CFMoto ATV Terralander CF800-2. Service Manual

STEERING COLUMN

Position the vehicle on level ground.Put your hands

on the grips and shake the handlebar in the direction

illustrated in the right figure to check for free play.

If there is a free play,determine the source of it.

If the free play comes from steering column,tighten

the steering column locking nut or remove steering

column for further inspection and repair.

Position the vehicle on level ground.Turn the handle-

bars slowly to left or right to check for agility.

If the handlebars feel rough when turning somewhere,

inspect the wiring,cables or tie-rod ends for

interference.If no interference,check the steering bear-

ing for damages.

WARNING:

Inspect the agility of handlebars before every

ride.Steering failure may result in severe injury

or death.

BRAKE SYSTEM

Front Brake Lever Free Play

Check the free play of front brake lever and the perfor-

mance of front brake.

Free play of front brake lever:0mm

3-6

3 INSPECTION AND ADJUSTMENT

MASTER CYLINDER,FRONT BRAKE

Check brake fluid level.

If the brake fluid level is below the mark”Lower”,check

master cylinder,brake lines and connections for leaks.

Remove the 2 retaining screws no.3 to open the res-

ervoir cap.

Add DOT 3 or DOT 4 brake fluid only.Never exceed

the mark no.1.

z When adding brake fluid,always avoid dirt or water.

z Always use specified brake fluid.

z Don’t spill brake fluid on plastic or rubber parts,as

it would damage them.

z Turn handlebar to left or right to keep the master

cylinder level before the reservoir cap removal.

FRONT BRAKE DISC&BRAKE PADS

Inspect brake pads from the marked place.

Replace brake pads if they are worn to service limit

groove.

CAUTION:

Pads should be replaced as an assembly.

Brake Disc Inspection&Replacement

Inspect brake disc for excessive wear or damage.Re-

place brake disc when its thickness is less than 2.

5mm.

Brake Disc

Front brake disc service limit thickness:2.5mm

Brake Fluid Replacement

Replace brake fluid every year.

3-7

MASTER CYLINDER ASEEMBLY,4-

WHEEL BRAKE

Check brake fluid level.

If brake fluid level is below the mark no.2,inspect master

cylinder,brake lines and connections for leaks.

Unscrew reservoir cap no.1 to remove it.

Add DOT 3 or DOT 4 brake fluid only.Never exceed

the mark “UPPER”.

z When adding brake fluid,always avoid dirt or water.

z Always use specified brake fluid.

z Don’t spill brake fluid on plastic or rubber parts,as

it would damage them.

z Turn handlebar to left or right to keep the master

cylinder level before the reservoir cap removal.

REAR BRAKE DISC& REAR BRAKE

PADS

Inspect rear brake pads from the marked place.

Replace rear brake pads if they are worn to service

limit groove.

CAUTION:

Pads should be replaced as an assembly.

Brake Disc Inspection&Replacement

Inspect brake disc for excessive wear or damage.Re-

place brake disc when its thickness is less than 2.

5mm.

Front brake disc service limit thickness:2.5mm

Brake Fluid Replacement

Replace brake fluid every year.

3-8

3 INSPECTION AND ADJUSTMENT

WHEEL

Position the vehicle on level ground.Elevate the ap-

propriate side of the vehicle by plaing a suitable stand

or other tool under the footrest frame.Shake the wheel

to check for free play or looseness.If any free play or

looseness is found,inspect A-arms,axle,rim bolts and

nuts and tighten them if necessary.

If free play or looseness still remains,inspect bearing,

A-arm bushings and ball joint pin and replace if needed.

FRONT Wheel TOE-IN

Position the vehicle on level ground to measure the

front wheel toe-in.

Toe-in:B-A=0-10mm

If the measurement is out of specification,adjust the

tie rod(no.1) locking nuts no.2.

CAUTION:

Drive the vehicle slowly after the adjustment is

completed.Ensure that handlebar works properly.

3-9

TIRE PRESSURE

Use tire pressure gauge to measure tire pressure.

CAUTION:

Test tire pressure when the tire is cold.

Maintain proper tire pressure.Improper inflation

may affect ATV maneuverability,comfort,or uneven

Tire Pressure Gauge

wear to different tires.

