. Replace if damaged.
12.4.4 Cylinder Head Cover Assy

Assembly 5 3
6
Install valve rocker arms 1 .
Install washers 2 .
Install o-rings 3 .
Install rocker arm shafts 4 .
Install bolts 5 .
Install strainer cover 6 . 4
Install camshaft plug 7 . 6
7
Note: Replace with new o-rings after 1
rocker arm removal and inspection. 2 122503
12-25
CFMOTO
12.4.5 Camshaft Disassembly 2
Remove the camshaft from cylinder head.

Remove bolts 1 .
Remove timing sprocket 2 .
122601
12.4.6 Camshaft Inspection
Inspect cam shaft for damage, crack,

scratch or wear. Replace if any defect
occurs.
Measure the cam journal diameter and
height with micrometer. If out of standard,
replace with new parts.
If there are problems like abnormal

noises, big vibration or low output power,
check the cam lift and connecting surface
situation. The camshaft wear can lead to
such problems.
12.4.6.1 Cam Wear A

1 2
Cam wear influences valve performance A
which decreases the engine outout power.
The wear limit of intake/exhaust cam is:
Intake cam 1 : 33.6695 mm
Exhaust cam 2 : 33.314 mm
Measure the cam wear value with

micrometer. If out of wear limit, replace
with new parts. 122602
(Micrometer specification: 0~25 mm)
12.4.6.2 Camshaft Journal Diameter

Measure the camshaft journal outer
diameter A with micrometer. Replace with
a new camshaft if out of standard.
Standard of camshaft outer diameter A
21.959 mm~21.98 mm
Tool: micrometer 0~25 mm
12-26
12 Engine Assy
12.4.6.3 Camshaft Bearing Wear
Install camshaft and measure the
clearance between camshaft and bearing
hole to check if it is out of service limit
depending on wear situation.
Camshaft connecting surface clearance

service limit: 0.15 mm
1
Measuring method: 1
-Clean the dirt on cylinder head and
cylinder head cover.
-Put the plastigauge axially on the
122701
camshaft outer surface 1 and then install
them together on cylinder head.
-Install cylinder head cover. Tighten the
cylinder head cover bolts in criss-cross
way.
-Remove cylinder head cover and read the
max impress width of plastiguage, which is
the measured value.
Tool: plastigauge
Note: Do not rotate camshaft after

install plastigauge. If the measured
value is out of service limit, measure 1
the camshaft axle diameter. If the
diameter is out of standard, replace
with a new camshaft. Otherwise,
replace cylinder head and cylinder
head cover. 2
12.4.7 Camshaft Assy Assembly
Install timing sprocket 1 . 122702

Install bolts 2 .
2
Installation refers to Engine Installation
section.
1
12.4.8 Cylinder Head Disassembly

Remove bolt 1 .
Remove washer 2 . 3
Remove tensioner plate 3 .
122703
12-27
CFMOTO
Place valve spring compressing tool 1 to

the center of valve 2 as the arrow shows.
1 2
122801
Place valve spring compressing tool 1 to

the valve spring upper seat 3 . Tighten the 3
tool to press the valve spring.
2
Use tweezers to remove valve lock clip 2 . 4
5
Loose valve spring compressing tool 1 . 1
Remove valve spring upper seat 3 .
Remove valve outer spring 4 .
Remove valve inner spring 5 .
122802
2
Pull air intake valve 1 from the other side.
Remove valve stem seal ring 2 .
1
Remove valve spring seat 3 . 3
Air exhaust valve removal refers to inlet

valve removal procedures.
Note: Replace with new valve stem
122803
seal rings after removing valves. The
removed seal rings are sorted into
waste.
12.4.9 Cylinder Head Inspection

12.4.9.1 Tensioner Plate Inspection
Inspect the tensioner plate 1 and chain 2
for wear and damage. Replace with new
parts if severely worn or terribly damaged.
122804
12-28
12 Engine Assy
12.4.9.2 Cylinder Head Inspection
Cylinder Head deformation

-Clean the carbon deposit in combustor
and junction surface.
-Use knife-edge ruler and filler gauge
to measure the deformation of junction 1
surface 1 between cylinder head and
cylinder body in different positions. If the
value is out of limit, replace with new
cylinder head.
122901
Cylinder head deformation limit value: 0.03
mm
Tool: knife-edge ruler, filler gauge
A A
Valve seat width

-Apply the paint evenly on valve seat A
. Insert the valve and rotate it. In order to
have a clear trace, lock the valve head
with valve grinder.
122902
-The trace of the valve head should be
continuous. And the width should conform
to the standard range. Otherwise, the
valve should be grinded.
Valve seat width standard: 0.9mm~1.1mm
Tool: valve grinder
1 2
Valve cone width 1 .

Valve seat junction surface width 2 .
122903
12-29
CFMOTO
12.4.9.3 Valve Stem Inspection
Valve stem seal ring
Note: Replace with new valve stem
seal rings after removing valves. The
removed seal rings are sorted into 1
waste.
Valve stem
Inspect valve stem for abnormal wear and
bend. Replace if necessary.
Valve stem diameter
123001
Exhaust valve
4.955mm~4.97mm
Inlet valve
4.975mm~4.99mm
Junction between valve stem and valve

pipe
-Lift the valve around 10 cm from the valve
seat. Use the dial gauge to measure the
deviation in the vertical direction of "X"
and "Y". If the deviation value is out of
standard, replace the valve or cylinder
head. If the valve stem diameter is within
the standard, replace the cylinder head.
Measure the deviation value again after
replacement.
Deviation value (air intake and exhaust)： 123002

0.25 mm
Tool: dial gauge, magnetic stand
Valve stem run-out

-Support the valve 2 with V-block 1 as
2
picture shows. Use dial gauge to measure
the valve stem run-out value. 1
Valve stem run-out limit value: 0.05 mm

Tool: magnetic seat, dual gauge (1/100)
and V-block 1 123003
Valve head run-out

-Use dial gauge to measure valve head 2
2
vibration as picture shows. If the value is
out of service limit, replace a new valve.
Valve head vibration service limit: 0.03 mm
1
Tool: magnetic seat, dial gauge (1/100)
and V-block 1
123004
12-30
12 Engine Assy
Valve head surface wear

-Inspect every valve head for wear.
Replace if worn abnormally or damaged.
Measure valve head thickness "T". If less
than standard, replace valves.
Valve head thickness service limit: 0.7 mm
T
123101
Valve stem end condition

-Inspect valve stem end for corrosion and
wear. Service the valve stem if worn. If the A
length A is less than service limit, replace
with new valves.
Valve stem end length service limit: 2.1 mm
123102
12.4.9.4 Valve Spring

