To remove the entire front top plastic panel on a CFMOTO 950EX:

1. Remove the front access cover by grasping the edge, pulling upward to release the grommet pins, and lifting it off.
2. Remove the front LH & RH access covers by grasping and removing them.
3. Remove the middle panel by first removing:
- Four expansion screws (060401),
- Five expansion screws (060402),
- Four expansion screws (060403),
- Two bolts (060404).
4. Then remove two bolts securing the middle LH and RH panels.
5. Remove middle LH panel and middle RH panel.

Installation is the reverse of removal.

This answer is automatically generated

MARTIN

May 22, 2025

hola como puedo borrar el check in de la pantalla de un zforce 1000 sport r

James B Bakkestuen

April 14, 2025

How do you remove the spacer that holds the magneto on the crankshaft? I have removed the bolt but the spacer will not come off.

Summary of Contents for CF MOTO ZForce 950EX

Page 1 CFMOTO SERVICE MANUAL 950EX 950Sport 1000Sport CF1000US CF1000US-A CF1000UTR-B © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 2 CFMOTO 20191228 Edition Number: Edition Item: CF1000US CF1000US-A CF1000UTR-B (5BY#-00WX02-6000) SM-20191228 www.cfmoto.com © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 3 CFMOTO FOREWORD INDEX INDEX T h i s m a n u a l o u t l i n e s C F 1 0 0 0 U S , Safety Information CF1000US-A, CF1000UTR-B maintenance Specifications/Vehicle Data i n f o r m a t i o n , r e m o v a l & i n s t a l l a t i o n Maintenance procedures, inspection &...
Page 4: Table Of Contents
CFMOTO 1.1 Service Manual ................... 01-2 1.2 Safety Tips ..................01-2 1.3 Hazardous Level and Symbol............01-2 1.4 Operation Notice................. 01-2 1.5 General Precaution................01-3 1.5.1 Avoid Carbon Monoxide Poisoning ........... 01-3 1.5.2 Avoid Corrosion Injury by Electrolyte ........01-3 1.5.3 Avoid Injury ..................
Page 5: Service Manual
01 Safety Information 1.1 Service Manual Before maintenance, please read this service manual carefully. This manual introduces maintenance information, removal & installation procedures, checking & adjustment methods, troubleshooting and technical specifications with detailed images and diagrams to guide maintenance technicians. It will help improve the efficiency of vehicle repair and maintenance.
Page 6: General Precaution
CFMOTO For those parts that will be reused after removal, clean them up and inspect for damages or cracks. Replace it if damaged. Ensure vehicle safety after repair or maintenance. 1.5 General Precaution 1.5.1 Avoid Carbon Monoxide Poisoning CAUTION: Exhausted gas is poisonous. Do not run the engine in a closed or poorly ventilated area for a long time.
Page 7: Cautions For Removal And Installation
01 Safety Information 1.6 Cautions for Removal and Installation CAUTION: 1. Use only genuine CFMOTO parts, lubricants and service products. 2. Store removed components separately in order for correct installation. 3. Clean the vehicle of mud, dust and debris before servicing. 4.
Page 8: Engine Break-In
CFMOTO 1.7 Engine Break-in There are many moving components inside the engine such as the piston, piston rings, cylinder, crankshaft, gears, etc. During the initial use period, proper run-in for every critical component is necessary. Break-in helps engine components match to each other and adjust to working conditions.
Page 9: Instructions And Captions
01 Safety Information CAUTION: Improper handling of fuel or oil can cause pollution. Fuel or oil is not allowed to enter into groundwater, soil, or pipe systems. CAUTION: CFMOTO recommends to use - 35°C mixed, anti-corrosion and high boiling coolant. Please only use spare parts and accessories approved or recommended by CFMOTO.
Page 10 CFMOTO 2.1 Unit Conversion Table and Symbols ..........02-2 2.2 Identification Number Locations ............02-3 2.3 Main Specifications ................02-4 2.4 Specifications for Service..............02-6 2.5 Fastener Torque Tables ..............02-11 2.6 Grease and Sealant ................02-15 2.7 Service Products ................02-15 2.8 Service Tools ..................
Page 11: Unit Conversion Table And Symbols
02 Specifications/Vehicle Data 2.1 Unit Conversion Table and Symbols Unit Conversion Table Item Unit conversion 1kgf/cm²=98.0665kPa Pressure 1psi= 6.895kPa = 0.06895bar 1mmHg=133.322Pa=0.133322kPa 1kgf·m=9.80665N•m Torque 1N·m= 8.85(lbf•in) 1N·m= 0.7375621(lbf•ft) 1mL=1cm =1cc Volume 1L=1000cm Force 1kgf=9.80665N Length 1in=25.4mm Symbols Voltage Electric current Ω...
Page 12: Identification Number Locations
CFMOTO 2.2 Identification Number Locations Model: CF1000US / CF1000US-A / CF1000UTR-B 1. Vehicle identification number (VIN): LCELV1Z1 / LCELV1ZG / LCELV1ZB 2. Engine identification number (EIN): 2V91Y ~ 020201 1 VIN Location 020202 2 EIN - PTO 02-12 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 13: Main Specifications
02 Specifications/Vehicle Data 2.3 Main Specifications Vehicle Specification Model CF1000US CF1000US-A CF1000UTR-B Size: length×width×height 3020×1650×1850 2990×1565×1820 3135×1820×1820 Wheelbase 2285mm Min. ground clearance 340mm 310mm 310mm Dry weight 685kg 680kg 690kg Passengers 2 person (includes driver) Rear cargo box maximun load 100kg Max.
Page 14 CFMOTO Engine Specification Type CVT+Gearshift Transmission Gears 2 forward, 1 reverse, 1 parking Shift/Order Manual/L-H-N-R-P Clutch type Dry CVT CVT ratio range 2.88~0.70 Final 1.333(20/15, Bevel gear) Transmission Secondary 1.952(41/21) Speed Gears Gear ratios L gear: 2.529(43/17); H gear: 1.143(32/28) R gear: 2.231(29/13) Total ratio: L: 6.585;...
Page 15: Specifications For Service
02 Specifications/Vehicle Data Specification Wheel/Tire CF1000US CF1000US-A CF1000UTR-B Front tire 29×9.00 R14 27×9.00 R14 27×9.00 R14 Rear tire 29×11.00 R14 27×11.00 R14 27×11.00 R14 Wheel bolt pattern M12×1.25-6h M12×1.25-6h M12×1.25-6h Wheel nut pattern M12×1.25-6H M12×1.25-6H M12×1.25-6H 2.4 Specifications for Service Lubrication Item Standard...
Page 16 CFMOTO Coolant temperature Resistance B terminal-Earth Resistance A-C terminals (°C) (Ω) (kΩ) Coolant 28.528±0.004 temperature sensor 2.795±0.0025 temperature vs 216~264 0.98±0.00227 resistance 74.6~90.6 0.334±0.00204 32~36 0.133±0.00252 System Approximately 4.5L (4.8 qt.) Coolant capacity Reservoir 410mL (upper line) Commercially available, -35°C anti-freezing, Coolant type anti-corrosive and high boiling point Mix ratio...
Page 17 02 Specifications/Vehicle Data Ignition / EFI / Electrical Item Standard Ignition controller Bosch ECU Type Resistance control Model DCPR8E(NGK) Spark plug Spark clearance 0.8mm~0.9mm Spark specification >8mm,1 kPa Primary 740Ω~780mΩ Ignition coil resistance Secondary 10.1kΩ~11.1 kΩ Ignition primary ≥1.5V, 200r/min Peak voltage Pulse starter ≥25kV...
Page 18 CFMOTO Valve / Camshaft / Rocker Arm / Cylinder Head Item Standard - mm Limit Remark Valve diameter Valve thickness IN & EX 0.06~0.14 Valve clearance (Cold engine) 0.11~0.19 Valve guide diameter IN & EX 5.000~5.012 5.045 4.965~4.980 4.93 Valve stem outer diameter 4.955~4.970 4.93 0.020~0.047...
Page 19 02 Specifications/Vehicle Data Cylinder / Piston / Piston Ring / Connecting Rod / Crankshaft Item Standard - mm Limit Remark Cylinder compression pressure 1000kPa Cylinder taper 0.038 0.090 Cylinder roundness 0.015 0.020 Cylinder hole clearance 90.99~91.01 Above 8mm from Piston diameter 90.94~90.96 90.85 piston bottom...
Page 20: Fastener Torque Tables
CFMOTO 2.5 Fastener Torque Tables Torque Table - Vehicle Components Fasteners excluded in below table should also be torqued to specification. NOTE: Threads and contact area should be coated with oil. Item Type Torque(N•m) Front mounting shaft, engine 7030-000401 60~70 Rear LH mounting bolt, engine GB5789 M10×1.25×100 55~65...
Page 21 02 Specifications/Vehicle Data Item Type Torque(N•m) 29 Adjusting nut, steering tie-rod GB6173 M14×1.5 50~60 30 Lock nut, steering wheel GB6187 M12×1.25 50~60 Bolt, steering tie-rod&steering M12×1.25 70~80 motor rack Lock nut, steering universal GB5783 M8×35 35~45 shaft 33 Bolt, EPS&mounting bracket GB5789 M8×16 25~35 GB5780 M8×90...
Page 22 CFMOTO Torque Table - Engine Components Item Qty Type (mm) Torque (N·m) Remark Bolt M14×1.5 M14×1.5 Magnetic drain bolt M14×1.5 M14×1.5 A p p l y t h r e a d Screw plug ZM14 locker Drain bolt M12×1.5 M12×1.5 Flange bolt M8×12.5 (MAG side M8×12.5 crankcase)
Page 23 02 Specifications/Vehicle Data Lock nut M65×1.5, bearing M65×1.5 Apply thread locker Bolt M8×28 (Driven bevel bearing M8×28 seat) Screw T25 (shift drum) M5×8 Spring seat, shifting limit M12×1 Bolt M5×16 (Oil pump) M5×16 Apply thread locker Screw M8×20 (Overriding clutch) M8×20 Apply thread locker Bolt M6×30...
Page 24: Grease And Sealant
CFMOTO 2.6 Grease and Sealant Location Precautions Type Steering bearing Brake pedal moving point Suspension moving point Multifunction lithium grease Steering column inner face Seat lock moving point Cable, bearing and other moving parts lubrication Location Item Type Rear wheel hub Shock absorber knuckle bearing Lubrication Lithium grease for auto GB/T5671...
Page 25: Service Tools
02 Specifications/Vehicle Data 2.8 Service Tools Measuring Tools Tool name Specification Usage Remark 1 Vernier caliper 0mm~150mm Measure the length and thickness Measure rocker arm shaft, valve rod, 2 Micrometer 0mm~25mm camshaft’s diameter. 3 Micrometer 25mm~50mm Measure the max-range of cam 4 Micrometer 75mm~100mm Measure the piston size Cylinder inner...
Page 26 CFMOTO 3.1 Maintenance Schedule ..............03-2 3.1.1 Pre-Ride Maintenance Checklist ..........03-2 3.1.2 Break-In Maintenance Checklist ..........03-3 3.3.1 Periodic Maintenance Schedule ..........03-4 03-26 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 27: Maintenance Schedule
03 Maintenance Information 3.1 Maintenance Schedule The following icon keys are used to note special circumstances: ► = 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. ●...
Page 28: Break-In Maintenance Checklist
CFMOTO 3.1.2 Break-In Maintenance Checklist Perform these maintenance items at 20-hours or the distance interval, whichever arrives first. Break-in Maintenance (Perform at the interval that arrives first) Item Hour Calendar Miles (km) Remarks Lubricate all grease General lubrication 200 (320) points, pivots, cables, etc.
Page 29: Periodic Maintenance Schedule
03 Maintenance Information 3.1.3 Periodic Maintenance Schedule Perform maintenance at the interval that arrives first after the 20-hour break-in period: Periodic Maintenance Intervals (Perform at the interval that arrives first) Item Hour Calendar Miles (km) Remarks ► Brake pads Monthly 100 (160) Inspect pad thickness.
Page 30 CFMOTO Periodic Maintenance Intervals (Perform at the interval that arrives first) Item Hour Calendar Miles (km) Remarks Inspect routing and condition. Fuel filter and 100h 2000 (3200) Replace filter and high- hoses pressure hoses every 4 years. Cooling hoses 100h 1000 (1600) Inspect routing and condition.
Page 31 04 CVT System 4.1 CVT Special Tool ................4-2 4.2 CVT Removal ..................4-4 4.2.1 Preliminary Work ............... 4-4 4.2.2 CVT Case Cover Removal ............4-4 4.2.3 CVT Drive Pulley, Driven Pulley and Drive Belt Removal ..4-5 4.3 CVT Parts Inspection ................ 4-5 4.3.1 CVT Case Cover Inspection ............
Page 32: Cvt Special Tool
CFMOTO 4.1 CVT Special Tool Drive Pulley Removal Tool 0JY0-050000-922-002 040201 Driven Pulley Disassembly Tool (to disassemble driven pulley) 0800-052000-922-002 040202 Drive Pulley Holding Wrench 0JY0-050000-922-001 040203 Driven Pulley Holding Wrench 0JY0-052000-922-001 040204 04-32 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 33 04 CVT System Driven Pulley Sheave Separating Tool 0800-052000-922-003 040301 04-33 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 34: Cvt Removal
CFMOTO 4.2 CVT Removal 4.2.1 Preliminary Work Lock ball pin with an appropriate tool. Loosen nut Remove sway bar ball pin assy. 040401 Lock ball pin with calipers. Loosen nut Remove sway bar ball pin assy. 040402 Rotate sway bar assy underneath.
Page 35: Cvt Drive Pulley, Driven Pulley And Drive Belt Removal
04 CVT System Remove CVT case cover bolts Remove CVT case cover by pulling it away from the pulleys, then rotating it 90 degrees clockwise. Manuever the cover upward in the engine compartment to gain clearance for the lower part of the cover to clear the suspension arm, and remove it.
Page 36: Drive Belt Inspection
CFMOTO 4.3.2 Drive Belt Inspection Inspect drive belt for oil stain or damage. Inspect belt contact surface for cracks or damage. Measure belt width with vernier caliper. Replace with a new belt if damaged or beyond service limit. Drive belt service limit: 33.5 mm NOTE: Clean the belt thoroughly if oil 040601 and grease is on the belt surface.
