CFMoto ATV Terralander CF800-2. Service Manual

1 GENERAL INFORMATION

Maintenance information………… .…1-1

Tightening torque table……………1-13

Location of VIN/EIN ……… ……… …1-3

L ubricants and service products…1-19

General specifications……… ……… 1-4

W iring,pipes&cables ……… …… …1-20

Maint enanc e specificat ions… ……1-6

MIL/ EVAP system… …………… …….24

MAINTENANCE INFORMATION

Operation cautions

1. Engine exhaust fumes are poisonous and can result in loss of consciousness or death. Do not run the

engine in an enclosed or poorly ventilated area.

2. Do not touch the engine or muffler with bare hands after the engine has been just stopped to avoid burns.

Wear long-sleeve work clothes and gloves for operation.

3. Battery electrolyte (dilute sulfuric acid) is highly caustic and can result in burns from contact with skin and

eyes. If you spill electrolyte on skin,flush with water and seek for medical attention immediately. If you spill

electrolyte on clothes,flush with water if to avoid burns. Keep battery and electrolyte out of reach of children.

4. Coolant is poisonous. Do not drink or spill it on skin, eyes or clothes. If you spill coolant on skin,immediately

wash with soap and water. If you spill coolant on eyes, flush with water and seek prompt mediacal attention.

If you swallow coolant, induce vomit and see the doctor. Keep coolant out of reach of children.

5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask.

6. Gasoline is highly flammable. No smoking or fire. Also keep gasoline away from sparks. Vaporized gasoline

is also explosive. Operate in a well-ventilated area.

7. When the battery is being charged, it produces explosive gases. Charge the battery in a well-ventilated area.

8. Be careful not to get pinched by the turning parts like wheels and clutch.

9. When more than two people are operating, keep reminding each other for safety purpose.

Cautions for removal and installation

1. Use genuine CFMOTO parts, lubricants and service products.

3. Clean mud, dust before servicing.

2. Store the removed components separately in order for correct installation.

4. Replace the removed washers, o-rings, piston pin retainers, cotter pins with new ones.

5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers.

6. Clean and blow off the detergent after removal. Apply lubricants on the surface of moving parts. Measure the

data during removal for correct installation.

7. If you do not know the length of screws, install the screws one by one and make sure they are screwed in

with the same depth.

8. Check if the removed rubber parts are aged and replace if necessary. Keep the rubber parts away from

grease.

9. Pre-tighten the bolts, nuts and screws, then torque to specification.The basic sequence is from big to small,

from inner side to outer side and criss-cross.

10.Replace aged rubber parts when assembling. Do not splash gasoline,grease onto the surface,as this

could cause damage.

1-1

11. Apply or inject recommended lubricant to the specified lubrication points.

12. Use special tools when necessary.

13. When ball bearing is removed by pressing steel balls, it can not be reused.

14. Finger turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly.

Replace if the axial or radial play is too big.

z If the surface is uneven, clean with oil and replace if the cleaning does not work.

z When pressing the bearing into the machine or onto the shaft,if the bearing can not be securely seated,

replace it.

15. Install the one-side dust-proof bearing in the right direction. When assembling the open type or double-side

dust-proof bearing, install with manufacturer’s mark outward.

16. Keep the bearing block still when blowing dry the bearing after washing clean. Apply oil or lubricant before

installation.

17. Install the elastic circlip properly. Turn the circlip after assembling to make sure is has been installed into

the slot.

18. After assembling, check if all the tightened parts are properly tightened and can move smoothly.

19. Brake fluid and coolant may damage painting, plastic and rubber parts. Flush with water if splashed on

thses parts.

20. Install oil seal with the side of manufacturer’s mark outward.

z Do not fold or scratch the oil seal lip.

z Apply grease to the oil seal lip before assembling

21. When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if any, into the groove. Replace

the pipes or hoses that cannot be tightened.

22. Do not mix mud or dust into engine and/or the hydraulic brake system.

23. Clean the gaskets and washers of the engine casing before assembling. Remove the scratches on the joint

faces by polishing evenly with an oilstone.

24. Do not twist or bend the cables too much. Distorted or damaged cables may cause poor

25. When assembling the parts of protection caps, insert the caps to the grooves, if any.

ENGINE BREAK-IN

There are many movable components inside the engine, such as piston, piston ring, cylinder, crankshaft,

gears and so on.During initial use period, proper run-in for every critical component is necessary.Break-in can

help engine components match each other better and adjust working condition.Careful treatment of a new

engine will result in more efficient performance and a longer service life.

Recommended break-in period: First 20 hours

Operation guide:

0~10 Hours

Do not operate continously at more than 50% throttle position.

Cool down the engine for every 5~10 minutes after every 1 hour operation.

Avoid sudden acceleration.Vary the throttle position slowly and smoothly.Do not vary the throttle position

rapidly.

10~20 Hours

Avoid long-time run at more than 75% throttle position. Do not open throttle completely during the period.

ATTENTION:

1.Maintain and repair as regular procedures during break-in period.

2.After break-in, do not forget to check and maintain the engine before normal use.

1-2

1 GENERAL INFORMATION

Item

Specifications

Model type

CF800-2

Overall length

2310mm

Overall width

1180mm

Overall height

1340mm

Wheelbase

1480mm

Engine type

2V91W

Displacement

800ml

Fuel type and Octane No.