Valve spring is used for sealing between
valve and valve seat. The decrease of
spring force leads to the decrease of
engine output power and mechanical
noises.
Measure spring free length. If less than

limit value, replace with a new spring.
Valve inner spring free length limit value
(air exhaust and intake): 31 mm 1
Valve outer spring free length limit value
(air exhaust and intake): 32.5 mm 123103
Use spring scale 1 to measure the force

when the spring 2 is pressed to the
specific length. If the spring force is out of
standard, replace with new springs 2 .
Valve inner spring force standard (air
intake and exhaust): 33.7 N~44.3 N when 2
pressed to 26.8 mm
Valve outer spring force standard (air
1
intake and exhaust): 88.6 N~104 N when
pressed to 29.8 mm 123104
12-31
CFMOTO
Measure the spring angularity. Replace
springs if out of limit value.
Spring angularity limit value: 2°
12.4.10 Cylinder Head Assembly
Insert valve spring seat 1 into valve pipe 1

2 and then install them to the base.
123201
Use special tool: valve stem seal ring

installing tool 1 to insert the seal ring 2
on valve pipe. 2
123202
Clean the inlet/exhaust valves 1 with coal

oil. Apply engine oil on the top of intake/ 1 1
exhaust valve and insert them respectively
into the valve pipes on cylinder head.
2
Note: Do not damage the lips of

valve stem seal rings 2 .
Warning: The seal rings can not be

used again. Replace with a new on 123203
during installation.
12-32
12 Engine Assy
1
Install valve inner springs 1. 1
Install valve outer springs 2.
2 2
Note: When installing intake/exhaust
valve inner/outer spring, the thread
pitch of small side faces down.
123301
Place valve spring upper seat 2 . When

removing, use special tool: valve spring 2
compressing tool 1 to press the spring, 1
then place two valve lock clip 3 into the
grooves of valve stem end. Loose the 3 3
compressing tool.
123302
Note: Use rubber hammer to slightly

knock the end of the valve to check 1
the valve lock clip is installed into the
valve groove tightly.
Inspect the cylinder head for sealing: Insert

some clean agent in air inlet and exhaust
1 respectively. Wait for some time to
check valve seat 2 for leakage.
123303
12-33
CFMOTO
12.4.11 Cylinder Body Inspection
12.4.11.1 Cylinder Body Deformation

-Use knife-edge ruler and filler gauge to
measure the flatness of cylinder sealing
surface. As picture shows, measure at 7
points and record their values. If the value
is out of limit, replace with a new cylinder
body.
Cylinder body sealing surface flatness
limit value: 0.03 mm
123401
12.4.11.2 Cylinder Body Inner Diameter

Inspection A
-Inspect cylinder body interior for cracks,

scratches or other defects. Replace if it B
does.
-Measure the cylinder inner diameter with
diameter gauge separately at A, B and C
C
places in two crossing directions.
Cylinder body inner diameter standard: 123402
57 mm~57.01 mm
12.4.12 Piston Inspection

12.4.12.1 Piston Diameter
Use dial gauge to measure the diameter
at the position as picture shows where the
height is 7mm above the bottom. If the
diameter is less than limit value, replace
with a new piston.
7mm
Piston outer diameter standard:
56.995~56.97 mm
Piston outer diameter limit value: 56.94 123403
mm
Calculate the fit clearance between
piston and cylinder body according to
the measurement results above. If the
clearance is more than 0.10 mm, replace
cylinder body or piston, or both.
12-34
12 Engine Assy
12.4.12.2 Piston Ring Groove Clearance

Measure the clearance between every
piston ring and groove with filler gauge 1
. If out of service limit, replace with new
piston and piston rings.
Clearance between piston ring and groove

1
Piston ring (1)
0.02 mm~0.06 mm
Piston ring (2)
0.02 mm~0.06 mm 123501
Oil ring
0.14 mm~0.26 mm
12.4.12.3 Free Gap and Working Gap of

Piston Ring
Before installing piston ring, measure the
free gap of every ring with vernier caliper.
Then install the piston ring. Measure the
working gap of every ring with filler gauge.
If the gap is out of limit value, replace
piston rings.
Piston ring free gap limit value

1 ring: 7.5 mm
2 ring: 7.5 mm
Piston ring working gap limit value 123502
1 ring: 0.25 mm
2 ring: 0.25 mm
12.4.13 Piston Pin and Pin Hole

-Measure piston pin hole inner diameter
with dial bore gauge and piston pin outer
diameter with dial gauge. If the diameter is
out of the limit value, replace both piston
and piston pin.
Piston pin hole limit value: 14.030 mm 123503
12-35
CFMOTO
1
-Measure piston pin outer diameter 1 at
three measuring points with dial gauge.
Piston pin outer diameter limit value:
13.980 mm
123601
12.4.14 Crankshaft Connecting Rod

Assy Inspection
1
12.4.14.1 Small End Inner Diameter
Measurement
Measure connecting rod small end inner

diameter 1 . If out of service limit, replace
with new crankshaft connecting rod assy.
123602
Connecting rod small end inner diameter
limit value: 14.014 mm
12.4.14.2 Big End Clearance Inspection 1

2
-Put connecting rod big end aside and use 2
filler gauge 1 to measure the clearance 2
. (Standard: 0.10mm~0.45mm, limit value:
1.00 mm)
If out if limit value, replace with a new 123603
crankshaft.
12.4.14.3 Crankshaft Run-out Inspection

-Put the crankshaft connecting rod on
V-block as picture shows. Rotate the
crankshaft slowly and measure its run-out 1
value by dial gauge. If out of limit value,
replace or fix the crankshaft.
Crankshaft run-out limit value: 0.04 mm
123604
12-36
12 Engine Assy
12.4.14.4 Crankshaft Journal Clearance

Measure the crankshaft journal diameter
1 2
of both two sides, and compare to the
bearing inner diameter.
RH crankshaft journal diameter 1

27.990mm~27.997mm
LH crankshaft journal diameter 2

35.003mm~35.010mm
123701
If the measuring value is less than service

limit, replace with new crankshaft assy.
12.4.15 Balance Shaft Assy Inspection
12.4.15.1 Disassembly
Remove circlip 1 .
Remove balance shaft gear 2 , spring 3 ,
damper 4 and washer 5 .
Note: Replace with new circlip 1

when installing. The removed circlip
can not be used again.
3
4
12.4.15.2 Inspection
1
Inspect spring and washer for damage. 5
Replace if damaged. 2
12.4.15.3 Assembly 4
Install washer 5 on balance shaft 6 .
Install balance shaft gear 2 . 6
Install damper 4 and spring 3 .
Install new circlip 1 . 123702
12-37
CFMOTO
12.4.16 Magneto Rotor Inspection
Inspect rotor 1 for scratches or other

damages.
Inspect rotor spline for wear or other
1
damages.
Inspect
Inspect teeth of rotor outer race for lean or
other damages.
Inspect woodruff key and key groove on
crankshaft for wear or other damages.
Replace if any part above is severely 123801
damaged.
2 3 4
12.4.17 Overriding Clutch

