CFMoto ATV Terralander CF800-2. Service Manual

WARNING

To prevent burning yourself only remove the

radicator cap by wearing the appropriate safety

equipment.

Remove any parts to have access to engine cylinder

heads.

Unplug spark plug cable.

Clean spark plug area and remove spark plug from

cylinder head.

1.Spark Plug Cable

2.Spark Plug

Remove valve cover.

1.Valve Cover Screws

Rotate crankshaft until piston is at ignition TDC(Refer

2.Valve Cover

to CAMSHAFT TIMING in this chapter).

Using the dial gauge, turn the crankshaft and set the

piston to precisely ignition TDC.

1.Dial Gauge

07-8

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

NOTE: If a dial gauge is not available, use a screw-

driver or another similar suitable tool.

CAUTION: Do not scratch or damage piston/

cylinder surface.

NOTE: At ignition TDC the marks on the camshaft

timing gear have to be parallel to cylinder head base

as per following illustration.

1.Marks on Camshaft Timing Gear

2.Cylinder Head Base

3.Camshaft Locking Tool

Lock camshaft at TDC by using camshaft locking tool

(0800-024001-922-001).

Camshaft Locking Tool

07-9

LEAK TEST

Connect to adequate air supply.

Set needle of measuring gauge to zero.

NOTE: All testers have specific instructions on gauge

operation and required pressure.

Install gauge adapter into previously cleaned spark

plug hole.

Supply combustion chamber with air pressure.

Note the amount or percentage of leakage(depending

on tester).

Leakage Percentage

Engine Condition

0%-15%

Excellent condition

16%-25%

Good condition

26%-40%

Fair Condition

Poor condition, diagnose

1.Leak Tester

41%

and repair engine

2.Air Supply Hose

Diagnosis

Listen for air leaks:

-air escaping on intake port/throttle body means leak-

ing intake valve(s)

- air escaping on exhaust port means leaking exhaust

valve(s)

-air bubbles out of radiator means leaking cylinder head

gascket

-air/oil escaping from crankcase means damaged

gascket and/or loosened screws.

-air/coolant escaping from cylinder/head means dam-

aged gascket(s) and/or loosened screws(refer to IN-

TAKE MANIFOLD,CYLINDER HEAD AND

CYLINDER)

-air escaping into crankcase area means excessively

worn cylinder and/or broken piston rings(refer to IN-

TAKE MINIFOLD, CYLINDER HEAD AND

CYLINDER).

NOTE: For all the checkpoints mentioned above,

see the appropriate engine section to diagnose and

repair the engine.

Reassembly

Reverse the preparation procedure. Ensure to respect

torque values and use of appropriate products/

lubricants. Refer to exploded views in other sections

of this manual as required.

07-10

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

PROCEDURES

INTAKE MANIFOLD

Intake Manifold Removal

Disconnect fuel pump control plug.

Release fuel pressure by running engine until it runs

out of gas.

Remove seat, both side panels and fender. Refer to

VEHICLE BODY AND MUFFLER.

WARNING

The fuel hose may be under pressure. Cover the

fuel line connection with an absorbent rag. Slowly

disconnect the fuel hose to release the pressure.

Wipe off any fuel spillage.

1.Manifold Adapter

Remove the cover of air filter housing.

2.Throttle Body

Remove air filter.

3.Air Filter Housing

Unscrew bolts securing the air filter housing to frame.

Unscrew the lower clamp retaining the manifold

adapter between throttle body and intake manifold.

Remove teh manifold adapter.

Unplug fuel lines from injectors.

Disconnect both injectors.

Disconnect the manifold air pressure temperature

sensor(T-MAP Sensor).

Unscrew intake manifold from cylinders.

1.Injector Connector

Remove intake manifold from vehicle.

2.Fuel Line

Intake Manifold Inspection

Check intake manifold for cracks, warping at flanges

or any other damage. Replace if necessary.

Intake Manifold Installation

The installation is the reverse of the removal procedure.

However, pay attention to the following.

Torque manifold screws to 20N.m(15 lbf.ft)one cylin-

der at a time.

1.T-MAP Sensor

Re-enable fuel pump control plug.

07-11

VALVE COVER

Cover Removal

Remove distance screws of valve cover.

1.Distance Screws

2.Valve Cover

Remove valve cover and gasket.

Repeat the procedure for the other valve cover if

required.

Cover Inspection

Check the gasket on the valve cover if it is brittle,

cracked or hard. If so, replace the gasket.

Cover Installation

For installation, reverse the removal procedure. Torque

the cylinder screws in a crisscross sequence.

1.Valve Cover

2.Gasket

07-12

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

TIMING CHAIN TENSIONER

NOTE: Before removal and installation, make sure

that the respective cylinder is set to TDC ignition. Refer

to CAMSHAFT.

Tensioner Removal

WARNING

Timing chain tensioner is spring loaded. Never

perform this operation immediately after the en-

gine has been run because the exhaust system

can be very hot. Wait until exhaust system is

warm or cold.

1.Chain Tensioner Screw

Remove chain tensioner plug.

2.O-ring

Unscrew chain tensioner plug.

3.Spring

Remove O-ring and spring.

Unscrew screws retaining chain tensioner housing.

Remove chain tensioner housing with O-ring.

Screw tensioner plunger into housing several turns.

Tensioner Inspection

Check the housing for cracks or other damages. Re-

place if any.

Check chain tencioner plunger for free movement and/

or scoring.

Check if O-ring are brittle, cracked or hard. Replace if

any.

Check spring condition. Replace if broken or worn.

1.Chain Tnesioner Screws

2.Chain Tnesioner Housing

3.O-ring

4.Chain Tnesioner Plunger

07-13

Tensioner Installation

For installation, reverse the removal procedure.

However, pay attention to the following.

NOTE: Before installing the chain tensioner, make

sure that the camshaft timing gear can be moved back

and forth.