RQ-93 or higher unleaded gasoline

Dry weight

400 kg

Passengers

2 persons (including driver)

Total vehicle load allowed

2persons +105 kg =255 kg

AT26×9—12 49J

Front

AT26×9—14 48J

Tire

AT26×11—12 55J

Rear

AT26×11—14 54J

Min. ground clearance

270mm

Min. turning radius

8000mm

Starting

Electric start

Type

V-twin cylinder,4-stroke,liquid-cooled,8 valves,SOHC

Valves

SOHC /Timing chain drive

Bore×Stroke

91mm×61. 5mm

Compression ratio

10.3:1

Engine

Lubrication

Wet sump, replaceable oil filter

Oil pump

Rotor drive

Oil filter

Paper type, replaceable

Engine oil type

SAE15W-40/SG or higher

Cooling system

Liquid-cooled/close-loop cooling

Coolant type

-30℃anti-corrosion and anti-freezing

1-4

1 GENERAL INFORMATION

Item

Specifications

Air filter type

Paper filter element

Air intake

Type

0800-173000

devices

Throttle body

Diameter of throttle body

48mm

Fuel tank capacity

23 L

Clutch type

Wet shoes and auto centrifugal

Transmission type

CVT+ Gearshift

Gearshift

High, Low and Reverse

Gearshift

Manual operation/L-H-N-R-P

methods/orders

CVT ratio range

2.88~0.70

“H” gear

“L” gear

“R” gear

Drive train

Final ratio

1.333

Gearshi

Secondary ratio

1.952

ft ratio

Single gear ratio

1.143

2.529

2.231

Total ratio

2.975

6.585

5.807

Front

33 / 9 = 3.667

Ratio of drive gear

Rear

33 / 9 = 3.667

Output type

Front/Rear shaft drive

Rotation of engine output

When forward, clockwise (rear view)

Left

31º

Steering

Turn angle

Right

31º

Front

Hydraulic Disc

Brakes

Rear

Hydraulic Disc

Suspension

Double A-arm and independent

Frame type

Steel tube and plate

1-11

MAINTENANCE SPECIFICATIONS

Lubrication System

Ite m

Standards

Service Limit

Oil Change

3400ml(without oil filter replacement)

Oil Change

3500ml(with oil filter replacement)

Engine OiL

Capacity

Oil Capacity

3600ml

Oil

600ml(Note:fill after first start)

and Hose s

20W-50

Recommended engine oil:SAE 15w40 API SG.If it’s not

15W-40,15W-50

available,select alternative according to the following

Grade

10W-40,10W-50

specifications.

10W-30

API classifications: SG or higher

5W-30

Viscosity rating: according to the left chart

-30 -20 -10 0 10

20 30 40

-22 -4

14 32 50 68

86 104

Clearance Between

0.06-0.14mm

0.25mm

and Outer Roto r

Clearance Between Oute r

0.09-0.15mm

0.25mm

Rotor and Bore

Oil Pump Rotor

Rotor End Clearance

0.023-0.109mm

0.20mm

1500rpm:70-300kPa(90 ),Typical:180kP a

Oil Pressure

6000rpm:350-550kPa(90),Typical:420kP a

Air Intake System

Ite m

Standards and Specifications

Fuel Tank

Total Capacity

23L

Throttle Body Part NO

0800-173000

T-MAP Sensor Part No .

0800-175000

Fuel

0800-171000

1300

100rpm

1-6

1 GENERAL INFORMATION

I tem

Sta nd a rd s

S e r v i c e l im i t

F ull c a p a ci t y

3 0 0 0ml

C a p a ci t y o f r e s e r v oi r

380～6 0 0ml

C o ol a n t c a p a ci t y

ta n k

Sta n d a rd d e n si t y

50%

O p e ni n g p r e s s u r e

1 0 8 k p a (1 . 1 k g f /cm ²)

O p e ni n g

6 5±2℃

tempe ra tu re

F ull y o p e ni n g

85℃

Th e rm o s ta t

Tr a v el wh e n f ul l y

W h e n 85℃，＞5mm

o p e ni n g

W a te r

Resistant of B

Resistant of A,C

tempe ra tu re（℃）

terminal（Ω）

terminal（kΩ）

R el a ti o n sb e t we e n

-20

----

2 8 .5 8 2±0 .0 0 4

wa t e r t em p .an d r e si s ta n

t o f wa te r t em p . s e n s o r

-----

2 . 7 9 5±0 . 0 0 2 5

216.0-216.4

0.98±0 . 0 0 2 2 7

74.6-90.6

0 . 3 3 4±0 . 0 0 2 0 4

110

32-36

0 . 1 3 3±0 . 0 0 2 5 2

A r o u n d 8 8℃

O F F - ON

W o rki n g tem p . o f

the rm o s wi tc h

A r o u n d 8 2℃

ON - O F F

- 30℃ a n ti -f r e e zi n g , a n ti -c o r r o si ve a n d hi g h b oili n g p oi n t

C o ol a n t t y p e

1-7

1 GENERAL INFORMATION

Item

Standard value

Service limit

Longitude

1.0mm

2.0mm

Rim jump

Transverse

1.0mm

2.0mm

Front wheel

Remaining

3.0mm

Front tire

groove

Pressure

45kPa（0.45kgf／cm²）

Service

Item

Standard value

limit

Longitude

1.0mm

2.0mm

Rim jump

Transverse

1.0mm

2.0mm

Rear wheel

Remaining

3.0mm

Rear tire

groove

Pressure

45kPa（0.45kgf／cm²）

Item

Standard value

Service limit

Free play of brake lever

0mm

Front brake

Thickness of brake disc

3.5mm

2.5mm

Free play of brake lever

10-20 mm

Rear brake

Free play of brake pedal

0mm

Thickness of brake disc

7.5mm

6.5mm

1-8

1 GENERAL INFORMATION

Item

Standards

Type

Magneto 3-phase AC generator

Output

3-phase AC output

Resistance of coil（20℃）

0.2Ω-0.3Ω

Resistance of pick-up coil

250Ω-300Ω

AC Flywheel

Voltage without load(cold engine)

