CFMoto motorcycle CF650NK. Service Manual - part 30

SUSPENSION 13-9

●

 Compress [A] the fork [B] upside down to draw 

    out the oil into the suitable container [C].

●

  Pour in the speci

fi

 ed amount of oil.

    

Fork oil

    Viscosity   KAYABA KHL34-G10 or equivalent
    Amount (Per Side):
    When changing oil:
    approx.  390 mL (13.2 US oz.) 
    After disassembly  and completely dry:
    458 ±4 mL (15.5 ±0.14 US oz.)

NOTE

○

 

Move the outer tube up and down a few times, 

    to remove the air that is trapped in the fork oil in 
    order to stabilize the oil level.

●

 Hold the outer tube vertically in a vise and 

    compress the Fork completely.

●

 Wait until the oil level stabilizes.

●

 Use the fork oil level gauge [A] to measure the 

   distance between the top of the inner tube to the 
   oil level.

   

Special Tool -  Fork Oil Level Gauge

○

 Set the oil level gauge stopper [B] so that the   

    distance[C]from the bottom of the stopper to the 
    lower end of the pipe is the standard oil level 
    distance.

○

 A correct measurement can not be obtained  

  unless the level gauge pipe is placed in the  
   center of the inner tube.
   Oil Level (fully compressed,  without spring)
  

 Standard:

   115 ±2 mm (4.5 ±0.08 in.)

○

 Place the stopper of the level gauge at the top

  [D] of the inner tube [E] and pull the handle 
  slowly to draw out the excess oil from fork into 
   the gauge, thus attaining the standard level.

○

 If not oil is drawn out, there is not enough oil in 

  the fork.Pour in some more oil and measure  
   again.

●

 Repeat the same procedure for adjusting the 

   other fork.

●

 Install the fork spring [A], fork spring seat [B] and 

   collar [C].

●

 Inspect the top plug O-ring and replace it with a

   New.

13-10 SUSPENSION

Front Fork Disassembly

●

 Remove the front fork (see Front Fork Removal).

●

 Remove the top plug [A] with O-ring, take out the 

   Collar [B], fork spring seat [C], and fork spring [D]

●

 Drain the fork oil (see Front Fork Oil Change).

●

 Remove the Allen bolt [A] from the bottom of the 

   fork.

  

 Special Tools – 

   Fork Cylinder Holder Handle [B]
   Fork Cylinder Holder Adapter [C]

 

        NOTE

○

 

Hold the outer tube in a vise [D], stop the 

   cylinder unit [E] from turning by using the special 
    tools, and unscrew the Allen bolt.

●

 Remove the cylinder unit [A], washer, and the 

    spring [B] from the inner tube.

●

 Remove the following from the top of the outer 

   tube.
   Dust Seal [A]
   Retaining Ring [B]

●

 Separate the inner tube [A] from the outer tube 

   [B].

                

NOTE

○

 

From the compressed state, 

fi

 rmly pull down the   

   outertube a few times towards the direction of 
   elongation.

SUSPENSION 13-11

●

 Remove the following from the inner tube.

   Inner Guide Bushing [A]
   Outer Guide Bushing [B] Washer [C]
   Oil Seal [D]

●

 Remove the cylinder base [A] from the bottom of 

   the outer tube.

Front Fork Assembly

●

 Check the top plug O-ring and replace it with a   

   new one.

●

 Replace the following parts with new ones.

   Retaining Ring [A]
   Dust Seal [B]
   Oil Seal [C]
   Inner Guide Bushing [D]
   Outer Guide Bushing [E]
   Fork Bottom Allen Bolt Gasket [F]

●

 Install the guide bushing on the end of the inner 

   tube.

●

 Insert the cylinder unit and the spring into the 

   inner tube,and install the cylinder base [A] onto 
   the cylinder end [B], that protrudes from the 
   bottom

●

 Install the cylinder base starting with its stepped 

   end.

●

 Insert the inner tube, cylinder unit, washer, 

   spring, andcylinder base as a set into the outer 
   tube.

●

 Install the guide bushing into the outer tube.

●

 After installing the washer, install the oil seal [A] 

   by using the fork oil seal driver[B].

  

 Special Tool -  Fork Oil Seal Driver, 

Φ

41

●

 Install the retaining ring into the outer tube.

●

 Install the dust seal by hand

13-12 SUSPENSION

●

 Apply non-permanent locking agent to the 

   threads of the bottom Allen bolt [A].

●

 Hold the front fork horizontally in a vise [B].

●

 Hold the cylinder unit [C] with the special tools 

  and tighten the bottom Allen bolt to secure the 
   cylinder in place.

  

 Torque - Front Fork Bottom Allen Bolt:

   30N•m(3.1kgf•m,22ft•lb)
  Special Tools - Fork Cylinder Holder Handle 
   [D]

   Fork  Cylinder  Holder  Adapter  [E]: 57001-1057

●

 Pour in the speci

fi

 ed type of oil 

   (see Front Fork Oil Change)

Inner Tube Inspection

●

 Visually inspect the inner tube [A], and repair any 

   damage.