Apply engine oil on the plunger before installing.

NOTE: Slightly screw in the plunger until the timing

chain allows no more back and forth movement of the

Move Gear Back and Forth

camshaft timing gear. then screw in the plunger an

additional 1/8 turn to reach the required torque of 0.

1N.m(0.9 lbf.in).

CAUTION:Improper adjustment of the timing

chain will lead to severe engine damage.

Fit spring on one side into the slot of the plug screw

and on the other side into the plunger. Turn spring

only clockwise in order to fit the spring end into the

notch of the plunger and to avoid loosening the plunger

during spring installation. Do not preload the spring.

NOTE: Do not forget to place the O-ring on chain

tensioner plug.

Then compress the spring and screw in the plug screw.

Finally, tighten the plug screw to 4.5N.m(40 lbf.in).

07-14

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

CAMSHAFT TIMING GEAR

Gear Removal

Remove valve cover.

Turn crankshaft to TDC ignition of the respective

cylinder, see CAMSHAFT.

Unscrew timing chain tensioner.

Remove camshaft timing gear screw.

To prevent timing chain stretching during removal of

camshaft timing gear screw, use the camshaft lock-

ing tool(0800-024001-922-001).

Remove camshaft timing gear.

NOTE: Secure timing chain with a retaining wire.

Camshaft Locking Tool

Gear Inspection

Check camshft timing gear for wear or deterioration.

If gear is worn or damaged, replace it as a set(camshaft

timing gear and timing chain).

For crankshaft gear, refer to Chapter 8, see

CRANKSHAFT.

1.Camshaft Locking Tool

2.Camshaft Timing Gear Screw

3.Camshaft Timing Gear

07-15

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Camshaft timing gear and crankshaft must be at TDC

ignition before installing the timing chain.

CAUTION: Crankshaft and camshaft must be

locked on TDC ignition position to place cam-

shaft timing gear and timing chain in the

proper position.

The printed marks on the camshaft timing gear must

be parallel to the cylinder head base. See the follow-

ing illustration for a proper positioning.

1.Marks on Camshaft Timing Gear

When the camshaft timing gear and the timing chain

2.Cylinder Head Base

are installed, remove the crankshaft locking bolt as

3.Camshaft Timing Gear

well as the camshaft locking tool.

NOTE: Before installing the camshaft screw adjust

the chain tensioner(see CHAIN TENSIONER below)

and check again if marks on the timing gear are par-

allel to cylinder head base.

Reinstall all other removed parts.

1.Camshaft Locking Tool

2.Camshaft Screw

3.Camshaft Timing Gear

07-17

ROCKER ARM

Rocker Arm Removal

Remove valve cover.

Remove chain tensioner and camshaft timing gear.

Remove screw and camshaft retaining plate.

1.Cylinder Head

2.Screw

3.Camshaft Retaining Plate

Remove rocker arm shafts.

Remove rocker arm assembly(exhaust side and in-

take side) with adjustment screws and nuts.

1.Rocker Arm Shaft

2.Rocker Arm,Exhaust

3.Rocker Arm,Intake

4.Adjustment Screw

5.Locking Nut

07-18

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Remove thrust washers.

CAUTION: Pay attention not to lose thrust

washers or drop them into the timing chain

compartment.

1.2 Thrust Washers

2.Rocker Arm,Exhaust

3.Cylinder Head Spark Plug Side

4.Big Taper to Spark Plug Side

Rocker Arm Inspection

Inspect each rocker arm for cracks and scored fric-

tion surfaces. If any, replace rocker arm assembly.

Check the rocker arm rollers for freee movement, wear

and excessive radial play. Replace rocker arm assem-

bly if necessary.

Check rocker arm bore diameter. If diameter is out of

specification, change rocker arm assembly.

1.Rocker Arm,Exhaust

2.Roller

Rocker Arm Bore Diameter

A.Bore for Rocker Arm Shaft

12.000-12.018mm

New

(0.4724-0.4731in)

12.030mm

Service Limit

(0.4736in)

Check adjustment screws for free movement, cracks

and/or excessive play.

1.Free Movement of Adjustment Screw Top

07-19

Rocker Arm Shaft

Check for scored friction surfaces; if any, replace parts.

Measure rocker arm shaft diameter.

Rocker Arm Shaft Diameter

New

11.973-11.984mm

(0.4714-0.4718in)

Service Limit

11.960mm(0.4709in)

Any area worn excessively will require parts

replacement.

A.Measure rocker arm shaft diameter here

Rocker Arm Installation

NOTE: Use the same procedure for exhaust and

intake rocker arm.

Apply engine oil on rocker arm shaft.

Install the rocker arm shaft with the chamfered edge

first and use following procedure.

Insert a rocker arm pin through rocker arm pin bore.

Install a thrust washer then proper rocker arm(exhaust

side)or (intake side).

Push in rocker arm shaft until its chamfer reaches the

end of rocker arm bore.

1.Rocker Arm

2.Thrust Washer(Timing Chain Side)

3.Thrust Washer(Spark Plug Side)

Place the other thrust washer and push rocker arm

shaft to end position.

TIMING CHAIN

Refer to Chapter 8, see TIMING CHAIN.

07-20

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

CYLINDER HEAD

Cylinder Head Removal

The removal procedure is the same for both cylinder

heads.

Drain coolant(refer to COOLING SYSTEM).

NOTE: Before removing cylinder head, blow out re-

maining coolant by air pressure.During cylinder head

removal, the remianing coolant in cylinder head could

overflow into the engine and a little quantity of coolant

could drop into engine. In this case, the engine oil will

be contaminated.

Disconnect spark plug wire.

Disconnect temperature sensor connector, located at

rear cylinder head.

Remove both side panels and both inner fenders(refer

to VEHICLE BODY AND MUFFLER).