12.4.17.1 Overriding Clutch
Disassembly
1
Remove driven gear 4 .
Remove bolts 1 .
Remove overriding clutch 2 from magneto
rotor 3 .
123802
Note: If the overriding clutch has no
fault, it is not necessary to remove it.
1
12.4.17.2 Overriding Clutch Inspection
-Install driven gear on overriding clutch as
picture shows to check its action.
-Press on flywheel. If starter driven gear
only rotates counter-clockwise, it is
qualified.
123803
2 1 4
12.4.17.3 Overriding Clutch Assembly

Install overriding clutch 1 on rotor 2 .
3
Install bolts 3 .
Install driven gear 4 .
123804
12-38
12 Engine Assy
12.4.18 Starter Driven Gear, Dual Gear
and Dual Gear Shaft 3
2
Inspection
-Inspect starter driven gear 1 for wear and
damage.
-Measure the inner diameter and outer
diameter of starter driven gear 1 .
Service limit: 1
Outer diameter 3 : Replace if more than
22.10 mm 123901
Inner diameter 2 : Replace if less than
46.95 mm.
2
3 4
Inspect dual gear 2 and 4 for wear and

damage. Replace if severely worn and
damaged.
Inspect dual gear shaft 1 and 3 for wear
and damage. Replace if severely worn and
damaged. 1
123902
12.4.19 Clutch Parts Inspection

12.4.19.1 Primary Driven Gear
-If inner damping spring is worn, there
will be clearance between the gear and
clutch housing, which causes shake and
abnormal noise. Replace the primary
driven gear 1 if severe.
-Replace two gears if worn or damaged.
-Replace two gears if the noise is loud. 1
123903
12.4.19.2 Primary Drive Gear

-Inspect primary drive gear for wear or
damage. Replace if severely worn or
damaged.
Note: Align the dot mark with key

groove when installing.
1
123904
12-39
CFMOTO
12.4.19.3 Clutch Friction Disc

-Measure the thickness of clutch friction
disc 1 with vernier caliper. Replace the
whole set of clutch friction discs if out of
limit value.
Standard thickness: 2.9 mm~3.1 mm 1

Limit value: 2.8 mm
124001
12.4.19.4 Clutch Driven Disc

-Measure the deformation value of clutch
driven disc 1 with filler gauge and flatbed.
Limit value: 0.1 mm
Replace the whole set of clutch driven
1
discs 1 if out of limit value.
124002
12.4.19.5 Clutch Spring
Measure every spring free length 1 with

vernier caliper. Replace all springs if the 1
length of any of springs is less than limit
value.
Limit value: 29.5 mm
124003
12.4.19.6 Thrust Bearing and Clutch
Bracket
-Inspect thrust bearing and clutch bracket

1 , and roller needle for defects. Replace if
necessary.
124004
12-40
12 Engine Assy
12.4.20 Gearshift Assy
8 9 10 11 12 13 14 15
1 2 3 4 5 6 7
124101
1 Countershaft Assy. 6 Washer, spline 11 Fifth gear, countershaft
2 Second gear, countershaft 7 Third gear, countershaft 12 Washer, 15×25×1.5
3 Circlip 8 Fourth gear, countershaft 13 First gear, countershaft
4 Sixth gear, countershaft 9 Washer, spline 14 Bushing
5 Circlip 10 Circlip 15 Washer, 15×25×1.5
12.4.21 Main Shaft Assy
4 5 6 7
1 2 3
124102
1 Main shaft 4 Fifth gear, main shaft 7 Second gear, main shaft
Third and fourth gear,
2 Washer, 20×26×1 5
main shaft
3 Circlip 6 Sixth gear, main shaft
12-41
CFMOTO
Note: The removed circlip is sorted

into waste. Replace with new ones
when installing.
Gear
Inspect every gear teeth for color change,

pitting or wear. Replace if it does. Inspect
the arris for wear and crack or dislocation.
Replace if it does.
Note: The gears must be replaced
in pairs. Use the new circlip when
installing.
Shift fork
-Inspect shift fork bulge 1 and claw 2
. Replace with a new shift fork if it has 1
scratches or it is bending and damaged.
2
124201
Shift Drum
-Inspect the groove of shift drum and
cylindrical surface A. Replace if worn or A
damaged.
124202
Shift fork shaft

Inspect shift fork shaft 3 and 4 for 3
deformation, wear or damage. Replace if
necessary.
124203
12-42
12 Engine Assy
Move and/or rotate shift fork as picture

shows. If the movement isn't smooth,
replace shift fork or shift fork shaft.
124301
-Measure the thickness of shift for junction

place with vernier caliper.
Shift fork thickness standard: 4.80
mm~4.90 mm
Shift fork (middle) thickness standard: 5.30
mm~5.40 mm
124302
Inspect main shaft assy 1 and

countershaft assy 2 for bend, wear or
damage. Replace the whole set if it does.
1
124303
12.4.22 Gearshift Rod Inspection
-Inspect gearshift rod 1 for damage, bend 3

or wear. Replace if it does.
-Inspect return spring 2 for damage or 2

deformation. Replace if it does.
1
5
-Inspect shaft bushing 3 for wear or
damage. Replace if it does. 4
124304
12-43
CFMOTO
12.4.22.1 Gearshift Position Spring

-Inspect gearshift position spring 4 for
damage or wear. Replace if it does.
12.4.22.2 Gearshift Cam Position

Mechanism
-Inspect gearshift cam position stopper 5
for wear or damage. Replace if it does.
12.4.23 Crankcase Parts Inspection 1
Inspect RH crankcase cover 1 for crack or

damage. Replace in pairs if necessary.
124401
Inspect RH crankcase body for cracks or 2 3 4 5

damages. Replace in pairs if necessary.
Rotate the inner race of bearing 2 , 3
, 4 and 5 . If the bearing can not rotate 1
smoothly, or have noise or other defects,
Use bearing puller 1 to change the
bearings. Choose the suitable one to
remove the bearing. 124402
Inspect small sprocket cover 1 for cracks

1
or damages. Replace if it does.
124403
12-44
12 Engine Assy
Inspect RH side cover 1 for crack or

Inspect LH crankcase body 1 for crack or

1
Rotate the inner race of bearing 2 , 3

, 4 and 5 . If the bearing can not rotate 124501
smoothly, or have noise or other defects,
2 3 4 5
Use bearing puller 1 to change the
bearings. Choose the suitable one to
remove the bearing.
1
Note: When disassembling

crankcases, two oil seals on LH
crankcase must be removed and
replaced with new ones. 124502
12.4.24 Tensioner Inspection

