CFMoto motorcycle CF650NK. Service Manual - part 9

  GENERAL INFORMATION 1-3

Before Servicing

Before starting to perform an inspection service or carry out disassembly and installation on a motorcycle,
read the precautions given below. To facilitate acutal operations, notes, illustrations, photograghs, cautions
and descriptions have been included in each chapter wherever necessary.This section explains the items that
require particular attentions during removal and reassembly.

Special Notes for the Following:

Battery Ground

Before completing any service on the motorcycle,
disconnect the battery cables from the battery to
prevent the engine from accidentally turning over.
Disconnect the ground cable (-) first and then the
positive (+).When finishing the service, first connect
positive(+) cable to the positive (+) terminal of the
battery and then the negative (-) cable to the
negative (-) terminal.

Edges of Parts

When service parts with edges, wearing
gloves to prevent injury.

Solvent

Use a high-flush point solvent when cleaning parts.
High-flush point solvent should be used according to
directions of solvent manufacturer.

Cleaning Vehicle Before Disassembly

Clean the vehicle completely before disassembly.Dirt
or other foreign materials entering into sealed areas
during vehicle disassembly can cause excessive wear
 and reduce vehicle performance.

Disassembly

Assembly

  GENERAL INFORMATION 1-5

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse.Arrange the
parts according to the order of parts disassembled
and clean the parts in order prior to installation.

Storage of Removed Parts

After all the parts including subassembly parts have
been cleaned, store the parts in a clean area, put a
clean cloth or plastic sheet over the parts to protect
from any foreign materials that may collect before re-
assembly.

Inspection

Reuse of worn or damaged parts may lead to serious
accidents.Visually inspect removed parts for corrosion,
discoloration or other damage.Refer to the appropri-
ate sections of this manual for service limits on indi-
vidual parts. Replace the parts if any damage has been
found or if the part beyond the service limits.

Replacement Parts

Replacement parts must be CFMOTO genuine or rec-
ommended by CFMOTO. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins must be replaced
with new ones whenever disassembled

Assembly Order

In most cases assembly order is the reverse of
disassembly.However,if assembly order is provided in
the Service Manual, follow the procedures given.

1-6 GENERAL INFORMATION

Tightening Sequence

Generally, when installing a part with several bolts,
nuts or screws, start them all in their holes and tighten
them in snug fit. Then tighten them according to speci-
fied sequence to prevent case warpage  or deforma-
tion which can lead to malfunction.Conversely  when
loosening the bolts, nuts or screws, first loosen all of
them by a quarter turn and then remove them. If the
specified sequences is not indicated, tighten the fas-
teners alternating diagnoally.

Tightening Torque

Incorrect torque applied to  a bolt, nut or screw may
lead to serious damage. Tighten fasteners to the speci-
fied torque by using a good quality torque wrench.
Often, the tightening sequence is followed twice initial
tightening and final tightening torque.

Porper Force

Use common sense during disassembly and
assembly.excessive force can cause expensive or hard
to repair damage.When necessary, remove screws
that have non-permanent locking agent applied using
an impact driver. Use a plastic-faced mallet whenever
tapping is necessary.

Gasket and O-ring

Hardening, shrinkage, or damage of both gaskets and
O-ring after disassembly can reduce sealing
performance.

Liquid Gasket,Non-permanent Locking Agent

For applications that require Liquid Gasket or a non-
permanent locking agent, clean the surfaces so that
no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them
excessively, excessive application can clog  oil pas-
sages and causes serious damage.

  GENERAL INFORMATION 1-7

Press

For items such as bearing or oil seals that must be
pressed into place, apply small amount of oil on con-
tact area. Be sure to maintain proper alignment and
use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove ball or needle unless removal is
absolutely necessary. Replace with new ones
whenever removed. Press bearings with manufac-
turer and size marks facing out. Press bearing into
place by putting pressure on the correct bearing
race as shown.

Oil seal & Grease Seal

Do not remove pressed oil or grease seals unless re-
moval is absolutely necessary. Replace with new ones
whenever removed. Press new oil seals with manu-
facturer and size marks facing out.Make sure the seal
is aligned properly when installing.

Apply specified grease to the lip of the seal before
installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively
when installing to prevent deformation.

Grease

1-8 GENERAL INFORMATION

Lubrication

It is important to lubricate rotating or sliding parts dur-
ing assembly to minimize wear during initial operation.
Lubrication points are called out throughout this
manual.Apply specific oil or grease as specified.