Remove exhaust pipe springs or exhaust pipe clamp.

Unscrew exhaust pipe nuts

Unplug radiator inlet hose.

Remove air filter.

Remove throttle body.

Remove the intake manifold(see INTAKE MANIFOLD

1.Cylinder Head Screws M10

above).

2.Cylinder Head Screws M6

Remove the chain tensioner(see CHAIN TENSIONER

above).

Remove the valve cover and its gasket(see VALVE

COVER above).

Remove thecamshaft timing gear.

Unscrew cylinder head screws M6 and M10 retaining

cylinder head and cylinder to cylinder base.

Pull up cylinder head.

Remove chain guide.

Remove the cylinder head gasket and scrap it.

1.Cylinder Head

2.Timing Chain

3.Chain Guide

4.Cylinder Head Gasket

07-21

Cylinder Head Inspection

Inspect timing chain guide for wear, cracks or other

damages, Replace if any.

Check for cracks between valve seats, if any, replace

cylinder head.

Check mating surface between cylinder and cylinder

head for contamination, if any, clean both surfaces.

Clean oil support through the cylinder head from

contamination.

1.Oil Port to lubricate Camshaft Lobes Intake/Exhaust

Cylinder Head Installation

2.Oil Supply to Camshaft Bearing Journal Timing

Chain Side

NOTE: The cylinder heads are not identical in design.

3.Oil Supply to Camshaft Journal Spark Plug Side

Do not invert the cylinder heads at assembly.

For installation, reverse the removal procedure. Pay

attention to the following details.

Ensure dowel pin are in place.

CAUTION: Chain guide has to be fixed between

cylinder and cylinder head.

1.Chain Guide(fiexed between cylinder and cylinder

head)

2.Chain Tensioner Guide(mounted in Crankcase)

07-22

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Install a NEW cylinder head gasket.

First, torque cylinder head screws M10 in crisscross

sequence to 20N.m(15 lbf.ft), then finish by tightening

to 60N.m(44 lbf.ft).

Install cylinder head screws M6.

Check chain guide for movement.

1.Cylinder Head Screws M10

2.Cylinder Head Screws M6

CAMSHAFT

NOTE: The engine is equipped with two different

camshafts.

1.Camshaft of Cylinder 1

2.Camshaft of Cylinder 2

07-23

Camshaft Timing

NOTE: If a piston(of cylinder 1 or 2) is set to

TDCignition, the camshaft timing gear of the opposite

cylinder must be in the following position.

1.Marks on Timing Gear of Opposite Cylinder

2.Cylinder Head Base

Camshaft Timing Cylinder 2

Turn crankshaft until piston is at TDC ignition as fol-

lows

Remove spark plug of both cylinders.

Remove valve cover of both cylinders.

Remove plug screw cover.

1.Gasket

2.Cover

3.Screws

07-24

When rear piston is at TDC ignition, marks on mag-

neto flywheel” 2 “and on the left crankcase cover(centre

of bore) are aligned.

1.Mark “2” on MAG Flywheel

2.Notch on MAG Cover

3.CPS Location

At TDC ignition, the printed marks on the camshaft

timing gear have to be parallel to cylinder head base.

1.Marks on Camshaft Timing Gear

2.Cylinder Head Base

07-26

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

To lock crankshaft at TDC ignition, proceed as follows.

Remove from crankcase plug screw with sealing ring.

1.Plug Screw

2.Sealing Ring

3.Crankcase PTO Side,Front Side

Lock crankshaft with the crankshaft locking bolt ( 0800-

041000-922-001).

NOTE: Make sure the locking bolt engages in the

groove of the crankshaft.

1.Crankshaft Locking Bolt

07-27

Camshaft Timing Cylinder 1

Turn cylinder 2 to TDC ignition, see Camshaft Timing,

Cylinder 2.

NOTE: Do not lock crankshaft.

1.18mm Socket

2.Turn Crankshaft 280

Counterclockwise

Use a 18mm socket, turn crankshaft 280

counterclockwise, until marks on magneto flywheel

and left crankcase cover are aligned.

1.Mark “1” on MAG Flywheel

2.Notch on MAG Cover

3.CPS Location

07-28

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

NOTE: At TDC ignition, the printed marks on the

camshaft timing gear have to be parallel to cylinder

head base as per following illustration.

CAUTION: Crankshaft can not be locked at

cylinder 1 TDC ignition.

Camshaft Removal

The removal procedure is the same for both camshafts.

Each camshaft is different in design. Thus, it is impor-

tant not to mix up any parts of the camshaft assem-

bly with that of ths other cylinder. Keep parts as a

group.

1.Marks on Camshaft Timing Gear

Remove valve cover(see VALVE COVER above).

2.Cylinder Head Base

Remove chain tensioner(see CHAIN TENSIONER

above).

Remove camshaft timing gear(see CAMSHAFT TIM-

ING GEAR above).

Remove camshaft retaining plate.

1.Cylinder Head

2.Screw

3.Camshaft Retaining Plate

Remove rocker arms(see ROCKER ARM above).

Remove camshaft.

NOTE: For removal, rotate camshaft so that intake/

exhaust lobe shows to upper side of cylinder head.

1.Area for Cranshaft Lobes

2.Camshaft

3.Camshaft Retaining Plate

07-29

Camshaft Inspection

Check each lobe and bearing journal of camshaft for

Replace parts that are not within specifications.

scoring, scuffing,cracks or other signs of wear.

Measure camshaft journal diameter and lobee height

using a micrometer.

