CFMoto motorcycle CF650NK. Service Manual - part 25

 

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CFMoto motorcycle CF650NK. Service Manual - part 25

 

 

9-20 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

 Install the 2 connecting rod bolts.

 Apply molybdenum disulfide grease [B] to the 

  outer surface of the upper insert and the inner 
   surface of the connecting rod big end.

 Apply molybdenum disulfide oil solution [C] to 

  the inner surfaces of upper and lower bearing 
   inserts.

 The molybdenum disul

fi

 de oil solution is a mixture 

  of engine oil and molybdenum disulfide grease 
   with a weight ratio (10 : 1).

 Do not apply any grease or oil [D] to the cap 

    inside and cap insert outside.

 Install the inserts so that their nails [E] are on the 

   same side and 

fi

 t them into the recess of the con-

   necting rod and cap.

CAUTION

Wrong application of oil and grease could 
cause bearing damage.

 When installing the inserts [A], be careful not to 

   damage the insert surface with the edge of the 
   connecting rod [B] or the cap [C]. 

 One way to install  inserts is as follows. 

   Installation [D] to Cap 
   Installation [E] to Connecting Rod 
   Push [F]
   Spare Dowel Pin [G] 
   Connecting Rod Bolts [H]

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CRANKSHAFT/TRANSMISSION 9-21

Crankshaft and Connecting Rods

 Apply  molybdenum  disul

fi

 de  oil  solution  [MO]  

   to the threads and seating surfaces of  the big 
   end nuts and bolts.

 Install the crankshaft (see Crankshaft 

   Installation).

 Install each connecting rod on its original 

   crankpin.

NOTE

 

Install each connecting rod so that its oil jet [A] 

   faces the exhaust side (the front [B]) (see Engine 
  Oil Flow Chart in the Engine Lubrication System 
   chapter).

 

The connecting rod big end is bolted using the 

   rotation angle method, which can precisely 
   achieves the needed clamping force without 
   exceeding it unnecessarily

 First tighten the 2 nuts of a connecting rod alter

   nately to 40 N·m

 Loosen the 2 nuts completely.

 Tighten them alternatly to 29 N·m.

 After the connecting bolts are tightened to 29 N·

   m, the connecting rod can turn freely.

 Turn the connecting rod nuts clockwise 100°.

 Check if the connecting rod turns freely. If not, re-

   install the connecting rod bearing. 

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9-22 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Connecting Rod Bend

 Remove the connecting rod big end bearing  

   inserts, and reinstall the connecting rod big end 
   cap.

 Select an arbor [A] of the same diameter as the 

   connecting rod big end, and insert the arbor 
   through the connecting rod big end.

 Select an arbor of the same diameter as the 

   piston pin and at least 100 mm (3.94 in.) long, 
   and insert the arbor [B] through the connecting 
   rod small end.

 On a surface plate, set the big-end arbor on V 

   block [C].

 With the connecting rod held vertically,  use a 

   height gauge to measure the difference in the 
   height of the arbor above the surface plate over a 
  100 mm (3.94 in.) length to determine the amount 
   of connecting rod bend.
   If connecting rod bend exceeds the service limit, 
   the connecting rod must be replaced.
  

 Connecting Rod Bend Service Limit:  

   TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist

 With the big-end arbor [A] still on V block [C], 

   hold the connecting rod horizontally and measure 
   the amount that the arbor [B] varies from being 
   paralleled with the surface plate over a 100 mm 
   (3.94 in.) 
   length of the arbor to de- termine the amount of 
   connecting rod twist.
   If connecting rod twist exceeds the service limit, 
   the connecting rod must be replaced.
  

 Connecting  Rod Twist

   Service Limit:  TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance

 Measure connecting rod big end side clearance.

 Insert a thickness gauge [A] between the big end 

   and either crank web to determine clearance.

  

 Connecting Rod Big End Side Clearance

   Standard:  

0.15 ~ 0.30 mm  

   Service Limit:  0.55 mm 

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CRANKSHAFT/TRANSMISSION 9-23

Crankshaft and Connecting Rods

   If the clearance exceeds the service limit, replace 
   the connecting rod with new one and then check 
  clearance again. If clearance is too large after 
  connecting rod replacement, the crankshaft also 
   must be replaced.