Direction of Engine Rotation

When rotating crankshaft by hand, the free play of
amount of rotating direction will affect adjustment.
Rotate the crankshaft to positive direction (Clockwise
viewed from output side)

Electrical Wires

When connecting electrical wires, first to check color
of wires and unless special instruction, same color of
wires should be connected.

Instrument

Use a meter that has enough accuracy for an accu-
rate measurement. Read the manufacturer’s instruc-
tions completely before using the meter.Incorrect val-
ues may lead to improper adjustments.

GENERAL INFORMATION 1-9    

Marking Locations
Model: 

 

CF650       

VIN No.: 

 

LCEPEVL1-           

Engine serial No.:  283MT-

     

a 

VIN No.:

b 

Name Plate:

c 

Engine Serial N0.:

1-10  GENERAL INFORMATION

General Specifi cations

Items    

CF650 (650NK)

Dimensions:

Overall length

2120mm (83.5in.)

Overall width

780mm (30.7in.)

Overall height

1100mm (43.3in.)

Wheelbase

1415mm (55.7in.)

Road clearance

150mm (5.9in.)

Seat height

895mm (35.2in.)

Dry mass

206kg (454.3lb)

Curb mass

281kg (619.7lb)

Front:

129kg (284.5lb)

Rear:

152kg (335.2lb)

Fuel tank capacity

17L (4.5USgal.)

Performance

Minimum turning radius (LH or RH)

5.4m (17.8ft)

Engine

Type

2-cylinder in line, 4-strokes, DOHC, 8 valves and liquid-
cooled

Cooling system

liquid-cooled

Bore and stroke

83 × 60 mm (3.3 × 2.4 in.)

Displacement

649.3 cm³ (39.60 cu in.)

Compression ratio

11.3 : 1

Max. power

52 kW (70.6 PS) @8 500 r/min (rpm)

Max. torque

62 N•m (6.3 kgf•m, 46 ft•lb) @7 000 r/min (rpm)

Carburetion system

Fuel injection system

Starting system

Electric starter

Ignition system

ECU

Timing advance

Controlled by ECU

Ignition timing

From 10° BTDC @1 300 r/min (rpm)to 33° BTDC @6000r/
min (rpm)

Spark plug

CR8EI

Cylinder numbering methods

left to right 1-2

Firing order

1-2

Valve timing

Intake:
Open

31° BTDC

Close

61° ABDC

Duration

272°

GENERAL INFORMATION 1-11    

Items

CF650 (650NK)

Exhaust:
Open                                                              

50°BBDC

Close

30°ATDC

Duration

260°

Lubrication system

Forced lubrication(semi-dry sump) 

Engine oil

：

Type

API SG or API SH,SJ or SL with JASOMA

Viscosity

SAE 15W-40

Oil capacity

Without replacement of oil 

fi

 lter

：

2.0L

If replacement of oil 

fi

 lter

：

2.2L

If drain oil completely

：

2.6L

Drive train

Primary reduction system:
Type

Gear

Reduction ratio

2.095(88/42)

Clutch type

Wet, multi disc

Transmission:
Type

6-speed,constant mesh, return shift

Gear ratios:
1st 
2nd
3rd 
4th
5th
6th

2.353 (39/16)
1.714 (36/21)
1.333 (32/24)
1.111 (30/27)
0.966 (28/29)
0.852 (23/27)

Final drive system
Type

Chain drive

Reduction ratio

3.067(46/15)

Overall drive ratio

5.474

（

@ Top gear

）

Frame

Type

Tubular, diamond

Caster angle

（

Rake angle

）

24.5°

Trail

102mm (4.0in.)

Front tire
Type

Tubeless

Size

120/70R17 (58H)

Rim size

17×3.50

Rear tire
Type

Tubeless

Size

160/60R17 (69H)

Rim size

17×4.50

Front suspension
Type

Telescopic fork

Wheel travel

120mm (4.7in.)

1-12  GENERAL INFORMATION

Items

CF650 (650NK)

Rear suspension

Type

Swingarm

Wheel travel

125mm(4.9 in.)