Camshaft Cylinder1

Camshaft Lobe(exhaust)

New

31.98-32.1mm

(1.2591-1.2638in)

Service Limit

31.88mm(1.2551in)

Camshaft Lobe(Intake)

New

32.129-32.249mm

(1.2649-1.2696in)

Service Limit

32.03mm(1.2610in)

A.Camshaft Lobe(Exhaust Valves)

B.Camshaft Lobe(Intake Valves)

Camshaft Cylinder2

C.Camshaft Journal(Timing Chain Side)

Camshaft Lobe(exhaust)

D.Camshaft Journal(Spark Plug Side)

New

31.966-32.086mm

(1.2585-1.2632in)

Service Limit

31.87mm(1.2547in)

Camshaft Lobe(Intake)

New

32.163-32.283mm

(1.2663-1.2710in)

Service Limit

32.06mm(1.2622in)

Camshaft Journal(Timing Chain Side)

New

34.959-34.975mm

(1.3763-1.3770in)

Service Limit

34.950mm(1.3760in)

Camshaft Journal(Spark Plug Side)

New

21.959-21.980mm

(0.8645-0.9654in)

Service Limit

21.950mm(0.8642in)

Measure matching clearance between two ends of

camshaft and cylinder head.

Camshaft Bearing(Timing Chain Side)

New

35.007-35.025mm

(1.3782-1.3789in)

Service Limit

35.040mm(1.3795in)

Camshaft Bearing(Spark Plug Side)

New

22.012-22.025mm

(0.8666-0.8671in)

Service Limit

22.040mm(0.8677in)

A.Camshaft Bearing(Timing Chain Side)

B.Camshaft Bearing(Spark Plug Side)

07-30

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

CAMSHAFT INSTALLATION

For installation, reverse the removal procedure. Pay

attention to the following details.

CAUTION: The camshafts are not identical in

design. Do not invert the camshafts during

assembly. Any mis-up of the components will

lead to engine damage.

Place the camshaft retaining plate in the slot of the

1.Camshaft Retaining Plate Position

camshaft.

2.Slot Retaining Shaft

3.Direction of Movement

For other parts, refer to proper installation procedure.

07-31

VALVE SPRING

Valve Spring Removal

Remove rocker arm(see ROCKER ARM above).Re-

move cylinder head(see CYLINDER HEAD above).

Use valve spring compressor clamp(0180-022 006-922-

001)to compress valve spring.

WARNING

Always wear safety glasses when disassembling

valve springs. Be careful when unlocking valves.

Components could fly away because of the strong

spring preload.

Valve Spring Compressor Clamp

Valve Spring Compressor Cup

Align valve spring compressor clamp with the center

of Valve

07-32

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Remove valve cotters.

Withdraw valve spring compressor, valve spring retainer

and valve spring.

1.Valve Spring Compressor Clamp

2.Valve Spring Compressor Cup

3.Valve Cotter

Valve Spring Inspection

Check valve spring for visible damages, If any, replace

valve spring.

Check valve spring for free length and straightness.

Valve Spring Free Length

Normal New

40mm(1.575in)

Service Limit

38.2mm(1.504in)

A.Valve Spring Length

Replace valves springs if not within specifications.

Valve Spring Installation

For installation, reverse the removal procedure. Pay

attention to the following details.

Colored area of the valve spring must be placed on

top.

To ease installation of cotters, apply oil or grease on

them so that they remain in place while releasing the

spring.

NOTE: Valve cotter must be properly engaged in valve

stem grooves.

After spring is installed, ensure it is properly locked

by tapping on valve stem end with a soft hammer so

that valve opens and closes a few times.

1.Position of the Valve Spring

2.Valve Cotter

CAUTION: An improper locked valve spring

will cause engine damage.

07-33

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Valve Inspection

Valve Stem Seal

Always install new seals whenever valves are removed.

Valve

Inspect valve surface, check for abnormal stem wear

and bending. If out of specification, replace by a new

one.

Valve Out of Round

(Intake and Exhaust Valves)

New

0.005mm(0.0002in)

Service Limit

0.06mm(0.0024in)

Valve Stem and Valve Guide Clearance

Measure valve stem and valve guide in three places

using a micrometer and a small bore gauge.

A.Valve Stem Diameter

NOTE: Clean valve guide to remove carbon deposit

before measuring.

Change valve if valve stem is out of specification or

has other damages such as wear or friction surface.

Valve Stem Diameter

Exhaust Valve

New

4.955-4.970mm

(0.1951-0.1957in)

Service Limit

4.930mm(0.1941in)

Intake Valve

New

4.965-4.980mm

(0.1955-0.1960)

Service Limit

4.930mm(0.1941in)

Replace valve guide if valve guide is out of specifica-

1.Valve Seat

tion or has other damages, such as wear or friction

2.Exhaust Valve Contaminated Area

surface.

3.Valve Face(Contact Surface to Valve Seat)

Val ve Guide Diameter

(Intake and Exhaust Valves)

New

5 .000-5. 012mm

(0.1969-0. 1973in)

Service Limit

5 .045mm(0.1986in)

07-35

Valve Face and Seat

Check valve face and seat for burning or pittings and

replace valve or cylinder head if there are signs of

damage.

Ensure to seat valves properly. Apply some lapping

compound to valve face and work valve on its seat

with a lapping tool(see Valve Guide Procedure below).

Measure valve face contact width.

NOTE: The location of contact area should be in

center of valve seat.

Measure valve seat width using a caliper.

A.Valve Contact Surface Width

Valve Seat Contact Width

B.Valve Seat Contact Width

Exhaust Valve

New

1.20-1.40mm

(0.047-0.055in)

Service Limit

1.80mm(0.071in)

Intake Valve

New

1.10-1.30mm

(0.043-0.051)

Service Limit

1.70mm(0.067in)

If valve seat contact width is too wide or has dark spots,

replace the cylinder head.

Valve Installation

For installation, reverse the removal procedure. Pay

attention to the following details.

Install a NEW valve stem seal. Make sure thrust

washer is installed before installing seal.

Apply engine oil on valve stem and install it.