Specified Tire Pressure/Tire

Front

Rear

Pressure

45kPa(0.45kgf/cm²)

Size

See chapter 1

TIRE TREAD DEPTH

Replace tires when tire depth is worn to 1/8”(3mm) or

less.

3mm

CAUTION:

When tire depth is worn to 3mm or less,replace

tires immediately.

3-10

3 INSPECTION AND ADJUSTMENT

AXLE NUTS AND AXLE

Check front&rear axle nuts for looseness.

If axle nuts are loose,torque them to specified values.

Torque Specification:

Front:110-130N m(11.2kgf m-13.3kgf m)

Rear:110-130N m(11.2kgf m-13.3kgf m)

Wheel Bearing Free Play

Elevate the appropriate side of vehicle by placing a suit-

able stand under the footrest frame.Shake the wheel to

check for free play.

If there is a free play,inspect the wheel bearing.

SUSPENSION

Position the vehicle on level ground,push and release

the vehicle as illustrated.If the vehicle found unstable or

abnormal sound,check shocks for leaks,damages or

looseness to fasteners.

3-11

Shock Absorber Adjustment

The front and rear shock springs are adjustable.Ro-

tate the adjuster cam no.2 clockwise to decrease

the spring tension or counter-clockwise to increase

the spring tension.Always adjust two sides equally.

GEARSHIFT LINKAGE

Shift to check gearshift for smoothness.If not,attempt

to adjust the length of gearshift rod by turning the

locking nuts no.3.

FUEL SYSTEM

Fuel System Condition

Remove seat(

2-3);

Check fuel lines for aging,damage;

Replace fuel line if aging,damage found.

Inspect fuel tank breather hose and the hose of fuel

evaporation control system(if appliable) for damages,

bending.Replace the hoses if any damage found.

3-12

3 INSPECTION AND ADJUSTMENT

Throttle Lever no.1 Inspection

Inspect throttle lever no.1 for free play.

Free Play:3

5mm

3-5mm

Adjust throttle lever if free play is out of specification,

Slide sleeve no.3 out of place.loosen throttle cable

locking nut no.2.Turn adjuster to change the throttle

lever free play.

Reinstall locking nut no.2 and throttle cable

sleeve no.3.

If adjuster fails to change throttle lever free play to

specified value,replace throttle cable.

Speed Limiter

Speed limiter is designed to adjust throttle lever travel,

so as to limit the max speed.

Inspect the max length of limiter screw threads

Max limiter screw threads:a=12mm

Adjustment

Loose the locking nut.

Use a cross screw driver to turn the limiter screw

clockwise or counter-clockwise to adjust throttle le-

ver travel.

CAUTION:For beginners,keep the adjuster screw

clockwise turned to the max. For experienced

riders,turn the adjuster screw counter-clockwise

to change the throttle lever travel according to

speed requirements.

3-13

COOLING SYSTEM

CAUTION:

z For safety,check the coolant level in the reser-

voir tank,not radiator.Never open the pressure

cap when the engine is hot(more than 100

Escaping steam can cause severe burns.The

engine must be cool before removing pressure

cap.

z Coolant is toxic.Don’t drink nor spill on skin,eyes,

clothing.

If you spill coolant on your skin or clothing,

immediately wash it off with soap.

If you get coolant in your eyes,immediately

wash it off before medical attention.

If you swallow coolant,immediately spit it out

and gargle before medical attention.

z Coolant must be kept out of reach of children.

Coolant Level

Coolant would decrease due to evaporation,etc.In-

spect coolant level periodically.

CAUTION:

z Coolant is anti-rust and anti-freezing.Using tap water

will rust the engine,and may crack the engine

when it’s freezing. Always use specified coolant.

z Position the vehicle on level ground before cooling

system inspection.

z Start the engine and warm it up before inspecting

the cooling system.

Start the engine and warm it up.

Shut off the engine.

Inspect the coolant level,ensure that the level is be-

tween “LOWER” and “UPPER”.

3-14

3 INSPECTION AND ADJUSTMENT

When the coolant level is below the mark no.1-

”LOWER”,remove the reservoir tank cap and add cool-

ant to the mark no.2-”UPPER”.

Recommended Coolant:CFMOTO coolant.

Standard Mixture Ratio:50%(The freezing tem-

perature varies according to the mixture ratio.

