CF MOTO CF400-A 2017 Manuals

Manuals and User Guides for CF MOTO CF400-A 2017. We have 1 CF MOTO CF400-A 2017 manual available for free PDF download: Service Manual

CF MOTO CF400-A 2017 Service Manual

CF MOTO CF400-A 2017 Service Manual (443 pages)

Brand: CF MOTO | Category: Motorcycle | Size: 42.67 MB

Table of Contents

2 Periodic Maintenance

19
- Table of Contents
  19
- Periodic Maintenance Chart
  21
- Torque Specifications
  24
- Special Tools
  31
- Air Filter Element Cleaning
  32
- Throttle Control System Inspection
  33
- Idle Speed Inspection
  34
- Fuel Line Inspection (Fuel Leak, Damage, Installation Condition)
  35
- Cooling System
  36
- Coolant Level Inspection
  36
- Radiator Hose Damage and Installation Condition Inspection
  36
- Cylinder Head
  37
- Valve Clearance Inspection
  37
- Clutch
  43
- Clutch Operation Inspection
  43
- Wheels/Tires
  43
- Air Pressure Inspection
  43
- Wheel/Tire Damage Inspection
  44
- Tire Tread Wear, Abnormal Wear Inspection
  44
- Wheel Bearing Damage Inspection
  45
- Drive Chain
  45
- Drive Chain Lubrication Condition Inspection
  45
- Drive Chain Slack Inspection
  46
- Drive Chain Slack Adjustment
  46
- Wheel Alignment Inspection
  47
- Drive Chain Wear Inspection
  48
- Chain Guide Inspection
  48
- Brake System
  49
- Brake Fluid Leak (Brake Hose and Pipe) Inspection
  49
- Brake Operation Inspection
  50
- Brake Fluid Level Inspection
  50
- Brake Pad Wear Inspection
  51
- Brake Light Switch Operation Inspection
  51
- Rear Shock Absorber Oil Leak Inspection
  52
- Front Forks/Rear Shock Absorber Operation Inspection
  52
- Front Fork Oil Leak Inspection
  52
- Suspensions
  52
- Steering System
  53
- Steering Play Inspection
  53
- Steering Play Adjustment
  53
- Steering Stem Bearing Lubrication
  54
- Electrical System
  54
- Spark Plug Condition Inspection
  54
- Lights and Switches Operation Inspection
  55
- Engine Stop Switch Operation Inspection
  59
- Others
  60
- Chassis Parts Lubrication
  60
- Bolts, Nuts and Fasteners Tightness Inspection
  61
- Replacement Parts
  62
- Air Filter Element Replacement
  62
- Fuel Line Replacement
  62
- Coolant Change
  63
- Radiator Hose and O-Ring Replacement
  65
- Oil Filter Replacement
  66
- Brake Hose and Pipe Replacement
  67
- Master Cylinder Rubber Parts Replacement
  68
- Caliper Rubber Parts Replacement
  70
- Spark Plug Replacement
  72
3 Efi System

73
- Exploded View
  74
- ECU Pin Function
  76
- EFI Specification
  77
- Special Tools
  79
- EFI Servicing Precautions
  80
- EFI Trouble Shooting
  82
- General
  82
- EFI Diagnose Flow Chart
  86
- Diagnose Sheet
  87
- EFI System Trouble Shooting Form
  89
- General
  97
- Self Diagnose
  97
- Trouble Code List
  100
- EFI Trouble Back up
  102
- EFI Parts Service
  103
- Throttle Body
  103
- Intake Temp and Pressure Sensor
  107
- Water Temp Sensor
  110
- Crankshaft Position Sensor
  112
- Speed Sensor
  113
- Roll over Sensor
  116
- Oxygen Sensor
  117
- Ignition Coil
  120
- Trouble Indicating Light
  122
- Ecu
  125
- High Pressure Fuel Pipe
  127
- Fuel Pump
  129
- Injector
  135
- Throttle Cable and Lever
  140
- Throttle Body
  141
- Trouble Code List
  143
4 Cooling System

147
- Exploded View
  148
- Coolant Flow Chart
  150
- Special Tools
  153
- Coolant
  154
- Coolant Deterioration Inspection
  154
- Coolant Draining
  154
- Coolant Filling
  154
- Coolant Level Inspection
  154
- Pressure Testing
  154
- Coolant Reserve Tank Removal/Installation
  155
- Cooling System Flushing
  155
- Water Pump
  156
- Water Pump Installation
  156
- Water Pump Removal
  156
- Mechanical Seal Inspection
  157
- Water Pump Housing Assembly
  157
- Water Pump Housing Disassembly
  157
- Impeller Assembly
  158
- Pump Impeller Inspection
  158
- Radiator
  159
- Radiator and Radiator Fan Removal
  159
- Radiator and Radiator Fan Installation
  160
- Radiator Cap Inspection
  160
- Radiator Inspection
  160
- Radiator Filler Neck Inspection
  161
- Thermostat
  162
- Thermostat Inspection
  162
- Thermostat Installation
  162
- Thermostat Removal
  162
- Hose and Pipes
  164
- Hose Inspection
  164
- Hose Installation
  164
- Coolant Temperature Sensor
  165
- Coolant Temperature Sensor Inspection
  165
- Coolant Temperature Sensor Removal/Installation
  165
5 Engine Top