＞100V（AC），5000r/min

Max. output power

350W，5000r/min

Stable voltage

13.5V-15.0V, 5000r/min

Peak voltage of pick-up

≥1.5V，200 r/min

3-phase supply

power

Regulator type

thyristor trigger circuit

Capacity

12V 30Ah

Voltage

Fully recharged

14.4V

between

Battery

Not-fully recharged

≤11.8V

terminals

Recharging

Standard

1A／5～10H

current/time

Quick

5A／1H

Item

Standards

Ignition type

ECU

Type

Resistant-type

Standard

DCPR8E

(NGK)

Spark plug

Gap of spark plug

0.8-0.9mm

Characteristic

＞8mm，under 1Kpa

Ignition time

BTDC10º

1500r/min

Resistance

Primary

0.70Ω-0.75Ω

ignition coil

Secondly

6.0kΩ-7.0 kΩ

Peak voltage

Primary

＞150V

Pulse voltage

Resistance of starter relay coil

3Ω-5Ω

Resistance of auxiliary relay coil

90Ω-100Ω

Item

Standards

Main

30A

Fuse

Auxiliary

10A×1

15A×5

Headlight（Hi／Lo）

12V—35W/35W×2

Front position light

12V—5W×2

Brake light/Tail light

12V—21W/5W×2

Turn signal light

12V—10W×4

Light & Bulb

Dashboard indicator light

LED

Water temperature, fuel level,2x4 drive indicator

LCD

light

MIL

LED

1-8

1 GENERAL INFORMATION

Valves & Cylinder Head

Item

Standard value

Service limit

Remarks

Intake valve

φ33

——

Dia. Of valve neck

Exhaust valve

φ29

——

Thickness of valve neck

Intake/Exhaust

0.5

Intake

0.06-0.14

——

Valve clearance(cold engine)

Exhaust

0.11-0.19

——

Inner dia. Of valve guide

Intake/Exhaust

5.000-5.012

5.045

Gap between valve guide and

Intake

0.020-0.047

stem

Exhaust

0.030-0.057

Intake

90.1

Valve length

Exhaust

88.7

Intake valve

1.2±0.1

1.7

Width of valve seat seal

Exhaust valve

1.3±0.1

1.8

Valve spring free length

Intake/Exhaust

38.2

33: 200-235N

Elasticity of valve spring

Intake/Exhaust

23: 530-587N

Axial clearance of camshaft

0.12-0.28

Camshaft run-out

0.10

Bore diameter of rocker arm

Intake/Exhaust

12.000-12.018

12.03

Flatness of cylinder head bottom

0.03

0.05

surface

1-10

1 GENERAL INFORMATION

Cylinder, Piston, Piston Ring & Crankshaft

Item

Standards

Service limit

Remarks

Cylinder compression

1000kPa

Piston/Cylinder clearance

0.03-0.05

0.10

Flatness of cylinder top and bottom

0.03

0.05

surface

1st ring

0.25-0.40

1.5

Gap of piston ring

2nd ring

0.35-0.45

1.5

Oil ring

0.2-0.7

1.5

1st ring

1.17-1.19

Height of piston ring

2nd ring

1.47-1.49

Oil ring

2.37-2.47

1st ring

1.21-1.23

Height of piston groove

2nd ring

1.51-1.53

Oil ring

2.50-2.52

1st ring

0.02-0.06

0.15

Ring/Piston groove clearance

2nd ring

0.02-0.06

0.15

Oil ring

0.03-0.15

0.25

Piston bore

22.004-22.010

Inner diameter of small end of

22.01-22.02

22.06

connecting rod

Diameter of piston pin

21.995-22.000

21.980

Gap of piston/piston pin

0.004-0.015

0.08

Gap of piston pin/small end hole of

0.010-0.025

0.08

connecting rod

Side gap of big end of connecting

0.3-0.56

0.8

rod

Gap of connecting rod bearing

0.022-0.049

0.09

Gap of main bearing

0.02-0.05

0.09

Gap of crankshaft axial direction

0.05-0.35

0.6

1-11

1 GENERAL INFORMATION

Clutch + CVT + Gearbox

Item

Standard value

Service limit

Remarks

Inner dia. of clutch friction disc

140.00-140.15

140.5

Clutch engagement RPM

1800-2400r/min

Clutch locking RPM

3300-3900r/min

Belt width

34.5（Cord layer）

33.5

Free length of driven pulley spring

238.5

Hole dia. of driven pulley collar

38.10-38.14

38.30

Groove width of gearshift

6.10-6.20

6.30

Output gear width of driven shaft

6.10-6.20

6.30

Thickness of left and right gearshift fork

5.80-5.90

5.70

Clearance between gearshift fork and

0.20-0.40

0.50

engagement groove

Groove width of gearshift drum

8.05-8.10

Dia. of gearshift pawl pin

7.90-7.95

7.83

1-12

1 GENERAL INFORMATION

Tightening Torque

Items

Torque N·m(kgf·m)

Items

Torque N·m(kgf·m)

5mm Bolt,Nut

(0.5)

5mm Screw

(0.4)

6mm Bolt,Nut

(1.0)

6mm Screw

(0.9)

8mm Bolt,Nut

(2.0)

6mmSH Flanged bolt

(1.0)

10mm Bolt,Nut

(3.5)

6mm Flanged bolt, nut

(1.2)

12mm Bolt,Nut

(5.5)

8mm Flanged bolt, nut

(2.0)

10mm Flanged bolt, nut

(4.0)

Fasteners not included in below table should also be torqued to specification. Note: Threads and contact area should

be applied by engine oil.