Crankpin/Connecting Rod Big End Bearing 
Insert Wear

 Measure the crankpin diameter using a 

   micrometer.
   Crankpin [A] 

   

Crankpin Diameter Standards:

   37.984~38.00 mm
   Service Limit: 37.97 mm

   If any crankpin has worn past the service limit, re
   place the crankshaft with a new one.
   If the measured crankpin diameters are not less 
   than the service limit, but do not coincide with the 
  original diameter markings on the crankshaft, 
   make new marks on it.

   Crankpin Diameter Marks:

  

 2:       37.984~37.992 mm (1.4954~1.4957 in.)

   1: 

   37.993~38.000 mm (1.4958~1.4961 in.)

 Measure the connecting rod big end inside 

   diameter, and mark each connecting rod big end 
    in accordance with the inside diameter.

   

Connecting Rod Big End Inside Diameter 

    Marks:

   1:       41.000   41.008 mm (1.6142   1.6145 in.)
   2: 

41.009   41.016 mm (1.6145   1.6148 in.)

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9-24 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Match Mark [A]
Connecting Rod [B]
Diameter Mark [C]
Weight Mark [E]

 

Select the proper bearing insert [A] according to 

   the crankpin diameter mark and the big end 
    inside diameter mark.
    Size Color [B]

Con-rod Big 

End Inside 

Diameter 

Marking

Crankpin 

Diameter 

Marking

Size Color

1

1

Black

1

2

Blue

2

1

2

2

Green

Crankshaft Side Clearance

 

Insert a thickness gauge [A] between the crank-

   case main bearing and the crank web at the No.2 
   journal [B] to determine clearance.
   If the clearance exceeds the service limit, replace 
   the crankcase halves as a set.

  

 Crankshaft Side Clearance

   Standard:  

     0.05~0.20 mm 

   Service Limit:  0.40 mm (0.0157 in.)

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CRANKSHAFT/TRANSMISSION 9-25

Crankshaft and Connecting Rods

Crankshaft Runout

 

Measure the crankshaft runout.

   If the measurement exceeds the service limit, 
   replace the crankshaft.

   

Crankshaft Runout

   Standard:  

TIR 0.02 mm (0.0008 in.) or less

   Service Limit:  TIR 0.05 mm (0.0020 in.)

Crankshaft Main Bearing Insert/Journal Wear

 

Using a micrometer, measure the diameter of 

    the main bearing journal [A].
    Main Bearing Journal Diameter Standards:
    37.984~38.00mm
    Service Limit: 
    37.97 mm
   If the main bearing journal has worn past the   
   service limit, replace the crankshaft with a new 
    one.
   If the measured main bearing journal diameters 
   are not less than the service limit, but do not 
   coincide with the original diameter markings on 
    the crankshaft, make new marks on it.

   

Main Bearing Journal Diameter Marks:

   2:       37.984~37.992 mm (1.4954~1.4957 in.)
   1: 

   37.993~38.000 mm (1.4958~1.4961 in.)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

9-26 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

 

Select the proper bearing insert [A] in accordance 

  with the combination of the crankcase and 
   crankshaft coding.
   Size Color [B]

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CRANKSHAFT/TRANSMISSION 9-27

Balancer

Balancer Removal

 

Split the crankcase (see Crankcase Splitting).

 

Pull the balancer shaft with the balancer gear out 

   of the crankcase.

Balancer Installation

 

Apply molybdenum disul

fi

 de oil solution to the in-

   side of the balancer shaft bearing insert.

 

Align [A] the timing mark on the balancer gear [B] 

   with the timing mark on the balancer drive gear [C] 
   of the crankshaft.

 

Assemble the crankcase (see Crankcase 

    Assembly).

Balancer Shaft Bearing Insert/Journal 
Clearance

 Measure the balancer shaft bearing journal 

   diameter, using a micrometer.

  

 Blancer Shaft Bearing Journal Diameter 

   Standards:
   27.987~28.000 mm
   Service Limit:
   27.96 mm

   If the balancer shaft bearing journal has worn 
   past the service limit, replace the balancer shaft 
   with a new one.
   If the measured balancer shaft bearing journal di-
   ameter is not less than the service limit, but does 
   not coincide with the original diameter markings 
   on the balancer shaft, make new marks on it.

