CFMoto motorcycle CF650NK. Service Manual - part 12

PERIODIC MAINTENANCE 2-39



 Set the dimmer switch to high beam position.



 The low beam [A] and high beam [B] headlights should

   go on.



 The high beam indicator light (LED) [C] should go on.

If the high beam headlight and/or high beam indicator

   light (LED) does not go on, inspect or replace the
   following item.
   Headlight High Beam Bulb (see Headlight Bulb Replace-
   ment in the Electrical System chapter)
   Dimmer Switch (see Switch Inspection in the Electrical
   System chapter)



 Turn off the engine stop switch.



 The low beam and high beam headlights should stay

   going on.

If the headlights and high beam indicator light (LED)

   does go off, inspect or replace the following item.
   Headlight Relay in Relay Box (see Relay Circuit Inspec-
   tion in the Electrical System chapter)



 Turn off the ignition switch.



 The headlights and high beam indicator light (LED)

   should go off.

Headlight Aiming Inspection



 Inspect the headlight beam for aiming.

If the headlight beam points to one side rather than

   straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment



 Turn the horizontal adjuster [A] on the headlight with the

   screwdriver in or out until the beam points straight ahead.

If the headlight beam points too low or high, adjust the

   vertical beam.

Headlight Beam Vertical Adjustment



 Turn the vertical adjuster [A] on the headlight with the

   screwdriver in or out to adjust the headlight vertically.

2-40  PERIODIC MAINTENANCE

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NOTE

O

 

On high beam, the brightest points should be slightly

   below horizontal with the motorcycle on its wheels and

   the rider seated. Adjust the headlight to the proper

   angle according to local regulations.

Low Beam [A]
Height of Headlight Center [B]
High Beam [C]

Sidestand Switch Operation Inspection



 Inspect the sidestand switch [A] operation accordance

   to below table.

Sidestand Switch Operation

If the sidestand switch operation does not work, inspect

   or replace the following item.

PERIODIC MAINTENANCE 2-41

   Battery (see Charging Condition Inspection in the Electrical
   System chapter)
   Main Fuse 30 A (see Fuse Inspection in the Electrical System
   chapter)
   Ignition Fuse 10 A (see Fuse Inspection in the Electrical System
   chapter)
   Ignition Switch (see Switch Inspection in the Electrical System
   chapter)
   Sidestand Switch (see Switch Inspection in the Electrical
   System chapter)
   Engine Stop Switch (see Switch Inspection in the Electrical
   System chapter)
   Starter Button (see Switch Inspection in the Electrical System
   chapter)
   Neutral Switch (see Switch Inspection in the Electrical System
   chapter)
   Starter Relay (see Starter Relay Inspection in the Electrical Sys-
   tem chapter)
   Relay Box (see Relay Circuit Inspection in the Electrical System
   chapter)
   Starter Circuit Relay (see Relay Circuit Inspection in the Electri-
   cal System chapter)
   Harness (see Wiring Inspection in the Electrical System chapter)

If the all parts are good condition, replace the ECU (see ECU

   Removal/Installation in the Fuel System (EFI) chapter).

   Engine Stop Switch Operation Inspection

  

 First Step



 Turn on the ignition switch.



 Set the neutral position.



 Turn the engine stop switch to stop position [A].



 Push the starter button.



 The engine does not start.

If the engine starts, inspect or replace the following item.

   Engine Stop Switch (see Switch Inspection in the Electrical Sys-
   tem chapter)

Second Step



 Turn on the ignition switch.



 Set the neutral position.



 Turn the engine stop switch to run position [A].



 Push the starter button and run the engine.



 Turn the engine stop switch to stop position.



 Immediately the engine should be stop.

If the engine does not stop, inspect or replace the following item.

   Engine Stop Switch (see Switch Inspection in the Electrical Sys-
   tem chapter)

If the engine stop switch is good condition, replace the ECU (see

   ECU Removal/Installation in the Fuel System (EFI) chapter).

2-42  PERIODIC MAINTENANCE

Others

Chassis Parts Lubrication



 Before lubricating each part, clean off any rusty

   spots with rust remover and wipe off any grease,
   oil, dirt, or grime.



 Lubricate the points listed below with indicated

   lubricant.

NOTE

O

 

Whenever  the  vehicle  has  been  operated

   under wet or  rainy conditions,  or especially after

   using a high-pressure water spray, perform the

   general lubrication.

Pivots: Lubricate with Grease.

Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends

Cables: Lubricate with Rust Inhibitor.

