CFMoto ATV Terralander CF800-2. Service Manual - part 4

 

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CFMoto ATV Terralander CF800-2. Service Manual - part 4

 

 

08 CRANKCASE,CRANKSHAFT,GEARBOX
Crankcase Assembly
The assembly procedure of crankcase is the reverse
3
22
of disassembly procedure.However,pay attention to the
21
following details.
8
1
2
1. Clean oil passages and make sure they are not
20
7
clogged.
18
2. Clean all metal components.
19
3. Carefully clean contact surface between left and
6
17
5
right crankcase.
4. Install a new crankcase gasket.
11
12
13
14
15
5. Apply engine oil when install crankshaft bearing.
4
ATTENTION:Correctly reinstall crankshaft (refer
to CRANKSHAFT ).
Tighten screws on crankcase in sequence as shown
in right picture.
9
16
10
CRANKSHAFT
2
1
1.Crankshaft
2.Right Crankcase
08-11
Crankshaft Locking Procedure
NOTE:When crankshaft is locked, rear cylinder
(cylinder No.2 ) is at TDC ignition, crankshaft cannot
2
1
locked at TDC of front cylinder (Cylinder No.1)
Remove:
-Spark plug cable and spark plugs of both cylinders
-Valve covers of both cylinders
-Plug cover and gasket of plug cover
3
1.Gasket
2.Plug Cover
3.Screws
-Crankshaft position sensor(CPS)
1
2
1.Crankshaft position sensor
2.Screw
08-12
08 CRANKCASE,CRANKSHAFT,GEARBOX
-Screw and gasket washer
3
2
1
1.Screw
2.Washer
3.Left crankcase
Use 18mm socket to rotate crankshaft until
piston of cylinder No.2 is at TDC ignition.
1
1.18mm Socket
08-13
When piston of rear cylinder is at TDC, Marks on
magneto flywheel and magneto cover are aligned.
1
2
3
1. Mark “2” on magneto flywheel
2.Notch on magneto cover
3.CPS Location
Use screwdriver to check if V-type groove of crank-
shaft balancer is aligned with the hole.
1
1.Screwdriver
Lock crankshaft with crankshaft locking bolt (P/N:0800-
041000-922-001).
1
1.Crankshaft locking screw
08-14
08 CRANKCASE,CRANKSHAFT,GEARBOX
Crankshaft Removal
Refer to CRANKCASE.
Crankshaft Inspection
NOTE:Check each bearing journal of crankshaft for
scoring,scuffing,cracks and other signs of wear.
NOTE:Replace the crankshaft if the gears are worn
or otherwise damaged.
CAUTION: Components with less than the ser-
vice limit always have to be replaced. Other-
wise servere damage may be caused to the
engine.
1
Crankshaft Axial Play
NOTE: Axial play of crankshaft needs to be mea-
sured before splitting the crankcase.
1.Timing sprokcet (gear) of crankshaft
Use dial gauge to measure crankshaft axial play at
MAG side.
Crankshaft Axial Play
0.050-0.350
2
New
(0.002-0.014in)
3
Service Limit
0.6mm(0.024in)
1
If play is out of specification, replace crankcase and/
or crankshaft.
Connecting Rod Big End Axial Play
Using a feeler gauge,measure the distance between
butting face of connecting rods and crankshaft
counterweight.
1.Crankshaft
Connecting Rod Big End Axial Play
2.Connecting Rod
0.300-0.560
New
3.Gauge
(0.012-0.022in)
Service Limit
0.8mm(0.031in)
3
Connecting Rod/Piston Pin Clearance
Refer to INTAKE MANIFOLD,CYLINDER HEAD AND
1
CYLINDER.
2
Connecting Rod Big End Radial Play
Remove connecting rod from crankshaft.
NOTE: Make sure the same marking of connecting
rod to assemble together, do not mix it and exchange
between cylinder 1 and cylinder 2.
CAUTION:Always replace connecting rod
1.Connecting Rod Screws
2.Plain Bearing
screws no.1 if removing connecting rod.
3.Connecting Rod
08-15
Measure the diameter of crankpin and compare to in-
side diameter of connecting rod big end.
1
Install screws of connecting rod and measure inside
1.Crankshaft
diameter of connecting rod big end.
A.Diameter of Crankpin
Install bearing of connecting rod as original condition.
Use below-mentioned methods and torque to tighten.
Crankpin
A
43.946-43.960mm
Standard
(1.7302-1.7307 in)
Service Limit
43.93mm(1.7295 in)
Inside Diameter of Connecting Rod Big End
Service Limit
44.03mm(1.7335 in)
Clearance between Connecting Rod Big End
1.Inside Diameter of Connecting Rod Bid End
and Crankpin
Service Limit
0.09mm(0.0035 in)
Crankshaft Radial Play,MAG/PTO Side
Measure crankshaft on MAG/PTO side and compare
to inside diameter of MAG/PTO plain bearing(see
CRANKCASE).
Diameter of Crankshaft MAG/PTO Side
41.960-41.970mm
Standard
(1.652-1.6524 in)
1
Service Limit
41.935mm(1.651 in)
1.Crankshaft
A.Diameter of PTO Side Crankshaft
B.Diameter of MAG Side Crankshaft
Clearance between Crankshaft and Crankcase Hole
Service Limit
0.09mm(0.0035 in)
08-16
08 CRANKCASE,CRANKSHAFT,GEARBOX
Crankshaft Assembly
NOTE: Follow the table below to assemble