Page 37 04 CVT System Inspection Inspect every weight and sliding surface for damage or wear. Replace all sliders if any defect occurs. NOTE: Weight sliders must be replaced as a whole set. 040701 Inspect ramp plate sliders for wear or damage. Replace all sliders if any defect occurs.
Page 38 CFMOTO Spring Seat Inspect spring seat for damage. Replace if any defect is found. 040801 Steel Washer and Nylon Washer Measure thickness of the nylon and steel adjusting washer with a vernier caliper. Replace washers and adjust the thickness if beyond service limit. Adjusting washer thickness : 5mm~6mm 040802...
Page 39: Driven Pulley Inspection
04 CVT System On the stationary sheave: Install bearing Install spring seat Install steel washer Install nylon washer Install drive pulley spring 040901 Place the stationary sheave assembly in a work bench vise. Install moving sheave assembly on the stationary sheave Compress the moving sheave assembly then install drive pulley nut (left-hand...
Page 40 CFMOTO Remove cam plate Remove shaft key Remove driven pulley spring Remove driven pulley stationary sheave 041001 Inspection Driven Pulley Sheaves Inspect the stationary sheave surface for wear, damage or other defects. Replace if any defect is found. Inspect shaft sleeve for wear or other defects.
Page 41 04 CVT System ≥1.5mm 041101 Cam Plate Inspection Inspect cam plate contact surface for wear or other defects. Replace if necessary. 041102 Spring Inspection Measure spring free length. Replace with a new spring if less than service limit. Spring free length service limit: 214mm 041103 Assembly...
Page 42: Cvt Installation
CFMOTO Install driven pulley spring according to the marks made during removal. Install cam plate onto the spring according to the marks during removal. The marks on sliders should be aligned with those on cam plate. Install shaft key Factory Setting: B1 041201 U s e s p e c i a l t o o l : D r i v e n P u l l e y Disassembly Tool...
Page 43: Cvt Case Cover Installation
04 CVT System Use special tool: Drive Pulley Holding Wrench to hold the drive pulley. Install drive pulley bolt (left-hand thread). Tighten torque: 55N•m~65N•m Use special tool: Driven Pulley Holding Wrench to hold the driven pulley. Install driven pulley nut Tighten torque: 150N•m~180N•m 041301 4.4.2 CVT Case Cover Installation...
Page 44 CFMOTO Install left sway bar ball pin assy Secure ball pin with suitable tool, then install nut and torque to specification. Tighten torque: 30N•m~40N•m 041401 04-44 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 45 05 Engine 5.1 Special Tools for Engine ..............05-5 5.2 Engine Removal................05-16 5.2.1 Preliminary Work ..............05-16 5.2.2 Removal ................... 05-16 5.3 Engine Air Inlet/Outlet System ............. 05-19 5.3.1 Air Filter ................... 05-19 5.3.1.1 Removal ................05-19 5.3.1.2 Air Filter Parts Inspection ..........05-20 5.3.1.3 Air Filter Installation ............
Page 46 CFMOTO 5.4.28 Crankcase Disassembly ............05-49 5.4.29 Crankshaft Connecting Rod Assy and Main Shaft ... 05-50 5.4.30 Countershaft Assy, Shift Fork and Shift Drum ....05-50 5.5 Engine Parts Inspection..............05-51 5.5.1 Cylinder Head Cover .............. 05-51 5.5.2 Cylinder Head ................05-51 5.5.3 Parts Inspection ..............
Page 47 05 Engine 5.6.4 Bevel Gear Washer Adjustment ........... 05-100 5.6.5 First Cylinder Body and Piston ........... 05-101 5.6.6 Second Cylinder Body and Piston ........05-102 5.6.7 Gearshift Assy ............... 05-103 5.6.8 First Cylinder Timing Chain ..........05-104 5.6.9 Second Cylinder Timing Chain ..........05-105 5.6.10 Oil Pump ................
Page 48 CFMOTO 5.10.1 Fuel System Removal ............05-125 5.10.2 Fuel System Inspection ............05-128 5.10.3 Fuel System Installation ............. 05-131 05-48 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 49: Special Tools For Engine
05 Engine 5.1 Special Tools for Engine Magneto Rotor Removal Tool 0800-031000-922-001 050501 Front Output Shaft Oil Seal Installer 0800-060000-923-001 050502 Valve Stem Seal Ring Installer 152MI-022500-923-001 050503 Front Output Shaft Bearing Retainer Tool (to remove the retainer) 0180-060008-922-001 050504 05-49 ©...
Page 50 CFMOTO Supporting Block 0JWA-081000-921-002-2 050601 Oil Seal Cushion Block 0180-065002-923-002 050602 6203 Bearing Installer 152MI-060002-921-002 050603 PTO Crankcase Bearing (3206A) Installer 0180-012100-921-004 050604 05-50 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 51 05 Engine 30X45X7 Oil Seal Installer 0180-012006-923-001 050701 Oil Seal Installer 0JWA-012000-921-003 050702 Bearing 6205 Installer 0JWA-012000-921-004 050703 Front Output Shaft Bearing Retainer Tool 0JWA-012000-922-005 050704 05-51 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 52 CFMOTO Breather Seat Installer 0800-011105-923-001 050801 MAG Crankcase Main Shaft Bearing 6303 Installer 0180-011100-921-004 050802 Drive Bevel Gear Shaft Bearing 6305 Installer 0180-062103-921-002 050803 PTO Crankcase Bearing Compression Supporting Block 0800-012101-921-001 050804 05-52 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 53 05 Engine Front Output Shaft Bearing 6205 Installer 0180-062301-921-001 050901 15×25×5 Oil Seal Installer 0180-065002-923-001 050902 Rear Output Coupler Holding Wrench 0180-060006-922-001 050903 MAG Crankcase Crankshaft Bearing Installer 0180-014001-921-002 050904 05-53 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 54 CFMOTO MAG Crankcase Cover Bearing Installer 0800-014001-921-002 051001 Crankshaft Plain Bearing Protecting Sleeve 0GQ0-000000-922-001 051002 Gearshift Main Shaft Oil Seal Protecting Sleeve 0800-060004-922-002 051003 32X55X10 Oil Seal Installer 0JY0-013103-923-001 051004 05-54 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 55 05 Engine Magneto Rotor Holding Wrench 0800-031000-922-002 051101 Driven Bevel Gear Oil Seal Installer 0800-062204-923-001 051102 Spark Plug Wrench 0800-022800-922-001 051103 Drive Bevel Gear Holding Tool 0JYA-062100-922-003 051104 05-55 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 56 CFMOTO Oil Hose Adapter (to measure oil pressure) 0800-000000-871-001 051201 Valve Clearance Adjusting Wrench 1P39MB-022102-922-001 051202 Valve Spring Compressing Clamp 0180-022006-922-001 051203 Water Seal A/B Tool 0JWA-081000-922-002 051204 05-56 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 57 05 Engine Bevel Gear Lock Nut Socket B 0JYA-062100-922-002 051301 Driven Bevel Gear Bearing Limit Nut Tool 0800-062206-922-001 051302 Bevel Gear Side Clearance Measuring Tool 0JWA-062000-860-001 051303 Bearing Removal Tool 0800-011102-922-001 051304 05-57 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 58 CFMOTO MAG Crankcase Plain Bearing Supporting Tool 0800-011101-922-001 051401 PTO Crankcase Plain Bearing Supporting Tool 0800-012101-922-001 051402 CVT Crankcase Plain Bearing Installer 0JY0-013101-921-001 051403 Crankcase Bearing Removal Tool It is recommended to use such tools to remove bearings. 051404 05-58 ©...
Page 59: Engine Removal
05 Engine 5.2 Engine Removal 5.2.1 Preliminary Work Remove muffler (refer to Muffler section). Remove fuel tank (refer to fuel system section). Remove air filter inlet pipe (refer to Air Filter section). Remove CVT inlet and outlet pipes (refer to Body Covering Parts section). Remove gearshift assy (refer Gearshift Assy section).
Page 60 CFMOTO Loosen clamps Remove engine outlet pipe Remove engine inlet pipe 051601 Use lifting device to hang the engine. The lifting device has to be fixed. Lock nut on bolt to remove the bolt. 051602 Lock nut on bolt to remove the bolt. 051603 Lock nut on bolt to remove the bolt.
Page 61 05 Engine Loosen clamp 051701 Remove bolts Lift front drive shaft to separate it with the engine output flange coupler. 051702 Pry engine until output shaft and duct boot separate. Lift the engine with lifting device and put it on service bench. 051703 05-61 ©...
Page 62: Engine Air Inlet/Outlet System
CFMOTO 5.3 Engine Air Inlet/Outlet System 5.3.1 Air Filter 5.3.1.1 Removal Remove rear wheel fender. Remove rear rack assy. Remove CVT deco cover. Remove air filter service cover. Removal refers to Body Covering Parts section. 051801 Remove bolts Remove T-type bushings Remove CVT RH outer deco cover (refer to Body Covering Parts section).
Page 63: Air Filter Parts Inspection
05 Engine 5.3.1.2 Air Filter Parts Inspection Disassembly Loosen clamp Remove air filter outlet pipe 051901 Loosen clamp Remove breather hose Loosen clamp Remove indicator hose 051902 Loosen clasp Remove air filter cover Remove air filter element 051903 Inspection Inspect air filter cover , housing , breather hose and oil reserver...
Page 64 CFMOTO Air filter element cannot be cleaned. Replace the filter element if it is dirty (refer to Maintenance Chart). 052001 Inspect connecting hose and air filter inlet pipe for damage. Replace if it does. Clean connecting hose and air filter inlet pipe 052002 Installation...
Page 65: Air Filter Installation
05 Engine Loosen clamp Put clamp on air filter outlet pipe Install air filter outlet pipe Tighten clamp 052101 5.3.1.3 Air Filter Installation Put clamp on breather hose Loosen clamp to install breather hose Put clamp on air filter outlet pipe. Install air filter on throttle valve and tighten the clamp...
Page 66: Engine Inlet Pipe
CFMOTO Install bolt Install cargo box base plate. Install CVT RH outer deco cover. Install rear service cover. Install air filter cover. Install rear cargo box cover plate. Installation refers to Body Covering Parts section. 052201 5.3.2 Engine Inlet Pipe Removal Engine Inlet Pipe Remove bolt...
Page 67 05 Engine Fuel Injector Remove seal rings Remove bolts Remove fuel injector brackets 052301 Remove bushings Remove fuel injectors 052302 Throttle Valve Remove bolts Remove throttle valve Remove o-seal ring 052303 Remove bolt Remove T-MAP 052304 05-67 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 68 CFMOTO Loosen clamp Remove auxiliary air inlet pipe Loosen clamp Remove air inlet pipe joint hose 052401 Inspection Air Inlet Pipe, Auxiliary Air Inlet Pipe and Joint Hose Inspect auxiliary air inlet pipe , joint hose and air inlet pipe for cracks and damage.
Page 69 05 Engine Installation Loosen clamp and put it on air inlet pipe joint hose Install joint hose on air inlet pipe , and tighten the clamp Loosen clamp and put it on air inlet joint hose Install auxiliary air inlet pipe on joint hose , and tighten the clamp...
Page 70: Air Exhaust System
CFMOTO 5.3.3 Air Exhaust System 5.3.3.1 Muffler Assy Removal Remove rear LH&RH fenders Remove CVT LH&RH outer deco plates Remove rear rack assy (refer to Body Covering Parts chapter). 052601 Remove air filter cover and three bolts. Remove cargo box base plate assy (refer to Body Covering Parts chapter).
Page 71 05 Engine Remove bolts and springs. Remove graphite seal ring 052701 Remove bolt Remove bolt Remove engine upper mounting bracket Remove muffler body assy 052702 Remove bolts Remove heat insulator 052703 Remove bolts with springs and washers. Remove graphite seal ring 052704 05-71 ©...
Page 72: Muffler Parts Inspection
CFMOTO Remove muffler nuts Remove graphite seal ring Remove muffler rear pipe assy 052801 Remove muffler joint nuts Remove graphite seal ring Remove muffler front pipe assy 052802 5.3.3.2 Muffler Parts Inspection Muffler Body Assy Disassembly Remove bolt Remove muffler hanging bracket assy Remove engine upper bracket 052803 Remove M6 inner hex screws...
Page 73 05 Engine Remove M6 inner hex screws Remove muffler heat insulator 052901 Inspection Inspect engine upper bracket , muffler hanging bracket assy , muffler heat insulator , muffler body assy , graphite seal ring for damage. Replace if necessary. If exhaust air leaks in muffler junction area, inspect graphite seal ring for damage.
Page 74 CFMOTO Install muffler hanging bracket assy Install bolt Install engine upper bracket 053001 Muffler Rear Pipe Assy Inspect muffler rear pipe assy damage. Replace if it does. If the junction area of muffler occurs to smoke leaking, inspect graphite seal ring .
Page 75: Muffler Assy Assembly
05 Engine Assembly Install front pipe heat insulator parts Install inner hex screws 053101 Inspect heat insulator parts for damage. Replace if necessary. 053102 5.3.3.3 Muffler Assy Assembly Install graphite seal ring Install front pipe heat insulator parts Install muffler joint nuts 053103 Install muffler rear pipe assy Install graphite seal ring...