Brake type

Front

Double disc

Rear

Single disc

Electrical system

Battery

12V  10Ah

Headlight

Type

Semi-sealed beam

Bulb

Hi: H7 12V55W Low: H7 12V55W

Tail/Brake light

LED 12V 0.39W/1.55W

Alternator

Type

Three-phase AC

Rated output

25A/14V @5000 rpm

GENERAL INFORMATION 1-13    

Prefi xes for units

Units of Length

Pre

fi

 x

Symbol

Power

                           Km × 0.6214 = mile

Mega

M

×1000000

                           m × 3.281 = ft

Kilo

k

×1000

                           mm × 0.03937 = in

Centi

c

×0.01

Units of Torque

Milli

m

×0.001

  N·m × 0.1020 = Kgf·m

Micro

μ

×0.000001

N·m × 0.7376 = Ft·lb

Units of Mass

N·m × 8.851 = In·lb

Kgf·m × 9.807 = N·m

Kg × 2.205 = Lb

                           Kgf·m × 7.233 = Ft·lb

g × 0.03527 = oz

                           Kgf·m × 86.80=In·lb

Units of Volume

Units of Pressure

L × 0.2642 = gal (US)

                         KPa × 0.01020 = Kgf/cm

2

L × 0.2200 = gl (imp)

                              KPa × 0.1450 = psi

L × 1.057 = qt (US)

                              KPa × 0.7501 = cmHg

L × 0.8799 = qt (imp)

                              Kgf/cm

2 

× 98.07 = KPa

L × 2.113 = pint (US)

Kgf/cm

2 

× 14.22 = psi

L × 1.816 = pint(imp)

cmHg × 1.333 = KPa

mL × 0.03381 = oz (US)

Units of Speed

mL × 0.02816 = oz (imp)

mL×0.06102 = cuin

Km/h×0.6214=mph

Units of Force

Units of Power

N × 0.1020 = Kg

Kw×1.360=PS

N × 0.2248 = Lb

Kw×1.341=HP

Kg × 9.807 = N

PS×0.7355=KW

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart.....................................................................................................

2-3

Torque Specifications...............................................................................................................

2-6

Specifications and Service Limit...............................................................................................

2-11

Special Tools.............................................................................................................................

2-13

Periodic Maintenance procedures............................................................................................

2-14

Fuel System (EFI)...................................................................................................................

2-14

Air Filter Element Cleaning...................................................................................................

2-14

Throttle Control System Inspection......................................................................................

2-15

Idle Speed Inspection...........................................................................................................

2-16

Fuel Line Inspection (fuel leak, damage, installation condition)............................................

2-17

Cooling System......................................................................................................................

2-18

Coolant Level Inspection......................................................................................................

2-18

Radiator Hose Damage and Installation Condition Inspection..............................................

2-18

Engine Top End......................................................................................................................

2-19

Valve Clearance Inspection..................................................................................................

2-19

Valve Clearance Adjustment................................................................................................

2-20

Clutch.....................................................................................................................................

2-25

Clutch Operation Inspection.................................................................................................

2-25

Wheels/Tires...........................................................................................................................

2-25

Air Pressure Inspection........................................................................................................

2-25

Wheel/Tire Damage Inspection............................................................................................

2-26

Tire Tread Wear, Abnormal Wear Inspection........................................................................

2-26

Wheel Bearing Damage Inspection......................................................................................

2-27

Drive Train..............................................................................................................................

2-27

Drive Chain Lubrication Condition Inspection.......................................................................

2-27

Drive Chain Slack Inspection...............................................................................................

2-28

Drive Chain Slack Adjustment..............................................................................................

2-28

Wheel Alignment Inspection.................................................................................................

2-29

Drive Chain Wear Inspection................................................................................................

2-30

Chain Guide Inspection........................................................................................................

2-30

Brake System.........................................................................................................................

2-31

Brake Fluid Leak (Brake Hose and Pipe) Inspection............................................................

2-31

Brake Hose and Pipe Damage and Installation Condition Inspection...................................

2-31

Brake Operation Inspection..................................................................................................

2-32

Brake Fluid Level Inspection................................................................................................

2-32

Brake Pad Wear Inspection..................................................................................................

2-33

Brake Light Switch Operation Inspection..............................................................................

2-33

2-2 PERIODIC MAINTENANCE

Suspensions...........................................................................................................................

2-34

Front Forks/Rear Shock Absorber Operation Inspection......................................................

2-34

Front Fork Oil Leak Inspection.............................................................................................

2-34

Rear Shock Absorber Oil Leak Inspection............................................................................

2-34

Steering System.....................................................................................................................

2-35

Steering Play Inspection......................................................................................................

2-35

Steering Play Adjustment.....................................................................................................