Adjust the mixture ratio according to freeze

protection required in your area.)

When coolant is reduced significantly,inspect the

cooling system for leaks.If no coolant remains in the

reservoir tank no.3,there may be air in the cooling

system.Purge the cooling system of air.

Coolant Leakage

Inspect radiator hoses,water pump,and connections

for leaks.

If any leaks found,repair the cooling system.(

Chapter 4)

Inspect radiator hoses for aging,damages and cracks.

Hoses ages over time due to special working condi-

tions and may crack.Bend a hose to inspect for

cracks. If any damages or cracks found,replace it

with a new hose.

Inspect coolant hose clamps and tighten the loose

ones.

Inspect radiator fins for damages or mud.

Correct the fin bending.Use tap water or compressed

air to clean off the mud.

The radiator should be replaced when 20% fins are

damaged.

4.Coolant Radiator 5.Oil Radiator

3-15

GENERAL

WARNING

Never start engine without coolant.Some engine

parts such as the rotary seal on water pump shaft

can be damaged.

During installation,use the torque values and

service products as in the exploded views.

Clean threads before applying a threadlocker.Refer to

LUBRICANTS AND SERVICE PRODUCTS at the be-

ginning of this manual for complete procedure.

WARNING

Torque wrench tightening specifications must

strictly be adhered to.

Locking devices(e.g.:locking tabs,elastic stop

nuts,self-locking fasteners,etc.) must be installed

or replaced with new ones where specified.If the

efficiency of a locking device is impaired,it must

be replaced.

INSPECTION

COOLING SYSTEM LEAK TEST

WARNING

To avoid potential burns,don’t remove the radia-

tor cap or loosen the cooling drain plug if the

engine is hot.

Remove battery cover to access and remove radiator

cap.

Install the test cap(P/N 901-18.01.00-922-001 ) on

the filler neck.

Use a pressure/vaccum pump to pressurize system

to 103kpa(15PSI).

Check all hoses,radiator and cylinder(s)/base for cool-

ant leaks or air bubbles.

1.Special Radiator Cap.

04-4

04 COOLING SYSTEM

Inspection

Check general condition of hoses and clamps

tighteness.

Check the leak indicator hole if there is oil or coolant.

NOTE:Leaking coolant indicates a defective rotary

seal.Leaking oil indicates a defective inner oil seal.If

either seal is leaking,both seals must be replaced at

the same time.Refer to WATER PUMP SHAFT AND

SEALS in this section.

Another leak indicator hole is visible on the PTO side.

It indicates if the PTO gasket is in good condition.If a

1.leak Indicator Hole

liquid leaks by this hole,the PTO gasket replacement

is necessary.

MAINTENANCE

COOLANT REPLACEMENT

WARNING

To avoid potential burns,don’t remove the radia-

tor cap or loosen the cooling drain plug if the

engine is hot.

Use CFMOTO premixed coolant or a blend of 50%

antifreeze with 50% water.

To avoid antifreeze deterioration,always use the same

brand.Never mix different brands unless cooling sys-

tem is completely flushed and refilled.

CAUTION:To prevent rust formation or freez-

1.leak Indicator Hole

ing condition,always fill the system with the

CFMOTO premixed coolant or with 50% anti-

freeze and 50% water.Don’t use tap water ,

straight antifreeze or straight water in the

system.Tap water contains minerals and impu-

rities which build up in the system.During cold

weather,straight water causes the system to

freeze while straight antifreeze thickens and

does not have the same efficiency.Always use

ethylene glycol antifreeze containing crrosion

inhibitors specifically recommended for alumi-

num engines.

Draining the System

WARNING

Never drain or refill cooling system when engine is hot.

Remove the radiator cap.

04-5

Partially unscrew cooling drain plug located below

water pump housing.

When cooling system is drained completely,remove

cooling drain plug completely and install a new washer.

Screw the cooling drain plug and torque it to 10N.m

(89Ibf.in)

Under LH Footrest

1.Cooling Drain Plug

Refilling the System

Remove related parts.

Unscrew bleeding screws on top of thermostat housing.

NOTE:Both two cylinders must be bled

1.Bleeding Screws

04-6

04 COOLING SYSTEM

With vehicle on a flat surface,engine cold,refill radiator.