●

 Nicks or rust damage can sometimes be repaired 

   by using a wet-stone to remove sharp edges or 
   raised areas whichcause seal damage
   If the damage is not repairable, replace the inner 
   tube.Since damage to the inner tube damages 
   the oil seal, replace the oil seal whenever the 
   inner tube is repaired or replaced

CAUTION

If the inner tube is badly bent or creased, 
replace it. Excessive bending,  followed by 
subsequent straightening, can weaken the 
inner tube.

 

●

 Temporarily assemble the inner and outer tubes, 

   and pump them back and forth manually to check 
   for smooth operation. 

●

 If you feel binding or catching, the inner and 

   outer tubes must be replaced.

 

WARNING

A straightened inner or outer fork tube may 
fall in use, possibly causing an accident. 
Replace a badly bent or damaged inner or 
outer tube and inspect the other tube carefully 
before reusing it. 

Dust Seal Inspection 

●

 Inspect the dust seal [A] for any signs of 

    deterioration or damage.
    Replace it if necessary.

!

SUSPENSION 13-13

Fork Spring Inspection

●

 Measure the free length [A] of the fork spring [B].

   If the measured length is shorter than the service 
   limit, the spring must be replaced. 
  If the free length of the replacement spring and 
   that of the remaining spring vary greatly, 
  the remaining spring should also be replaced in 
  order to keep the fork legs balanced to ensure 
   stability. 

   Fork Spring Free Length
   Standard: 

     277.8mm(10.94in.)

   Service Limit:     272mm(10.7in.)

13-14 SUSPENSION

Spring Preload Adjustment

●

 Using the hook wrench [A], turn the adjusting nut 

   [B] to adjust the spring preload.

●

 Using the hook wrench [A], turn the adjusting

●

 The standard adjuster setting for average-build 

   rider of 68kg (150 Ib) with no passenger and no 
   accessories is 3rd position.
   Spring Preload Setting
   Standard Position:     3rd position
   Adjustable Range:  

1st to 7th position

●

 If the compression of the spring is not suited to    

  the operating conditions, adjust it to an 
  appropriate position by referring to the table 
   below.

  

Spring Preload Adjustment

Adjuster

Position

Damping

Force

Shock 

Absorber 

Hardness

Load

Road

Conditions

Driving

Speed

1st

↑
↓

7st

Weak

↑
↓

Strong

Soft

↑
↓

Hard

Light

↑
↓

Heavy

Good 

↑
↓

Bad

Low

↑
↓

Highway

Rear Shock Absorber Removal

●

 Remove:

   Frame Covers (see Frame Cover Removal in the   
   Frame chapter)
   Muf

fl

 er Body

  (see Muffler Body Removal in the Engine Top 
   End Chapter)

●

 Raise the rear wheel off the ground with jack

   

Special Tools – Jack

   Jack Attachment

●

 Squeeze the brake lever slowly and hold it with a 

   band[A].

WARNING

Be sure to hold the front brake when removing 
the shock absorber, or the motorcycle may 
tall over. It could cause an accident and injury.

●

 Remove

●

 Right Stay Cover[A]

!

SUSPENSION 13-15

●

 Remove:

   Upper Shock Absorber Bolt [A]
   Lower Shock Absorber Nut and Washer
   Lower Shock Absorber Bolt [B]

●

 Remove the shock absorber [C] from backward.

Rear Shock Absorber Installation

●

 Installation is the reverse of removal.

●

 Apply grease to the lip of oil seals.

●

 Be sure to install the oil seals to the shock 

   absorber.

●

 Tighten:

  

 Torque - Rear Shock Absorber Bolt :

   59N•m(6.0kgf•m,44ft•lb)
   Rear Shock Absorber Nut:
   59N•m(6.0kgf•m,44ft•lb)

●

 Install the removed parts (see appropriate 

   chapters).
   

Rear Shock Absorber Inspection

●

 Remove the rear shock absorber (see Rear 

   Shock Absorber Removal)

●

 Visually inspect the following items. Smooth 

   Stroke Oil Leakage Crack or Dent
   If there is any damage to the rear shock 
   absorber, replace it.

●

 Visually inspect the rubber bushing.

   If it shows any signs of damage, replace it.

13-16 SUSPENSION

Swingarm Removal

●

 Remove:

   Chain Cover Bolts [A] and Cover [B]
  

●

 Remove:

  Right Side Cover (see Side Cover Removal in   
   the Frame chapter)

  

Frame Covers (see Frame Cover Removal in the 

   Frame chapter)

●

 Remove the brake hose banjo bolt from the rear 

   caliper,free the brake hose [A] from the clamps 
   [B], and removethe foot peg stay with the rear  
   master cylinder.(see Rear Caliper Removal in the   
   Brakes chapter)

●

 Remove:

   Muf

fl

 er Body (see Muf

fl

 er Body Removal in the   

   Engine Top End chapter)
  Rear Wheel  (see Rear Wheel Removal in the  
   Wheels/Tires chapter)

●

 Raise the rear wheel off the ground with jack

   Special Tools - Jack
  Jack Attachment

●

 Remove the lower shock absorber nut and bolt 

   [A].