Ref. No.

Items

Part number

Qty

Torque（N·m）

Mount bolt, upper part of engine

GB5789 M8×35

35～45

Bolt, upper bracket of engine

GB5789 M10×1.5×20

40～50

Mount bolt, front and left side of engine

GB5789 M10×1.25×125

40～50

Mount bolt, front and right side of engine

GB5789 M10×1.25×100

40～50

Mount bolt, front bracket of engine

GB5789 M8×20

35～45

Mount bolt, rear part of engine

GB5789 M10×1.25×170

40～50

Bolt, rear bracket of engine

GB5789 M8×20

35～45

Bolt, rocker arm

GB5789 M10×1.25×70

40～50

GB5789 M10×1.25×50

Bolt, front shock absorber

40～50

GB5789 M10×1.25×70

GB5789 M10×1.25×50

Bolt, rear shock absorber

40～50

GB5789 M10×1.25×70

Bolt, bracket of rear wheel axle

GB5789 M10×1.25×140

40～50

Mount nut, rim

901B-070002

70～80

Nut, rim shaft

901-07.00.03

110～130

Bolt, rear brake caliper

GB70 M10×1.25×20

30～40

Bolt, front brake disc

901-08.00.03

25～30

Bolt, front brake caliper

GB5789 M8×16

15～25

Bolt, cover of handlebar

GB5789 M8×55

15～25

Mount bolt, muffler

GB5789 M10×1.25×70

40～50

Lower bolt, muffler body

GB5789 M8×68

15～25

Bolt, muffler clamp

GB5789 M8×35

15～25

Bolt, rear axle

GB5787 M10×1.25×110

40～50

Bolt, front axle

GB5787 M10×1.25×90

40～50

Bolt, front axle

GB5787 M10×1.25×25

40～50

Bolt, bracket of front axle

GB5789 M8×14

15～25

Bolt, rear end of rear drive shaft

9010-300001

40～50

Bolt, front end of rear drive shaft

9010-290001

30～40

Bolt, front drive shaft

9010-290001

30～40

1-13

1 GENERAL INFORMATION

Item

Qty

Dia. Of thread(mm)

Torque (N.m)

Remarks

Bolt M14X1.5

M14×1.5

Plug screw, oil passage of left crankcase

ZM14

Apply glues

Oil drain boltM12×1.5

M12×1.5

Flange bolt M8×12.5 (left crankcase)

M8×12.5

Screw R21/8 (oil passage)

R21/8

Apply glues

Nut M6(right crankcase)

Stud AM6×35-8.8 (right crankcase)

AM6×35

Threadlocker

Screw M6×12（CVT cover）

M6×12

Bolt of wiring clamper(left crankcase cover)

M5×10

Threadlocker

Screw of oil seal plate(left crankcase cover)

M6×8

Bolt M12×1.25(Magneto rotor)

M12×1.25

105

Threadlocker

Adjust nut, valve clearance

Bolt, timing sprocket

Threadlocker

Plunger, tensioner

M16×1.5

0.1

Plug screw, tensioner

M18×1

4.5

Bolt, cylinder

M10

20,60

Thrust nut M8（exhaust pipe）

Spark plug

M12×1.25

Stud M8x42（exhaust pipe）

M8×42

Threadlocker

Plug screw M12×1.5（head of cylinder 1）

M12×1.5

Tapping screw ST5.5×13(thermostat cap)

ST5.5×13

Screw, tensioner plate

M6×15.5

Threadlocker

Bolt M8, intake manifold

Bolt, connecting rod

M9×1

10,20,50

Nut M18x1.5(left)（right crankcase）

M18×1.5

Left thread

1-14

1 GENERAL INFORMATION

To be continued

Item

Qty

Thread Dia. (mm)

Torque (N.m)

Remarks

Nut, drive shaft（CVT drive pulley）

M20×1.5

115

Threadlocker

Nut,main shaft（CVT driven pulley）

M20×1.5

115

Threadlocker

Lock nut, bevel gear

M22×1

145

Bolt M8x28(bearing seat, drive bevel gear)

M8×28

Screw M8x5（bearing holder, drive bevel gear）

M8×5

Stopper nut,M65X1.5(driven bevel gear)

M65×1.5

110

Threadlocker

Nut M8X28(bearing housing, driven bevel

M8×28

gear)

Screw T25(shift fork drum)

M5×8

Spring seat, Limit

M12×1

Screw M5×16（oil pump）

M5×16

Threadlocker

Screw M8X20（overriding clutch）

M8×20

Threadlocker

Bolt M6×30（Magneto stator）

M6×30

Threadlocker

Bolt, valve cap

Bolt M6×45(thermostat cap, cylinder 1)

M6×45

Bolt M6×25

(Tensioner, thermostat cap

M6×25

cylinder 2）

Water temperature sensor

M12×1.5

Switch of oil pressure

M10×1

Threadlocker

Retainer, bearing (left)

Threadlocker,l

M55×1.5

eft thread

4.5-5.5

Other bolts

8-12

1-15

1 GENERAL INFORMATION

Engine Service Tools

Item

Tool name

Specifications

Purposes

Vernier caliper

0-150mm

Measure length and thickness

Micrometer

0-25mm

Measure outer diameter of rocker arm shaft, valve stem, camshaft

Dial gauge

25-50mm

Measure Max. travel of camshaft

Dial gauge

75-100mm

Measure size of piston skirt

Inner dia. of cylinder

Measure cylinder size & pressure

meter

Inside

caliper

Measure inner diameter of rocker and piston pin hole, connecting

10-34mm

micrometer

rod hole

Dial indicator

1/100

Measure jump

Knife straight edge

Measure flatness

Feeler gauge

Measure flatness and adjust valve clearance

Oil guage

Measure fuel level of carburetor

Plastigauge

Measure fit clearance

Spring balance

Measure elasticity of spring

RPM meter

Measure RPM

Compression tester

Measure cylinder compression

and adapter

Oil pressure meter

Measure oil pressure

Air pressure meter

Measure opening pressure of radiator cover

Ohmmeter

Measure resistance and voltage

Amperometer

Measure current of switch

Thermometer

Measure coolant temp.