Page 76 CFMOTO Install graphite seal ring Install muffler joint nuts 053201 Install heat insulator Install bolts 053202 Install muffler body assy Install bolt Install engine upper bracket Install bolt 053203 Install graphite seal ring Install bolts with springs. 053204 05-76 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 77 05 Engine Connect oxygen sensor connectors. Install seat rear back plate assy Install ECU, ECU service cover diagnosis connector. (refer to Body Covering Parts chapter). 053301 Install driver seat Install passenger seat (Installation procedures refer to Seat section.) 053302 Install cargo box base plate assy Install three bolts and air filter cover (refer to Body Covering Parts chapter).
Page 78: Air Filter Element
CFMOTO 5.3.3.4 Air Filter Element Removal Remove air filter cover L o o s e n c l a s p s t o r e m o v e a i r f i l t e r protection cover Remove air filter element Installation Reverse the removal procedures for...
Page 79: Engine Disassembly
05 Engine 5.4 Engine Disassembly Put engine on work bench and fixate it, in case the engine falls down to cause injury and damage. 5.4.1 CVT CVT removal procedures refer to 04 CVT chapter. Remove bolts Remove nuts 053501 Remove CVT case Remove dowel pins Remove roller needle Remove seal gasket...
Page 80: Thermostat And Thermostat Seat
CFMOTO Put a container under magnetic drain bolt to store the drained engine oil. Remove magnetic drain bolt Remove washer 053601 Transmission Oil Remove oil dipstick 053602 Put a container under magnetic drain bolt to store the drained engine oil. Remove magnetic drain bolt Remove washer 053603...
Page 81: Oil Cooler
05 Engine Remove bolts Remove the thermostat seat and water pipe. Remove o-seal ring 053701 5.4.4 Oil Cooler Remove bolt Remove bolt Remove bolt Remove water pipe bracket 053702 Loosen clamp Pull out oil cooler water outlet pipe 053703 Remove bolts Remove oil cooler oil inlet pipe Remove bolts Remove oil cooler oil outlet pipe...
Page 82: First Cylinder Tdc Adjustment
CFMOTO 5.4.5 First Cylinder TDC Adjustment Remove bolts Remove plug Remove seal gasket Remove bolt Remove RPM sensor 053801 Use a socket to rotate bolt counter- clockwise. Watch the mark "I" through viewing hole. Rotate using the socket until the mark is at the center of the hole. Such position is the TDC of first (starter side) cylinder.
Page 83: First Cylinder Head
05 Engine 5.4.8 First Cylinder Head NOTE: The timing sprocket scale should be at the position as picture shows, paralleling with cylinder head lower surface Remove timing sprocket bolt Remove timing sprocket N O T E : H o o k t i m i n g c h a i n a f t e r removing sprocket, in case the chain falls inside the engine.
Page 84: Second Cylinder Tensioner
CFMOTO 5.4.10 Second Cylinder Tensioner Remove bolts Remove tensioner Remove seal gasket NOTE: Make marks on tensioner during removal, to prevent getting mixed up during installation. 054001 5.4.11 Second Cylinder Head Cover Use special tool: Spark Plug Wrench (0800-022800-922-001) to remove spark plug Remove bolts Remove second cylinder head cover...
Page 85: Air Bag
05 Engine Remove roller needle Remove cylinder head gasket Remove chain guide NOTE: Make marks on chain guides during removal, to prevent getting mixed up during installation. 054101 5.4.13 Air Bag Remove bolt Remove air bag bracket Remove clamp Remove air bag 054102 5.4.14 Oil Filter Remove bolts...
Page 86: Starter Motor
CFMOTO Remove bolt Remove water pump impeller Remove water seal washer NOTE: Pay attention not to damage water pump impeller during removal. The bolt is left-hand thread. 054201 5.4.16 Starter Motor Remove bolts Remove starter motor 054202 5.4.17 MAG Crankcase Cover Remove bolts Remove wire clips 054203...
Page 87: Magneto Rotor
05 Engine Remove dowel pins Remove roller needle 054301 5.4.18 Magneto Rotor Use special tool: Magneto Rotor Holding Wrench to fix rotor Remove bolt Remove spacer Use special tool to remove magneto rotor 054302 Remove woodruff key Remove driven gear 054303 5.4.19 Starter Dual Gear Remove breather shaft...
Page 88: Breather Parts
CFMOTO 5.4.20 Breather Parts Remove breather part Remove circlip Remove washer Remove breather idle gear NOTE: The breather idle gear shaft is not allowed to remove. 054401 5.4.21 Oil Pump Idle Gear and Water Pump Idle Gear Remove circlip Remove washer Remove oil pump idle gear Remove breather shaft Remove water pump idle gear...
Page 89: First Cylinder Timing Chain
05 Engine Remove oil pump shaft Remove oil pump inner rotor from oil pump shaft. Remove roller needle from oil pump shaft. Remove oil pump outer rotor 054501 5.4.23 First Cylinder Timing Chain Remove chain guard Remove threaded pin shaft Remove tensioner plate Remove timing chain 054502...
Page 90: First Cylinder And Piston
CFMOTO Remove bolt Remove washer Remove gearshift driven sector gear assy 054601 Remove gearshift limit spring seat Remove retainer Remove spring and steel ball with magnet. NOTE: Pay attention to retainer and steel ball during removal, in case they get lost. 054602 5.4.26 First Cylinder and Piston Remove first cylinder...
Page 91: Second Cylinder And Piston
05 Engine 5.4.27 Second Cylinder and Piston Remove second cylinder Remove seal gasket Remove roller needle NOTE: Make marks on cylinders during removal, to prevent getting mixed up during installation. 054701 Rotate crankshaft until second cylinder piston exposes. Remove from either side: Remove piston pin circlip Remove piston pin Remove piston...
Page 92: Crankshaft Connecting Rod Assy And Main Shaft
CFMOTO Remove PTO crankcase body Remove dowel pins Remove roller needle 054801 5.4.29 Crankshaft Connecting Rod Assy and Main Shaft Remove crankshaft connecting rod assy Remove main shaft 054802 5.4.30 Countershaft Assy, Shift Fork and Shift Drum Remove bolts Remove drive bevel gear assy Remove countershaft assy , shift fork and shift drum...
Page 93: Engine Parts Inspection
05 Engine 5.5 Engine Parts Inspection 5.5.1 Cylinder Head Cover Inspect the seal ring on cylinder head cover for cracks or hardening. Replace if necessary. 054901 5.5.2 Cylinder Head Disassembly Remove bolt Remove camshaft holding strip 054902 Loosen value clearance adjusting nuts Use special tool: Valve Clearance Adjusting Wrench to loosen adjusting screws 054903...
Page 94 CFMOTO Remove rocker arms Remove air intake rocker arm Remove air exhaust rocker arm Remove retainers Rotate camshaft to proper position to remove it. 055001 Put the valve compressing clamp at the center of the valve as picture shows. 055002 Put the valve compressing clamp at the valve spring upper seat...
Page 95: Parts Inspection
05 Engine 5.5.3 Parts Inspection Cylinder Head Inspection -Clean the carbon deposit in combustor and on junction surface -Inspect cylinder head valve seat for cracks. Replace if necessary. -Use knife-edge ruler and filler gauge to inspect the junction area between cylinder head and body for deformation a n d d a m a g e .
Page 96 CFMOTO ●Measure the clearance between camshaft and cylinder head on both sides. Camshaft bearing hole diameter (timing chain side) A 35.007 mm~35.025 mm (1.3782 in~1.3789 in) Service limit 35.040 mm(1.3795 in) Camshaft bearing hole diameter (spark plug side) B 22.012 mm~22.025 mm (0.8666 in~0.8671 in) 055201 Service limit...
Page 97 05 Engine Rocker Arm Shaft ●Inspect every rocker arm shaft wear and scratches. Replace if it does. ●Measure rocker arm shaft diameter Rocker arm shaft diameter 11.973 mm~11.984 mm (0.4714 in~0.4718 in) 11.960 mm Service limit (0.4709 in) Valve Stem Seal Ring 055301 NOTE: Replace with new valve stem seal rings during installation.
Page 98 CFMOTO Valve stem diameter Exhaust valve 4.955 mm~4.970 mm (0.195 1in~0.1957 in) Service limit 4.930 mm (0.1941in) Intake valve 4.965mm~4.980mm (0.1955in~0.1960in) Service limit 4.930mm (0.1941in) Valve Bevel and Valve Seat Inspect valve bevel and valve seat for being burnt or sunk. Replace valves or cylinder head if necessary.
Page 99: Cylinder Head Assy
05 Engine Valve Spring Inspect valve spring for visible damage. Replace if it does. Inspect valve spring free length. Valve spring free length 40 mm (1.575 in) Service limit 38.2 mm (1.504 in) Replace valve spring if beyond service 055501 limit.
Page 100: Cylinder Body
CFMOTO Install valve spring Put valve spring upper seat in place. Use special tool: Valve Spring Compressing Clamp to compress spring. Put two valve lock clips into the groove of valve stem with tweezers. Loosen the tool. 055601 Rotate camshaft to proper position to install camshaft.
Page 101: Timing Chain Tensioner
05 Engine Cylinder Taper Measure cylinder body inner diameter. Replace cylinder body and piston rings if it beyond service limit. Measure cylinder inner diameter at 3 recommended positions. 1 First diameter measuring position 2 Second diameter measuring position 3 Third diameter measuring position A 6 mm (0.2362 in) B 43 mm (1.6930 in) 055701...
Page 102: Piston
CFMOTO 5.5.7 Piston Piston Diameter Inspect piston for scratches, cracks or other damage. Replace if necessary. Measure piston at 8 mm ( 0.315 in) perpendicularly (90°) to piston pin with a micrometer. The measuring value should be within service limit. Replace if not. Piston size 90.940 mm~90.960 mm 055801...
Page 103 05 Engine Place the ring 8mm~16mm(5/16in.~5/8in.) from top of cylinder when measuring the piston ring open clearance. NOTE: In order to Put the ring at the correct position, use piston as a pusher. Use feeler gauge to measure piston ring working open clearance.
Page 104: Timing Chain
CFMOTO Piston/Cylinder Clearance Adjust and lock micrometer to the piston dimension. With the micrometer set to the dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to 0(zero). Position the dial bore gauge 20 mm (0.787 in) above cylinder base, measure perpendicularly (90°) to piston pin axis.
Page 105: Shift Gear Assy
05 Engine 5.5.10 Shift Gear Assy Drive Sector Gear Inspect drive sector gear for cracks or other damage. Replace if necessary. Measure gear shaft diameter with vernier caliper. Replace if beyond service limit. Diameter service limit: 14.976 mm~14.994 056101 Driven Sector Gear Inspect driven sector gear for defects.
Page 106 CFMOTO Water Pump Impeller I n s p e c t w a t e r p u m p i m p e l l e r f o r damage. Replace if necessary. 056201 Water Pump Gear, Shaft, Oil Seal and Bearing Disassembly Rermove water pump gear...
Page 107 05 Engine Pry the water seal moving ring with a screw driver. 056301 Put the MAG crankcase cover on flat place and make sure the water pump bearing is floating. Fix crankcase cover, use a proper tool (like gearshift fork shaft) to knock the bearing out of hole in the...
Page 108 CFMOTO Water Seal Assy Inspect water seal assy for damage, leaking and sealing condition. Replace if necessary. 056401 Oil Seal Inspect oil seal , especially oil seal lip. Replace if necessary. 056402 Water Pump Impeller and Idle Gear Inspect water pump impeller for cracks or other damage.
Page 109 05 Engine Assembly A p p l y s o m e g r e a s e o n w a t e r p u m p bearing hole of MAG crankcase cover. Use special tool: MAG Crankcase Cover Bearing Installer to install water pump bearing...
Page 110: Oil Filter
CFMOTO Install washer Install roller needle Install water pump gear 056601 5.5.13 Oil Filter Replace with a new oil filter element Inspect o-seal ring for cracks or damage. Replace if necessary. Inspect oil filter cover for damage. Replace if necessary. NOTE: Replace with a new oil filter element after removal.
Page 111: Magneto Rotor
05 Engine Assembly Install overriding clutch on magneto rotor . Install bolts (with 243 thread locker) and tighten them. Tighten torque: 26±2 N•m Install driven gear 056701 5.5.15 Magneto Rotor Inspect rotor inside for scratches or other damage; Inspect rotor key grooves for wear or other damage;...
Page 112: Starter Dual Gear
CFMOTO Assembly Install magneto stator Install bolts Settle wires and install press plate Install bolts 056801 5.5.17 Starter Dual Gear Inspect starter dual gear for wear or damage. Replace if necessary. Inspect breather shaft for wear or damage. Replace if necessary. Inspect middle gear for wear or damage.
Page 113: Breather And Breather Idle Gear
05 Engine Measure bottom clearance (between inner and outer rotor) and side clearance (between outer rotor and crankcase). Replace oil pump if beyond service limit. Bottom clearance service limit: 0.25 mm Side clearance service limit: 0.25 mm 057001 5.5.20 Breather and Breather Idle Gear Inspect breather for damage or other defect.
Page 114 CFMOTO Crankshaft Axial Clearance N O T E : M e a s u r e c r a n k s h a f t a x i a l clearance before disassemble MAG and PTO crankcase. Use dial gauge to measure crankshaft axial play at MAG.