  

 Balancer Shaft Bearing Journal Diameter:

   2:  27.987~27.993 mm
   1: 27.994~28.000  mm

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9-28 CRANKSHAFT/TRANSMISSION

Balancer

 

Measure the crankcase bearing bore diameter for   

   the balancer shaft, and mark the upper crankcase 
   half in accordance with the bore diameter.

   

Crankcase Bearing Bore Diameter Marking:

   1 :  31.000~31.008 mm
   2 :  31.009~31.016 mm

 Select the proper bearing insert [A] in accor

   dance with the combination of the crankcase 
   and the balancer shaft coding.
   Size Color [B]

Crankcase  

Bearing Bore 

Diameter Mark

Crankshaft 

Main Journal 

Diameter Mark

Bearing Insert

Blue

2

Brown

Blue

1

Black

None

2

None

1

Blue

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CRANKSHAFT/TRANSMISSION 9-29

Transmission

Shift Pedal Removal

 Remove:

   Shift Lever Bolt [A]
   Shift Lever [B]

Shift Pedal Installation

 Align the mark [A] on the shift shaft with the slit [B] 

   on the shift lever.

 Tighten the shift lever bolt securely.

External Shift Mechanism Removal

 Remove:

   Engine Oil (Drain, see Engine Oil Change in the 
   Periodic Maintenance chapter)
   Shift Pedal (see Shift Pedal Removal)
   Engine Sprocket (see Engine Sprocket Removal 
   in the Final Drive chapter)
   Neutral Switch Lead Connector (Disconnect) 
   Shift Shaft Cover Bolts [A]
   Shift Shaft Cover Screw [B]
   Shift Shaft Cover [C]

 Remove the shift shaft assembly [A].

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9-30 CRANKSHAFT/TRANSMISSION

Transmission

 Remove:

   Clutch (see Clutch Removal in the Clutch 
   chapter).
   Gear Positioning Lever Bolt [A]
   Gear Positioning Lever [B], Spacer, Washer and 
   Spring.

External Shift Mechanism Installation

 Install the gear positioning lever [A] as shown.

   Spring [B]
   Washer [C] 
   Spacer [D] 
   Bolt [E]

 Hook the spring at gear positioning lever, pushing 

   up [F] the hook portion, as shown.

 Apply a non-permanent locking agent to the gear 

   positioning lever bolt and tighten it.
   Torque - Gear Positioning  Lever Bolt:  12 N·m 
   (1.2 kgf·m,106 in·lb)

 Install the shift shaft assembly.

 Apply [A] molybdenum disul

fi

 de oil solution to the 

   rubbing surface between the lever [B] and pawl [C]       
and move them two or three times up and down to 
   lubricate them. 

 Be sure that the washer [A] is on the shaft.

 Be sure that the spring hook portions [B] are as      

   shown.

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CRANKSHAFT/TRANSMISSION 9-31

Transmission

 When the new needle bearing [A] is installed in 

   the shift shaft cover [B], press and insert the new 
   needle bearing until it is bottomed.

   

Special Tool -  Bearing Driver Set

 When the new oil seal [C] is installed in the shift 

   cover, press and insert the new oil seal so that its 
   surface is 

fl

 ush with the end of the hole.

   Special Tool -  Oil Seal Installer

 Install the shift shaft cover.

 Be sure that the dowel pins [A] are in position.

 Install the new gasket [B].

 Apply a non-permanent locking agent to the shift 

   shaft cover screw [A].

 Do not apply a non-permanent locking agent to 

    the shift shaft cover bolts [B,C,D, E].

 Tighten the cover screw lastly.

   T

orque - Shift  Shaft  Cover  Bolts:   12 N·m 

   Shift Shaft Cover Screw:  5 N·m

External Shift Mechanism Inspection

 Examine the shift shaft [A] for any damage.

   If the shaft [A] is bent, replace it.
   If the splines [B] are damaged, replace the shaft.
  If the springs [C] are damaged, replace the 
   spring.

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9-32 CRANKSHAFT/TRANSMISSION

Transmission

 Check the return spring pin [A] is not loose.