1.Valve Spring Lower Seat

2.Sealing Lips of Valve Stem Seal

CAUTION: Be careful when valve stem is

passed through sealing lips of valve stem seal.

To ease installation of cotters, apply oil or grease on

them so that they remain in place while releasing the

spring.

After spring is installed, ensure it is properly locked

by tapping on valve stem end with a soft hammer so

that valve opens and closes a few times.

CAUTION: An improper locked valve spring will

cause engine damage.

07-36

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

VALVE GUIDE

Valve Guide Removal

Remove cylinder head(see CYLINDER HEAD above).

Remove valves(see VALVE above)

NOTE: Clean valve guide area from contamina-

tion before removal.

Use valve guide remover(0800-022102-922-001)and a

hammer, drive the valve guide out of cylinder head.

Valve Guide Remover

1.Valve Guide Remover

2.Valve Guide

07-37

Valve Guide Inspection

Always replace valve stem seals whenever valve guides

are removed.

Clean the valve guide bore before reinstalling the valve

guide into cylinder head.

Valve Guide Inspection

Reverse the removal procedure for installation.Pay

attention to the following details.

Use valve guide installer(0800-022102-922-002)to in-

stall valve guide.

Valve Guide Installer

NOTE: Apply loctite(antiseize lubricant) on valve

guide prior to install it into the cylinder head.

CAUTION: Push valve guide in the cold cylinder

head as per following illustration.

Valve Gui de

(Measurement “A”)

New

14.70-15.30mm(0.5787-0.6024)

1.Valve Guide Installer

2.Valve Guide

1.Thrust Surface of Cylinder Head

2.Valve Guide

A.Measurement from Thrust Surface to Valve Guide

Top

07-38

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Valve guide to be adjusted in diameter by using a

reamer.

Valve Guide Diameter

(Intake and Exhaust Valves)

New

5 .000-5. 012mm(0.1969-0.1973in)

NOTE: Ensure to turn reamer in the right direction.

Use cutting oil and make brakes to clean reamer/

valve guide from metal shavings.

1.Valve Guide

A.Valve Guide Diameter

Apply some lapping compound to valve face and work

valve on its seat with a lapping tool.

NOTE: Ensure to seat valves properly. Apply mark-

ing paste to ease checking contact pattern.

Repeat procedure until valve seat/valve face fits

together.

1.Valve Seat

2.Valve Face(contact surface to valve seat)

3.Turn valve while pushing against cylinder head

A.Valve Seat Angle 45

CYLINDER

Cylinder Removal

Remvoe chain tensioner(see CHAIN TENSIONER).

Remove the camshaft timing gear(see CAMSHAFT

TIMING GEAR).

Remove cylinder head(see CYLINDER HEAD).

Pull cylinder.

Discard cylinder base gasckets.

1.Cylinder

2.Piston Assembly

3.Cylinder Base Gasket

4.Camshaft Timing Chain

07-39

Cylinder Inspection

Check cylinder for cracks, scoring and wear ridges on

the top and bottom of the cylinder.If so, replace

cylinder.

Cylinder Taper

Measure cylinder bore and if it is out of specifications,

B A

replace cylinder and piston rings.

Measure cylinder bore at 3 recommended positions.

See the following illustration.

Cylinder Taper IN Diameter

(Intake and Exhaust Valves)

New（maximum）

0.038mm(0.0015in)

1.First Measuring of Diameter

Service Limit

0.090mm(0.0035in)

2.Second Measuring of Diameter

Distance between measurements should not exceed

3.Third Measuring of Diameter

the service limit mentioned above.

A.7mm(0.276 in)from Cylinder Bottom

B.68mm(2.68 in)

Cylinder Out of Round

Measure cylinder diameter in piston axis direction from

C.32mm(1.260 in)

top of cylinder. Take another measurement 90

from

first one and compare.

NOTE: Take the same measuring points like de-

scribed in Cylinder Taper above.

Cylinder Out Of Round

(Intake and Exhaust Valves)

New（maximum）

0.015mm(0.0006in)

Service Limit

0.020mm(0.0008in)

A.Perpendicular to Crankshaft Axis

B.Parallel to Crankshaft Axis

07-40

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Cylinder Installation

Reverse removal procedure for installation. Pay atten-

tion to the following details.

CAUTION: Always replace cylinder base gasket

before installing cylinder.

First mount cylinder 2.Then remove crankshaft lock-

ing bolt(P/N 529 035 617). Turn engine to piston 1 at

TDC, mount cylinder 1.Cylinder can not be pushed

fully over the piston unless the piston is located at

TDC.

pply engine oil in the bottom area of the cylinder

Piston Ring Compressor Tool

bore and also on the brand of the piston ring compres-

sor tool(0800-040003-922-001).

NOTE: Put timing chain through the chain pit then

put the cylinder in place.

CAUTION: Chain guide has to be fixed between

cylinder and cylinder head.

NOTE: After both cylinders are installed, turn crank-

shaft until piston of cylinder 2 is at TDC ignition and

lock crankshaft. Refer to CAMSHAFT.

Install cylinder head and the other parts in ac-

cordance with the proper installation procedures.

PISTON

Piston Removal

1.Piston Ring Compressor Tool

Remove cylinder head(see CYLINDER HEAD above)

2.Piston

Remove cylinder(see CYLINDER above).

3.Cylinder

Place a rag under piston and in the area of timing

chain compartment.

WARNING

Piston circlips are spring loaded.

Remove one piston circlip and discard it.

NOTE: Removal of both piston circlips is not neces-

sary to remove piston pin.

1.Piston Circlip

07-41

Push piston pin out of piston.

Detach piston from connecting rod.

1.Piston

2.Piston Pin

Piston Inspection

Inspect piston for scoring, cracking or other damages.

Replace piston and piston rings if necessary.

Using a micrometer, measure piston at 8mm(0.315

in)perpendicularly(90

)to piston pin.