Page 115 05 Engine Crankshaft Inspection Measure crankshaft journal diameters on both sides. Compare them with sliding bearing inner diameter (refer to Crankcase section). Crankshaft main journal diameter (CVT/MAG side) 41.960 mm~41.970 mm Service limit 41.935 mm Crankshaft main journal axial clearance 057101 (CVT/MAG side) Service limit...
Page 116 CFMOTO Measure crankshaft connecting rod journal diameter . Compare it with connecting rod big end bearing inner diameter. (Install connecting rod plain bearings. Install bolts and tighten them, then measure connecting rod big end bearing inner diameter.) 057201 Connecting rod journal diameter 43.930 mm~43.950 mm (1.7295 in~1.7303 in) Service limit...
Page 117 05 Engine Connecting rod plain bearing (sign) 1.519 mm~1.523 mm, black 1.523 mm~1.528 mm, blue 1.514 mm~1.519 mm, red Plain Axial Big hole Journal bearing clearance (sign) (sign) (sign) (mm) Black Blue 0.028~0.049 Black Assembly According to the tables above, choose the proper plain bearings.
Page 118: Transmission Assy
CFMOTO 5.5.23 Transmission Assy Shift Fork Assy 057401 Circlip 12 Spring seat Fork spring, thick Shift fork, RH Shaft, shift fork Fork spring, thin Shift fork, LH Shift Fork/Shaft Inspect shift forks for severe wear or damage. Inspect shift fork claw for bending. Measure shift fork claw thickness.
Page 119 05 Engine Measure shift fork pin diameter (LH&RH). Replace if beyond service limit. Shift fork pin diameter (LH&RH) 7.9 mm~7.95 mm (0.311 in~0.313 in) Service limit 7.83 mm (0.308 in) 057501 Put shift fork onto the shift fork shaft, then move the shaft as illustrated.
Page 120 CFMOTO Shift Drum Inspect shift drum grooves for damage or severe wear. Replace if necessary. Inspect parking cam on shift drum for damage or severe wear. Replace if necessary. Inspect thrust washer for damage. Replace if necessary. 057601 Parking Swing Arm Inspect parking swing arm for cracks or damage.
Page 121 05 Engine 057701 Washer 17.5×32×1 Driven high gear Driven low gear Driven shaft Needle bearing Driven output shaft Washer 24.5×33.5×1 Driven reverse gear Shifting slide sleeve Circlip 29 Retainer 29 Parking gear Gear Driven shaft output gear is for reverse gear shifting.
Page 122: Reverse Intermediate Gear
CFMOTO Driven Shaft Check driven shaft for damage. Check driven shaft for pitting, break and severe wear. Replace if necessary. Measure driven shaft journal diameter. Replace if beyond service limit. Driven shaft Service limit 16.978 mm (0.6684 in) 23.974 mm (0.9439 in) 057801 5.5.24 Reverse Intermediate Gear Disassembly...
Page 123 05 Engine Assembly Install washer Install needle bearing Install reverse intermediate gear Install washer Install circlip NOTE: The removed circlips can not be reused. Replace with new ones during installation. 057901 5.5.25 Drive Bevel Gear Disassembly Remove circlip Remove output driven gear Remove circlip Use special tool: Drive Bevel Gear Holding tool...
Page 124 CFMOTO Put the clean drive bevel gear bearing seat on work bench. Apply engine oil on bearing evenly inside and outside. Use special tool: 63/28 Bearing Installer to Install 62/28 needle bearing into the hole on drive bevel gear bearing seat. The bearing should be rotated freely without stuck feeling after installation.
Page 125 05 Engine Remove bolts Remove driven bevel gear adjusting washers Remove driven bevel gear bearing seat 058101 Inspection Inspection driven bevel gear assy damage. If yes, disassemble and replace fault parts. If not, it is not necessary to disassemble. 058102 Remove o-seal ring Remove oil seal 058103...
Page 126: Driven Bevel Gear
CFMOTO Inspect o-seal ring for cracks, aging or other damage. Replace if necessary. Inspect driven bevel gear bearing seat assy for damage. Replace if necessary. Inspect driven bevel gear bearing. Replace if stuck or damaged. 058201 Inspect drive bevel gear for scratches, wear or other damage.
Page 127 05 Engine Apply engine oil on o-seal ring install it on driven bevel gear. Apply grease on oil seal lip. Use special tool: Driven Bevel Gear Oil Seal Installer to install oil seal on driven bevel gear bearing seat. 058301 Install speed sensor Install bolts without being tightened...
Page 128 CFMOTO Inspection Inspect bearing for smooth rotation and abnormal wear. If yes, remove bearing from front output shaft and replace with a new one. During installation, apply some 648 sealant on front output shaft installing surface first. Then put 6205 bearing on front output shaft.
Page 129: Mag Crankcase Cover
05 Engine For valve open temperature inspection, hang thermostat into the container full of water. Heat the water slowly. The thermostat should be fully immersed without touching container wall and bottom. Hang a thermometer at the same level without touching wall and bottom either.
Page 130 CFMOTO Oil Strainer Remove cap nuts Remove bolts Remove oil strainer outer side plate with a straight screw driver. Remove oil strainer outer washer with a screw driver. Remove oil strainer with nipper pliers. 058601 Inspection Oil temperature&pressure sensor and speedometer sensor inspection refers to Electrical System chapter.
Page 131: Pto Crankcase
05 Engine Installation Use special tool: MAG Crankcase Main Shaft Bearing 6303 Installer to install 6303 bearings NOTE: The bearing should rotate freely without stuck feeling after installation. Bearing surface with marks should face outside. No damage on crankcase. 058701 5.5.31 PTO Crankcase Gear Sensor Remove bolts...
Page 132 CFMOTO Assembly Place PTO crankcase as picture shows. Install steel ball Put o-seal ring on screw plug Put retainer and spring together on screw plug. Then rotate the relief valve screw plug assy for installation. Disassembly (status 2) 058801 Remove screw plug Remove o-seal ring Remove spring and steel ball...
Page 133 05 Engine PTO Crankcase Inspect PTO crankcase for cracks or damage. Replace the whole set if necessary. Inspect bearings for stuck issue or damage. Replace if necessary. Inspect plain bearings for severe wear or damage. Replace the whole crankcase if damaged. 058901 Bearing Rotate bearing inner ring with finger.
Page 134 CFMOTO Front Output Bearing and Oil Seal Removal Use special tool: Front Output Bearing Retainer Tool to remove the bearing retainer Remove bearing with bearing puller. Remove oil seal 059001 NOTE: The removed oil seal can not be reused. Replace with new ones during installation.
Page 135 05 Engine Oil Seal Inspect oil seal for damage or leak. Replace if necessary. Removal Remove oil seal 059101 Installation Apply 648 sealant on oil seal outer surface. Use special tool: Oil Seal 32×55×10 Installer to install oil seal into the hole on CVT case.
Page 136 CFMOTO Inspect o-seal ring for damage or hardening. Replace if necessary. Clean oil cooler and oil cooler base. Blow to dry oil cooler oil trail and water trail respectively with air gun. Inspect oil trail and water trail on oil cooler and base.
Page 137: Thermostat Seat And Water Pipe
05 Engine Inspect two-way joint for damage. Replace if damaged. 059301 Loosen clamp and put it on oil cooler water outlet pipe. Install oil cooler water outlet pipe on two- way joint NOTE: Installation must be made according to the mark. "MARK" sign on water pipe should be aligned with the center of two-way joint bulge.
Page 138 CFMOTO Inspect oil cooler oil inlet pipe , oil outlet pipe for oil leak or damage. Inspect joint bolt for damage or being stuck. Replace fault parts if necessary. 059401 05-138 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 139: Engine Assembly
05 Engine 5.6 Engine Assembly CAUTION: Once the retainer is removed, it cannot be reused. The open end of the retainer cannot be too much widened. Check retainers in place after installation. N O T E : I n s p e c t e v e r y p a r t b e f o r e installation.
Page 140: Drive Bevel Gear Assy
CFMOTO Apply grease on shafts. Install shift drum and setting it into low gear position. Install main shaft . Rotate main shaft to make sure it rotates freely without stuck feeling and noise. There should be some clearance between teeth. 059601 Install needle bearing Install driven low gear...
Page 141: Crankshaft Connecting Rod Assy
05 Engine 5.6.3 Crankshaft Connecting Rod Assy Apply some engine oil on MAG crankcase plain bearings and crankshaft journal. Install crankshaft connecting rod assy NOTE: The connecting rod, which is closed to MAG crankcase, should be set into second cylinder. Rotate crankshaft a little bit to install it in 059701 place.
Page 142: Bevel Gear Washer Adjustment
CFMOTO 5.6.4 Bevel Gear Washer Adjustment When crankcase and/or bevel gears (in pair) and/or bevel gear seat get replaced, the washers must be adjusted. CAUTION: Make sure the clearances between gears and teeth are within a appropriate range. Bevel Gear Side Clearance Install drive and driven bevel gear on crankcase.
Page 143: First Cylinder Body And Piston
05 Engine Rotate driven bevel gear several circles forward and backward. Remove drive and driven bevel gear assy to see the dye coating results. Status A On the top Status B In the middle Status C On the bottom If the teeth surface contact area is qualified (Status B), continue following procedures.
Page 144 CFMOTO After piston installation, adjust the piston rings as picture shows: There should be 180 degrees angle between piston top ring open second ring open Oil ring expander open and top ring open should be the same. There should be 120 degrees angle between oil control ring and oil ring expander open There should be approximately 30 degrees...
Page 145: Gearshift Assy
05 Engine After piston installation, adjust the piston rings as picture shows: There should be 180 degrees angle between piston top ring open second ring open Oil ring expander open and top ring open should be the same. There should be 120 degrees angle between oil control ring and oil ring expander open...
Page 146: First Cylinder Timing Chain
CFMOTO NOTE: During gearshift driven sector gear installation, the quadrate groove should be aligned with quadrate bulge on shift drum. 0510201 Install dowel pin Install new gasket Install gearshift drive sector gear assy Install gearshift cover Install bolts 0510202 NOTE: The marks on shift drive and driven sector gear should be aligned as picture shows.
Page 147: Second Cylinder Timing Chain
05 Engine 5.6.9 Second Cylinder Timing Chain Put timing chain into crankcase from second cylinder. Set it on crankshaft timing sprocket. Hook it to prevent it from falling down. Install tensioner plate from second cylinder. Apply 243 thread locker and install tensioner plate screw Tighten torque: 8N•m~12N•m.) Install chain guard...
Page 148: Oil Pump Idle Gear And Water Pump Idle Gear
CFMOTO 5.6.11 Oil Pump Idle Gear and Water Pump Idle Gear Install oil pump idle gear Install washer Install circlip Install breather shaft Install water pump idle gear 0510401 5.6.12 Breather Assy Install breather assy Install breather idle gear Install washer Install circlip 0510402 5.6.13 Starter Dual Gear...
Page 149: Magneto Rotor
05 Engine Install magneto rotor Install spacer Install bolt with thread locker but not tighten it. Use special tool: Magneto Rotor Holding Wrench to fix magneto rotor. Tighten bolt M12×1.25 bolt tighten torque: 70 N•m NOTE: During installation, align the woodruff key with the key groove on 0510501 magneto rotor.
Page 150: Starter Motor
CFMOTO 5.6.16 Starter Motor Install starter motor Install bolts 0510601 5.6.17 Water Pump Install water seal washer Install water pump impeller Install bolt with thread locker (Left-hand thread). M12×17 bolt tighten torque: 10N•m NOTE: Pay attention not to damage water pump impeller during installation. Bolt is left-hand thread.
Page 151: Air Bag
05 Engine 5.6.19 Air Bag Install air bag Install clamp Install air bag bracket Install bolt 0510701 5.6.20 First Cylinder TDC Adjustment Rotate bolt with a socket until the "I" mark is at the center of the hole. Such position is the the TDC for first cylinder. 5.6.21 First Cylinder Head Assy 0510702 Install roller needles...
Page 152: First Cylinder Valve Clearance Adjustment
CFMOTO Set timing sprocket in timing chain. Make the marker lines on timing sprocket parallel with cylinder head lower surface Install timing sprocket bolt with thread locker. Tighten torque: 30N•m. N O T E : I n s t a l l t i m i n g s p r o c k e t s according to the made marks, to prevent incorrect installation.
Page 153: First Cylinder Head Cover
05 Engine Valve clearance 0.06 mm~0.14 mm Intake valve (0.0024 in~0.0055 in) 0.11 mm~0.19 mm Exhaust valve (0.0043 in~0.0075 in) N O T E : I n s p e c t a n d a d j u s t v a l v e clearance when the engine is cold.
Page 154: Second Cylinder Tensioner
CFMOTO Install cylinder head assy Install bolts .(Pre-tighten to 20N•m in criss-cross pattern, and then tighten to 60N•m.) Install bolts . M6×80 bolt tighten torque: 10N•m. NOTE: Install cylinder head assy according to the made marks, to prevent incorrect installation. NOTE: Hook the timing chain during 0511001 installation, in case it falls into engine.