When the coolant comes out by the thermostat hous-

ing hole,install the bleeding screw with its washer and

torque to 5 N.m(44 Ibf.in).

Fill up the radiator and intall radiator cap.

Fill the reservoir tank and keep the coolant level even at

“LOWER” mark,then install reservoir tank cap.

Run the engine until thermostat opens,then shut off the

engine.

Recheck the coolant level in reservoir tank after the egine

is completely cooled down.Refill coolant if necessary.

Maintain coolant level between “LOWER” and “UPPER”.

1.Washer

2.Bleed ing Screw

NOTE:Each year or every 100 hours or when vehicle

reaches 3000km(1865mi),check coolant concentration

(freezing point) with proper tester.

PROCEDURES

THERMOSTAT

The thermostat is a single action type.

Thermostat Removal

NOTE:Thermostat is located on the top of cylinder

head,on intake side(front cylinder).

Install a hoe pincher on both radiator hoses.

Remove:

thermostat housing screws and pull thermostat

cover.

1.Thermostat Cover

2.Screws

thermostat with seal ring out of the hole.

1.Thermostat with Seal Ring

04-7

Thermostat Test

To check thermostat,put it in water and heat water.

Thermostat should open when water temperature

reaches 65

(149

Check if the seal ring is brittle,hard or damaged.If so,

replace the seal ring.

Thermostat Installation

For installation,reverse the removal procedure,pay atten-

tion to the following details.

Install the thermostat cover then torque screws to 6N.m

(53Ibf.in).

Check coolant level in radiator and reservoir tank and top

up if necessary.

CAUTION:

Don’t forget to bleed the cooling system.Refer to

COOLANT REPLACEMENT.

RADIATOR CAP

Using a pressure cap tester,check the efficiency of

radiator cap.If the efficiency is feeble,install a new

110kPa(16PSI) cap(don’t exceed this pressure).

RADIATOR

Radiator Inspection

Check radiator fins for clogging or damage.Remove

insects,mud or other obstructions with compressed

air or low pressure water.

Radiator Removal

Drain cooling system

Remove front facia and radiator shroud,refer to VE-

HICLE BODY AND MUFFLER.

Remove:

RH inner fender

radiator mounting bolts

overflow hose

support and reservoir tank

1.Radiator Mounting Bolts

Unplug radiator fan.

Remove radiator.

04-8

04 COOLING SYSTEM

Radiator Installation

Reverse the removal procedure for installation.Pay at-

tention to the following details.

RESERVOIR TANK

The coolant expands as the temperature (up to 100 to

110

212 to 230

)) and pressure rise in the system.

If the limiting system working pressure cap is reached

110kPa(16PSI),the pressure relief valve in the tempera-

ture cap is lifted from its seat and allows coolant to

flow through the overflow hose into the reservoir tank.

Ensure ventilation holes are not obstructed.

Removal

Remove:

1.Reservoir Tank

2.Overflow Hose

RH inner fender(refer to VEHICLE BODY AND

MUFFLER).

coolant support bolt

overflow hose

support and reservoir tank

Empty coolant tank.

Installation

Reverse the removal procedure for installation.

COOLANT TEMPERATURE SENSOR

(CTS)

1.Bolt

Refer to ELECTRICAL SYSTEM for inspection and

2.Reservoir Tank

renewal process of CTS.

04-9

RADIATOR FAN RELAY

Installation

NOTE:Relay may be inverted by 180

at installation

and it will work correctly.Ensure to align tabs of relay

with terminals of fuse holder at installation.

1.Radiator Fan Relay

Relay Operation Test

The easiest way to check the relay is to remove it and

bypass it with a jumper.If the radiator fan is activated,

replace the relay.See illustration to find where to by-

pass the relay.

2. Bypass the Relay

Relay Continuity Test

Remove relay.

Use multimeter and select the position.

Probe relay as follows.

Terminals

Resistance

Open circuit

(0L)

3.Probe Relay

04-10

04 COOLING SYSTEM

Connect battery as follows.

Terminals

Resistance

0.5

max.

(continuous)

If relay fails any test,replace it.

RADIATOR FAN

Operation

The thermal switch controls the radiator operation.