Timing light

Measure ignition timing

Torque wrench

One set

Measure tightening torque

Alcohol light

Warm up or increase temp.

Magnetic meter seat

Mounting dial indicator

Plate

Auxiliary measurement

V-shaped bluff

Auxiliary measurement for jump

Nipper

Mounting valve lock-clip

Double clip reed

Disassembly and assembly of double clip

Pinching tools

Disassembly and assembly of retainer

Impact driver

Disassembly of crosshead bolt

Screw driver

Plus driver

1-16

1 GENERAL INFORMATION

Service Tools

Part number

Tool name

Purposes

0800-000000-871-001

Joint, oil hose

Measure oil pressure

0800-014001-922-003

Remover, bearing 60/28 of left crankcase

Remove bearing 60/28

0800-014001-921-002

Press tool, bearing of left crankcase

Press bearing

0800-041000-922-001

Screw, locking crankshaft

Lock crankshaft

0800-031000-922-001

Remover, magneto rotor

Remove magneto rotor

0800-013201-922-001

Remover, bearing 6003 of CVT case

Remove bearing 6003

0800-013201-921-001

Damper, CVT case cover

Support CVT case cover when

pressing bearing

0800-052000-922-003

Split tool, drive & driven pulley

Split driven fixing and moving

sheave to install belt

0800-051204-923-001

Installation tool, drive pulley oil seal

Install drive pulley oil seal 35×42×4

0800-052000-922-002

Remover, driven pulley

0800-052000-922-001

Wrench, CVT driven pulley

Fix nut of driven pulley when

installation

0800-013101-922-001

Remover, bearing 6208 of CVT case

Remove bearing

0800-013101-921-001

Damper, CVT case

Support CVT case when pressing

bearing

0800-013104-923-001

Installation tool, clutch housing oil seal

Install oil seal of CVT clutch

housing34×55×9

9010-180100-922-001

Radiator test cap

Measure cooling system pressure

0800-014001-922-002

Puller, oil seal

Remove oil seal

0800-014001-922-001

Puller, bearing

Remove bearing

0800-014001-921-003

Press tool, bearing

Press bearing

0800-022800-922-001

Sleeve, spark plug

Disassemble/install spark plug

0800-024001-922-001

Locking tool, camshaft

Lock up and fix camshaft

0800-000000-871-002

Joint, cylinder pressure meter

Measure cylinder pressure

0800-022102-922-001

Remover, valve guide

Remove valve guide

0800-022102-922-002

Installer, valve guide

Install valve guide

0800-040003-922-001

Compressor, piston ring

Compress piston ring when

installation

0800-040005-922-001

Installer, circlip

Install circlip of piston pin

0800-011201-923-001

Oil seal installer, breather

Install oil seal of breather

0800-011201-921-003

Installation jig, breather gear shaft

Support breather gear shaft

0800-011201-921-001

Press tool, breather gear shaft

Press breather gear shaft

0800-011101-922-001

Support tool, left crankcase plain

bearing

Support left crankcase when

removing

removing plain bearing

0800-012101-922-001

Support tool, right crankcase plain

bearing

Support right crankcase when

removing

removing plain bearing

0800-011102-922-001

Remove/install tool, roller bearing

Remove/install bearing

0800-060000-923-001

Press tool, front output shaft oil seal

Install oil seal35×61×9 of front output

shaft

1-17

1 GENERAL INFORMATION

0800-062301-923-001

Installer, front output shaft

Install front output shaft

0800-062206-922-001

Nut sleeve, driven bevel gear bearing

Install/remove nut of driven bevel

gear

0800-062204-923-001

Press tool, oil seal of driven bevel gear

Install oil seal of driven bevel gear

34×50×7

0800-062000-922-001

Backlash measurement tool

Measure backlash between drive

bevel gear and driven bevel gear

0800-060002-922-001

Remover, shaft of reverse immediate gear

Remove shaft of reverse immediate

gear

0800-011000-922-001

Remover, left crankcase bearing

Remove bearing of left crankcase

0800-012000-922-001

Remover, right crankcase bearing 5206

Remove bearing 5206

0800-012101-921-001

Damper, right crankcase

Support right crankcase

0800-011101-921-001

Damper, left crankcase

Support left crankcase

0800-060000-922-001

Press tool, reverse immediate gear shaft

Press reverse immediate gear shaft

0180-014001-921-001

Press tool, left crankcase cover bearing 60/28

Press bearing 60/28

0180-013201-921-001

Press tool, CVT case cover bearing 6003

Press bearing 6003

0180-013207-923-001

Press tool, oil seal of CVT case cover

Press oil seal

0180-051000-922-001

Holding Wrench, CVT drive pulley

Stop rotation of drive pulley

0180-013101-921-002

Press tool, CVT case bearing 6207

Press bearing

0180-053100-921-002

Press tool, clutch housing

Press clutch housing

0180-053100-921-001

Damper, clutch housing

Support clutch housing when

pressing clutch

0180-054000-922-001

Holding wrench, clutch

Stop clutch rotation

0110-080005-923-001

Press tool, oil seal of water pump

Install oil seal

10×20×5 of water

pump

0010-081004-921-001

Press tool, water seal

Press water seal

0180-022006-922-001

Valve spring compressor clamp

Compress, remove valve spring

0180-060008-922-001

Wrench, circlip of front output shaft bearing

Install/Remove front output shaft

bearing circlip

0180-062201-921-003

Press tool, driven bevel gear shaft bearing

Press bearing

（6207C3）

0180-062103-921-002

Press tool, drive bevel gear shaft bearing

Press bearing

（6305）

0010-060002-921-002

Installer, bearing 6203