Inspect tensioner 1 for damages, normal 1
2
performance. Replace if necessary.
Performance stationarity Inspection
1. Press the push/pull arm 2 to the end.
2. Loose the arm to check whether it can
return smoothly and gently. Replace if it
returns roughly.
Inspect chain tensioner push/pull if it can
stretch out and draw back smoothly or
have scratches. Replace if it does. 124503
Replace with new seal gasket when
installing.
2
12.4.25 Speed Sensor Inspection
Removal
Remove bolts 1 .
Remove speed sensor 2 .
Inspection
Speed sensor 2 inspection refers to
1 1
Electrical Chapter.
124504
12-45
CFMOTO
Installation 1
Install speed sensor 1 .
Install bolts 2 .
2 2
124601
12.4.26 Magneto Inspection
Inspect magneto stator 1 .
Inspect magneto stator 1 condition.
Replace if damaged.
Inspect metal coil for damages, age or

other failures. Replace if it does. 1
Note: The inspection and service 124602

of electrical parts in engine refers to
Electrical Chapter.
12-46
12 Engine Assy
12.5 Engine Assembly
12.5.1 Transmission Case Installation
Note: Check every part before

assembly. Make sure there is no part
lost and clean all the parts with coal oil
or gasoline. No dirt or metal debris is
allowed to remain.
Note: The removed seal gasket can

not be used again. Use a new gasket
when installing. The remaining gasket
on crankcase or parts must be cleaned.
Warning: The removed circlip can

not be used again. Use new circlips
when installing. Check if they are
installed in place after installation.
Note: The removed oil seal can not

be used again. Use new oil seals when 5
installing.
1
LH crankcase installation 2
3 4
Install gearshift cam position plate 1 . 124701
Install washer 2 .
Install gearshift cam position mechanism
3.
Install bolt 4 .
Install gearshift position spring 5 .
2
Install washer 1 on shift drum 2 . 4
Install pin 3 into the hole 4 and lock
1
washer 1 on the shift drum.
3 124702
Install shift drum assy 1 on gearshift cam

position plate 2 . 1
3
Note: During installation, the pin 3
should be inserted into the groove on 2
gearshift cam position plate 4 . 4
124703
12-47
CFMOTO
Combine main shaft assy 1 and

countershaft assy 2 together and install
them into the LH crankcase.
2
124801
1
Match middle shift fork 1 with main shaft
assy and shift drum.
Match shift fork 2 with countershaft and
shift drum. 2
124802
1
2
Install middle shift fork shaft 1 .
Install shift fork shaft 2 .
124803
2
12.5.2 Crankshaft and Balance shaft 1
3 3
Installation
Install the crankshaft 1 into LH crankcase.
The side with teeth faces upwards.
Install balance shaft assy 2 into LH
crankcase.
Note: Align the marks on balance

shaft gear surface and crankshaft gear
surface during installation. 124804
12-48
12 Engine Assy
12.5.3 Crankcase Installation 2
Clean the remaining glue on crankcase.

Install dowel pins 1 .
Apply sealing glue on RH crankcase 2
evenly and continuously. 1
1
124901
1
Install bolts 1 .
Pre-tighten the bolts and then tighten them
in criss-cross way. Set the torque with 1
torque wrench.
Tighten torque: 10 N·m~12 N·m
1
Note: Check if the crankshaft

124902
can rotate freely after crankcase
installation. Crankshaft block is not
allowed to exist.
Install neutral gear stopping pin 1 .

Install neutral gear position spring 2 .
Install washer 3 . 1
Install bolt 4 . 2
3
4 124903
12.5.4 Gearshift Assy Installation

1
Combine pawl springs 1 and gearshift 1
pawl pins 2 and install them to the 2
2
mounting places 3 . 3 3
5
Install pawl 4 and pawl 5 . 4
Note: The mounting direction of 124904
RH pawl 5 and LH pawl 4 can not be
mistaken. The large shoulder should
face upwards.
12-49
CFMOTO
Hold the LH pawl 1 and RH pawl 2 with 4 1

hand or plier.
Install gearshift cam given gear 3 on shift 3
drum 4 .
2
125001
3
4
Install gearshift pawl plate 1 .
Install bolts 3 . 1
Install gearshift cam guide 2 .

3
Install bolts 4 .
2
125002
Install gearshift rod assy 1 .

Lock the spring 2 at the position as picture 1
shows.
125003
12.5.5 Piston Installation
Install cylinder body gasket 1 .

Install dowel pins 2 . 2
125004
12-50
12 Engine Assy
Install piston pin circlip on one side in

advance.
Install piston 1 .
Install piston pin 2 .
Install piston pin circlip 3 on the other 1 2
side. After installation, make the angle of 3
30o between circlip opening and pin seat
opening.
Note: The removed circlip can not 125101

be used again. Use new circlips when
installing. If the new piston pin circlip
deforms, replace with new ones.
12.5.6 Cylinder Body Installation

Apply engine oil on cylinder body.
Install cylinder body 1 .
1
Note: There are three rings on

2
piston. The opening of ring 3 aligns to 3 4
the mark "O" side. Make the angle of
125102
180o between ring 3 opening and ring
2 opening. The upper and lower film
loops of oil ring 4 stay the same as
ring 2 and ring 3 . And make the angle
of 60 o between upper film loop and
bushing ring. During installation, press
every ring into the ring groove, then
install it into the cylinder. Installation
for other rings apply the same
procedures.
1
Install cylinder head gasket 1 . 125103
Put the timing chain 1 form the cylinder

chain house. Hang the lower side on the
timing gear 2 of crankshaft. Tighten the
chain use hand.
Note: Hook the timing chain in case

it falls down into the cylinder body. 2
125104
12-51
CFMOTO
Put chain guide 1 inside chain house. The 1

upper end insert into the cylinder groove,
and the lower end into the of chain guide
groove 2 on left crankcase.
2 125201
12.5.7 Magneto Rotor Installation
Install the magneto rotor 1 on the starter 2

big gear 2 .
Rotate it counter-clockwise. Block is not 1
allowed to exist.
125202
Install magneto rotor assy 1 on crankshaft.