Radiator fan should turn on when coolant tempera-

ture reaches 88

(190.4

) and should turn off when

4.Connect Battery

the coolant cools down at 84

(183.2

Radiator Fan Test

If radiator fan doesn’t turn on when the coolant tem-

perature exceeds 88

(190.4

),use the following

troubleshooting chart to resolve the problem.

04-11

Yes

Is fan working?

Everything is ok

Check accessories fuse(30A) and

Yes

Replace fuse(s)

fan fuse(20A).Is fuse burned?

Bypass the relay

Check relay 1

Yes

Fan turns?

Replace relay

Apply 12 volts on fan connector

Check fan

Fan turns?

Replace fan

Yes

Check thermal switch

Thermal switch works?

Replace CTS

Yes

Check wiring harness

and connectors

All work well?

Repair or replace de-

Yes

fective part(s)

Removal

Remove radiator shroud.

Remove the bolts.

Remove the radiator fan.

Installation

Reverse the removal procedure for installation.

WATER PUMP HOUSING

It’s located on the engine MAG side.

04-12

04 COOLING SYSTEM

Removal

WARNING

To avoid potential burns,don’t remove the radia-

tor cap or loosen the cooling drain plug if the

engine is hot.

Drain the cooling system.

Remove outlet hose from water pump housing.

Remove screws retaining water pump housing.

Pull water pump to remove it.

1.Cooling Drain Plug

2.Sealing ring

3.Screws

4.Water Pump Housing

Inspection

Check if gasket is brittle,hard or damaged and replace

as necessary.

Installation

Reverse the removal procedure for installation.

CAUTION:To prevent leaking,take care that

the gasket is exactly in groove when you

reinstall the water pump housing.

Tighten screws of water pump housing in a

criss cross sequence.

1.Gasket

WATER PUMP IMPELLER,GEARS,

SEALS,SHAFT

Removal

Drain cooling system.Refer to this chapter.

Empty engine oil.Refer to LUBRICATION SYSTEM.

Remove water pump housing.Refer to this chapter.

Remove the crankcase cover,MAG side.Refer to

crankcase.

Remove the water pump intermediate gear and breather

shaft.

1.Intermediate Gear,Water Pump

2.Breather Shaft

04-13

Using appropriate pliers,remove and discard the re-

taining ring securing water pump gear on water pump

shaft.

Remove water pump gear.

Remove needle pin and gasket of water pump shaft.

1.Water Pump Impeller Assembly

2.Gasket

3.Needle Pin

To remove water pump impeller assembly from left

crankcase cover, briskly tap the water pump shaft end.

CAUTION:Take care not to damage impeller

wings during installation.

Using an appropriate slotted screwdriver,pry out the

rotary seal.

1.Slotted Screwdriver

2.Rotary Seal

Using 2 slotted screwdrivers ,remove outer part of wa-

ter pump stationary seal.

1.Stationary Seal,Water Pump

2.Slotted Screwdrivers

04-14

CAUTION:

Be careful not to damage the rotary seal surface.

Inspection

Check impeller for cracks or other damages.Replace

impeller if damaged.

Inspect water pump intermediate gear and water pump

gear for cracks,wear and other damages(especially

on the snap mechanism to the needle pin).Replace if

necessary.

Turn the bearing inner ring by hand. The bearing should

run smoothly,peacefully.If it’s stuck or has noise or

other defects,replace it.

Installation

1.Bearing

For installation,reverse the removal procedure.However,

pay attention to the following.

NOTE:For installation,use the torque values in the

exploded view.Ensure to apply engine oil on

intermeadiate shaft,water pump shaft and oil seal in-

ner surface.Don’t use oil in the press fit area of the oil

seal abd rotary seal.

CAUTION:Always replace rotary seal and

stationary seal at the same time.Meanwhile,

install a new oil seal(behind the rotary seal).

Use the oil seal pusher(P/N 0110-080005-923-001) to

Seal Pusher

install oil seal.

Apply oil on oil seal lip.

When installing the oil seal on the pusher,make sure

sealing lip poits outside.

Using oil seal pusher,install the oil seal in place.

1.Oil seal

2.Seal Pusher

04-16

04 COOLING SYSTEM

Place appropriate cushion blocks under the crankcase

cover to keep it level.

Using bearing pusher to push the bearing into left crank-

case press fit area.

NOTE:The left crankcase cover may be damaged if

no appropriate cushion bolks placed under it.