Press bearing

0180-012100-921-004

Installer, bearing 3206A

Press bearing

0180-011100-921-004

Press tool, gearshift shaft bearing 6303

Press bearing

0040-012001-921-002

Press tool, bearing 6203

Press bearing

1-18

1 GENERAL INFORMATION

Lubricants and Service Products

Item

Type

Lubrication points

Remarks

SAE15W-40

Engine oil

Cylinder,Crankcase,Cylinder

API : SG or higher

head,see page（10-3）

(Alternative please see page 1-6)

Molybdenum

Piston pin, valve stem, valve

disulfide grease

oil seal, camshaft

Oil seal, O-ring and other

rubber seals. Sealed

Grease

No. 3 MoS2 grease

bearing, CVT bearing and

bushing

Coolant

Coolant capacity

-30℃Anti-freezing, anti-corrosive,

Engine cooling system

depends on

high-boiling coolant

radiator pipes

Silicone sealant

Loctite5699

Crankcase splitting

surfaces,contact surface

between crankcase and

cylinder,contact surface

between cylinder head and

valve cover

Threadlocker

KB243

Some threads

Retaining compound

KB648

Oil seal

1-19

WIRING,PIPES& CABLES LOCATION

1.Fuse box 2.Negative cable, battery 3.Battery case 4.Positive cable,battery 5.Starter relay 6.PDA connector

7.Radiator cap 8.Relay of headlight

9.Fan relay

10. 2x4 drive relay 11. 4x4 drive lock relay 12. Relay of

brake light 13. Relay of fuel pump 14. Starter auxiliary relay (1) 15. Starter auxiliary relay(2) 16. Flasher relay

17. Cap,reservoir tank

NOTE:Before check or repair above items, front top cover shoud be removed, but when check starter relay,

it can be operated from upper part of front left wheel.

1.Dashboard connector 2.Connector of ignition switch 3.Connector,cigeratte lighter 4.Connector,left handle-

bar switch

5.Winch control unit 6.Connector,right headlight 7.ECU connector 8.ECU 9.Connector, right handlebar switch

10.Connector, winch motor switch

Before checking above items, seat, front rack, left and right side panel, cover of air filter and front fender should

be removed.

1-20

1.Connector,tail light/brake light/rear turn light 2.Connector, rear licence light 3.Breather hose, fuel evaporated

system(Note:For Euro standard, ATV is without fuel evaporated system, so the breather hose is only for

balancing pressure of fuel tank. It’s important to avoid hose blocked, otherwise fuel pump will be damaged. At

the same time, avoid to overfill fuel. 4.Connector, trailer power socket 5.Trailer power socket

Attention: Voltage of trailer power socket (DC12V) Max. current is less than 10A. The socket is only used for

power supply for rear turn light of trailer, tail light and rear licence light.

1.Throttle cable 2.Connector, pick-up coil 3.Throttle body 4. TPS 5. Air by-pass valve6. Injector 7. Water temp.

sensor 8. Water pipe 9. Air intake temp. sensor 10. Ignition coil

1-22

MIL

MIL is located at position

When the light flashes, it will indicate there’s some-

thing wrong in vehicle.The flash code consists of 4

digits.

Example

0650

“0” means flash 10 times;

“6” means flash 6 times;

“5” means flash 5 times;

“0” means flash 10 times.

Detailes please refer to page (15-27).

Also PDA can be used for diagnosis. please see page

(1-19) and (15-26) to know “How to use PDA”.

EVAP(Evaporative Emission Control System)

The system is only assembled for specified regions (such as USA california state). For European countries

and other regions, it’s not available.

If there is something wrong for EVAP, please contact local dealer for service. Do not modify the system without

approval, otherwise it will not in accordance with related laws and regulations. After disassembling the system,

check if fuel hoses are good, if any air or fuel leakage, if any blocked, if any damaged.Evaporative fuel goes into

canister through disorption hose. When engine stops, carbon inside canister can adsorp evaporative fuel.

When engine starts, fuel inside canister will go to combustion chamber through disorption hose to avoid going

out to pollute air. Meanwhile adsorption hose can balance air pressure inside fuel tank to protect fuel tank and

fuel pump.

Working Flow Layout

Fuel

Tank

Engine

Throttle Body

Air Filter

1. Clamp 2.Vacuum pipe of canister 3. Two way valve 4. Vaccum pipe (2) 5.Evaporative fuel pipe(2) 6.Evapo-

rative fuel pipe(1) 7.Clamp 8.Water pipe joint 9.Evaporative fuel pipe (3) 10.Clamp 11.Canister

1-24

2 BODY AND MUFFLER

Maintenance Information

2-1

Rear Fender

2-10

T roubleshooting

2-1

LH Footboard,LH Headlight Protector..2-11

F ront Rack,Battery Cover

2-2

Rear LH Bumper Guard,Rear Bumper, Bumper

R ear Rac k

2-3

Protector……………………………………2-12

Passenger Seat,Driver Seat

2-4

Front Bumper,Headlight trim

2-1 3

Air Filter Cover,Dashboard Cover

2-5

Taillight Trim,Rear F ascia

2-14

Gearshift Lever Knob, Lever Indicator,

Front LH Sus pension Protector,

LH Side Panel

2-6

Rear LH Sus pension Prot ec tor

2-15

RH Side Panel,Front Fender Extension,LH..2-7

Fuel Tank

2-16

Front Fender Extension,RH,

Muff ler

2-17

R ear Fender Extension,LH

2-8

Body and Accessories

2-18

C enter Front Fas cia,Front Fender

2-9

MAINTENANCE INFORMATION

Operation Cautions

WARNING:

Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special atten-

tion should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should

be done in a well-ventilated place.