●

 Remove the drive chain (see Drive Chain 

    Removal in the Final Drive chapter).

●

  Unscrew the swingarm pivot shaft nut [A].

●

 Pull off the pivot shaft [B], and remove the 

    swingarm.

Swingarm Installation

●

 Installation is the reverse of removal.

○

 Apply grease to the lip of the oil seals.

○

 Be sure to install the oil seal and collar to the 

   swingarm.

●

 Tighten the pivot shaft nut.

  

 Torque - Swingarm Pivot Shaft Nut:  

   108 N•m (11.0 kgf•m,80 ft•lb)

●

 Install the removed parts 

   (see appropriate chapters).

SUSPENSION 13-17

Swingarm Bearing Removal

●

 Remove:

   Swingarm (see Swingarm Removal)
   Collar [A]
   Oil Seals [B]
   Sleeve [C]
   Circlip [D]
   

Special Tool -  Inside Circlip Pliers

●

 Remove the ball bearing and needle bearings.

   Special Tool -  Oil Seal & Bearing Remover [A]

Swingarm Bearing Installation

●

 Replace the ball and needle bearings [A] with 

   new ones

●

 Install the ball and needle bearings so that the 

   manufacturer’s marks face out.

   

Special Tools - Bearing Driver Set

   Stem Bearing Driver, 

Φ

28 [B]     

   Spacer, 

Φ

28

.

13-18 SUSPENSION

●

 Install the needle bearings [A], ball bearing [B]   

   and oil seals [C] position as shown.

   Circlip [D]
   25mm(0.98in.)[E]
   17mm(0.67in.)[F]
   1mm(0.04in.)[G]
   0.5mm(0.02in.)[H]
   1mm(0.04in.)[I]
   23.5mm(0.93in.)[J]
   6mm(0.24in.)[K]

Swingarm Bearing, Sleeve Inspection

CAUTION

Do not remove the bearing for inspection. 
Removal may damage them.

●

 Inspect the needle bearings [A] and ball bearing   

   installed in the swingarm.

○

 The rollers and ball in a bearing normally wear 

  very little, and wear is difficult to measure.  
   Instead of measuring, visually inspect the bearing 
   for abrasion, discoloration, or other damage.
  If the needle bearing and sleeve [B] show any 
  sings of abnormal wear, discoloration, or 
   damage, replace them as a set.

SUSPENSION 13-19

●

 Turn the bearing in the swingarm back and forth 

   [A] while checking for plays, roughness, or 
    binding.
   If the bearing play, roughness, or binding is 
    found,  replace the bearing.

●

 Examine the bearing seal [B] for tears or leakage.

  If the seal is torn or is leaking, replace the 
   bearing.

Swingarm Bearing Lubrication

NOTE

○

 

Since the bearings are packed with grease and 

    sealed lubrication is not required.

Chain Guide Inspection

●

 Refer to the Chain Guide Wear Inspection in the 

   Periodic, Maintenance chapter.

STEERING 14-1

Steering

Table of Contents

Exploded View.............................................................................................................................

14-2

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

14-4

Steering.......................................................................................................................................

14-5

Steering Inspection.................................................................................................................

14-5

Steering Adjustment................................................................................................................

14-5

Steering Stem..............................................................................................................................

14-6

Stem, Stem Bearing Removal.................................................................................................

14-6

Stem, Stem Bearing Installation..............................................................................................

14-7

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

14-8

Steering Stem Warp................................................................................................................

14-9

Stem Cap Deterioration, Damage...........................................................................................

14-9

Handlebar.................................................................................................................................... 14-10

Handlebar Removal................................................................................................................ 14-10
Handlebar Installation............................................................................................................. 14-10

14-2 STEERING

Exploded View

STEERING 14-3

No.

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

1

Front Fork Clamp Bolts (Lower)

20

2.0

15

AL

2

Front Fork Clamp Bolts (Upper)

20

2.0

15

3

Handlebar Holder Bolts

25

2.5

18

S

4

Left Switch Housing Screws

3.5

0.36

31in·lb

5

Right Switch Housing Screws

3.5

0.36

31in·lb

6

Steering Stem Head Bolt

108

11.0

80

7

Steering Stem Nut

20

2.0

15

AD:  Apply adhesive.

AL:   Tighten the two clamp bolts alternately two times to ensure even tighten torque.

G:    Apply grease.

L:  Apply 

a 

non-permanent 

locking 

agent. 

Replacement Parts

S:   Follow the speci

fi

 ed tightening sequence.

14-4 STEERING

Special Tools

Steering Stem Nut Wrench     

                                 

Steering Stem Bearing Driver, 

Φ

42.5

Bearing Driver Set      

                             

Steering Stem Bearing Driver Adapter, 

Φ

41.5

STEERING 14-5

Steering Inspection

Refer to the Steering Play Inspection in the 
Periodic Maintenance chapter.

Steering Adjustment

Refer to the Steering Play Adjustment in the 
Periodic Maintenance chapter.