CFMoto ATV CF800-2 4x4. Service Manual - part 8

NOTE

Adjust the engine idling speed before  Adjusting the

 throttle lever free play on Page 114.

1. Loosen nut 

①.

2. Turn adjustment nut 

② 

to

 

lever

 

travel

：

a 

:

3

–

5 mm

.

3. Fasten nut 

①.

Front brake pad check

Check the brake pads 

① 

for damage and wear

.

If 

your dealer replace the pads as a set.

NOTE

he wheels need to be removed to check

brake pads 

①.

-115-

②

①

Maintenance & Lubrication

Rear brake pad inspection

Inspect the brake pads for damage and wear.

 

If the 

thickness 

b 

is less than 1.5 mm have your dealer

replace the pads. 

Inspect brake fluid level

Insufficient brake fluid ma y let air enter the brake system,

 

possibly causing the brakes to become ineffective. 

Before riding,check that the brake fluid is above the 
lower level and replenish when necessary. The front brake fluid master

 

cylinder reservoir is located 

the right of the handlebar. The rear brake fluid master cylinder reservoir is near the rear brake pedal.

 

-116-

①

①

Maintenance & Lubrication

Inspect brake fluid level

Observe these precautions:

1. When checking the fluid level, make sure the top of the master cylinder reservoir is level by turning

the handlebars.

2. Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing

 leakage and poor brake performance.

NOTE

Recommended brake fluid: DOT3 or DOT 4.

3. Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and 

lead to poor brake performance.

4. Be careful that water does not enter the master cylinder reservoir when refilling. Water will signi-

ficantly

lower the boiling point of the fluid and may result in vapor lock.

5. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid imme-

diately.

6. Have your dealer check the cause if the brake fluid level goes down.

-117-

Maintenance & Lubrication

Brake fluid change

Complete fluid replacement should be done only by 

trained service personnel. Have your dealer replace the

following components during periodic maintenance or 

when they are damaged or leaking.

●

Replace the oil seals every two years

；

●

Replace the brake hoses every four years.

Front lever free play

The front brake lever should have a free play of zero

mm (zero in) at the lever end. If not, have your dealer

check the brake system

.  

DANGER(After servicing):

Make sure the brakes operate smoothly and that the

 

free play is correct

;

●

Make sure the brakes do not drag

.

Make sure the brakes are not spongy.

●

All air must be bled from the brake system. Replacement of brake components requires professional

 

knowledge

.

These procedures should be performed by your dealer.

-118-

Maintenance & Lubrication

Rear brake lever free play adjustment

The rear brake lever free play

c

should be 0.5-2mm;

1. Loosen the locknut

①.

2. Turn the adjusting bolt

 ② 

in

a 

direction to increase

free play, and in direction 

b 

to decrease free play.

3.

 

Tighten

 

the

 

locknut

 ①.

If correct free play cannot be obtained, ask your dealer
to make that adjustment.

●

Be sure not to step on the brake pedal.

●

Make sure the brake pedal does not move.

-119-

①

②

Maintenance & Lubrication

Rear brake padal hight adjustment

Adjust the rear brake before inspecting the rear brake pads.

NOTE

The top of the brake pedal should be positioned110

-120

mm above the top of the footrest

.

If

 

not

,

ask

 

your dealer to adjust it

. 

DANGER

After servicing

： 

●

Make sure the brakes operate smoothly and that 

the free

 

play is correct.

●

Make sure the brakes do not drag

;

●

All air must be bled from the brake system.

Replacement of brake components requires 

professional knowledge. These procedures should be 

performed by your dealer.

Rear brake light switch

The rear brake light switch, which is activated by the brake pedal and brake levers, is properly adju-

sted when the brake light comes on just before braking takes effect.

-120-

Maintenance & Lubrication

Rear brake light switch

Check switch assembly or cable is properly fixed in case light failure

.

Cable inspection and lubrication

DANGER

Inspect cables frequently. Replace damaged cables.

 

Lubricate the inner cables and the cable ends. 

If the cables do not operate smoothly, ask your dealer to replace

 

them.

NOTE

Recommended lubricant: SAE 10W30

Rear knockle upper and lower pivot Lubrication:

Lubricate the inner cables and the cable ends. If the 

cables do not operate smoothly, ask your dealer to 
replace them.

-121-

Maintenance & Lubrication

NOTE

Recommended lubricant:

 

Lithium-soap-based grease

Wheel removal

1. Loosen the wheel nuts.

2. Elevate the ATV and place a suitable stand under the frame.

3. Remove the nuts from the wheel.

4. Remove the wheel.

Wheel installation:

1. 

Install the wheel and the nuts.

NOTE

●

Tapered nuts are used for both the front and rear

 

wheels. Install the nut with its tapered side towards 

the wheel

 

●

The arrow mark on the tire must point toward the rotating direction of the wheel.

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Maintenance & Lubrication

2. Lower the ATV so that the wheel is on the ground.
3. Tighten the wheel nuts to the specified torque.

NOTE

Wheel nut torque: Front: 55 N m

; 

Rear: 55 N m 

.

 

Battery

This machine is equipped with

 

service

-

needless

 

battery

.

Therefore it is not necessary to check

 

the

 

electrolyte or

 

add distilled water in the battery. If the battery seems to have discharged, consult 

your dealer.

 

Battery specification

：

12V 30Ah

NOTE

-123-

①

Maintenance & Lubrication

WARNING

Do not try to remove the sealing caps of the battery cells. You may damage the battery.

DANGER

Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out 

of reach of children.