Install the woodruff key into the groove on
magneto rotor 2 . 2
Install nut 3 . 1
M12×1.25 nut tighten torque: 60-65N ·m
3
125203
12.5.8 Dual Gear II Installation 1

Install dual gear II 1 with the big gear side
facing towards dual gear shaft hole.
Install dual gear shaft 2 .
2
125204
12-52
12 Engine Assy
12.5.9 Magneto Stator Installation 5 4
Install magneto stator 1 and make the 3

magneto stator wires go through the 6
clearance of fixing trigger on LH side
1
cover.
Install M5×25 bots 2 with 243 thread
locker.
Install trigger 3 . 2
Install M5×12 bots 4 with 243 thread
locker.
Use special tool: trigger clearance 125301
adjusting tool to adjust the clearance to 0.7
mm~0.9 mm. 1
Put the wires into the wire groove and then
install the wire clamp 5 .
Install M5×12 bot 6 with 243 thread
locker.
Note: Apply sealant glue into the

groove of trigger position rubber 2
bushing. Press it into the open groove
on LH front cover, and then install the 3
LH side cover on LH crankcase. 125302
Install dowel pin 1 and 2 .

Install seal gasket 3 .
Note: The removed seal gasket is

sorted into waste disposal. Use new
seal gaskets when installing. 2 1
Install LH side cover assy 1 .

Install bolts 2 .
125303
12.5.10 Starter Motor Installation 1
Use a rubber hammer to slightly knock to

install stater motor 1 .
Install bolts 2 .
Note: Before installation, apply some
engine oil on o-ring of the starter motor
positioning surface. When installing, 2
the seal ring of the starter motor is
allowed to deform. 125304
12-53
CFMOTO
Install dual gear I 1 with big end facing

outside.
Install dual gear shaft 2 . 2
Install gear cover 3 of LH front cover. 4
Install bolts 4 .
3
125401
12.5.11 Cylinder Head Installation
Install dual pins 1 .
Note: Hook the timing chain, in case 1

it falls into the engine body.
125402
Install cylinder head cover 1 .

Install nuts 2 . 4
Install nuts 3 . 2
Note: When installing cylinder head,

make the timing chain 4 go through
the cylinder head chain room, and
hook it in case the chain falls into the
1
engine body.
3
125403
12.5.12 Camshaft Installation

2
Install camshaft position plate 1 .
Install camshaft assy 2 . 1
Put the timing sprocket on timing chain in
advance during installation.
125404
12-54
12 Engine Assy
12.5.13 Timing Adjustment

Remove bolt 1 .
Rotate nut 2 with sleeve. Seeing through
the bolt 1 hole, stop rotating when the "1"
mark is in the center of the bolt hole.
1 2
125501
Rotate the camshaft until the timing 1

sprocket 1 stays as picture shows. Two
mark lines 2 on timing sprocket parallels
with the cylinder head edge 3 .
2
125502
12.5.14 Cylinder Head Cover Installation
1
Install dowel pins 1 .
Apply "0515" sealant glue on the junction
surface on cylinder head and cover.
125503
Install cylinder head cover 1 .

3
Valve clearance adjustment refers to
Inspection section.
2
125504
12-55
CFMOTO
Install filter strainer cover 1 .
125601
12.5.15 Tensioner Installation
Remove bolt 1 . 4 5
3 2
Install press the push/pull arm 2 to the 1
end.
Install seal gasket 3 .
Install tensioner 4 .
Install bolts 5 .
Install bolt 1 .
Note: The removed gasket is sorted 5

into waste. Use new seal gaskets
during installation. 125602
1
12.5.16 Clutch Assy Installation
Install washer 1 .
125603
Install primary driven gear assy 1 . 2

3
Install shaft bushing 2 .
Install washer 3 .
1
125604
12-56
12 Engine Assy
1
Install retainer 1 .
Use special tool: clutch stopping wrench 3
to lock clutch.
Install nut 2 .
2
3
125701
Install clutch friction discs I 1 .

Install clutch driven discs 2 .
Install clutch friction discs II 3 .
4
Note: Align the marks 4 on clutch
friction discs.
1 2 3 2 3 2 3 2 1
125702
Install thrust bearing & clutch bracket 2 4

and washer 3 on clutch rod 1 . 5 6
Install clutch rod 1 on clutch pressure 1 2 3
plate 4 .
Install clutch pressure plate 4 .
Install springs 5 .
Install bolts and washers 6 .
Note: After installation, the thread 6
side of clutch rod 1 faces the rear side 5 125703
of the engine.
12.5.17 Primary Drive Gear Assy and Oil

Pump Installation 3
Install guide key 1 . 2

Install oil pump drive gear 2 . 1
Install primary drive gear assy 3 .
Note: Align the guide hole and guide
block when installing oil pump drive
gear and primary drive gear assy. 125704
12-57
CFMOTO
Install oil pump assy 1 .

Install bolts 2 . 1
125801
Install shaft pin 1 .

3
Install oil pump driven gear 2 .
Install circlip 3 . 4
Note: Shaft pin 1 should lock into 2

the reserved groove 4 on oil pump
driven gear 2 .
1
125802
Install washer 1 .
2
Install nut 2 (left-hand thread). 1
After installation, knock washer 1 to

upwarp the edge with a hammer.
125803
12.5.18 Balance Shaft Nut Installation
1
Install washer 1 .
Install nut 2 (left-hand thread).
125804
12-58
12 Engine Assy
1
12.5.19 RH Side Cover Installation
2
Install stud 1 .
Install RH side cover gasket 2 .
Install dowel pins 3 . 3
3
125901
Install RH side cover 1 .

Install bolts 2 .
1
2
125902
12.5.20 Oil Filter Installation
Install seal ring 1 .
125903
Install oil filter element 1 .

Install spring 2 on oil filter cover 4 .
Install seal ring 3 on oil filter cover 4 .
Install oil filter cover 4 . 4
Install nuts 5 . 5
1
3
2
125904
12-59
CFMOTO
12.5.21 Engine Drain Bolt Installation
Install drain bolt 1 .

1
126001
12.5.22 Gear Sensor Installation

2
Put o-seal ring 1 on gear sensor 2 . 1
Install gear sensor 2 .
Install screw kits 3 .
126002
12.5.23 Drive Sprocket Installation 2

Install countershaft oil seal press plate 1 . 2
Install bolts 2 .
126003
Install drive sprocket 1 .

Align the spline of sprocket key 2 and
countershaft. Rotate the guard to the 1
suitable angle.
Install bolts 3 . 2
126004
12-60
12 Engine Assy
Install speed sensor disc 1 .

Install inner hex bolts 2 .
1
126101
12.5.24 Rear LH Cover Installation
2
1
126102
12.5.25 Gearshift Pedal Lever

Installation
Install gearshift pedal lever 1 .

Install bolt 2 .
2
1
126103
12.5.26 Screw Plug and Spark Plug

Installation 1 2
Put o-seal ring 1 on bolt 2 of front LH

side cover.
Install front LH side cover bolt 2 .
126104
12-61
CFMOTO
Pre-tighten spark plug 2 with hand.