2-35

Steering Stem Bearing Lubrication.......................................................................................

2-36

Electrical System....................................................................................................................

2-36

Spark Plug Condition Inspection..........................................................................................

2-36

Lights and Switches Operation Inspection...........................................................................

2-37

Headlight Aiming Inspection.................................................................................................

2-39

Sidestand Switch Operation Inspection................................................................................

2-40

Engine Stop Switch Operation Inspection............................................................................

2-41

Others.....................................................................................................................................

2-42

Chassis Parts Lubrication....................................................................................................

2-42

Bolts, Nuts and Fasteners Tightness Inspection...................................................................

2-43

Replacement Parts.................................................................................................................

2-44

Air Filter Element Replacement............................................................................................

2-44

Fuel Line Replacement........................................................................................................

2-44

Coolant Change...................................................................................................................

2-45

Radiator Hose and O-ring Replacement..............................................................................

2-47

Engine Oil Change...............................................................................................................

2-48

Oil Filter Replacement..........................................................................................................

2-48

Brake Hose and Pipe Replacement.....................................................................................

2-49

Brake Fluid Change.............................................................................................................

2-49

Master Cylinder Rubber Parts Replacement........................................................................

2-50

Caliper Rubber Parts Replacement......................................................................................

2-52

Spark Plug Replacement.....................................................................................................

2-54

INSPECTION

  *ODOMETER READINGS

→

   km×1000

See 
Page

Every

1

6

12

18

24

30

36

■

 Air 

fi

 lter element - clean

●

●

●

2-14

■

Valve clearance-inspect

42000km

2-19

Throttle control system (play, smooth return, 
no drag) - inspect

year

●

●

●

●

2-15

Idle speed - inspect

●

●

●

●

2-16

■

 Fuel leak (fuel hose and pipe) - inspect

year

●

●

●

●

2-17

■

 Fuel hose and pipe damage - inspect

year

●

●

●

●

2-17

year

●

●

●

●

2-17

■

Throttle body—clean

●

●

●

●

●

●

—

Coolant level - inspect

●

●

●

●

2-18

Coolant leak (radiator hose and pipe) - 
inspect

year

●

●

●

●

2-18

Radiator hose damage - inspect

year

●

●

●

●

2-18

Radiator hose installation condition - inspect

year

●

●

●

●

2-18

■

 Air intake system damage - inspect

●

●

●

Clutch and Drive Train

Clutch operation (play, disengagement, 
engagement) - inspect

●

●

●

●

2-25

Drive chain lubrication condition - inspect #

600km

2-27

Drive chain slack - inspect #

1000km

2-28

Drive chain wear - inspect #

●

●

●

2-30

■

 Drive chain guide wear - inspect

●

●

●

2-30

Whichever
Comes
First

FREQUENCY

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good 
running condition.The initial maintenance is vitally important and must not be neglected.

■

:This service must be performed by an authorized CFMOTO dealer.

*:For higher odometer readings,repeat at the frequency interval established here.
#:Service more frequently when operating in servere conditions;dusty,wet,muddy,high speed,or frequent  
   starting/stopping.

1.Periodic Inspection

■

 Fuel hose and pipe installation condition

- inspect

Ļ

             PERIODIC MAINTENANCE 2-3     

             PERIODIC MAINTENANCE 2-3     

             PERIODIC MAINTENANCE 2-3     

             PERIODIC MAINTENANCE 2-3     

     