Remove and Install muffler after it is fully cold.

z This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe, muffler and fuel tank.

z Hoses, cables and wires should be routed properly.

z Replace the gasket with a new one after muffler is removed.

z After muffler is installed, check if there is any exhaust leakage.

Tightening Torque

Muffler Rear Fixing Bolt: 35-45N m

Muffler Exhaust Pipe Bolt: 35-45N m

Muffler Body Fixing Bolt: 35-45N m

Troubleshooting

Loud exhaust noise

z Broken muffler

z Exhaust leakage

Insufficient power

z Deformed muffler

z Exhaust leakage

z Muffler clogged

2-1

2 BODY AND MUFFLER

AIR FILTER COVER

Removal

Remove passenger seat(

2-4);

Remove driver seat(

2-4);

Lift the rear of air filter cover no.1 to disengage plastic

latches then pull the air filter cover backward to re-

move it.

Installation

Reverse the removal procedure for installation.

DASHBOARD COVER

Remove passenger seat set(

2-4);

Remove driver seat(

2-4);

Remove air filter cover(

2-5);

Remove push rivets no.4;

Remove tapping screws no.3;

Remove dashboard cover no.2;

Unplug dashboard connectors no.5;

Unplug cigarette lighter connector no.6;

Unplug ignition switch connector no.7.

Installation

Reverse the removal procedure and direction for

installation.

2-5

GEARSHIFT LEVER KNOB

Removal

Loosen locking nut no.2;

Remove gearshift lever knob by turning it

counterclockwise.

Installation

Reverse the removal procedure and direction for

installation.

GEARSHIFT LEVER INDICATOR

Removal

Remove gearshift lever knob;

Remove screw no.4;

Remove lever indicator no.3.

Installation

Reverse the removal procedure and direction for

installation.

LH SIDE PANEL

Removal

Remove passenger seat set(

2-4);

Remove driver seat(

2-4);

Remove air filter cover(

2-5

Remove gearshift lever knob ;

Remove lever indicator;

Remove push rivets no.5;

Remove bolts no.6;

Remove tapping screws no.8 retaining front and rear

fender;

Remove latch no.9;

Remove side panel.

Installation

Reverse the removal procedure and direction for

installation.

2-6

2 BODY AND MUFFLER

CENTER FRONT FASCIA

Removal

Remove the 2 tapping screws no.2;

Remove push rivets no 3;

Remove center front fascia.

Installation

Reverse the removal procedure for installation.

FRONT FENDER

Removal

Remove front rack(

2-2);

Remove passenger seat(

2-4);

Remove operator seat(

2-4);

Remove air filter cover(

2-5);

Remove dashboard front cover(

2-5);

Remove gearshift lever knob(

2-6);

Remove lever indicator(

2-6);

Remove front LH&RH fender extension(

2-7);

Remove L&R side panel(

2-7);

Remove front center fascia;

Remove push rivets no.5&7;

Remove bolts no.4;

Remove tapping screws no.6;

Remove bolts no.8;

Remove bolts no.9;

Remove bolts no.10;

Remove bolts no.12;

Remove fuse box;

Remove front fender no.11.

Installation

Reverse the removal procedure for installation.

2-9

2 BODY AND MUFFLER

LH FOOTBOARD

Removal

Remove passenger seat(

2-4);

Remove driver seat(

2-4);

Remove air filter cover(

2-5);

Remove side panel(

2-6);

Remove the bolts,nuts retaining front and rear

mudguard;

Remove bolts no.1;

Remove screws no.1;

Remove LH footboard no.2.

Installation

Reverse the removal procedure for installation.

RH FOOTBOARD

Removal

Remove gearshift lever knob(

2-6);

Remove lever indicator(

2-6);

Refer to LH Footboard Removal&Installation.

HEADLIGHT PROTECTOR,LH

Removal

Remove bolts no.4;

Remove headlight protector,LH.

Installation

Reverse the removal procedure for installation.

HEADLIGHT PROTECTOR,RH

Removal&Installation

Refer to LH Headlight Protector

Removal&Installation.

2-11

2 BODY AND MUFFLER

FRONT BUMPER

Removal

Remove front bumper protector(

2-12);

Remove bolt no.2;

Remove front bumper no.1.1

Installation

Reverse the removal procedure for installation.

HEADLIGHT TRIM

Removal

Remove front rack(

2-2);

Remove passenger seat(

2-4);

Remove driver seat(

2-4);

Remove air filter cover(

2-5);

Remove dashboard cover(

2-5);

Remove font LH&RH fender extension(

2-7);

Remove LH&RH side panel(

2-6);

Remove center front fascia(

2-9);

Remove front fender(

2-9);

Remove bolts no.4;

Remove bolts no.5;

Disconnect headlight connectors;

Remove headlight trim no.3.

Installation

Reverse the removal procedure for installation.