1.Bearing

2.Crankcase Cover,MAG Side

3.Bearing Pusher

Apply loctite(silicone sealant) on stationary seal

surface.

Gently tap the seal pusher to install stationary seal in

place.

1.Stationary Seal,Water Pump

2.Crankcase Cover,MAG Side

3.Seal Pusher

04-17

Install the water pump impeller assembly with rotary

seal into left crankcase cover.

NOTE:Before water pump impeller installation,

clean the rotary seal and stationary seal surface,or

water may enter the crankcase.

1.Water pump Impeller Assembly

2.Left(MAG Side) Crankcase Cover

Install thrust washer on water pump shaft.

Push impeller by hand to fully expose shaft hole that

needle pin can be installed.

Install pin and position it at equal distance out of shaft

hole so water pump gear can be installed.

1.Water Pump Impeller Assembly

2.Gasket

3.Needle Pin

Align the water pump gear groove with needle pin,then

install water pump gear on the shaft.

Make sure gear properly snaps on pin.

Install a new retaining ring on pump shaft end.

1.Needle Pin

2.Water Pump Gear

04-18

5 ENGINE REMOVAL AND INSTALLATION

Maintenance Information

5-1

Differential and gearcase removal and installation...5-6

Engine removal and installation

5-2

Gearshift linkage removal and installation

5-8

MAINTENANCE INFORMATION

Operation Cautions:

z When performing engine removal and installation,use jack or other appropriate tools to securely support the

vehicle.Take care not to damage the engine,bolts and cables.

z Wrap the frame in appropriate areas where might be scratched to avoid damage during removal and installation.

z It’s not necessary to remove the engine when servicing the following parts:

-oil pump.

-throttle body,air filter.

-valve cover,cylinder head ,cylinder,camshaft.

-CVT system,CVT cover.

-magneto cover,AC magneto,water pump

-piston,piston ring ,piston pin

-front differential,rear gearcase

z It’s necessary to remove engine when servicing the following parts:

-crankshaft

-transmission.

Tightening Torque:

Engine mounting bolts (upper)

GB5789 M8X35

(35-45)Nz m

Engine mounting bracket bolts (upper)

GB5789 M10X1.5X20

(40-50)Nz m

Engine mounting bolts (front left)

GB5789 M10X1.25X125

(40-50)Nz m

Engine mounting bolts (front right)

GB5789 M10X1.25X100

(40-50)Nz m

Engine mounting bracket bolts (rear)

GB5789 M8X20

(35-45)Nz m

Engine mounting bolts (rear)

GB5789 M10X1.25X170

(40-50)Nz m

Engine mounting bracket bolts (rear)

GB5789 M8X20

(35-45)Nz m

5-1

ENGINE REMOVAL

Remove plastics ( VEHICLE BODY AND

MUFFLER,Chapter 2);

Remove air filter ( AIR INTAKE system);

Remove throttle body( ELECTRICAL SYSTEM);

Drain coolant;

Drain engine oil;

Remove hose clamp no.2;

Remove coolant inlet hose no.1;

Remove hose clamp no. 4;

Remove coolant outlet hose no.3;

Remove hose clamp no.5;

Remove engine external oil pipe no.6;

Disconnect magneto connector,CPS connector,cool-

ant temperature sensor connector,gear position sen-

sor connector,TPS connector,idle air control valve

connector,high pressure fuel line and throttle cable,

etc;

Remove muffler( VEHICLE BODY AND

MUFFLER,Chapter 2);

5-2

ENGINE INSTALLATION

After placing engine on the vehicle,install engine mount-

ing bolts and nuts (front left) first,then (front right) and

(rear).

Install engine inlet/outlet coolant hoses/oil pipes by

clamps onto the engine.Connect starter motor posi-

tive/negative cables.

Connect all connectors.Install CVT breather duct,spark

plus cap.Install shifting plate,air filter,throttle body and

other removed parts.

FRONT/REAR GEARCASE REMOVAL

AND INSTALLATION

Removal

Raise the vehicle off ground with jack.Ensure the ve-

hicle would not tip or fall.

Remove plastics

(

VEHICLE BODY AND

MUFFLER,Chapter 2);

Remove front/rear wheels and A-arms.