Page 155: Second Cylinder Valve Clearance Adjustment
05 Engine 5.6.28 Second Cylinder Valve Clearance Adjustment Fix nut with wrench. Use special tool: Valve Clearance adjusting wrench to loosen adjusting screw Insert filler gauge of appropriate thickness between rocker arm and valve spring lock clip The filer gauge can be moved without 0511101 much force.
Page 156 CFMOTO 5.6.31 Oil Cooler Assy Install oil cooler assy Install bolts Install oil cooler oil inlet pipe Install joint bolts with washers. Install oil cooler oil outlet pipe Install joint bolts with washers. 0511201 Loosen clamp and put it on oil cooler water outlet pipe Install oil cooler water outlet pipe Tighten clamp...
Page 157: Drain Bolt
05 Engine Install thermostat Install thermostat cap Install bolts 0511401 5.6.33 Drain Bolt Crankcase Put washer on magnetic drain bolt Install magnetic drain bolt Add engine oil. 0511402 Transmission Gear Case Put washer on magnetic drain bolt Install magnetic drain bolt Add transmission oil.
Page 158: Cvt Case
CFMOTO 5.6.35 CVT Case Install dowel pins Install roller needle Install seal gasket Install seal gasket Install CVT case 0511401 Install bolts Install nuts Detailed information refers to 04 CVT System. 0511402 05-158 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 159: Engine Installation
05 Engine 5.7 Engine Installation Hang engine on vehicle. Connect engine rear output shaft and rear gear case output shaft. Then put down engine. NOTE: Apply some grease in output shaft coupler before installation. 0511501 Install engine cushion blocks Put down the engine slowly. Install bolt with nut.
Page 160 CFMOTO Install and tighten clamp 0511601 Push front drive shaft forward to align with engine output flange coupler. Install bolts with thread locker. Tighten torque: 40N•m~50N•m. 0511602 Loosen clamp and put it on engine water outlet pipe Install engine water outlet pipe tighten clamp Loosen clamp and put it on engine...
Page 161: Cooling System
05 Engine 5.8 Cooling System 5.8.1 Sealing Inspection CAUTION: Never open radiator cap or remove water pipe and radiator parts before engine is cooled down, to prevent getting burnt. Run the engine (idle). Stop the engine until fan works. Inspect cooling system each part for leak.
Page 162 CFMOTO Coolant Filling Remove the relief screw on thermostat cap. NOTE: Both two cylinders must be vented. 0511801 Place the vehicle on flat ground and cool down engine. Add coolant to radiator until it comes out from the hole on thermostat cap.
Page 163: Lubrication System
05 Engine 5.9 Lubrication System 5.9.1 Engine Oil Level Inspection Ensure vehicle is on a level surface. Start the engine and allow it to idle for a few minutes. Stop the engine and wait for a few minutes to allow oil flow down to crankcase. Inspect the oil level.
Page 164: Transmission Oil Inspection
CFMOTO Clean drain bolt. R e p l a c e w i t h a n e w s e a l w a s h e r i f damaged. Install and tighten drain bolt with seal washer. Tighten torque: 20 N•m Oil Filter Element Replacement O i l f i l t e r e l e m e n t r e m o v a l a n d...
Page 165: Transmission Oil Replacement
05 Engine 5.9.4 Transmission Oil Replacement Ensure vehicle is on a level surface before operation. NOTE: The transmission oil can be very hot. Wait until engine temperature is appropriate. Place a pan under the transmission oil drain bolt to store the drained oil. Clean the drain bolt area.
Page 166 CFMOTO Oil pressure 1300r/min 6000r/min Min. 100kPa 500kPa Regular 200kPa 580kPa Max. 400kPa 700kPa I f t h e e n g i n e o i l p r e s s u r e b e y o n d specifications, check parts described in Trouble Shooting section.
Page 167: Fuel System
05 Engine 5.10 Fuel System DANGER: Never fuel near spark or lighted cigarette. Stop engine before fueling. Do not spill fuel on high-temperature components of the vehicle. If the fuel spills, wipe off the fuel immediately. WARNING: Fuel in the tank will expand when gets heated, and may overflows when it is overfilled.
Page 168 CFMOTO Loosen clamp Pull out fuel vapor hose I Pull out fuel vapor hose II Remove nuts Remove canister Remove seat bracket 0512401 Loosen clamp Pull out fuel vapor hose III Remove fuel vapor hose. 0512402 D i s c o n n e c t c a n i s t e r c o n t r o l v a l v e connector Pull out canister control valve Remove fuel vapor hose.
Page 169 05 Engine Pull out quick joint Pull out quick joint 0512501 Open high pressure oil hose clips remove high press oil hose. 0512502 Removal (without EVAP) Remove bolts Remove bolts 0512503 Remove bolts Pull out quick joint Pull out fuel pump connectors. Remove fuel pump 0512504 05-169...
Page 170 CFMOTO Pull out quick joint Pull out quick joint 0512601 Open high pressure oil hose clips remove high press oil hose. 0512602 5.10.2 Fuel System Inspection Fuel Tank Disassembly Remove bolts Remove fuel pump 0512603 Inspection Inspect fuel tank for damage or leaks. Replace if necessary.
Page 171 05 Engine Fuel Pump Pressure Inspection Pressure Inspect fuel pump for damage. Replace if gauge damaged. Battery Ensure that the battery voltage doesn't drop below 12V. Hose NOTE: A small amount of remaining fuel may come out of the hose when removing fuel pump.
Page 172 CFMOTO Inspection Inspect high pressure oil hose 1 oil hose 2 for break, damage, crack or hardening. Replace if necessary. 0512801 Inspect EFI fuel filter for damage. Replace if necessary. Fuel filter belongs to maintenance parts. Replace it periodically according to the maintenance schedule.
Page 173 05 Engine 5.10.3 Fuel System Installation Installation (with EVAP) Install fuel tank Install bolts Connect quick joint Connect fuel pump connectors. 0512901 Fix high pressure oil hose by clipping oil hose clips 0512902 Connect quick joint Connect quick joint 0512903 Install seat bracket Install canister Install nuts...
Page 174 CFMOTO Install canister control valve Connect canister control valve connector 0513001 Put clamp on fuel vapor hose . Install and fix fuel vapor hose. Then tighten clamp 0513002 Install bolts Install bolts Install body plastic parts, gearshift assy and hand brake assy, etc. 0513003 Installation (without EVAP) Install fuel tank...
Page 175 05 Engine Fix high pressure oil hose by clipping oil hose clips 0513101 Connect quick joint Connect quick joint 0513102 Install bolts Install bolts Install body plastic parts, gearshift assy and hand brake assy, etc. 0513103 05-175 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 176 06 Body Covering Parts 6.1 Seat ......................06-2 6.2 Front Top Cover ..................06-2 6.2.1 Front Service Cover ...............06-2 6.2.2 Seat Lower Fender .................06-2 6.2.3 Passenger Seat Lower Fender .............06-2 6.2.4 Seat Middle RH Protection Plate ..........06-3 6.2.5 Middle Protection Cover ...............06-3 6.2.6 Middle Panel ...................06-4 6.3 Lock Hook .....................06-5 6.3.1 Dashboard Panel ................06-5...
Page 177: Seat
CFMOTO 6.1 Seat Removal Loosen lock clip Lift up passenger seat Remove passenger seat Driver seat removal follows the same removal procedures. NOTE: The seat shall be pushed to the highest position during removal. Installation Reverse the removal procedures for 060201 installation.
Page 178: Seat Middle Rh Protection Plate
06 Body Covering Parts 6.2.4 Seat Middle RH Protection Plate Removal Remove five expansion screws. Remove seat middle RH protection plate Middle LH protection plate follows the same removal procedures. Installation Reverse the removal procedures for installation. 060301 6.2.5 Middle Protection Cover Removal Remove two screws Remove rear ventilation plate connecting...
Page 179: Middle Panel
CFMOTO 6.2.6 Middle Panel Removal Remove four expansion screws 060401 Remove five expansion screws 060402 Remove four expansion screws 060403 Remove two bolts 060404 06-4 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 180: Dashboard Panel
06 Body Covering Parts Remove two bolts Remove middle LH panel and middle RH panel Installation Reverse the removal procedures for installation. 060501 6.3 Lock Hook Removal Remove two inner hex bolts Remove side door lock hook Installation Reverse the removal procedures for installation.
Page 181 CFMOTO Remove four expansion screws 060601 Pry dashboard panel with a screw driver. Pull out dashboard upper plate Unplug all switch connectors 060602 Remove four expansion screws Remove screw 060603 Remove dashboard panel assy Installation Reverse the removal procedures for installation.
Page 182 06 Body Covering Parts 6.3.2 Storage Box Cover Assy Removal Remove self-tapping screws Remove storage box cover assy Installation Reverse the removal procedures for installation. 060701 6.4 Front Wheel Fender (Status 1) Removal Remove seven expansion screws Remove front RH wheel fender rear part Front LH wheel fender rear part follows the same removal procedures.
Page 183: Damping Deco Guard
CFMOTO 6.6 Damping Deco Guard Removal Remove three expansion screws 060801 Remove two expansion screws Remove LH damping deco guard RH damping deco guard removal applies the same removal procedures. Installation Reverse the removal procedures for installation. 060802 6.7 Headlight Panel Removal Remove bolts 060803...
Page 184: Cab
06 Body Covering Parts Remove headlight panel Installation Reverse the removal procedures for installation. 060901 6.8 Cab 6.8.1 Rear View Mirror Removal Remove four bolts Remove rear view mirrors. Installation Reverse the removal procedures for installation. 060902 6.8.2 Cab Removal Remove eight bolts 060903 Remove four bolts...
Page 185: Side Door (Status 1)
CFMOTO 6.9 Side Door (Status 1) Removal Remove four bolts Remove side door 061001 Remove ten screws Remove LH upper door inner plate 061002 Remove three self-tapping screws Remove three screws Remove LH upper door deco cover 061003 Remove two bolts Remove LH side door rear protection plate RH side door follows the same removal procedures.
Page 186: Side Door (Status 2)
06 Body Covering Parts Remove inner hex screw Remove side door lock kit Installation Reverse the removal procedures for installation. 061101 6.10 Side Door (Status 2) Removal The removal procedures for LH upper door inner plate, LH upper door deco cover, LH side door rear protection plate and lock kit are the same as status 1.
Page 187: Winch Deco Cover
CFMOTO 6.12 Winch Deco Cover Removal Remove four bolts Remove winch deco cover Installation Reverse the removal procedures for installation. 061201 6.13 Front Inner Fixed Plate Removal Remove bolts Remove front inner fixed plate Installation Reverse the removal procedures for installation.
Page 188: Front Fender
06 Body Covering Parts 6.15 Front Fender Removal Remove four expansion screws 061301 Remove bolt 061302 Remove bolt Remove LH front fender RH front fender follows the same removal procedures. 061303 Remove eleven M6 bolts Remove front fender Installation Reverse the removal procedures for installation.
Page 189 CFMOTO 6.16 Rear Fender (Status 1) Removal Remove five expansion screws Remove six bolts Remove LH rear fender RH rear fender follows the same removal procedures. 061401 6.17 Rear Fender (Status 2) Removal Remove five expansion screws Remove seven bolts Remove LH rear fender RH rear fender follows the same removal procedures.
Page 190: Rear Rack Cover Plate
06 Body Covering Parts 6.18.2 Rear Rack Cover Plate Removal Remove five bolts Remove rear rack cover plate Installation Reverse the removal procedures for installation. 061501 6.19 Rear Side Protection Plate Removal Remove seven expansion screws. 061502 Remove four expansion screws Remove bolt 061503 Remove three expansion screws...
Page 191: Ecu Cover
CFMOTO 6.20 Seat LH Protection Plate Removal Remove three expansion screws Remove bolt Remove seat LH protection plate Seat RH protection plate follows the same removal procedures. Installation Reverse the removal procedures for installation. 061601 6.21 Seat Rear Protection Plate 6.21.1 ECU Cover Removal Remove two bolts...
Page 192: Foot Pedal
06 Body Covering Parts 6.21.4 Rear Ventilation Plate Removal Remove self-tapping screws Remove rear ventilation plate Installation Reverse the removal procedures for installation. 061701 6.22 Seat Front Protection Plate Removal Remove bolt Remove four expansion screws Remove RH seat front protection plate LH seat front protection plate follows the same removal procedures.
Page 193: Air Filter Cover
CFMOTO 6.25 Air Filter Cover Removal Lift and remove the air filter cover in the direction of the arrow shown in the picture. Installation Reverse the removal procedures for installation. 061801 6.26 Rear Cargo Box Base Plate Removal Remove three bolts 061802 Remove two screws Remove rear cargo box base plate...