→

See Page

Every

1

6

12

18

24

30

36

Wheels/Tires

Tire air pressure - inspect

year

●

●

●

●

2-25

Wheel/tire damage - inspect

●

●

●

2-26

Tire tread wear, abnormal wear - inspect

●

●

●

2-26

■

Wheel bearing damage - inspect

year

●

●

●

2-27

Footrest—lubricate

●

●

●

●

—

Brake System

Brake 

fl

 uid leak (brake hose and pipe) - 

inspect

year

●

●

●

●

●

●

●

2-31

Brake hose and pipe damage - inspect

year

●

●

●

●

●

●

●

2-31

Brake pad wear - inspect #

●

●

●

●

●

●

2-33

Brake hose and pipe installation condition

- inspect

year

●

●

●

●

●

●

●

2-31

Brake 

fl

 uid level - inspect

6 months

●

●

●

●

●

●

●

2-32

Brake operation (effectiveness, play, no 
drag) - inspect

year

●

●

●

●

●

●

●

2-33

Brake light switch operation - inspect

●

●

●

●

●

●

●

2-33

Suspensions

Front forks/rear shock absorber operation

(damping and smooth stroke) - inspect

●

●

●

2-34

Front forks/rear shock absorber oil leak - 
inspect

year

●

●

●

2-34

Steering System

■

Steering play - inspect

year

●

●

●

●

2-35

■

Steering stem bearings - lubricate

year

●

2-36

Electrical System

Lights and switches operation - inspect

year

●

●

●

2-37

Headlight aiming - inspect

year

●

●

●

2-39

Sidestand switch operation - inspect

year

●

●

●

—

Engine stop switch operation - inspect

year

●

●

●

—

Chassis

■

Chassis parts - lubricate

year

●

●

●

—

■

Bolts,nuts tightening torque—inspect

●

●

●

●

—

Whichever
comes 

fi

 rst

FREQUENCY

INSPECTION

*ODOMETER READING

            km×1000

↓

2-4 PERIODIC MAINTENANCE

CHANGE/REPLACE ITEM

 *ODOMETER READING   
  

→

km×1000

See Page

Every

1

12

24

36

48

■

Air 

fi

 lter element#

2 years

2-14

Engine oil #

6 months

Every 6000 km

2-48

Oil 

fi

 lter

6 months

Every 6000 km

2-48

■

Fuel line

4 years

●

—

■

Coolant

2 years

●

2-45

■

Radiator hose 

2 years

●

—

■

Brake hose and pipe

4 years

●

—

■

Brake 

fl

 uid (F/R)

2 years

●

●

2-50

■

Rubber parts of master cylinder and 

caliper

4 years

●

—

■

Spark plug

●

●

●

●

2-54

Whichever 
comes 

fi

 rst

FREQUENCY

↓

 PERIODIC MAINTENANCE 2-5

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

Electronic Fuel Injection(EFI)

Coolant Temp. Sensor

12

1.2

106in·lb

Speed Sensor Bolt

8

0.80

69in·lb

L

Fuel Pump Bolts

5

0.5

—

L,S

Oxygen Sensor 

60

6.60

44.3

Cooling System

Radiator Hose Clamp Bolts

2.5

0.25

—

Water Pump Impeller Bolt

10

1.0

87in·lb

Water Pump Cover Bolts

10

1.0

87in·lb

Water Pump Drain Bolt

7.0

0.70

62in·lb

Thermostat Housing Bolts

10

1.0

87in·lb

Coolant Temp. Sensor

12

1.2

106in·lb

Baf

fl

 e Plate Bolts

6

0.60

52in·lb

See text

Engine Top End                               

Valve Cover Bolts

10

1.0

87in·lb

Camshaft Cap Bolts

12

1.2

106in·lb

S

Cylinder Head Bolts (M10 New Bolts)

54

5.5

40

MO,S

Cylinder Head Bolts (M10 Used Bolts)

49

5.0

36

MO,S

Cylinder Bolt (M8)

27.5

2.8

20

MO,S

Cylinder Nut (M10)

49

5.0

36

MO,S

Cylinder Head Bolts (M6)

12

1.2

106in·lb

S

Cylinder Bolts (M6)

12

1.2

106in·lb

S

Intake Manifold Bolts

12

1.2

106in·lb

Intake Manifold Clamp

2.0

0.2

1.5

Camshaft Chain Tensioner Bolts

12

1.2

12

Camshaft Chain Tensioner Nuts Mounting Bolts

20

1.2

20

Camshaft Sprocket Bolts

15

1.5

11

L

Spark Plug

15

1.5

11

Exhaust Pipe Manifold Holder Nuts

17

1.7

12

Muf

fl

 er Body Mounting Bolt (Front)

20

2.0

15

Torque Specifi cations

The following tables list the tightening torque for the major fasteners requiring use of a threadlocker.
  Letters used in "emarks" column mean:
AL:    Tighten the two clamp bolts alternately two times to ensure even tightening torque;
EO:   Apply engine oil;
L:      Apply a threadlocker to the threads;
Lh:    Left-hand threads;
MO:  Apply molibdenum disul

fi

 de oil solution(mixture of engine oil and molybdenum disul

fi

 de grease in a  

         weight ratio 10:1);
R:     Replacement Parts;  
S:     Follow the speci

fi

 ed tightening sequence; 

Si:    Apply silicone grease (ex.PBC grease); 
SS:  Apply silicone sealant

2-6 PERIODIC MAINTENANCE