   If it is loose, unscrew it, apply a non-permanent 
    locking agent to the threads, and tighten it.

 

  Torque - Shift Shaft Return Spring Pin:   

   29 N·m (2.9 kgf·m, 21 ft·lb)

 Check the gear positioning lever [A] and its 

   spring for breaks or distortion.
   If the lever or spring are damaged in any way, re-
   place them.

 Visually inspect the shift drum cam [B].

  If they are badly worn or if they show any 
   damage, replace it.

Transmission Assy Removal

 Remove:

   Shift Shaft Assembly (see External Shift Mecha-
   nism Removal)
  Neutral Switch Holder Bolt [A] Neutral Switch 
   Holder [B] and Pin Shift Drum Holder [C] and Pin

 Remove: Collar [A]

                 O-ring [B]

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CRANKSHAFT/TRANSMISSION 9-33

Transmission

 Remove:

   Clutch (see Clutch Removal in the Clutch  
   chapter)
   Transmission Case Bolts [A]

 If the transmission assy is to be disassembed, 

    remove the following.
    Shift Rod Plate Bolt [B]
    Shift Rod Plate [C]
    Gear Positioning Lever Bolt [D]
    Gear Positioning Lever [E] with Spring, Washer 
    and Spacer.

 Pull the transmission assy [A] out of the 

   crankcase.

Transmission Assy Disassembly

 Remove the transmission assy (see Transmission 

   Assy Removal).

 Remove the following from the transmission case 

   [A].
   Shift Rods [B]
   Shift Forks [C] 
   Drive Shaft [D] 
   Output Shaft [E]

 Remove:

   Shift Drum Cam Bolt [A]
   Shift Drum [B] and Pin
   Shift Drum [C]

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9-34 CRANKSHAFT/TRANSMISSION

Transmission

Transmission Assy Assembly

 When the new ball bearings [A] are installed in 

   the transmission case [B], press and insert them 
   until they are bottomed.

 

  Special Tool -  Bearing Driver Set 

 

Install the following on the transmission case [A].

   Shift Drum [B]
   Pin [C]
   Shift Drum Cam [D]

 Align the pin with the hole on the shift drum cam.

 Apply a non-permanent locking agent to the shift 

   drum cam bolt [E] and tighten it.

   

Torque - Shift Drum Cam Bolt: 10 N·m

 Install the following as a set.

   Drive Shaft [F]
   Output Shaft [G]

 Install the forks as shown.

 Position the one [H] with shortest ears on the 

   drive shaft and place the pin in the center groove 
   in the shift drum.

 The two forks [J] on the output shaft are identical.

 Install the shift rods, noting the groove position.

 The rod [K] length of the output shaft side is 

   shorterthan the rod [L] length of the drive shaft 
    side.

 Apply molybdenum disulfide oil solution to the 

   transmission gears shown with X marks [M].

 Be sure that the spacer [N] is on the output shaft.

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CRANKSHAFT/TRANSMISSION 9-35

Transmission

Transmission Assy Installation

 Assemble the transmission assy (see Transmis

   sion Assy Assembly).

 Be sure that the dowel pins [A] are in position.

 Apply grease to the O-ring [B] on the oil pipe.

 Install the transmission assy on the crankcase.

 Tighten the transmission case bolts.

   Torque - Transmission Case Bolts: 20 N·m (2.0 
   kgf·m, 15 ft·lb)
 

 Install the gear positioning lever (see External 

   Shift Mechanism Installation).

 Install the shift rod plate.

   Torque - Shift Rod Plate Bolt: 9.8 N·m (1.0 kgf·
   m, 87 in·lb)

 Set the gear positioning lever to the neutral 

    position [A].

 Check that the drive and output shaft turn freely.

 Install: Pin [A]

   Shift Drum Holder [B] Pin [C]
   Neutral Switch Holder [D]
   Neutral Switch Holder Screw [E]

 Apply a non-permanent locking agent to the 

   neutral switch holder screw and tighten it.

   Torque - Neutral Switch Holder Screw: 4.9 N·m 
   (0.50 kgf·m, 43 in·lb)

 Apply grease to the O-ring [A] and install its posi-

   tion [B] on the output shaft.

 Apply grease to the lip of the oil seal [C].

 Install the collar [D].

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