Clutch Cable
Throttle Cables



 Lubricate the cables by seeping the oil between

   the cable and housing.

O

 

The cable may be lubricated by using a commer-

   cially available pressure cable lubricator with an
   aerosol cable lubricant.



 With the cable disconnected at both ends, the

   inner cable should move freely [A] within the cable
   housing.

If cable movement is not free after lubricating, if

   the cable is frayed [B], or if the cable housing is
   kinked [C], replace the cable.

PERIODIC MAINTENANCE 2-43

Bolts, Nuts and Fasteners Tightness Inspection



 Check the tightness of the bolts and nuts listed here.

   Also, check to see that each cotter pin is in place and in
   good condition.

NOTE

O

 

For the engine fasteners, check the tightness of them

   when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the speci-

   fied torque following the specified tightening sequence.
   Refer to the appropriate chapter for torque specifications.
   If torque specifications are not in the appropriate chapter,
   see the Standard Torque Table. For each fastener, first
   loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

   Bolt, Nut and Fastener to be checked

   Engine:
      Clutch Lever Pivot Nut
      Engine Mounting Bolts and Nuts Exhaust Pipe Mani-
      fold Holder Nuts Muffler Body Mounting Bolts

   Wheels:
      Front Axle
      Front Axle Clamp Bolt
      Rear Axle Nut
      Rear Axle Nut Cotter Pin

   Brakes:
      Brake Lever Pivot Nut
      Brake Pedal Bolt
      Brake Rod Joint Cotter Pin
      Caliper Mounting Bolts
      Front Master Cylinder Clamp Bolts
      Rear Master Cylinder Mounting Bolts

   Suspension:
      Front Fork Clamp Bolts
      Rear Shock Absorber Bolt and Nut
      Swingarm Pivot Shaft Nut

   Steering:
      Steering Stem Head Bolt
      Handlebar Holder Bolts

   Others:
      Footpeg Stay Bolts
      Front Fender Bolts
      Sidestand Bolt

2-44  PERIODIC MAINTENANCE

Replacement Parts

Air Filter Element Replacement



 Refer to the Air Cleaner Element Cleaning.

Fuel Line Replacement



 Remove the fuel tank (see Fuel Tank Removal in

   the Fuel System (EFI) chapter).



 Be sure to place a piece of cloth [A] around the

   fuel hose joint.



 Insert a minus screw driver [B] into the slit [C] on

   the joint lock.



 Turn [A] the driver to disconnect the joint lock [B].



 Pull [C] the fuel line joint [D] out of the delivery

   pipe.



 Install the new fuel line.



 Insert [A] the fuel line joint [B] straight onto the

   delivery pipe until the hose joint clicks.



 Push [C] the joint lock [D].



 Push and pull [A] the fuel line joint [B] back and

   forth more than two times and make sure it is
   locked and doesn't come off.

If it comes off, reinstall the hose joint.



 Run the fuel line correctly.



 Install the removed parts (see appropriat chapters).



 Start the engine and check the fuel line for leaks.

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Be prepared for fuel spillage; any spilled fuel

must be completely wiped up immediately.

When the fuel line is disconnected, fuel spills

out from the line and the pipe. Cover the line

connection with a clean shop towel to prevent

fuel spillage.

When removing and installing the fuel line

joint, do not apply strong force to the outlet

pipe on the fuel pump and delivery pipe on

the throttle body assy. The pipes made from

resin could be damaged.

Make sure the fuel hose joint is installed

correctly on the delivery pipe or the fuel could

leak.

WARNING

!

!

WARNING

PERIODIC MAINTENANCE 2-45

Coolant Change



 Remove:

   Right Center Fairing (see Center Fairing Removal
   in the Frame chapter)
   Lower Fairing (see Lower Fairing Removal in the
   Frame chapter)
   Reserve Tank Bolts [A] Reserve Tank [B]



 Put [A] the projection [B] on the reserve tank into

   the hole [C] on the frame bracket, and place the
   reserve tank on the right side of frame.



 Place a container under the water pump drain bolt

   [A], then remove the drain bolt.

To avoid burns, do not remove the radiator

cap or try to change the coolant when the

engine is still hot. Wait until it cools down.

Coolant on tires will make them slippery and

can cause an accident and injury. Immedi-

ately wipe up or wash away any coolant that

spills on the frame, engine, or other painted

parts. Since coolant is harmful to the human

body, do not use for drinking.

!

WARNING

2-46  PERIODIC MAINTENANCE



 Remove the radiator cap [A] in two steps. First turn the

   cap counterclockwise to the first stop. Then push and
   turn it further in the same direction and remove the cap.