2-13

TAILLIGHT TRIM

Removal

Remove rear rack(

2-3);

Remove passenger seat(

2-4);

Remove operator seat(

2-4);

Remove air filter cover(

2-5);

Remove rear LH&RH fender extension(

2-8);

Remove LH&RH side panel(

2-6);

Remove rear mudguard(

2-10);

Remove rear LH&RH bumper guard(

2-12);

Remove rear bumper(

2-12);

Remove bolts no.2;

Disconnect tail light,license plate light,rear turn lights

connectors;

Remove taillight trim no.1.

Installation

Reverse the removal procedure for installation.

REAR FASCIA

Removal

Remove rear LH&RH bumper guard(

2-12);

Remove rear bumper(

2-12);

Remove bolts of taillight trim;

Remove bolts no.4;

Remove rear fascia no.3.

Installation

Reverse the removal procedure for installation.

2-14

FUEL TANK

Removal

WARNING:

Gasoline is highly flammable, therefore smoke and

fire are strictly forbidden in the work place.

Special attention should also be paid to sparks. Gaso-

line may also be explosive when it is vaporized, so

operation should be done in a well-ventilated place.

Remove passenger seat set(

2-4);

Remove driver seat(

2-4);

Remove bolts no.4;

Remove push rivets no.1;

Remove bolts no.2;

Remove bolts no.6;

Remove bolts no.7;

Remove rear plastic parts;

Disconnect fuel pump connector;

Unplug high pressure fuel line connector;

Remove fuel tank breather hose and hoses of fuel

evaporation control system;

Disconnect fuel pump connector;

Remove bolts no.5;

Remove bolts no.9;

Remove fuel tank no.8.

2-16

2 BODY AND MUFFLER

MUFFLER

WARNING:

Remove and Install muffler after it is fully cold.

Removal

Remove passenger seat set(

2-4);

Remove operator seat(

2-4);

Remove air filter cover(

2-5);

Remove RH side panel(

2-7);

Remove LH side panel(

2-6);

Remove bolts&nuts no.2;

Remove heat shield no.1;

Remove bolts&nuts no.4;

Remove heat shield no.3;

Remove bolts no.7;

Remove heat shield no.6.

Remove bolts no.9;

Remove heat shield no.8;

Remove bolt no.10 and the clamp;

Installation

Reverse the removal procedure for installation.

NOTE:

Replace the gasket on the exhaust port when installing.

2-17

3 INSPECTION AND ADJUSTMENT

Maint enance Information………… ……3-1

Suspension Syst em……… ………… ..3-11

Maintenance Interval…………………3-2

Gearshift Linkage, Fuel System… ….3-12

Maintenance Procedure……………..3-3

Throttle Lever…………………………3-13

Steering C ol umn, Brake S ys tem…. 3-6

Cooling System…………………………3-14

Wheel……………………… ……………...3-9

Lighting System… ………… ……… …3-16

MAINTENANCE INFORMATION

Operation Cautions

WARNING:

z Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness result-

ing in severe injury or death.Never run an engine in an enclosed area.

z Don’t perform the maintenance immediately after the engine stops,as the exhaust system and en-

gine become very hot.Serious burns could result from the contact with the exhaust system or

engine.Wear long-sleeved uniform and gloves to operate when necessary.

z Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Spe-

cial attention should also be paid to sparks.Gasoline may also be explosive when it is vaporized, so

operation should be done in a well-ventilated place.

z Don’t get pinched by the drive system and other rotational parts.

ATTENTION:

Always position the vehicle on level ground.

3-1

3 INSPECTION AND ADJUSTMENT

Maintenance Intervals

Careful periodic maintenance will assure your vehicle good performance, reliability, economy and durability.

Inspection, adjustment, lubrication and other details are explained in below periodic maintenance chart.

ATTENTION：Maintenance intervals in the following chart are based upon average riding conditions.

Vehicles subjected to severe use must be inspected and serviced more frequently.

A：Adjust

10 hours or 300km

C：Clean

Every 25 hours or 750km

I： Inspect

Every 50 hours or 1500km

L：Lubricate

Every 100 hours or 3000km or 1year

R：Replace

Every 200 hours or 6000km or 2 years

Remark

Engine

Engine Oil and Filter

Valve Clearance

I，A

Condition of Engine Seals

Engine Mounting Fasteners

Air Filter

Coolant

Radiator Cap, Cooling System

Pressure Test

Spark Plug

Fuel System

Throttle Body

I，L

CVT

CVT Belt

Primary Pulley, Driven pulley

I，C

Clutch

3-2

3 INSPECTION AND ADJUSTMENT

O：Maintenance Interval

Maintenance Interval

Task

Inspection Item

Every 6

Criteria

Daily

Yearly

Months

Handlebar

Agility

Damage

Steering

Installing condition

System

Free play of ball joint pin

Front brake lever:0mm

Free play

Brake Lever

Main brake(FR&RR) lever: 0mm

Braking performance

Brake

Looseness&damage

lines&fittings

Brake fluid should be between

FR&RR brake fluid level

“LOWER” and “UPPER”

If front brake disc thickness is less

Brake System

Brakedisc&pads

than 2.5mm or rear brake disc

wear&damage.

thickness is less than

6.5mm,replace the disc.

Front tire:45kP（0.450kgf/cm²）

Tire pressure

Rear tire:45kPa（0.45kgf/cm²）

Crack&damage

Tread depth&abnormal

Tread depth should be more than

wear

3.0mm.

Wheel

Looseness of wheel

nuts&axle

FR wheel bearing free

play

RR wheel bearing free

play

A-arm

Free play&damage

Shock

Leaks or damages

FR Diff

Leaks&lubrication

RR Gearcase

Leaks&lubrication

Keep the oil level even with the

Gearcase/Diff

Leaks&oil level

bottom threads of fill plug hole.

3-3

CFMoto ATV Terralander CF800-2. Service Manual - part 1