Page 194: Rear Rack Assy
06 Body Covering Parts Remove three bolts Remove rear rack outer deco cover Installation Reverse the removal procedures for installation. 061901 6.27 Rear Rack Assy Removal Remove four bolts Remove rear rack assy Installation Reverse the removal procedures for installation. 061902 06-19 ©...
Page 195 07 Powertrain 7.1 CV Drive Shaft.................. 07-2 7.2 CV Drive Shaft Service ..............07-2 7.2.1 CV Drive Shaft Inspection ............07-2 7.2.1.1 Shaft Cage Dust Boot ............07-3 7.3 Drive Shaft..................07-4 7.3.1 Front Drive Shaft Removal ............07-4 7.3.2 Rear Drive Shaft Removal ............07-4 7.3.3 Drive Shaft Maintenance ............
Page 196: Cv Drive Shaft
CFMOTO 7.1 CV Drive Shaft Removal Remove wheels. Remove shock absorbers. Remove LH&RH steering knuckles (refer to Chapter 09). Pull out CV drive shaft in the horizontal direction. Other CV drive shafts apply the same removal procedures. 7.2 CV Drive Shaft Service 7.2.1 CV Drive Shaft Inspection 1.
Page 197: Shaft Cage Dust Boot
07 Powertrain 7.2.1.1 Shaft Cage Dust Boot Removal Remove clamps Pull dust boots towards middle shaft Remove circlip Remove housing Remove circlip Remove universal shaft assy Remove dust boots Replace with new dust boots during installation. Installation Reverse the removal procedures for installation.
Page 198: Drive Shaft
CFMOTO 7.3 Drive Shaft 7.3.1 Front Drive Shaft Removal Remove bolts on front gear case. 070401 Remove bolts on engine. Remove front drive shaft 7.3.2 Rear Drive Shaft Removal 070402 Remove rear gear case assy (refer to Rear Gear Case Disassembly section). Remove four bolts on rear gear case.
Page 199: Drive Shaft Installation
07 Powertrain Rear Drive Shaft Inspection 1. Inspect rear drive shaft dust boots for damage. Replace if necessary. 2. Inspect rear drive shaft middle spline for damage or abnormal wear. Replace if necessary. NOTE: Inject 15g~18g grease into both spline joints. 070501 7.3.4 Drive Shaft Installation 7.3.4.1 Front Drive Shaft Installation...
Page 200: Front And Rear Gear Case
CFMOTO 7.4 Front and Rear Gear Case 7.4.1 Maintenance Information Lubrication Schedule Item Specification Capacity Interval Front gear case 0.33L Break-in Periodic SAE80W/90 GL-5 200miles 3000miles Rear gear case 0.40L (320km) (4800km) 7.4.2 Inspection and Maintenance If trouble below is found, there may be something wrong with front or rear gear case. Please maintain the vehicle.
Page 201: Front Gear Case Disassembly
07 Powertrain 7.4.3 Front Gear Case Removal DANGER: Before inspection, make sure the operation is made on flat ground and the vehicle is jacked up. Do not put any limbs under the vehicle, in case of injury caused by sudden fall during inspection.
Page 202: Fork
CFMOTO 7.4.5 Fork Removal Remove inner hex screws Remove pin shaft Remove fork 070801 7.4.6 Front Gear Case Cover Removal Remove eight M8 bolts Remove front gear case cover 070802 7.4.7 Differential Assy Removal Remove differential assy 070803 Remove spline sleeve Remove circlip 070804 Remove spline bushing...
Page 203 07 Powertrain 7.4.8 Front Gear Case Input Shaft Removal Remove input shaft nut Remove input coupler 070901 Remove seal ring Remove oil seal 070902 Remove limit retainer with special tool: bearing retainer locking tool. 070903 Remove bearing Remove drive bevel gear 070904 Front gear case input shaft exploded view...
Page 204: Parts Inspection
CFMOTO 7.4.9 Parts Inspection Spline Bushing Assy Inspection Inspect spline bushing and bushing for break, damage, severe wear or teeth deletion. Replace if any defect is found. 071001 Rack Assy Inspection Inspect rack assy for break, damage, severe wear or teeth deletion. Replace if any defect is found.
Page 205 07 Powertrain Oil Seal Inspection Remove all oil seals . The removed oil seals are sorted as waste. Inspect oil seals lips and contact surfaces. Replace with new parts if any defect is found. 071101 Bearing Inspection Inspect if every bearing clearance is appropriate, rotation is smooth, raceway, steel balls, needle roller and retainer are...
Page 206: Installation
CFMOTO 7.4.9.1 Installation Installation Reverse the removal procedures for Auxiliary Tighten installation. measuring tool Follow the drawing on the right to adjusting gear side clearance: Install auxiliary measuring tool and tighten the bolt (M14×1.25×60). Set the dial gauge. Make sure the gauge testing point is 21mm to the center.
Page 207 07 Powertrain If gear tooth contact is found to be correct ③ (pattern 2), continue the next step. If gear tooth contact is found to be incorrect (pattern 1 and 3), the shim thickness between the drive pinion gear and ring gear must be changed and the tooth contact re-checked until correct.
Page 208: Rear Gear Case (Version 1)
CFMOTO NOTE: In the premise of NOTE A and B, install the motor with screws doweled during installation. 071401 7.5 Rear Gear Case (Version 1) Removal Loosen clamp 071402 Remove three bolts 071403 Remove two bolts 071404 Remove rear gear case assy 071405 07-14 ©...
Page 209: Rear Gear Case Disassembly (Version 1)
07 Powertrain 7.6 Rear Gear Case Disassembly (Version 1) 7.6.1 Rear Gear Case Cover Removal Put a pan under rear gear case. Remove oil drain bolt Remove washer Drain oil. 071501 Remove six M8 bolts Remove two M10 bolts Remove rear gear case cover 071502 7.6.2 Driven Bevel Gear Assy Removal...
Page 210: Drive Bevel Gear Assy
CFMOTO Remove eight M10 bolts Remove bearing Remove driven bevel gear Remove washer Remove mounting seat. 7.6.3 Drive Bevel Gear Assy Removal 071601 Remove M10 bolt Remove washer Remove coupler Remove oil seal Remove four M8 bolts Remove bearing seat Remove bearing Remove adjusting washer Remove bearing seat washer...
Page 211: Rear Gear Case (Version 2)
07 Powertrain 7.7 Rear Gear Case (Version 2) Removal Loosen clamp 071701 Remove three bolts 071702 Remove bolts 071703 Remove rear gear case assy. 071704 07-17 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 212: Rear Gear Case Disassembly (Version 2)
CFMOTO 7.8 Rear Gear Case Disassembly (Version 2) 7.8.1 Rear Gear Case Cover Removal Put a pan under rear gear case. Remove oil drain bolt Remove washer Drain oil. 071801 Remove M5 bolts Remove sensor 071802 Remove six M8 bolts Remove two M10 bolts Remove rear gear case cover 071803...
Page 213 07 Powertrain Remove bearing Remove eight M10 bolts with washers Remove washer Remove driven bevel gear Remove LH shaft gear Remove LH planet gear 071901 Remove bearing Remove washer Remove six M10 bolts Remove RH cover 15 16 17 19 Remove inner teeth friction pad Remove inner protruding friction pad Remove outer teeth friction pad...
Page 214: Drive Bevel Gear Assy
CFMOTO 7.8.3 Drive Bevel Gear Assy Removal Remove M14 bolt Remove washer Remove coupler Remove oil seal Remove four M8 bolts Remove bearing seat Remove bearing Remove adjusting washer Remove bearing washer Remove drive bevel gear assy 072001 7.8.4 Rear Gear Case Inspection Driven Bevel Gear Inspection Inspect driven bevel gear for teeth wear,...
Page 215 07 Powertrain Oil Seal Inspection All oil seals are removed and sorted as waste. Replace with new ones during installation. Inspect oil seal lip and jointing surface for damage. Replace if any defect is found. 072101 Bearing Inspection Inspect if every bearing clearance is appropriate, rotation is smooth, raceway, steel balls, needle roller and retainer are in good condition.
Page 216: Installation
CFMOTO 7.8.4.1 Installation Installation Reverse the removal procedures for installation. Rear Gear Case Bevel Gear Clearance Adjustment Follow the drawing on the right to adjusting gear side clearance: Install auxiliary measuring tool and tighten the bolt (M14×1.25×60). Set the dial gauge. Make sure the gauge testing point is 21mm to the center.
Page 217 07 Powertrain If gear tooth contact is found to be correct (pattern 2), continue the next step. ③ If gear tooth contact is found to be incorrect (pattern 1 and 3), the shim thickness between the drive pinion gear and ring gear must be changed and the tooth contact re-checked until correct.
Page 218 08 Brake System 8.1 Brake Caliper ................... 08-2 8.2 Brake Disc and Mounting Seat ............08-3 8.3 Brake Fluid ..................08-3 8.4 Brake Pedal ..................08-5 8.5 Parking Brake .................. 08-5 08-1 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 219 CFMOTO 8.1 Brake Caliper Removal - Front Remove wheel (refer to 09 chapter). Remove two bolts Remove front RH brake caliper Remove banjo bolt Remove brake fluid hose Front LH brake caliper follows the same removal procedures. 080101 Removal - Rear Remove wheel (refer to 09 chapter) Loosen two nuts Remove joint...
Page 220 08 Brake System 8.2 Brake Disc and Hub Removal Remove wheel (refer to 09 chapter). Remove brake caliper. Remove retainer Remove M30 nut Remove brake disc and hub 080201 Inspection Inspect brake disc surfaces for wear or damage. Replace if necessary. Replace brake disc if the thickness less than 4.0 mm.
Page 221 CFMOTO Inspection Brake fluid level should be between upper line and lower line. Add brake fluid if the level is below or near the lower line. Upper Reduce brake fluid if the level is above or near the upper line. NOTE: Brake fluid will reduce the braking effect after using for a long time.
Page 222 08 Brake System Repeat the procedures until there is clean brake fluid in the hose and the fluid does not have air. Tighten the bleed screw and keep the fluid level according to requirement after system bleeding or fluid replacement. Inspect brake effect after operation to make sure the brake function works and brake pedal free play is qualified.
Page 223 CFMOTO Parking Brake Performance Inspection The vehicle is fully loaded and stays on a hill with a slope of 12%. If it slips from the slope, tighten brake cable and adjust it to the desired position. Put the vehicle on level ground, release hand brake. The vehicle can be pushed without load.
Page 224 09 Suspension System 9.1 Tire ....................09-2 9.2 Rim Bracket ..................09-5 9.3 Shock Absorber (Status 1) ............. 09-6 9.4 Shock Absorber (Status 2) ............. 09-8 9.5 Front Swing Arm ................09-10 9.6 Rear Suspension ................09-11 9.6.1 Rear Swing Arm Rod .............. 09-11 9.6.2 Rear Sway Bar .................
Page 225: Tire
CFMOTO 9.1 Tire Removal Remove four M12 wheel nuts Remove tire Inspection DANGER: Operation must be made on the level ground during suspension maintenance. Make sure the vehicle is supported stably. Any part of body is not allowed to put under tires, in case 090201 it drops down to cause injury.
Page 226 09 Suspension System Tire status 1 29×9.00 29×11.00 Pressure: Item Standard Value Service Limit Longitude 0.5mm jump Transverse 0.5mm Remaining groove 3.0mm F r o n t 110kPa(1.12kgf/cm Recommended by wheel Pressure(US) Tire 16PSI manufacture: 100kPa(1.01kgf/cm 150kPa(1.53kgf/cm Pressure(EU167) 14.5PSI 22PSI Item Standard Value Service Limit...
Page 227 CFMOTO Position the vehicle on a level ground. Elevate the front part of the vehicle with tools. Make sure no other force on the wheel. Shake front wheel to check for free play or looseness. If any free play or looseness is found, inspect swing arms, axle, rim bolts and nuts.
Page 228: Rim Bracket
09 Suspension System 9.2 Rim Bracket Removal Remove pin Remove hex slotted flange nut 090501 Remove brake caliper (refer to 08 chapter). Remove rim bracket 090502 Inspection Inspect rim bracket bolts for looseness. Replace rim bracket if loose. 090503 Installation Reverse the removal procedures for installation.
Page 229: Shock Absorber (Status 1)
CFMOTO 9.3 Shock Absorber 9.3.1 Front Shock Absorber Removal Remove two nuts Remove front shock absorber Inspection Inspect shock absorber for cracks or damage. Replace if necessary. Clean the dirt on shock absorber. 090601 Adjustment Loosen lock nut with shock absorber wrench.
Page 230: Shock Absorber (Status 2)
09 Suspension System 9.3.2 Rear Shock Absorber Removal Remove CVT deco guard. Remove two bolts and nuts Remove rear shock absorbers 090701 Remove two bolts Remove rear shock absorber fender 090702 Inspection Inspect shock absorber appearance for cracks or damage. Inspect shock absorbers for leaking.
Page 231: Front Swing Arm
CFMOTO Adjust the shock absorber according to the load. “S” direction is to increase the resistance. “F” direction is to decrease the resistance. Shock Absorber Specification: (adjustable): 19±3 Rebound resistance gear Delivery state: 12th gear Compression resistance (A): 18±2 gear 090801 Delivery state: 13th gear Compression resistance (B): 18±2 gear...