The measuring dimension should be as described in

the following tables. If not, replace piston.

1.Measuring perpendicularly (90¡ã) to pston pin

A.8 mm(0.315 in)

Piston Measurement

New

90.950-90.970mm

(3.5807-3.5815in)

Service Limit

90.85mm(3.577in)

1.Micrometer set to the piston dimension

07-42

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Piston/Cylinder Clearance

Adjust and lock micrometer to the piston dimension.

With the micrometer set to the dimension, adjust a

cylinder bore gauge to the micrometer dimension and

set the indicator to 0(zero).

Position the dial bore gauge 20mm(0.787 in)above

cylinder base, measuring perpendicularly(90

)to pis-

ton pin axis.

Read the measurement on the cylinder bore gauge.

The result is the exact piston/cylinder wall clearance.

Piston/Cylinder Clearance

1.Use the micrometer to set the cylinder bore gauge

New

0.030-0.050mm

2.Dial Bore Gauge

(0.0012-0.0020in)

Service Limit

0.100mm(0.0040in)

NOTE: Make sure used piston is not worn.

if clearance exceeds specified tolerance, replace pis-

ton by a new one and measure piston/cylinder clear-

ance again.

NOTE: Make sure the cylinder bore gauge indicator

is set exactly at the same position as with the

micrometer, otherwise the reading will be false.

1.Indiacator set to 0(zero)

07-43

Connecting Rod/Piston Clearance

Using synthetic abrasive woven, clean piston pin from

deposits.

Inspect piston pin for scoring, cracking or other

damages.

Measuring piston pin. See the following illustration for

the proper measurement positions.

Piston Pin Diameter

New

21.995-22.000mm

(0.8659-0.8661in)

Service Limit

21.980mm(0.7866in)

Replace piston pin if diameter is out of specifications.

Measure inside diameter of connecting rod small end

bushing.

A.Piston Pin Diameter

Connecting Rod Small En d Diameter

New

22.010-22.020mm

(0.8665-0.8669in)

Service Limit

22.060mm(0.8685in)

Replace connecting rod if diameter of connecting rod

small end is out of specifications. Refer to BOTTOM

END for removal procedure.

Compare measurement to obtain teh connecting

rodpiston clearance.

Connecting Rod/Piston Pin Clearance

Service Limit

0.080m m(0.0 035in)

Piston Installation

1.Bore Gauge

2.Connecting Rod

Reverse the removal procedure for installation. Pay

attention to the following details.

Apply engine oil on the piston pin.

Insert piston pin into piston and connecting rod.

CAUTION: Make sure the mounting direction of

the piston is correct.

For each cylinder, install piston with the punched ar-

row on piston dome pointing toward the rear side of

the engine.

Front Cylinder: Mark on top of piston must show to

intake side.

Rear cylinder: Mark on top of piston must show to

exhaust side.

1.Piston of Cylinder 1

2.Mark on piston must show to exhaust side of cylinder 1

3.Piston of Cylinder 2

4.Mark on piston must show to exhaust side of cylinder 2

07-44

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Use the piston appropriate circlip installer (0800-

040005-922-001)to assemble the NEW piston circlip

as per following procedure:

CAUTION: Always replace disassembled

piston circlip(s) by new ones. Place a rag on

cylinder base to avoid dropping the circlip

inside the engine.

Circlip Installer

Place circlip in sleeve as per following illustration.

1.Piston Pin Circlip

2.Sleeve

3.Assembly Jig from Piston Clip Installer

Push taper side of assembly jig until circlip reaches

middle of sleeve.

Align sleeve with piston pin axis and push push as-

sembly jig until engages in piston.

1.Hold piston while pushing circlip in place

2.Sleeve

3.Assembly Jig

4.Direction to push circlip

07-45

NOTE: Take care that the hook of the piston circlip

Using a feeler gauge, check ring end gap.Replace ring

is positioned properly.

if gap exceeds above described specified tolerance.

PISTON RINGS

Ring Removal

Remove the piston(see PISTON above).

Ring Inspection

Ring/Piston Groove Clearance

Using a feeler gauge measure each ring/piston groove

clearance. If the clearance is too large, the piston and

piston rings should be replaced.

Ring/Pi ston Groove Clearance

Piston Ri ng(1)

New

0.020-0.060mm

(0.0008-0.0024in)

Service Limit

0.150mm(0.0059in)

Piston Ri ng(2)

New

0.020-0.060mm

CORRECT POSITION OF THE PISTON CIRCLIP

(0.0008-0.0024in)

Service Limit

0.150mm(0.0059in)

Oil Scraper Ring

New

0.030-0.150mm

(0.0012-0.0059in)

Service Limit

0.250mm(0.0098in)

Ring End Cap

Piston Ri ng(1)

New

0.25-0.40mm

(0.010-0.016in)

Service Limit

1. 50mm(0.059in)

Piston Ri ng(2)

New

0.30-0.45mm

1.Feeler Gauge

(0.012-0.018in)

2.Piston

Service Limit

1.50mm(0.059in)

Oil Scraper Ring

New

0.20-0.70mm

(0.008-0.028in)

Service Limit

1.50mm(0.059in)

To measure the ring end gap, place the ring in the

cylinder in the area of 8 16mm(5/16 5/8in) from top

of cylinder.

NOTE: In order to correctly position the ring in the

cylinder, use piston as a pusher.

07-46

07 INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER

Ring Installation

Reverse the removal procedure for installation.

NOTE: First install spring and then rings of oil scraper

ring.

Install oil scraper ring first, then piston ring(2) with the

word “N and TOP” facing up, then piston ring(1) with

the word “N and TOP” facing up.

CAUTION: Ensure that top and second rings

are not interchanged.

1.Upper Compression Ring

NOTE: Use a ring expander to prevent breakage dur-

2.Lower Compression Ring

ing installation.The oil ring must be installed by hand.