Use special tool: spark plug sleeve 1 to
tighten the spark plug 2 .
1 2
126201
12-62
12 Engine Assy
12.6 Engine Installation

12.6.1 Engine Installation
Lift the engine to the suitable height.
Install bolt 1 .
1
Note: There is a nut behind the bolt
1 . During installation, hold the nut
with hand first and then lock it with a
wrench, at last tighten the bolt.
126301
1
Combine the rear fork, engine and footrest
bracket 3 together.
3
Install rear fork shaft 1 .
Install bolt 2 .
Note: There is a nut behind every

2
bolt. During installation, hold the nut
with hand first and then lock it with a 126302
Install engine front suspension plate 1 .

Install bolt 2 . 2
Install bolt 3 .

bolt. During installation, hold the nut 1
wrench, at last tighten the bolt. 126303
Install bolt 1.
Install bolt 2.
2

bolt. During installation, hold the nut
1
126304
12-63
CFMOTO
12.6.2 Engine LH/RH Lower Guard

Installation
2
Install engine LH lower guard bracket 1 .

Install bolt 2 .
1
126401
Install LH lower guard 1 .

2
126402
Install RH lower guard bracket 1 .

Install bolts 2 . 2 2
126403
Install RH lower guard 1 .

126404
12-64
12 Engine Assy
12.7 Air Intake System

12.7.1 Throttle Body Removal
1
Loosen air filter clamp 1 .
Note: Do not adjust throttle limit

screw 2 . 2
126501
Loosen throttle valve connecting pipe

clamp 1 . 1 1
Remove throttle body 2 .
2
126502
Remove bolt 1 .
Remove fuel injector 2 .
2
126503
Remove bolts 1 .
Remove air intake pipe 2 .
1
2
1
126504
12-65
CFMOTO
12.7.2 Throttle Body Inspection 1

Inspect throttle body 1 for crack or
damage. Replace if damaged.
Electrical elements inspection refers to

Electrical System chapter.
126601
12.7.3 Fuel Injector
Disassembly
Push the fuel injector cap spring 2 with

1
fingers.
Remove fuel injector cap 1 .
Separate the fuel injector cap spring 2 2
and fuel injector 3 .
Inspect 3
Fuel injector inspection refers to Electrical

System chapter. 126602
Assembly
Install fuel injector cap spring 2 on fuel
injector 3 .
Install fuel injector cap 1 .
Clip the flange of fuel injector cap 1 into
the groove on fuel injector cap spring 2 .
1
Inspect the air intake pipe 1 for crack or
damage. Replace if damaged.
126603
12-66
12 Engine Assy
12.7.4 Throttle Body Installation

2
Install air intake pipe 1 .

Install bolt 2 .
1
2
126701
Install fuel injector 1 . 2

Install bolt 2 .
126702
Tighten bolt 1 .
1
Note: Do not adjust throttle limit
screw 2 .
126703
Install throttle valve body 1 .

Tighten screws 2 .
2 2
1
126704
12-67
CFMOTO
12.8 Lubrication System
12.8.1 Engine Oil Volume Inspection

Place the engine in level position.
Start the engine, keep the engine idling for
several minutes.
Stop the engine, wait for several minutes
until all the oil drains into crankcase, then
inspect the oil level.
Inspect the oil level through the oil level
viewer 3 . If above the upper level 1 , then
drain some engine oil. If below the lower 1 3
level 2 , then add some oil. Repeat the
above process until the oil level reaches 2
126801
the proper position.
12.8.2 Engine Oil Replacement

Before replacing engine oil, Make sure the
engine is in level position.
Oil and oil filter should be replaced at the
same time and should be replaced when
engine is warmed up.
Note: The engine temperature may
be high during replacement. Wait until
the it is suitable.
Note: Oil filter element removal,
1
installation and engine oil drain refer
to Engine Removal and Installation
sections. 2
Note: The drained engine oil

condition can reflect the engine
condition. Inspect if there is metal 3
debris in the oil. If yes, it means the
engine has problems inside. Inspect 126802
the engine to seek the problem.
Remove fuel filling bolt plug 1 .
Note: Pay attention to the seal ring

2 when removing. In case it falls into
the engine or gets lost.
Add approximately 1250mL engine oil

through the bolt plug hole 3 .
Repeat the above process until the engine
oil is proper.
12-68
12 Engine Assy
12.8.3 Oil Strainer

12.8.3.1 Oil Strainer Removal 8
Remove bolt plug 1 . 8
Remove washer 2 . 7
6
Remove bolts 3 .
Remove strainer cover 4 . 6
5
Remove oil strainer o-ring 5 .
4
Remove screws 6 .
Remove strainer assy 7 . 3
Remove washer 8 .
1 2 126803
12.8.3.2 Oil Filter Strainer Inspection
Inspect oil filter strainer assy. Replace a
new one if damaged.
Inspect o-ring on the filter strainer cover.
Replace if hard, broken or damaged.
Inspect filter strainer cover. Replace if
damaged.
Clean all the removed parts, including
the oil filter strainer mounting hole on the
right case. Use air gun to dry them after
cleaning.
Note: Protect your eyes when
cleaning, to avoid chemicals in
cleaning agent which makes your eyes
blind.
12.8.3.3 Oil Filter Strainer Installation

Insert screw 2 into filter strainer 3 , and 1
place washer 1 on screw 2 . 1
Install filter strainer 3 . 2 3
Install o-ring 4 on the filter strainer cover
2
5.
4
Install filter strainer cover 5 . 5
Install bolts 6 .
Install washer 7 . 6
Install bolt 8 .
8 7 126901
12.8.3.4 Oil Pressure Inspection

Engine oil pressure is an important value
which reflects if engine runs well or not.
Oil pressure value:
10 kPa~30 kPa at 3000 r/min
If oil pressure are much higher or much
lower, it may reflect the situations below:
12-69
CFMOTO
1. Oil pressure too low:
-Oil passage leakage
-Oil pump malfunction
-Both above situations
2. Oil pressure too high:
-Oil viscocity too high
-Oil passage blocking
-Oil filter blocking
-All above situations
Oil pressure testing process

Remove the main oil passage bolt 1 .
Connect oil pressure gauge 2 and ignition
coil.
Install the oil pressure gauge 3 and
adapter into the main oil passage hole.
Following below process for engine
heating. 1
Summer: Idling for 10 minutes at 2000r/
min.
Winter: Idling for 20 minutes at 2000r/min. 127001
After heating engine, increase the rotating
speed to 3000r/min, then read and record
the number shown on oil pressure gauge Connecting
3.
ignition coil
After testing, apply some thread locker on 1

main oil passage bolt, and install the bolt
into the main oil hole.
Tightening torque: 23N·m