Antidote:

EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of

magnesia, beaten egg or vegetable oil. Get prompt medical attention.

EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from 

sparks,flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed 

space.

Battery

 

maintenance

:

1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark 

place.

 

Completely recharge the battery before reinstallation.

2. A special battery charger (constant voltage/ampere or constant voltage) is required for recharging

 

battery. Use

 

a

 

conventional

 

battery

 

charger

 

may

 

shorten

 

the battery life.

3. Always make sure the connections are correct when putting the

 

battery back in the machine.

-124-

Maintenance & Lubrication

Fuse replacement

1. The main fuse case and the fuse box are 
located under front top cover

2. If a fuse is blown, turn off the main switch

and

 

install a new

 

fuse of the specified amperage.

Then turn on the switches. If

 

the fuse

immediately blows again, consult your dealer.

 Danger:

Always use a fuse of the specified rating.

Never use a material in place of the proper fuse.

1、Spare fuse 10A        2、Spare fuse：15A  
3、fuse: 10A                  4、fuse：15A  
5、Flash relay               6、Start relay Ⅱ 
7、Start  relayⅠ             8、Fuel pump relay     
9、Brake light relay     10、4x4 LOCK relay 

11、2x4 lock relay        12、Fan relay
13、Headlight relay     14、Main fuse：30A

-125-

① ②

14

③ ④

⑤ ⑥ ⑦ ⑧ ⑨

13

⑩ ②

11

②

12

Maintenance & Lubrication

WARNING

To prevent accidental short-circuit

,

turn off the main switch

 

when checking or replacing a fuse.

Headlight bulb replacement:

If a headlight bulb burns out, replace it as follows:

 

1.  Remove headlight cover

;

2

．

Remove the rubber cover at the rear of the headlight

by pulling

 

it off.

3.  Remove the headlight lock spring.

 

4

. 

Pull headlight bulb out from the headlight bulb holder. 

DANGER

5.

 

Wait for the bulb to cool before touching or removing it. Insert a new headlight bulb into the head-

light bulb holder

 

and then lock it by spring.

6. 

Install the bulb holder by turning it clock-wise.

7

．

Install the headlight cover with the bolts.

-126-

①

Maintenance & Lubrication

Headlight beam adjustment

WARNING

It is advisable to have your dealer make this adjustment.

Turn the adjusting screws

①

can raise or lower the beam.

Tail/brake light bulb replacement:

If the tail/brake light bulb burns out, replace it as follows:

1. Open rubber cover, take out tail light/brake

② 

and

 

turning

 

light

①;

2. Insert a new tail/brake light bulb, push it in, and the turning it clockwise

;

3. Install the tail/brake light cover with the screws.

-127-

①

②

①

Maintenance & Lubrication

Front and rear suspension adjustment

The spring preload can be

 

adjusted to suit the rider

'

s 

weight

 

and riding conditions.

NOTE

When adjusting the rear shock absorbers, the

rear wheels need to be removed.

 

adjust the spring

preload as follows.

To increase the spring preload, turn the adjusting ring 

in Direction

 

a 

.

To decrease the spring preload, turn the adjusting ring in Direction

b 

.

NOTE

A special wrench can be obtained at a dealer to make 

this adjustment.

Standard position: B

A- Minimum

 (

soft

)

E- Maximum

 (

hard

)

DANGER

Always adjust the shock absorbers on the left and right

side to the same setting.

-128-

Maintenance & Lubrication

Standard shock absorbers

Vehicle immersion

WARNING

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly
inspected. Take the vehicle to your dealer before starting the engine.

 

For

 

example

,

if

 

engine is not

 

properly handled after immersion

,

starting will damage the engine

.

 

-129-

Maintenance & Lubrication

Optional  shock  absorber  adjustment
（Front adjustment procedures）

Spring adjustment:

Loosen lock nut

② ，

Turn

 

adjust

 

nut

 ③ 

to

 

proper

 

hardness

, 

then

 

tighten

 

lock

 

nut

② .

Damping

 

restore

 

adjustment

：

Turn

 

adjuster

 ④ 

to

 

SLOW

 

side

 

until

 

to

 

end

 

and

 

counter

 

shifts

, 

then

 

turn

 

to

 

FAST

 

side

 

until

 

suitable

 

to

 

your

 

comfort

.

 

Damping

 

press

 

adjustment

：

Turn

 

adjuster

 ① 

to

 

HARD

 

side

 

and

 

counter

 

shifts

, 

then

 

turn

 

to

 

SOFT

 

side

 

until

 

suitable

 

to

 

your

 

comfort

.

After

 

adjustment

, 

keep

 

left

 

and

 

right

 

shock

 

absorber

 

balance

.

ATTENTION

Optional 2 shock absorber adjustment
（Rear adjustment procedures）

Spring

 

adjustment

：

Loosen

 

lock

 

nut

③ ，

Turn

 

adjust

 

nut

②

to

 

proper

 

hardness

, 

then

 

tighten

 

lock

 

nut

③ .

Damping

 

restore

 

adjustment

：

Turn

 

adjuster

 ① 

to

 

SLOW

 

side

 

until

 

to

 

end

 

and

 

counter

 

shifts

. 

then

 

turn

 

to

 

FAST

 

side

 

until

 

suitable

 

to

 

your

 

comfort

.

Damping

 

press

 

is

 

not

 

possible

 

to

 

adjust

.

After

 

adjustment

, 

keep

 

left

 

and

 

right

 

shock

 

absorber

 

balance

.

ATTENTION

-130-

①

②

③

④