O

 The coolant will drain from the radiator and engine.



 Turn over [A] the reservoir tank, remove the cap, and

   pour the coolant into a suitable container.



 Place the reserve tank on the right side of frame.



 Tighten the drain bolt with the gasket.

O

 Replace the drain bolt gasket with a new one.

   

Torque - Water Pump Drain Bolt:  7.0 N m

   (0.70 kgf m,  62 in lb)



 When filling the coolant, choose a suitable mixture

   ratio by referring to the coolant manufacturer's
   directions.

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant:

50%

Freezing Point:

-

35 °C 

(-31 

°F

) Total Amount:

1.2 L (1.3 US qt)



 Fill the radiator up to the filler neck [A] with coolant.

NOTE

O

 

Pour in the coolant slowly so that it can expel the air

   from the engine and radiator.



 Check the cooling system for leaks.



 Tap the radiator hoses to force any air bubbles caught

   inde.



 Fill the radiator up to the filler neck with coolant.

Soft or distilled water must be used with the

antifreeze in the cooling system.

If hard water is used in the system, it causes

scales accumulation in the water passages,

and considerably reduces the efficiency of the

cooling system.

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PERIODIC MAINTENANCE 2-47



 Temporarily install the reserve tank to the frame

   with two bolts.



 Fill the reserve tank up to the "F" (full) level line

   [A] with coolant and install the cap [B].



 Start the engine, warm it up thoroughly until the

   radiator fan turns on and then stop the engine.



 Check the coolant level in the reserve tank after

   the engine cools down.

If the coolant level is lower than the "L" level line,

   add coolant to the "F" level line.

Do not add more coolant above the "F" level

line.

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Radiator Hose and O-ring Replacement



 Drain the coolant (see Coolant Change).



 Remove:

   Thermostat Housing [A] (see Water Pump Re-
   moval in the Cooling System chapter)
   Water Pump Cover [B] (see Water Pump Removal
   in the Cooling System chapter) Hoses [C]
   O-rings [D]



  Apply grease to the new O-rings and install them.



 Install the new hoses and tighten the clamps

   securely.



 Fill the coolant (see Coolant Change).



 Check the cooling system for leaks.

2-48  PERIODIC MAINTENANCE

Engine Oil Change



 Situate the motorcycle so that it is vertical after

   warming up the engine.



 Unscrew the oil filler plug [A].



 Place on oil pan beneath the engine.



 Remove the engine oil drain bolt [A] to drain the

   oil.

O

 The oil in the oil filter can be drained by removing

   the filter (see Oil Filter Replacement).

Replace the drain bolt gasket [B] with a new one.



 Tighten the drain bolt.

   

Torque - Engine Oil Drain Bolt: 30 N m (3.0

   kgf m, 22 ft lb)



 Pour in the specified type and amount of oil.

Recommended  Engine Oil

Type: API SE, SF or SG

API SH, SJ or SL with JASO MA Viscosity: SAE

10W-40

Capacity:

1.7 L (1.8 US qt) (when filter is not

removed)

1.9 L (2.0 US qt) (when filter is removed)

2.4 L (2.5 US qt) (when engine is completely dry)

NOTE

O

 

Although 10W-40 engine oil is the recommended

   oil for most conditions, the oil viscosity may need

   to be changed to accommodate atmospheric con-

   ditions in your riding area.

O

 

Check the oil level (see Oil Level Inspection in the

   Engine Lubrication System chapter).

Oil Filter Replacement



 Drain the engine oil (see Engine Oil Change).



 Remove the oil filter [A] with the oil filter wrenc [B].

   

Special Tool -  Oil Filter Wrench

PERIODIC MAINTENANCE 2-49



 Replace the filter with a new one.



 Apply engine oil to the gasket [A] before installati-

  on.



 Tighten the filter with the oil filter wrench.

   

Torque - Oil Filter: 17.2 N m (1.75 kgf m, 13

   ft lb)

NOTE

O

 Hand tightening of the oil filter can not be allowed

   since it does not reach to this tightening torque.

O

 Pour in the specified type and amount of oil (see

   Engine Oil Change).

Brake Hose and Pipe Replacement



 Remove the banjo bolts [A].



 When removing the brake hose, take care not to

   spill the brake fluid on the painted or plastic parts.



 When removing the brake hoses [B], temporarily

   secure the end of the brake hose to some high
   place to keep fluid loss to a minimum.

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Brake fluid quickly ruins painted plastic surfa-

ces; any spilled fluid should be completely w-

ashed away immediately.