166
- Exploded View
  168
- Specifications
  173
- Special Tools and Sealant
  174
- Cylinder Head Cover
  176
- Cylinder Head Cover Installation
  176
- Cylinder Head Cover Removal
  176
- Timing Chain Tensioner
  179
- Timing Chain Tensioner Installation
  179
- Camshaft Installation
  181
- Camshaft/Timing Chain
  181
- Camshaft Run-Out
  184
- Camshaft/Camshaft Cap Wear
  184
- Timing Chain Removal
  185
- Cylinder Compression Measurement
  186
- Cylinder Head
  186
- Cylinder Head Removal
  187
- Cylinder Head Installation
  188
- Cylinder Head Wear
  189
- Valve Clearance Adjustment
  190
- Valve Clearance Inspection
  190
- Valve Installation
  190
- Valve Removal
  190
- Valves
  190
- Valve Guide Installation
  191
- Valve Guide Removal
  191
- Valve-To-Guide Clearance Measurement
  192
- Valve Seat Inspection
  193
- Valve Seat Repair
  193
- Cylinder Installation
  194
- Cylinder Removal
  194
- Cylinder/Piston
  194
- Piston Removal
  195
- Piston Installation
  196
- Cylinder Wear
  197
- Piston Ring/Piston Ring Groove Wear
  197
- Piston Ring Groove Width
  198
- Piston Ring Thickness
  199
- Piston Ring Cut Clearance
  200
- Intake Manifold
  201
- Intake Manifold Installation
  201
6 Clutch

202
- Exploded View
  203
- Specifications
  205
- Special Tool and Sealant
  206
- Clutch Cover
  207
- Clutch Cover Removal
  207
- Clutch Cover Installation
  208
- Release Shaft Installation
  209
- Release Shaft Removal
  209
- Clutch Cover Disassembly
  210
- Clutch Cover Assembly
  211
- Clutch
  212
- Clutch Removal
  212
- Clutch Installation
  213
- Clutch Plate Warp Inspection
  217
- Clutch Plate, Wear, Damage Inspection
  217
- Clutch Spring Free Length Measurement
  217
- Clutch Housing Finger Inspection
  218
- Clutch Housing Spline Inspection
  218
7 Engine Lubrication System

219
- Exploded View
  220
- Engine Oil Flow Chart
  222
- Specifications
  224
- Special Tools and Sealant
  225
- Engine Oil and Oil Filter
  226
- Oil Level Inspection
  226
- Engine Oil Change
  227
- Oil Filter Replacement
  227
- Oil Pan
  228
- Oil Pan Removal
  228
- Oil Pan Installation
  229
- Oil Pressure Relief Valve
  231
- Oil Pressure Relief Valve Inspection
  231
- Oil Pressure Relief Valve Installation
  231
- Oil Pressure Relief Valve Removal
  231
- Oil Pump
  232
- Oil Pump Removal
  232
- Oil Pump Installation
  233
- Oil Pressure Measurement
  234
- Oil Pressure Switch
  235
- Oil Pressure Switch Installation
  235
- Oil Pressure Switch Removal
  235
8 Engine Removal and Installation

236
- Exploded View
  237
- Engine Removal
  239
- Engine Removal/Installation
  239
- Engine Installation
  242
9 Crankshaft /Transmission

243
- Exploded View
  245
- Specification
  249
- Crankcase Splitting
  252
- Crankcase Assembly
  254
- Crankshaft and Connecting Rods
  260
- Crankshaft Installation
  260
- Crankshaft Removal
  260
- Connecting Rod Installation
  261
- Connecting Rod Removal
  261
- Connecting Rod Bend
  264
- Connecting Rod Big End Side Clearance
  264
- Connecting Rod Twist
  264
- Crankshaft Side Clearance
  266
- Crankshaft Main Bearing Insert/Journal Wear
  267
- Crankshaft Runout
  267
- Balancer
  269
- Shift Mechanism Removal
  271
- Shift Pedal Installation
  271
- Shift Pedal Removal
  271
- Transmission
  271
- Shift Mechanism Installation
  272
- Shift Mechanism Inspection
  273
- Transmission Assy Removal
  274
- Transmission Assy Disassembly
  275
- Transmission Assy Assembly
  276
- Transmission Shaft Assembly
  278
- Transmission Shaft Disassembly
  278
- Shift Fork Bending
  281
- Shift Fork Guide Pin/Drum Groove Wear
  281
- Shift Fork/Gear Groove Wear
  281
- Ball and Needle Bearing Replacement
  282
- Ball and Needle Bearing Wear
  282
- Gear Dog and Gear Dog Hole Damage
  282
10 Tire and Rim