3.Oil Scraper Ring

Check that rings rotate smoothly after installation.

Space the piston ring end gaps

apart and do

not align the gaps with the piston pin bore or the thrust

side exis.

1.Don’t align ring gap with piston thrust side axis

2.Don’t align ring gap with piston pin bore axis

A.120

07-47

08 CRANKCASE,CRANKSHAFT,GEARBOX

CRANKCASE,CRANKSHAFT,TRANSMISSION

SERVICE TOOLS

Description

P/N

Page

Breather Oil Seal Installer

0800-011201-923-001

Installation Jig,Breather Gear Shaft

0800-011201-921-003

Press Tool,Breather Gear Shaft

0800-011201-921-001

Left Crankcse Support Sleeve

0800-011101-922-001

Right Crankcse Support Sleeve

0800-012101-922-001

Plain Bearing Remover/Installer

0800-011102-922-001

Crankshaft Locking Bolt

0800-041000-922-001

Wrench,Front Output Shaft Circlip

0180-060008-922-001

Press Tool,Front Output Shaft Oil Seal

0800-060000-923-001

Installer,Front Output Shaft

0800-062301-923-001

Install Handle

0800-062206-922-001

Drive Pinion Gear Oil Seal Installer

0800-062204-923-001

Ring Gear Needle Bearing Installer

0180-062201-921-003

Drive Pinion Gear Needle Bearing Installer

0180-062103-921-002

20/21

Backlash Measurement Tool

0800-062000-922-001

Remover,Reverse Intermediate Gear Shaft

0800-060002-922-001

Remover,Left Crankcase Bearing

0800-011000-922-001

Remover,Right Crankcase Bearing 5206

0800-012000-922-001

Damper,Right Crankcase

0800-012101-921-001

Installer,Bearing 6203

0010-060002-921-002

Installer,Bearing 3206A

0180-012100-921-004

Damper,Left Crankcase

0800-011101-921-001

Press Tool,Reverse Intermediate Gear Shaft

0800-060000-922-001

Press Tool,Gearshift Shaft Bearing 6303

0180-011100-921-004

0040-012001-921-002

Press Tool,Bearing 6203

SERVICE PRODUCTS

Description

P/N

Page

Threadlocker

Engine coolant

Enigne oil

08-1

08 CRANKCASE,CRANKSHAFT,GEARBOX

GENERAL

During assembly/installation,use the torque value and

serivce products as shown in the exploded view(s).

WARNING

Torque Wrench Tightening specifications must

strictly be adhered to .Locking devices (e.g.:lock

ing tabs ,elastic stop nuts ,self-locking fasteners,

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

where specified .

NOTE:Before disassembly ,drain engin oil and en-

gine coolant.

DRIVE GEARS

The drive gears are located on the MAG side behind

the magneto cover.

Removal

Remove :

-Magneto cover(refer to Magneto Cover Removal,

Chapter 11 )

-Retainer ring no.10

-Magneto,driven gear

-Oil pump intermediate gear

-Breather intermediate gear

-Oil pump gear (refer to LUBRICATION SYSTEM)

-water pump gear

-Breather gear

1.Oil Pump Gear

Inspection

2.Oil Pump Intermediate Gear

Oil Pump Intermediate Gear/Breather Interme-

3.Breather Intermediate Gear

diate Gear/Oil Pump Gear

4.Breather Gear

Inspect gears for wear or damage,replace if damaged.

Breather Gear

The engine is equipped with a breather gear which

prevents engine oil coming out though the breathing

system into the air box.

Inspect gear for wear or damage .

Check ball bearing for excessive play and smooth

operation .Replace breather gear assembly if necessay

Installation

The installation essentially the reverse of the removal

procedure ,but pay attention to the follow details:

08-5

1.Replace the oil seal of the breather gear.

Inspection

2.Adequately oil the ball bearing of the breather gear.

Inspection is the same for both timing chains.

3.All drive gears on the same plane.

Check timing chain on camshaft timing gear for ex-

4.Replace the retainer ring no.10.

cessive radial play.

Check chain condition for wear and teeth condition.

Service Tools:

If chain is excessively worn or damaged,replace it as

Breather Oil Seal Installer

a set(camshaft timing gear and timing chain)

0800-011201-923-001

Installation

Installation Jig,Breather Gear Shaft

Installation is the same for both timing chains.

0800-011201-921-003

Press Tool,Breather Gear Shaft

0800-011201-921-001

TIMING CHAIN

The engine is equipped with two chains .one is lo-

cated on the magneto side .the second is loacted on

the CVT side.

Removal(MAG side)

Remove:

-valve cover chain tensioner,camshaft timing gear(refer

to INTAKE MANIFOLD,CYLINDER HEAD AND

CYLINDER)

-Magneto,driven gear,oil pump intermediate gear,

breather intermediate gear.

-Timing chain guide and lower timing chain guide.

Carefully pull the timing chain sideward and down from

the crankcase.

NOTE:Mark the operation direction of the timing chain

before removal.

1.Timing Chain Guide

2.Timing Chain

Removal(CVT side)

3.Chain Tensioner

Remove:

-valve cover chain tensioner and camshaft timing gear

(refer to INTAKE MANIFOLD,CYLINDER HEAD AND

CYLINDER)

-CVT cover CVT drive gear CVT driven gear£¬Belt

Note Mark operation direction of the belt .

-CVT case Clutch

-Timing chain guide and lower timing chain guide.

Carefully pull the timing chain sideward and down from

the crankcase.

Note:Mark the operation direction of the timing chain

before removal.