Page 232 09 Suspension System Remove bolt Remove LH upper swing arm Remove LH lower swing arm Front RH swing arm follows the same removal procedures. Inspection Inspect swing arms for cracks or damage. Replace if necessary. 090901 Inspect swing arm for smooth movement. Add grease through grease nozzle if blocking or stuck.
Page 233: Rear Sway Bar
CFMOTO 9.5.2 Rear Sway Bar Removal Remove nut Remove ball pin Remove nut Remove rear LH wheel shaft cover Rear RH wheel shaft cover follows the same removal procedures. Remove rear sway bar Installation 091001 Reverse the removal procedures for installation.
Page 234 10 Steering System 10.1 Steering System ................10-2 10.1.1 Steering Wheel ................ 10-2 10.1.2 Steering Column and EPS ............. 10-2 10.1.3 Steering Motor ................ 10-3 10.2 Gearshift Assy ................10-5 10.3 EPS ....................10-6 10.3.1 EPS failure code table ............10-8 10.3.2 EPS Fault Analysis and Troubleshooting ......
Page 235: Steering Column And Eps
CFMOTO 10.1 Steering System 10.1.1 Steering Wheel Removal Remove steering wheel deco cover 100201 Remove nut Remove steering wheel 100202 10.1.2 Steering Column and EPS Remove two inner hex bolts Remove dashboard LH guard Dashboard RH guard follows the same removal procedures.
Page 236: Steering Motor
10 Steering System Loosen bolt Remove steering column 100301 Remove bolt Remove upper steering universal shaft assy 100302 Unplug connectors. Remove three bolts Loosen EPS 100303 Loosen two bolts Remove steering universal shaft assy 100304 10.1.3 Steering Motor Removal Remove steering knuckle nuts (refer to 09 chapter).
Page 237 CFMOTO Inspection Position the vehicle on level ground. Turn the steering wheel slowly to inspect for smooth movement. I n s p e c t m a i n c a b l e a n d w i r e s f o r interference if there is blocking or stuck feeling.
Page 238: Gearshift Assy
10 Steering System 10.2 Gearshift Assy Removal Remove three bolts Remove gearshift assy 100501 Loosen bolt Remove gearshift rod Inspection Inspect shift lever for smooth movement. Adjust it according to following procedures if not smooth. 100502 Adjustment Adjust shift lever. Shift lever at N gear.
Page 239: Eps
CFMOTO 10.3 EPS EPS (electric power steering) system controls the motor based on the speed and the torque of the steering wheel, providing corresponding assistance to help the driver complete the steering. The system consists of a steering shaft assembly and a controller (ECU).Because the system adopts the speed induction type, it can provide obvious help when the car speed is...
Page 240 10 Steering System EPS Operation System If the vehicle is equipped with the EPS system: 1. Turn on power switch, EPS indicator light will be lighted. 2. Start engine, EPS indicator light goes off and EPS starts working. NOTE: There is no part in EPS system that allows users to disassemble for repair.
Page 241: Eps Failure Code Table
CFMOTO 10.3.1 EPS failure code table When malfunction occurs, the EPS indicator light will flicker. Do not turn off the power, please observe the flicker frequency and record flicker regular pattern in one period. Then scan Malfunction failure code table to get and diagnose which malfunction it is. Failure codes come from the EPS indicator light flicker frequency.
Page 242: Eps Fault Analysis And Troubleshooting
10 Steering System 10.3.2 EPS Fault Analysis and Troubleshooting Failure Probable Reason Troubleshooting Phenomenon 1. Connectors of wire is 1. Check whether wire connectors bad contact are fully inserted S t e e r i n g w i t h o u t 2.
Page 243 11 Cooling System 11.1 Cooling System................11-2 11.2 Fan Motor ..................11-3 11.3 Radiator Fan Inspection ..............11-4 11.4 Cooling System Sealing ..............11-6 11.5 Coolant ................... 11-7 11-1 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 244 CFMOTO 11.1 Cooling System Removal Remove radiator cover 110201 Place a container under the engine water pump. Remove drain bolt Drain coolant. 110202 Remove coolant reservoir (refer to chapter 06). Remove radiator water inlet pipe (refer to chapter 06). Loosen two steel clamps Loosen three water pipe clamps Remove water pipe clasps 110203...
Page 245 11 Cooling System 11.2 Fan Motor Removal Remove four bolts Remove fan Installation Reverse the removal procedures for installation. 110301 Inspection Inspect the radiator fin to see jammed or damaged. Use compressed air or low pressure water to clean the muds or other dirt.
Page 246 CFMOTO 11.3 Radiator Fan Inspection Use the following troubleshooting chart to solve the problem. Is fan working? Everything is good. Check accessories Replace fuse. fuse(15A) ) if burned? Check relay 1. Bypass the relay Fan works? Replace relay. Apply 12V on Check fan.
Page 247 11 Cooling System Radiator Fan Relay Relays Installation NOTE: Relay can be inverted by 180° to ensure installation and working. Ensure to align tabs of relay with terminals of fuse holder when installation. 110501 Relay Function Inspection The easiest way to check the relay is to remove it and bypass it with a jumper.
Page 248 CFMOTO 11.4 Cooling System Sealing Inspection Install tester on reservoir tank connector CAUTION: Never open radiator cap before engine cools down, in case of being burnt by high temperature vapor. Blow 0.15Mpa dry compressed air for 30s. If the pressure decreases in 30s, it means there is leakage in cooling system.
Page 249 11 Cooling System 11.5 Coolant Open radiator cap. Add coolant until there is no bubble inside the exceeded coolant from outlet port. Loosen air relief bolt on engine (just several threads) until coolant overflows from the hole on exhaust bypass. Tighten the air relief bolt.
Page 250 CFMOTO 12.1 Diagnosis Tool ................12-3 12.2 Signal and Illumination System ........... 12-4 12.2.1 Battery ..................12-4 12.2.2 Battery Charging ..............12-5 12.2.3 Charging Voltage Inspection ..........12-5 12.3 Earth Wire Inspection ..............12-6 12.4 Fuse ....................12-6 12.5 Light Maintenance Information ............ 12-6 12.6 Illumination Inspection ..............
Page 251 12 Electrical System 12.16.2 Diagnosis Tool and Connector .......... 12-34 12.17 Fault Diagnosis ................12-36 12.17.1 Engine Body ................ 12-36 12.18 Fault Code Table ................ 12-40 12.18.1 Diagnosis by Fault Code ............ 12-42 12.18.2 Fault Diagnosis by Engine Problems ......12-52 ©...
Page 252: Diagnosis Tool
CFMOTO 12.1 Diagnosis Tool Tool: PDA Function: Read/clear EFI system fault codes, observe data stream. 120301 Tool: Digital Multimeter Function: Measure voltage, current and resistance and other parameters in EFI system. 120302 12-10 © CFMOTO Powersports, Inc. This manual is subject to all applicable copyright laws. Reproduction or duplication in any form, whole or in part, is strictly prohbited.
Page 253: Signal And Illumination System
12 Electrical System 12.2 Signal and Illumination System 12.2.1 Battery CAUTION: 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.
Page 254: Battery Charging
CFMOTO 12.2.2 Battery Charging CAUTION: 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.
Page 255: Earth Wire Inspection
12 Electrical System 12.3 Earth Wire Inspection Shut down all electrical devices and engine. Inspect earth wire for normal function. Inspect bolt for looseness. 120601 12.4 Fuse Main fuse 40A (wire color: R and R/W) 120602 EPS fuse 40A (wire color: R/W and R/W) 12.5 Light Maintenance Information 120603 Pre-cautions...
Page 256: Illumination Inspection
CFMOTO Maintenance standard Item Standard Standard Main Fuse Secondary 5A×1 10A×2 15A×4 40A×1 30W (High-beam) 14.2W (Low-beam) Headlight 3.5W (position light) 23W (turn light) Light and Brake light 4.5W bulb Signal indicator LCD+LED Rear license light H2 W5W bulb 12.6 Illumination Inspection Turn ON ignition switch.
Page 257: Tail Light Assy
12 Electrical System 12.7.2 Tail Light Assy Remove self-tapping screws Remove tail light assy Installation Reverse the removal procedures for installation. NOTE: The headlight and tail light are consisted of LED lights. When the light 120801 damages, replace the whole set. 120802 1 Position light 2 Turn light(EU) 3 Brake light 12.8 Horn...
Page 258: Switches
CFMOTO 12.9 Switches Unplug connectors between switches and main cable. Inspect switch performance. Stop switch Color R Gr Y B Gr B B Br Gr B Function ● ● ● ● ● ● ● ● Illumination switch Color B Br Br B Br W L B Br G B Function ●...
Page 259 12 Electrical System Override switch Color Gr B G B G B B Br Function ● ● ● ● ● ● ● Turn light switch (EU) Color Sb G B B Br Function ● ● ● ● ● ● ● ●...
Page 260: Ignition Switch Lock
CFMOTO 12.10 Ignition Switch Lock Removal Remove upper dashboard panel refer to 06 chapter. Remove ignition switch lock by rotating it counter-clockwise. Inspection Follow the tables below to inspect ignition switch lock performance. ● ● means the connection is normal. Color Y Gr R 121101...
Page 261: Charging System
12 Electrical System 12.12 Charging System 12.12.1 Charging system wiring 121201 1 Magneto 3 Stable voltage 5 Battery 2 Regulator 4 Fuse 6 Load Magneto Coil Resistance Measure resistance between 3-phase magneto stator coil. If the resistance is out of specification, replace with a new stator.
Page 262 CFMOTO Regulator 121301 Use multimeter to measure resistance between connectors. Replace the regulator If any data is beyond standard. After engine works and battery is full charged, if the voltage between positive and negative terminal exceeds 15V or is lower 12V, replace with a new regulator. ∞...
Page 263: Starter Relay
12 Electrical System 12.12.2 STARTER RELAY Put DC12V between positive and negative t e r m i n a l . U s e m u l t i m e t e r t o c h e c k connection between 2 contacts.
Page 264: Engine Starting Note
CFMOTO 12.12.4 Engine Starting Note Properly route according to starting schematic diagram. Before start engine, check if all parts are installed correctly. EFI parts connection refers to EFI section. Check air intake system. Check fuel system to ensure there is no block or leaks.
Page 265: Efi System
12 Electrical System 12.13 EFI system 12.13.1 EFI structure Ignition coil Fuel pump E-throttle Oxygen sensor T-MAP Trigger Fuel injector Oxygen sensor 121601 12.13.2 Sensors A sensor is a device that measures a physical quantity and converts it into a signal which can be read by an observer or by an instrument.
Page 266: Efi System Maintenance Notice
CFMOTO 12.13.5 EFI System Maintenance Notice ●Always use genuine CFMOTO parts for maintenance. Otherwise it can not assure a normal performance to EFI system. ●During the maintenance procedure, never try to break down the EFI components. ●In the course of maintenance, EFI parts must be handled carefully. ●Ignition switch must be shut off before connecting or disconnecting connectors.
Page 267: Structure And Performance Of Efi Parts
12 Electrical System 12.14 Structure and Performance of EFI Parts 12.14.1 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 121801 optimal condition.ECU pin function:...
Page 268 CFMOTO 121901 ECU pin view Limit Data: Value Item Unit Min. Standard Max. Normal 14.0±0.1 Battery voltage Limit function 6.0~9.0 16.0~18.0 Limit and time Keep part of function, can of battery over 26.0V diagnose the trouble voltage Working temperature °C Storage temperature °C NOTE: It is not allowed to load on...
Page 269 12 Electrical System 1#: Throttle control actuator motor negative 2#: TPS ground 3#: TPS power 4#: Throttle control actuator motor positive 5#: TPS 2 6#: TPS 1 122001 TPS connector Circuit connecting with ECU. 122002 1 ECU 2 TPS 12-27 ©...
Page 270: T-Map
CFMOTO 12.14.3 T-MAP This sensor monitor intake air pressure, which provides the engine load signal to ECU. Pin function: 1. Ground 2. Air intake temp. signal 3. To 5V power 122101 4. Air intake pressure signal Circuit connecting with ECU. 3 4 1 2 122102 1 ECU...
Page 271: Air Intake Temp. Sensor
12 Electrical System The relationship between output voltage and pressure. Pressure range: 10kPa~115kPa 4.65 Absolute Pressure Pabs in KPA 122201 12.14.4 Air Intake Temp. Sensor This sensor is an NTC thermo resistance. The resistance is getting higher with coolant temperature, but not in linear relationship.
Page 272: Coolant Temp. Sensor
CFMOTO The relationship between sensor temperature and resistance. 60000 50000 40000 30000 20000 10000 -10000 Temp. (°C) Resistance (OHM) 122301 12.14.5 Coolant 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.
Page 273: Oxygen Sensor