 Immediately wash away any brake fluid that spills.

Brake Fluid Replacement

NOTE

O

 The procedure to change the front brake fluid is

   as follows. Changing the rear brake fluid is the

   same as for the front brake.



 Level the brake fluid reservoir.



 Remove the reservoir cap and diaphragm.



 Remove the rubber cap from the bleed valve [A] on

   the caliper.



 Attach a clear plastic hose [B] to the bleed valve,



and run the other end of the hose into a container.



 Fill the reservoir with fresh specified brake fluid.

2-50  PERIODIC MAINTENANCE



 Change the brake fluid.

O

 

Repeat this operation until fresh brake fluid comes out from

   the plastic hose or the color of the fluid changes.
1.  Open the bleed valve [A].
2.  Apply the brake and hold it [B].
3.  Close the bleed valve [C].
4.  Release the brake [D].

NOTE

O

 The fluid level must be checked often during the changing

   operation and replenished with fresh brake fluid. If the fluid

   in the reservoir runs out any time during the changing oper-

   ation, the brakes will need to be bled since air will have en

   tered the brake line.

O

 Front Brake:  Repeat the above steps for the other caliper.



 Remove the clear plastic hose.



 Install the diaphragm and reservoir cap.



 Tighten:

   Torque - Front Brake Reservoir Cap Screws: 1.0 N m

   (0.10 kgf m, 9 in lb)



 Follow the procedure below to install the rear brake fluid

   reservoir cap correctly.

O

 

First, tighten the rear brake fluid reservoir cap [B] clock-wise

   [C] by hand until slight resistance is felt indicating that the
   cap is seated on the reservoir body, then tighten the cap an
   additional 1/6 turn [D] while holding the brake fluid reservoir
   body [A].



 Tighten the bleed valve, and install the rubber cap.

   Torque - Bleed Valve: 7.8 N m (0.80 kgf m, 69 in lb)



 After changing the fluid, check the brake for good braking

   power, no brake drag, and no fluid leakage.

If necessary, bleed the air from the lines.

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly



 Remove the front master cylinder (see Front Master Cylin-

   der Removal in the Brakes chapter).



 Remove the reservoir cap and diaphragm, and pour the br-

   ake fluid into a container.



 Unscrew the locknut and pivot bolt, and remove the brake

   lever.



 Pull the dust cover [A] out of place, and remove the circlip

   [B].
   

Special Tool -  Inside Circlip Pliers



 Pull out the piston [C], secondary cup [D], primary cup [E],

   and return spring [F].

Do not remove the secondary cup from the piston

since removal will damage it.

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PERIODIC MAINTENANCE 2-51

Rear Master Cylinder Disassembly

NOTE

O

 

Do not remove the push rod clevis for master cylinder

   disassembly since removal reguires brake position ad-

   justment.



 Remove the rear master cylinder (see Rear Master Cyl-

   inder Removal in the Brakes chapter).



 Slide the dust cover on the push rod out of place, and

   remove the circlip.
  

 Special Tool -  Inside Circlip Pliers



 Pull out the push rod with the piston stop.



 Take off the piston [A], secondary cup [B], primary cup

   [C] and return spring [D].

   Do not remove the secondary cup from the piston

   since removal will damage it.

Master Cylinder Assembly



 Before assembly, clean all parts including the master

   cylinder with brake fluid or alcohol.



 Apply brake fluid to the new parts and to the inner wall

   of the cylinder.



 Take care not to scratch the piston or the inner wall of

   the cylinder.



 Tighten the brake lever pivot bolt and locknut.



 Apply silicone grease.

   Brake Lever Pivot Bolt



 Tighten:

   

Torque - Brake Lever Pivot Bolt:  1.0 N·m

   (0.10 kgf·m, 9 in·lb)

   Brake Lever Pivot Bolt Locknut:  5.9 N·m (0.60

   kgf·m, 52 in·lb)

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Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for

cleaning brake parts. Do not use any other fluid

for cleaning these parts.  Gasoline, engine oil, or

any other petroleum distillate will cause deterio-

ration of the rubber parts. Oil spilled on any part

will be difficult to wash off completely, and will

eventually deteriorate the rubber used in the disc

brake.

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2-52  PERIODIC MAINTENANCE

Caliper Rubber Parts Replacement

Front Caliper Disassembly



 Remove:

   Front Caliper (see Front Caliper Removal in the
   Brakes chapter)
   Brake Pads (see Front Brake Pad Removal in the
   Brakes chapter)



 Using compressed air, remove the pistons.