1.Timing Chain

08-6

08 CRANKCASE,CRANKSHAFT,GEARBOX

The installation essentially the reverse of the remove

procedure ,but pay attention to the follow details:

Note:Ensure to perform proper valve timing .lock crank-

shaft (see crankshaft )and camshaft at TDC ignition

(refer to intake manifold ,cylinder head and cylinder

section).Install timing chain with camshaft timing gear

then ,adjust chain tension (refer to intake manifold ,

cylinder head and cylinder section).Loosen crankshaft

,turn 440 degree on clockwise direction (from CVT side)

and camshaft at TDC ignition,Install timing chain with

camshaft timing gear then ,adjust chain tension,to

perform proper valve timingrefer to intake manifold ,

cylinder head and cylinder section).

CAUTION:Improper valve timing will damage en-

gine components.

TIMING CHAIN TENSIONER

Removal

Refer to TIMING CHAIN above.

Inspection

Check timing chain tensioner for wear ,cracks or other

damage ,replace if necessary.

Installation

1.Chain Tensioner

The installaiton is the reverse of the removal proce-

2.Screw

dure .

CRANKCASE

NOTE:Before disassembly ,drain engin oil and en-

gine coolant.

Crankcase Disassembly

NOTE:Before splitting the crankcase,measure crank-

shaft axial play (refer to CRANKSHAFT).

Remove:

-Front drive shaft,ring gear

-CVT cover,CVT,belt,CVT air guide and clutch(refer to

CVT AND CLUTCH)

-Drive gears(refer to DRIVE GEARS)

NOTE:Oil pump removal from crankcase is not nec-

essary ,but recommended to see condition of oil pump.

-Left crankcase cover and electric starter(refer to

MAGNETO SYSTEM )

-electric starter drive gear(refer to STARTING

SYSTEM)

-oil filter(refer to LUBRICATION SYSTEM)

08-7

-Cylinder head and cylingder( refer to INTAKE

MANIFOLD,CYLINDER HEAD AND CYLINDER)

-Timing chain,tensioner and guide.(refer to TIMING

CHAIN,TENSIONER AND GUIDE).

Remove all bolts of crankcase.

1.11 bolt M6X45

2.4 bolt M8X60

3.4 bolt M8X50

4.2 bolt M6X50

5.1 bolt M6X80

Carefully split crankcase halves by using a soft ham-

mer .

NOTE:During disassembly ,do not damage the seal-

ing surface of the crankcase halves.

Pull crankshaft out of crankcase.

Crankcase Cleaning

WARNING

Use safety goggles to avoid eye injuries.

Clean crankcase using a part cleaner;

Dry crankcase using compressed air;

1.Soft Hammer

Clean oil passage.

08-8

08 CRANKCASE,CRANKSHAFT,GEARBOX

Crankcase inspection

Check crankcase halves for cracks or other damage.

replace if necessary.

Check plain bearing for scoring or other damages.

NOTE:Measure plain bearing inside diameter and

compare to magneto and CVT side journal diameter

of crankshaft(refer to CRANKSHAFT).Replace if the

measurements are out of specification.

plain bearing inside diameter(CVT/MAG)

service Limit: 42.100mm(1.6575in)

Plain Bearing Replacement

plain bearing removal

1.Oil bore

Caution:Alway support crankcase halves properly when

2.Plain bearing

ball bearings or plain bearings are removed .Damages

3.Measure plain bearing inside diameter

to crankcase halves may occur if this procedure is not

performed correctly .

NOTE:Always use a press for removal of plain bearing.

Remove plain bearing with the proper plain bearing re-

move/installer.

Carefully push the plain bearings out from the crank-

case half inside towards the outside.

NOTE:Place the proper crankcase support sleeve

under crankcase halves before removing plain bear-

ings .

NOTE:During disassembly ,do not damage the seal-

ing surface of the crankcase halves.

Service Tools:

Left crankcse support sleeve

0800-011101-922-001

Right crankcse support sleeve

1.Crankcase half

0800-012101-922-001

2.Crankcase support sleeve

Plain bearing remover/installer

3.Plain bearing remover/installer

0800-011102-922-001

Plain Bearing Installation

NOTE:Crankcase and plain bearing must be installed

as a pair as shown in the following table:

Crankcase

Plain Bearing

Red (A)

Red

Blue(B)

Blue

CAUTION:Unless otherwise instructed,never use

hammer to install ball bearings or plain bearings,

use press only.

Install plain bearings with the proper plain bearing re-

mover/installer in a cool crankcase.Do not lubricate

plain bearing and /or crankcase for installation.

08-9

NOTE:Place proper crankcase support sleeve un-

der the crankcase halves before installing the plain

bearings(refer to bearing removal procedure).

Carefully press-in the plain bearings in the same di-

rection as during disassembly,from then crankcase

inside towards the outside.

During disassembly ,make sure not to damage the

sealing surface of the crankcase halves.

CAUTION:Mark position of oil bore on crankcase

1.Oil positon marked on crankcase

half and on plain bearing remover/installer .Align

2.Plain bearing remover/installer

mark on plain bearing remover/installer with

mark on crackcase half.

NOTE:Wrong oil bore will stop supply to plain bear-

ing and will cause engine damaged.

CAUTION:The partition of the palin bearing in

left crankcase must be positoned near to oil bore

in clockwise direction.(refer to No.2 in next

installation)

CAUTION:The partition of the palin bearing in

right crankcase must be positoned near to oil bore

in clockwise direction.(refer to No.2 in next

1.Oil bore

installation)

2.The partition of the plain bearing

3.Left crankcase

NOTE:Use an o-ring (

42x1-1.5mm 0.04-0.05in))

to hold plain bearing in place during installation,the o-

ring will disappear in the groove of the palin bearing

remover/installer.

Service Tools:

Left crankcse support sleeve

0800-011101-922-001

1.Oil bore

Right crankcse support sleeve

2.The partition of the plain bearing

0800-012101-922-001

3.Right crankcase

Plain bearing remover/installer

0800-011102-922-001

08-10

CFMoto ATV Terralander CF800-2. Service Manual - part 3