127002
127003
12-70
13 Handlebar Assy
13.1 Handlebar Lever�� 13-1
13.1.1 LH Rear View Mirror�� 13-1
13.1.2 Handlebar Lever�� 13-1
13.1.3 Handlebar Cover�� 13-3
13.2 Handlebar Inspection�� 13-4
13.2.1 Throttle Cable Free Play�� 13-4
13.2.2 Clutch Lever Inspection�� 13-4
13.2.3 Handlebar Interference Inspection �� 13-4
13.1 Handlebar Lever

13.1.1 LH Rear View Mirror
Loosen nut 1 .
Rotate the LH rear view mirror 2
clockwise.
Remove LH rear view mirror 2 .
RH rear view mirror refers to LH rear view
mirror removal procedures.
1
Installation
installation.
130101
13.1.2 Handlebar Lever
Remove two inner hex bolts 1 .
130102
13-1
CFMOTO
Remove clutch lever 2 .
130201
Remove two crossing bolts 1 . 3

Remove LH handlebar switches assy 4 .
130202
Remove two crossing bolts 5 .

Remove RH handlebar switches assy 6 .
5
130203
Note: Insert the throttle cable into

7
the RH hand grip when installing LH
handlebar switches.
130204
13-2
13 Handlebar Assy
Note: Align the dowel pins 9 during

installation. 9
10
130301

Remove LH balancer 12 .
RH balancer removal refers to LH balancer 11
removal procedures.
12
130302
Pull out LH hand grip 13 and RH hand grip

14 . 13 14
Installation
13.1.3 Handlebar Cover

Removal 1
Remove four inner hex bolts 1 . 3
Remove handlebar cover 2 .
Remove handlebar 3 .
Installation 2
installation.
Handlebar lock bolt tighten torque: 25
N•m
Note: The handlebar should be

installed in the center position. Make
even clearance between upper cover
and lower seat.
13-3
CFMOTO
13.2 Handlebar Inspection
13.2.1 Throttle Cable Free Play
Inspect throttle lever if it is smooth to grip
or return.
Inspect throttle cable free play.
Free play: 2mm~6mm
Throttle Cable Free Play Adjustment

Initial adjustment: Loosen nut 2 , place the 2 1
adjusting screw tube 1 to proper position 130401
and then tighten the nut 2 .
1
13.2.2 Clutch Lever Inspection

Inspect clutch lever free play.
Free play: 10mm ~20mm
130402
Initial adjustment: Loosen lock nut 2 and

rotate the adjusting nut 3 for adjustment.
3
130403
Major adjustment: Loosen lock nut 3 and

rotate the adjusting nut 4 for adjustment.
3 4
130404
13.2.3 Handlebar Interference
Inspection
Turn the handlebar left and right to check
whether cables interfere front wheel.
130405
13-4
14 Triple Clamps
14.1 Special Tool�� 14-1
14.2 Triple Clamps�� 14-1
14.2.1 Upper Triple Clamp�� 14-1
14.2.2 Front Fork Pipe and Lower Triple Clamp Assy�� 14-2
14.1 Special Tool
Fixing Nut Tool (to remove and install lock nut)
A003-002878
140101
14.2 Triple Clamps
14.2.1 Upper Triple Clamp 2

Removal
Remove upper connecting fixing nut 1 .
Remove washer 2 .
Remove upper triple clamp 3 . 1
3
140102
4
Use special tool 5 to removal the fixing
nut 4 .
5
140103
14-1
CFMOTO
14.2.2 Front Fork Pipe and Lower Triple
Clamp Assy
Removal 1
Remove front fork pipe and lower triple
clamp assy 1 .
5
6
140201
Remove upper bearing retainer 2 .

Remove steel ball assy 3 . 3 2
Remove upper bearing top race 4 .
Remove lower bearing retainer 5 .
Remove steel ball assy 6 .
140102
Inspection
Inspect steel ball assy 6 and 3 for wear
or missing. Replace if yes.
Inspect bearing cage 7 for cracks and
abnormal wear. Replace if yes.
Installation
installation.
Upper triple clamp fixing nut tighten torque:
50~60 N•m
7
140203
Note: During installation and
replacement, apply enough grease on
bearing top race 7 .
14-2
14 Triple Clamps
Front Fork Pipe and Lower Triple Clamp Assy
6
7
10
11
12
140301
Fixing nut, upper
1 4 Fixing nut 7 Bearing race 10 Bearing race
triple clamp
Wa s h e r, u p p e r Retainer, upper Retainer, lower
2 5 8 11 Steering column
triple clamp bearing retainer bearing retainer
3 Upper triple clamp 6 Steel ball assy 9 Steel ball assy 12 Lower triple clamp
14-3
15 Ignition System
15.1 Starter Motor�� 15-2
15.1.1 Brush�� 15-2
15.1.2 Commutator�� 15-2
15.1.3 Armature Coil�� 15-3
15.1.4 Oil Seal�� 15-3
15.2 Starter Relay�� 15-3
15.3 Engine Starting Notice�� 15-4
15-1
CFMOTO
15.1 Starter Motor
1 2 3
5
Outer side Brush
1 5 9 Washer 4 6 4
cover connector
Starter
Brush Inner side
2 6 motor 10
bracket cover
drum
Brush
3 7 Washer 11 O-ring
spring
4 O-ring 8 Armature
10 11
7 8 9
150201
15.1.1 Brush
Inspect brush for damage, crack or other
defects.
Replace the brush assy if necessary.
150202
15.1.2 Commutator
Inspect commutator if it changes color,
damages or wears.
If damaged, replace a new one. d
If the surface of the commutator changes
color, wipe it with sand paper and then use
a dry cloth to clean the surface. B
If it wears too much, saw part of insulator
(B). The distance between (B) and (A) is d.
d≥1.5mm 150202
15-2
15 Ignition System
15.1.3 Armature Coil

Use multimeter to check the connection
situation between sections, section and
armature shaft.
If there is no connection between sections
or section and armature are connected,
replace a new armature. 150301
15.1.4 Oil Seal

Inspect the oil seal lip for damage or
leakage.
Replace a new one if necessary.
150302
15.2 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.
150303
Turn multimeter to DIODE.
Note: The voltage loaded between

terminals can not exceed 2 minutes,
otherwise, starter relay may overheat
or burn.
Use multimeter to measure starter relay

coil resistance, if the reading is out of
specification, replace a new relay.
Starter Relay Coil Resistance: 3 Ω~5 Ω 150303
15-3
CFMOTO
15.3 Engine Starting Notice