283
- Specifications and Service Limit
  286
- Front Wheel Installation
  288
- Front Wheel Removal
  288
- Special Tools
  288
- Wheel (Rims)
  288
- Rear Wheel Installation
  290
- Rear Wheel Removal
  290
- Axle Inspection
  292
- Wheel Inspection
  292
- Balance Adjustment
  293
- Balance Inspection
  293
- Balance Weight Installation
  293
- Balance Weight Removal
  293
- Tire Installation
  295
- Tire Removal
  295
- Tire Repair
  297
- Hub Bearing
  298
- Hub Bearing Inspection
  298
- Hub Bearing Installation
  298
- Hub Bearing Removal
  298
11 Chain Drive System

299
- Exploded View
  300
- Special Tools
  302
- Drive Chain
  303
- Drive Chain Lubrication
  303
- Drive Chain Removal
  303
- Drive Chain Slack Adjustment
  303
- Drive Chain Slack Inspection
  303
- Drive Chain Wear Inspection
  303
- Wheel Alignment Inspection/Adjustment
  303
- Drive Chain Installation
  304
- Engine Sprocket Removal
  307
- Sprocket, Coupling
  307
- Engine Sprocket Installation
  308
- Rear Sprocket Installation
  308
- Rear Sprocket Removal
  308
- Coupling Bearing Installation
  309
- Coupling Bearing Removal
  309
- Coupling Installation
  309
- Coupling Bearing Inspection
  310
- Coupling Damper Inspection
  310
- Sprocket Wear Inspection
  310
- Rear Sprocket Warp Inspection
  311
12 Breakingsystem

312
- Exploded View (Front Brake)
  314
- Exploded View (Rear Brake)
  316
- Specifications
  318
- Special Tools
  319
- Brake Lever Position Adjustment
  320
- Brake Pedal Position Adjustment
  320
- Brake Pedal Position Inspection
  320
- Brake Pedal Installation
  321
- Brake Pedal Removal
  321
- Front Caliper Removal
  323
- Rear Caliper Removal
  323
- Caliper Fluid Seal Damage
  324
- Front Caliper Assembly
  324
- Front Caliper Disassembly
  324
- Rear Caliper Assembly
  324
- Rear Caliper Disassembly
  324
- Rear Caliper Dust Boot and Friction Boot Damage
  324
- Caliper Piston and Cylinder Damage
  325
- Rear Caliper Holder Shaft Wear
  325
- Brake Pad Wear Inspection
  326
- Brake Pads
  326
- Front Brake Pad Installation
  326
- Front Brake Pad Removal
  326
- Rear Brake Pad Installation
  326
- Rear Brake Pad Removal
  326
- Front Master Cylinder Installation
  327
- Front Master Cylinder Removal
  327
- Master Cylinder
  327
- Front Master Cylinder Disassembly
  328
- Master Cylinder Assembly
  328
- Rear Master Cylinder Disassembly
  328
- Rear Master Cylinder Installation
  328
- Rear Master Cylinder Removal
  328
- Master Cylinder Inspection
  329
- Brake Disc
  330
- Brake Disc Installation
  330
- Brake Disc Removal
  330
- Brake Disc Warp
  330
- Brake Disc Wear
  330
- Brake Fluid
  331
- Brake Fluid Level Inspection
  331
- Brake Hose Inspection
  333
- Brake Hose Removal/Installation
  333
13 Suspension

334
- Specifications
  339
- Special Tools
  340
- Front Shockabsorber
  341
- Front Shockabsorber Installation
  341
- Front Shockabsorber Removal
  341
- Rear Shock Absorber Removal
  343
- Rear Shockabsorber
  343
- Spring Preload Adjustment
  343
- Rear Shock Absorber Inspection
  344
- Rear Shock Absorber Installation
  344
- Swingarm
  345
- Swingarm Installation
  345
- Swingarm Removal
  345
- Swingarm Bearing Installation
  346
- Swingarm Bearing Removal
  346
- Swingarm Bearing, Sleeve Inspection
  347
- Chain Guide Inspection
  348
- Swingarm Bearing Lubrication
  348
14 Steering System

349
- Exploded View
  350
- Special Tools
  352
- Steering Bearing Removal
  353
- Steering Bearing Installation
  354
- Steering Stem Warp
  356
- Handlebar
  357
- Handlebar Installation
  357
- Handlebar Removal
  357
- Clutch Lever Assy Installation
  358
16 Electrical System

369
- Specifications
  370
- Special Tools
  371
- Parts Location
  372
- Wiring Diagram
  374
- Precautions
  376
- Battery
  378
- Charging System
  384
- Overriding Clutch
  391
- Ignition System
  401
- Lighting System
  411
- Dashboard
  424
- Switches and Sensors
  427

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