1.Nut 2.Bolt#1 3.Blt#2 4.Front Differential 5.Bolt#3 6.Front Propshaft 7.Clamp

8 . Front Differential Breather Hose

9.Bolt#4 10.Rear Gearcase 11.Rear Gearcase Breather Hose

12.Rear Brake Disc 13.Bolt#5 14.Rear Propshaft

5-6

Remove the 18 bolts which connect propshafts and

gearcases(see 5,bolt 3);

Remove propshafts,gearcases,and brake discs.

Installation

Reverse the removal procedure for installation.

Tightening Torque:

Front differential mounting bolt :40-50Nz m

Rear gearcase mounting bolt :40-50Nz m

①

Front and rear propshaft bolt :40-50Nz m

1.Propshaft Bolts

GEARSHIFT LINKAGE

Removal

Remove passenger seat(

2-4);

Remove driver seat(

2-4);

Remove air filter cover(

2-5);

Remove left side panel (

2-6);

Remove gearshift lever knob(

2-6);

Remove gearshift lever indicator(

2-6);

Remove bolt no.2 and shifting plate;

Loosen gearshift rod adjustment nuts no.1,remove

gearshift rod;

Remove gearshift locking cable no.5;

Remove the 3 bolts of gearshift bracket and then re-

move the linkage.

Installation

Reverse the removal procedure for installation.

After installation,check gearshift linkage for smooth-

ness and agility.If gearshifting sticks,adjust nuts no.1

to change the length of gearshift rod.

5-8

06 AIR INTAKE SYESTEM

GENERAL

During assembly/installation, use the torque values

and service products as in the exploded views.Clean

threads before applying a threadlocker.Refer to LU-

BRICANTS AND SERVICE PRODUCTS at the be-

ginning of this manual for complete procedure.

WARNING

Torque wrench must be used when tightening.

Locking devices(e.g.:locking tabs,elastic

stop nuts, cotter pin,etc.) must be replaced

with new ones.

PROCEDURES

AIR FILTER

Air Filter Removal

CAUTION: Never remove or modify any compo-

nent in the air filter housing. The engine manage-

ment system is calibrated to operate specifically

with these components. Otherwise, engine perfor-

mance degradation or damage can occur.

Remove passenger seat,driver seat. Refer to VEHICLE

BODY AND MUFFLER.

Release clamps and remove air filter cover.

1.Clamps

Loosen clamps and remove air filter housing(upper).

2.Air Filter Housing

NOTE: If vehicle is used in dusty area,inspect more

frequently than specified in MAINTENANCE CHART.

If lilquid/deposits are found, squeeze and dry the foam

filter. Replace filter element if damaged.

CAUTION: Do not start engine if liquid or deposit

are found. If there is oil in the air filter housing,

check engine oil level. Oil level may be too high.

Pour air filter cleaning solution or an equivalent into a

bucket. Put the foam filter in to soak. Do not wash

filter element.

While filter soaks, clean inside of air filter housing.

1.Clamp

2.Air Filter

06-3

Rinse foam filter with warm water and let it dry

completely.

Blow low pressure compressed air on filter element to

clean it.

Air Filter Installation

Properly reinstall removed parts in the reverse order of

their removal.

AIR FILTER HOUSING

Air Filter Housing Removal

Remove seat, side panels;

Refer to VEHICLE BODY AND MUFFLER;

Loosen clamp and hose tie;

Disconnect breather hose;

1.Clamp

2.Hose Tie

3.Breather Hose

Remove air filter housing mounting bolts;

1.Bolt

06-4

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

INTAKE MANIFOLD,CYLINDER HEAD AND CYLINDER

SERVICE TOOLS

Description

P/N

Page

Spark plug spacer

0800-022800-922-001

Camshaft locking tool

0800-024001-922-001

Crankshaft locking bolt

0800-041000-922-001

Valve spring compressor clamp

0180-022006-922-001

Valve guide remover

0800-022102-922-001

Valve guide installer

0800-022102-922-002

Piston ring compressor

0800-040003-922-001

Piston pin circlip installer

0800-040005-922-001

SERVICE PRODUCTS

Description

P/N

Page

Coolant

Engine oil

Loctite

07-1

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

CYLINDER HEAD I

Threadlocker

Engine Oil

T1See

Procedure

T11

Inside

Threadlocker

Engine Oil

Threadlocker

Engine Oil

60N.m (44 lbf.ft)