Properly 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 block or leaks.
Test fuel pressure with fuel pressure 150401
gauge.
Pressure in fuel pump outlet:
0.25MPa±0.01MPa
Check EFI with PDA for fault. if there
is,eliminate the trouble according to DTC
(Diagnostic Trouble Code).
Close the throttle and turn the engine stop
switch to “RUN”, then push starter switch
for 3~5s to run the engine.
After starting,warm up until idle speed is
stable and check it.
Idle RPM: 1500r/min±150r/min
15-4
16 Clean and Conservation
16.1 Motorcycle Clean�� 16-1
16.2 Inspection and Maintenance in Winter �� 16-2
16.1 Motorcycle Clean

Note: Clean the motorcycle periodically, to help it keep value and appearance.
Avoid direct sunlight on the motorcycle while cleaning.
Seal air exhaust system to prevent water into the system.
Clean chunks of dirt with gentle water-jet in advance.
Use common motorcycle cleaner to clean serious smudges and wipe it with hairbrush.
Note:
Use the hot water with specialized cleaner for motorcycle and a piece of sponge.
It is not allowed to use the cleaner directly on dry vehicle body. Flush the vehicle
with water in advance.
If the vehicle has been used in snow-melting salt, clean it with cold water.
Otherwise, the hot water will exacerbate erosion.
Dry the car completely after washing the motorcycle with gentle water-jet.
Remove the seal plug for exhaust system.
Warning: The dirty or damp braking system will reduce the braking
performance. Pay attention to keep the brake system clean and dry.
After cleaning, run the vehicle for some distance until the engine reaches certain
temperature.
Push the guard upwards from the handlebar, in order to let the water evaporate.
After the motorcycle cools down, lubricate all sliding parts and bearing parts.
Clean the chain.
Use anti-rusting agent on exposed metal parts (except brake discs and exhaust system).
Use gentle curing agent on all painting parts.
Note: Do not polish the plastic parts which is in delivery. Otherwise, it will
serious effects on the quality.
Use gentle cleaning agent and curing agent on all plastic parts and powder-coated parts.
Lubricate ignition switch lock/steering lock with engine oil.
16-1
CFMOTO
16.2 Inspection and Maintenance in Winter
Note:
If the motorcycle is used in winter, it must be taken into consideration that the
street is covered with snow-melting salt. Therefore, protective measures must be
taken against erosion.
If the vehicle has been used in snow-melting salt, clean it with cold water.
Otherwise, the hot water will exacerbate erosion.
Clean the motorcycle.
Clean brake system.
Note:
If the vehicle has been used in snow-melting salt, clean it with cold water after the
brake calipers and brake pads cool down. Dry all the parts after cleaning. Do not
remove brake parts when cleaning.
Use waxy preservative liquid for engine, swing arms and other exposed or galvanized
parts (except brake pad).
Note:
The preservative liquid is not allowed to get into the brake pads. Otherwise, it will
reduce the braking effect seriously.
Clean the chain.
16-2
17 Storage
17.1 Parking�� 17-1
17.2 Motorcycle Use after Storage�� 17-1
17.1 Parking
Note:
If parking for a long time, please execute the following measures.
Before parking the motorcycle, please check its functions and wear condition.
If the bike needs maintenance, service or adjustment, operate it during parking
(when service station has less work), which prevents long wait at the service
station before peak season arrives.
•Add fuel additives for the last refueling before parking the motorcycle.
•Add fuel.
•Clean the motorcycle.
•Replace engine oil, oil filter and clean oil strainer.
•Check coolant and coolant level.
•Check tire pressure.
•Remove battery.
•Charge the battery.
Without direct sunlight condition, battery storage temperature: 0 ～ 35℃
Place the vehicle at a dry place without obvious temperature fluctuation.
Advice to use wheel bracket to lift the motorcycle.
Cover the motorcycle with breathable canvas or cover.
Note:
It is not allowed to use air-proof material to cover the motorcycle. Otherwise, the
moisture can not get out which causes erosion.
The short-time running of the engine will cause severe damage if the motorcycle
has parked. The temperature of the engine is not high enough after short-time
running. The moisture that comes into being during combustion condenses after
the engine cools down, which causes valve body and exhaust pipes erosion.
17.2 Motorcycle Use after Storage

•Remove the motorcycle from front wheel bracket.
•Remove the motorcycle from rear wheel bracket.
•Install battery.
•Inspect and maintain the motorcycle before use every time.
•Drive the motorcycle to test it.
17-1
Appendix A
Start diagram
Appendix B
EFI diagram
Appendix C
Electrical diagram

Manual Servicio Papio125

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Servicio Papio125

Uploaded by

Copyright:

Available Formats

PAPIO-III

How to get Long Service Life:

How to use this manual:

Note: The liquor (dilute sulfuric acid)

Note: The battery may produce

Note: Never touch the rotating or

■ Replace t he removed washer s,

■ Clean and blow off the detergent

■ Check if the disassembled rubber

■ If remove the ball bearing by pressing

■ The circlip with chamfering side

■ Clean the gaskets and washers of the

■ Do not twist or bend the cables too

7 Auxiliary relay 8 Diagnostic connector 9 Fuse box

Fuel tank assy

Adsorption pipe II, engine

2.1 Maintenance before Operation

3.1 General Specifications

Air Inlet System

Thread dia. Torque

Engine Consumption Materials & Assembling Materials

5.1 LH&RH Panel

Reverse the removal procedures for 3

5.2 Fuel Tank Guard

5.2.1 Inner Side Plate

Remove two self-tapping screws 3 .

Lift fuel tank cap.

Remove three inner hex bolts 5 .

5.3 Fuel Tank 2

Note: Fuel tank inversion is forbidden.

Fold and pull out the adsorption hose 3 .

Warning: Do not spill fuel on high

Loose fuel pump connector 5 .

6.1 Maintenance Information

6.3 Dashboard and Headlight

Remove three screws 3 .

Remove three headlight mounting bolts 4 .

6.4 Turning light

6.5 Rear Fender Bracket and Rear

6.6 Tail Light/Brake Light

Remove two inner hex bolts 2 on the two

Power function chart

6.9 Rear Brake Switch 1

6.10 Left Handlebar Switch

Clutch switch Horn switch 4

Connect fuel level sensor and main cable.

Note: Check leakage after fuel level

Shut down all the electrical devices and

If the vehicle is not used, recharge

Charging Voltage Inspection

If less than specification:

7.1 Air Filter

Note: Check air filter every 5000km,.

Note：Do not use brake hose to hang

Remove air filter 8 .

increase fuel consumption, inspect and 1

Note: Keep filter element clean during

Note: Ensure all parts be fixed and

●This EFI system is designed to be used

●The DFI part connectors A have seals B

●Make sure that measuring points are

●After measurement, remove the needle

●Measure the electrical resistance of the A