12 Electrical System Coolant Temp. Sensor Inspection Measure resistance between pin A and C with multimeter: ECU resistance (A-C) Temp. °C Resistance(Ω) -20±0.1 13.71~16.49 25±0.1 1.825~2.155 80±0.1 0.303~0.326 110±0.1 0.1383~0.1451 If the resistance is beyond standard, the sensor is damaged. Replace with new one. Measure sensor pin B resistance with multimeter: Temp.
Page 274 CFMOTO Circuit connecting with ECU. 122501 1 ECU 3 Oxygen senor 2 2 Oxygen sensor1 4 +12V Oxygen sensor characteristic table Item Specification Exhaust air temp. (°C) Voltage (mV) at λ=0.97(CO=1%) 840±70 710±70 Sensor voltage (mV) at λ=1.10 20±50 55±30 Sensor inner resistance (kΩ) ≤1.0 ≤0.1...
Page 275: Trigger
12 Electrical System 12.14.7 Trigger The trigger transfers signal of engine speed to ECU and by which ECU to confirm engine speed ignition angle and injecting phase. 122601 Circuit connecting with ECU. Trigger Resistance Measurement Set multimeter to 1×2kΩ. Trigger coil resistance: 950Ω±50Ω(20°C) 122602 Replace a new one when resistance is beyond value range.
Page 276: Speed Sensor
CFMOTO 12.14.8 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 s q u a r e w a v e b y t h e c h a n g e o f t h e magnetic field.
Page 277: Gear Sensor
12 Electrical System 12.14.9 Gear Sensor This sensor is used to provide the gear position signal for meter display. Pin function: L(Low gear) H(High gear) N(Neutral gear) R (Reverse gear) P(Parking gear) When each pin at a certain gear position, there is connection between this pin and engine.
Page 278 CFMOTO 12.14.10 Fuel Pump 初初初初始始始始图图图图 This fuel pump assembly includes fuel pump,plastic support,preliminary filter,fine filter and pressure regulator. It supplies fuel for engine under a certain pressure and flow. Pins and Function: 1 to ground.
Page 279 12 Electrical System 12.14.11 Fuel Injector One end of fuel injector is installed on fuel injector seat, and the other attaches to the injector cap. Fuel injector is controlled by ECU to inject fuel at stated time into the engine. This injector nozzle is a 4-hole style.
Page 280: Ignition Coil
CFMOTO 12.14.12 Ignition Coil Ignition coil transforms the low voltage of primary coil to high voltage of secondary coil by sparking from spark plug and igniting the mixture of air and fuel in cylinder Pin function: Ignition coil pin 1 of first cylinder connects ECU pin 100.
Page 281: Electrical Throttle Pedal
12 Electrical System Ignition coil parameter chart table: Item Value Unit Standard Stated Voltage Running voltage 16.5 Resistance Primary 0.74 0.76 0.78 Ω (20°C~25°C) Secondary 10.1 10.6 11.1 kΩ Current 12.15 Electrical Throttle Pedal Unplug all connectors before removing electrical throttle pedal. A C E Remove three bolts Remove throttle pedal...
Page 282: Efi Self-Diagnosis
CFMOTO Voltage(V) 4.1±0.2 2.05±0.2 0.75±0.1 0.375±0.1 18° Pedal position-signal output relationship 0° Pedal position(°) 12.16 EFI Self-diagnosis The ECU constantly monitor sensors, actuators and circuits, MIL and battery voltage, etc, the ECU itself, and inspects 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.
Page 283 12 Electrical System 12.16.2 Diagnosis Tool and Connector OBD diagnosis connector is located behind passenger cushion. There are 16 pins on diagnosis tool, which connects to OBD diagnosis connector. The picture refers to operation panel of PDA. When it comes to detailed keys operation and function, refer to PDA manual.
Page 284 CFMOTO 2. Fault Display PDA monitors IAP sensor, IAT sensor,coolant temperature sensor, TPS, O2S, O2S heater circuit, air-to-fuel ratio revision, fuel injector, fuel pump relay, CPS, speed signal, idle speed, idle air control valve, system voltage, ECU, FI indicator and displays the fault code.
Page 285 12 Electrical System 12.17 Fault Diagnosis 12.17.1 Engine Body Trouble Reason Solution Inspect the electrical system ● Fuse melted Inspect or replace ● Battery low Inspect or charge ● Cable problem Inspect or replace Inspect the spark plug ● Ignition coil bad connection Inspect or replace ●...
Page 286 CFMOTO Trouble Reason Solution 1. Coolant level low Fill 2. Cooling system got bubble Drain and refill 3. Water temp sensor problem Replace 4. Thermostat problem(Not open in high heat) Replace 5. Inspect the leaking hole to see leaking Replace the water seal 6.
Page 287 12 Electrical System Trouble Reason Solution 1. Belt getting narrow Replace 2. Inspect the main sliding wheel ● Rolling ball wearing Replace ● Main roller track wearing Replace 3. Drive/Driven pulley axial sliding Clean or replace not smooth 4. Driven pulley sprint too strong Replace Abnormal 5.
Page 288 CFMOTO Trouble Reason Solution 1. Valve clearance not fit Adjust or replace 2. Tensioner bad Replace 3. Chain conductor wearing Replace Cylinder head 4. Chain getting longer or sprocket wearing Replace noise 5. Sprocket bolt loose Tighten 6. Valve rocker arm or camshaft wearing. Adjust or replace 7.
Page 289 12 Electrical System 12.18 Fault Code Table Code Statement P062912 Fuel Pump "A" Control Circuit High P062811 Fuel Pump "A" Control Circuit Low P062713 Fuel Pump "A" Control Circuit /Open P026212 Cylinder 1 Injector Circuit High P026111 Cylinder 1 Injector Circuit Low P020113 Injector Circuit/Open –...
Page 290 CFMOTO Code Statement 46 P012317 Throttle/Pedal Position Sensor/Switch "A" Circuit High 47 P012216 Throttle/Pedal Position Sensor/Switch "A" Circuit Low 48 P012129 Throttle/Pedal Position Sensor/Switch "A" Circuit Range/Performance 49 P022317 Throttle/Pedal Position Sensor/Switch "B" Circuit High 50 P022216 Throttle/Pedal Position Sensor/Switch "B" Circuit Low 51 P022129 Throttle/Pedal Position Sensor/Switch "B"...
Page 291 12 Electrical System 12.18.1 Diagnosis by Fault Code Instruction: 1. Make sure the fault is stable at the moment. Or, it may cause wrong diagnosis. 2. The AVO meter mentioned below is digital AVO meter. Do not use analog style meter to test the electrical parts.
Page 292 CFMOTO Fault code: P003013 Oxygen sensor heating control circuit defective Operation procedure Result Next step Reconnect 1 Improper connection or bad contact for connectors. Next step Service cable Open circuit of oxygen sensor heating control circuit pin. Next step Oxygen sensor heating control circuit VIO doesn't Service cable connect main relay.
Page 293 12 Electrical System Fault code: P011817 Coolant temperature sensor high voltage Operation procedure Result Next step Connect PDA and turn ignition switch to "ON". Do not start engine. Check if "coolant temperature sensor value" of data flow is lower than coolant minimum Next step temperature.
Page 294 CFMOTO Fault code: P012317 TPS signal circuit high voltage Operation procedure Result Next step Next step 1 Check if the cable has good connection. Reconnect Inspect and Remove TPS connector to check if ECU throttle signal service cable pin is short to power or has open circuit. Next step Replace sensor...
Page 295 12 Electrical System Fault code: P013116 Oxygen sensor signal circuit low voltage Operation procedure Result Next step 1 Connect PDA and turn ignition switch to "ON" position. Next step 2 Read and save fault freeze frame data. Next step Do not disconnect oxygen sensor connector. Measure Next step the voltage between cable 4 (black, oxygen sensor signal to power) and cable 3 (gray, oxygen sensor...
Page 296 CFMOTO Fault code: P013217 Oxygen sensor signal circuit high voltage Operation procedure Result Next step 1 Connect PDA and turn ignition switch to "ON" position. Next step 2 Read and save fault freeze frame data. Next step Do not disconnect oxygen sensor connector. Measure Next step the voltage of cable 1 (white, heating circuit to power) at Inspect cable...
Page 297 12 Electrical System Fault code: P013413 Oxygen sensor circuit signal defective Operation procedure Result Next step 1 Connect PDA and turn ignition switch to "ON" position. Next step 2 Read and save fault freeze frame data. Next step Do not disconnect oxygen sensor connector. Measure Next step the voltage of cable 1 (white, heating circuit to power) at Inspect cable...
Page 298 CFMOTO Fault code: P020113 First cylinder injector signal defective Operation procedure Result Next step Reconnect 1 Improper connection or bad contact for connectors. Next step Service and replace cable 2 Open circuit of injector. or injector Next step Service and replace cable 3 Injector VIO open circuit or injector damaged.
Page 299 12 Electrical System Fault code: P056317 Battery high voltage Operation procedure Result Next step Connect PDA and turn ignition switch to "OFF". Use multimeter to measure battery voltage to see if it is too Next step high. Service 2 Check if engine grounding point breaks down or not. Next step Service Magneto regulator damaged.
Page 300 CFMOTO Fault code: P062811 Fuel pump relay circuit low voltage Operation procedure Result Next step Service cable 1 Fuel pump relay circuit short to ground. Next step Service ECU 2 Fuel pump control pin of ECU short to ground. Diagnose Fault code: P069111 Fan relay control circuit low voltage (low speed) Operation procedure Result...
Page 301 12 Electrical System 12.18.2 Fault Diagnosis by Engine Problems Before trouble diagnosis by engine problems, initial checking should be done as follows. 1. Confirm if trouble light is ok. 2. Confirm there’s no fault code record by PDA checking. 3. Confirm there’s really trouble existing complained by end-users. Then check the following points.
Page 302 CFMOTO (1) When starting, engine cannot rotate or rotate slowly. Possible causes:1. Battery; 2. Starter motor; 3. Wiring or ignition switch; 4. Engine mechanical part. General operation procedures: Item Operation procedures Result Then Use multimeter to measure voltage between positive Yes Next step and negative terminals of battery, normal value Replace battery...
Page 303 12 Electrical System Item Operation procedures Result Then R e m o v e e n g i n e 4 Check cylinder pressure if it’s enough or not mechanical trouble Next step Connect PDA and switch on ignition to check ECU- Yes Use PDA to diagnose 20 and 35 pin if it is powered normally;...
Page 304 CFMOTO Item Operation procedures Result Then Next step Use fuel pressure meter and start engine to measure C h e c k a n d r e p a i r if fuel pressure is around 330kPa. fuel supply system Next step Disconnect high-tension cable and connect spark plug, keep it 5mm away from engine body, then start...
Page 305 12 Electrical System Item Operation procedures Result Then Yes Next step Use fuel pressure meter and start engine to check if Check and repair fuel pressure is around 330kPa. fuel supply system Yes Next step Disconnect spark plug cap and connect spark plug, keep it 5mm away from engine body, then start Check and repair engine to check if there’s blue and white spark.
Page 306 CFMOTO Item Operation procedures Result Then Yes Clean or replace 2 Check if air by-pass valve is blocked Next step C h e c k s p a r k p l u g i f i t ’ s u n d e r t e c h n i c a l Yes Next step specifications.
Page 307 12 Electrical System Item Operation procedures Result Then Yes Change fuel Check fuel quality and if it’s caused just after filling fuel. Next step R e m o v e e n g i n e Check cylinder pressure if it’s out of range. mechanical problem Next step Connect PDA and switch on ignition to check ECU-...
Page 308 CFMOTO (9)Starting is ok, but idle speed is unstable or killed off when lights (or other electrical components) switched on. Possible causes: 1. Air by-pass valve; 2. Injector General operation procedures: Item Operation procedures Result Then Yes Clean it Remove air by-pass valve, check throttle body, air by-pass valve and it pipe if any carbon deposit.
Page 309 12 Electrical System (11)RPM cannot go up or engine stop when acceleration Possible causes: 1. Fuel with water; 2. Air intake sensor and TPS; 3. Spark plug; 4. Throttle body and its idle pipe; 5. Intake manifold; 6. Air by-pass valve; 7. Injector; 8. Ignition timing;...
Page 310 CFMOTO (12) Slow acceleration Possible causes: 1. Fuel with water; 2. Air intake pressure sensor and TPS; 3. Spark plug; 4. Throttle body and its idle pipe; 5. Intake manifold; 6. Air by-pass valve; 7. Injector; 8. Ignition timing; 9. Exhaust pipe General operation procedures: Item Operation procedures...
Page 311 12 Electrical System Item Operation procedures Result Then Check if any clutch slippery, or tire pressure too Yes Repair low, or brake too tight, or tire size incorrect and so Next step Check&repair air intake Check air filter if any blocked, and intake manifold system if any leakage.
Page 312 ZFORCE 950 HO - 2022 Without BCM Module...

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CF MOTO ZForce 950EX Service Manual

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04 Cvt System

05 Engine

06 Body Covering Parts

07 Powertrain

09 Suspension System

10 Steering System

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