 Cover the piston area with a clean, thick cloth [A].



 Blow compressed air [B] into the hole for the

   banjo bolt to remove the piston.

To avoid serious injury, never place your

fingers or palm in front of the piston. If you

apply compressed air into the caliper, the

piston may crush your hand or fingers.

WARNING

!



 Pull out the pistons by hand.



 Remove the dust seals [A] and fluid seals [B].



 Remove the bleed valve [C] and rubber cap [D].

NOTE

O

 

If compressed air is not available, with the brake

   hose still attached, apply the brake lever to

   remove the piston. The remaining process is as

   described above.

Front Caliper Assembly



 

Clean the caliper parts except for the pads.

For cleaning the parts, use only disc brake

fluid, isopropyl alcohol, or ethyl alcohol.

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

 Install the bleed valve and rubber cap.

  Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m,

  69 in·lb)



 Replace the fluid seals [A] with new ones.



 Apply brake fluid to the fluid seals, and install

   them into the cylinders by hand.



 Replace the dust seals [B] with new ones if they

   are damaged.



 Apply brake fluid to the dust seals, and install

   them into the cylinders by hand.

PERIODIC MAINTENANCE 2-53



 Apply brake fluid to the outside of the pistons, and

   push them into each cylinder by hand.



 Check the shaft rubber friction boot [A] and the

   dust cover [B] replace them with new ones if they
   are damaged.



 Apply a thin coat of PBC (Poly Butyl Cuprysil)

   grease to the caliper holder shafts [C] and holder
   holes [D] (PBC is a special high-temperature,
   water-resistance grease).



 Install the anti-rattle spring [A].



 Install the pads (see Front Brake Pad Installation

   in the Brakes chapter).



 Wipe up any spilled brake fluid on the caliper with

   wet cloth.

Rear Caliper Disassembly



 Remove the rear caliper (see Rear Caliper Re

   moval in the Brakes chapter).



 Remove the pads and anti-rattle spring (see Rear

   Brake Pad Removal in the Brakes chapter).



 Using compressed air, remove the piston.



 Cover the piston area with a clean, thick cloth [B].



 Blow compressed air [A] into the hole for the

   banjo bolt to remove the piston.

To avoid serious injury, never place your

fingers or palm inside the caliper opening. If

you apply com- pressed air into the caliper,

the piston may crush your hand or fingers.

N

O

I

T

U

A

C



 Remove the dust seal and fluid seal.



 Remove the bleed valve and rubber cap.

NOTE

O

 

If compressed air is not available, with the brake

   hose still attached, apply the brake pedal to

   remove the piston. The remaining process is as

   described above.

Rear Caliper Assembly



 Clean the caliper parts except for the pads.

For cleaning of the parts, use only disc brake

fluid, isopropyl alcohol, or ethyl alcohol.

N

O

I

T

U

A

C



 

Install the bleed valve and rubber cap.

   Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m,

   69 in·lb)

2-54  PERIODIC MAINTENANCE



 Replace the fluid seal [A] with a new one.



 Apply brake fluid to the fluid seal, and install it into

   the cylinder by hand.



 Replace the dust seal [B] with a new one if it is

   damaged.



 Apply brake fluid to the dust seal, and install it

   into the cylinder by hand.



 Apply brake fluid to the outside of the piston, and

   push it into the cylinder by hand.



 Replace the shaft rubber friction boot [A] and dust

   cover [B] if they are damaged.



 Apply a thin coat of PBC (Poly Butyl Cuprysil)

   grease to the caliper holder shafts [C] and holder
   holes [D] (PBC is a special high-temperature,
   water-resistance grease).



 Install the anti-rattle spring [A] in the caliper as

   shown.



 Install the pads (see Rear Brake Pad Installation

   in the Brakes chapter).



 Wipe up any spilled brake fluid on the caliper with

   wet cloth.

Spark Plug Replacement



 Remove:

   Ignition Coils (see Ignition Coil (Ignition Coil
   together with Spark Plug Cap) Removal in the
   Electrical System chapter)



 Remove the spark plugs using the 16 mm plug

   wrench [A].
  Owner's Tool - Spark Plug Wrench, 16 mm

o 

Insert the spark plug vertically into the plug hole

   with the spark plug installed in the plug wrench
   [A]. Owner's Tool - Spark Plug Wrench, 16 mm

o

 Tighten:

   Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11

   ft·lb)

o

 Install:

   Ignition Coils (see Ignition Coil (Ignition Coil
   together with Spark Plug Cap) Installation in the
   Electrical System chapter)