6N.m (53 lbf.in)

30N.m (22 lbf.ft)

4.5N.m (40 lbf.in)

20N.m (15 lbf.ft)

0.1N.m (0.89 lbf.in)

12N.m (106 lbf.in)

T10

16N.m (141 lbf.in)

10N.m (89 lbf.in)

T11

5N.m (44 lbf.in)

7N.m (62 lbf.in)

07-3

CYLINDER HEAD II

Engine

T 1 S e e

Oil

Procedure

Inside

Engine Oil

Threadlocker

T10

T11

Threadlocker

Engine Oil

60N.m (44 lbf.ft)

6N.m (53 lbf.in)

30N.m (22 lbf.ft)

4.5N.m (40 lbf.in)

20N.m (15 lbf.ft)

0.1N.m (0.89 lbf.in)

12N.m (106 lbf.in)

T10

16N.m (141 lbf.in)

10N.m (89 lbf.in)

T11

5N.m (44 lbf.in)

7N.m (62 lbf.in)

07-4

GENERAL

Components which are identical for both cylinders/

cylinder heads are identified in the two exploded views

by the same number. Components which are different

or which are, for instance, present of one of the cylin-

ders/cylinder heads but not on the other, have differ-

ent numbers. The information given below always re-

lates as a genaral rule.

Special reference is made in the text to work instruc-

tions which are not the same for cylinder no. 1 and

cylinder no.2.

When diagnosing an engine problem, always diagnose

cylinder 1 and 2 respectively.

Always place the vehicle on a level surface.

NOTE: For a better understanding, the many illus-

trations are taken with engine out of vehicle. To per-

form the following instructions if it is not necessary to

remove engine from vehicle.

Always disconnect BLACK(-) cable from the battery,

then RED(+) cable before working on the engine.

Even if the removal of many parts is not necessary to

reach another part, it is recommended to remove these

1.Cylinder 1 (Front)

parts in order to check them.

2.Cylinder 2 (Rear)

During assembly/installation, use the torque values

and service products as in exploded views.

Clean threads before applying a threadlocker.Refer to

LUBRICANTS AND SERVICE PRODUCTS at the be-

ginning of this manual for complete procedure.

WARNING

Torque wrench must be used when tightening.

Locking devices(e.g.: locking tabs, elastic stop

nuts,cotter pin,etc.)must be replaced with new

ones.

When disassembling parts that are duplicated in the

engine,(e.g.: values), it is strongly recommended to

note their position(PTO/MAG side, front/rear cylinder)

and to keep them as a “group”. If you find a defective

component, it would be much easier to find the cause

of the failure among its group of parts(e.g.: you found

a worn valve guide. A bent spring could be the cause

and it will be easy to know which one among the

springs is the cause to replace it if you grouped them

at disassembly). Also, since used parts have matched

together during the engine operation, they will keep

their matched fit when you reassemble them together

within their “group”.

07-6

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

MAINTENANCE

VALVE ADJUSTMENT

NOTE: Check and adjust valve clearance only when

engine is cold.

Remove valve cover.

Before checking or adjusting the valve clearance, turn

crankshaft to TDC ignition of the respective cylinder,

see CAMSHAFT.

Use feeler gauge to check the valve clearance.

Valve Clearance

Exhaust

0.11-0.19mm(0.0043-0.0075in)

Intake

0.06-0.14mm(0.0024-0.0055in)

If the valve clearance is out of specification, adjust

valves as folows.

NOTE: Use mean valve of exhaust/intake to ensure a

proper valve adjustment.

Hold the adjustment screw at the proper position and

torque the locking nut.

Repeat the procedure for each valve.

Before installing valve cover, recheck valve clearance

INSPECTION

LEAK TEST

Before performing the cylinder leak test, verify the

1.Adjustment Screw

following:

2.Locking Nut

-clamp(s) tightness

3.Feeler Gauge

-radiator and hoses

NOTE: For best accuracy, the leak test should be

done with the engine at normal operating temperature.

WARNING

Prevent burning yourself on hot engine parts.

Preparation

Disconnect battery

WARNING

Always respect this order for disassembly;

disconnect BLACK(-)cable first.

Remove radiactor cap.

07-7

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