crankshaft,connecting rod and connecting rod plain
bearing.
Inside Diameter of
Bearing of Con-
Connecting Rod
Crankpin
necting Rod
1
Big End
Black
A
Blue
Red
B
3
Black
2
1.Half Plain Bearing of Connecting Rod Big End
Cranksahft assembly procedure is the reverse of
2.Split Surface of the Connecting Rod
disassembly procedure.However,the following details
3.Nose of Plain Bearing in Line with Connecting Rod
should be noted.
Groove
1.When inside diameter of connecting rod big end is
less than service limit, replace and use new
connecting rod bearing.
2
2.After installing bearing into big end of connecting
rod,use compressed air to clean connecting rod
1
split surface.
3
NOTE: Oil inner surface of connecting rod plain bear-
ing and crankshaft pin surface before installation.
There is an oil passage plug at CFMOTO logo side of
cylinder 1 and cylinder 2 connecting rod.
1.CFMOTO Logo
Screw of connecting rod should be tightened by fol-
2.Plug of Oil Passage
3.Mark A or B on connecting shaft
lowing methods.
-Firstly torque to 10Nz m(7.5Ibfz ft).
DO NOT apply threadlocker.
-Then, torque to 20Nz m(15 Ibfz ft).
-Finally torque to 50Nz m(35.25 Ibfz ft).
1
1.Torque Wrench
08-17
CAUTION: Improper installation will cause
1
screw looseness and engine damage.
ATTENTION: Bearing of connecting rod big end and
piston pin rotation cannot be changed.
2
Crankshaft Installation
The procedure of crankshaft installation is the reverse
of removal, but following detailes should be cared.
Do not mix connecting rod of cylinder No. 1 and No.2
ATTENTION:Do not damage plain bearing of
crankcase when installing crankshaft (together
with connecting rod).
3
ATTENTION:Before installation of camshaft and
valve rocker arm, do not forget to install locking
1.Crankcase
bolt to make sure crankshaft on top dead position.
2.Connecting rod of cylinder No.1
3.Connecting rod of cylinder No.2
Engine Front Output Shaft Removal
Remove shaft collar, O-ring, oil seal and bearing
retainer.
Remove front output shaft.
Inspection
Inspect if bearing turns freely and smoothly,or has
abnormal wear.Replace if necessary.
Installation
Reverse the removal procedure for installation.Pay
attention to the following details.
5
3
4
2
Before installation, Oil bearing. Meanwhile,use a new
1
oil seal and grease should be applied on lip of oil seal.
1.Oil Seal
Use service tool to tighten bearing retainer (left thread)
2.Shaft Collar
by applying threadlocker.
3.O-ring
Tightening Torque: 80Nz m
4.Bearing Retainer
5.Front Output Shaft
Service Tool:
Bearing retainer socket:
0180-060008-922-001
Oil seal installer:
0800-060000-923-001
Installer,front output shaft:
0800-062301-923-001
08-18
08 CRANKCASE,CRANKSHAFT,GEARBOX
Ring Gear Removal
Remove ring gear bearing carrier screws;
Remove ring gear and adjustment shimshaft; Remove
output shaft collar, O-ring, and oil seal;
4
3
2
1
6
5
1.Shaft Collar
2.O-ring
3.Oil seal
4.Screws
5.Ring Gear Comp.
6.Adjustment Shim
Use protector to avoid ring gear damage,
fasten bearing carrier and press ring gear out;
1
2
3
1.Ring Gear Protector
2.Bearing Carrier
3.Ring Gear
08-19
Use bench vice to fix bearing carrier, then remove bear-
ing and use special wrench (0800-062206-922-001)to
remove thrust nut, finally remove bearing.
Ring Gear Inspection
Inspect gear for any surface damage,wear. Replcae if
1
necessary.
Inspect bearing for operation condition.
2
Ring Gear Installation
Installation procedure is the reverse of removal
procedure.Pay attention to the details
Use oil seal installer (0800-062204-923-001) to install
NEW oil seal and O-ring.
1.Special Tool
When replacement of right crankcase,ring gear or bear-
2.Bearing Carrier of Ring Gear
ing seat, adjustment shim should be chekced and
adjusted.
Service Tool:
Drive pinion gear bearing(6305) installer:
0180-062103-921-002
Ring gear bearing(6207C3) installer:
0180-062201-921-003
When installation, apply oil on bearing, oil seal, o-
ring; apply threadlocker on bearing thrust nut and
1
tighten to below torque.
Tightening Torque:110Nz m
Drive Pinion Gear Removal
2
Separate left and right crankcase(see CRANKCASE);
1. Screws
Remove drive pinion gear bearing carrier screws;
2.Drive Pinion Gear
Remove drive pinion gear;
Remove circlip of drive pinion gear and output driven
gear;
Use a clean rag to protect drive pinion gear shaft and
fix it on bench vice;
Loosen drive pinion gear nut and remove drive pinion
gear and adjustment shim;
1.Nut
08-20
08 CRANKCASE,CRANKSHAFT,GEARBOX
Drive Pinion Gear Inspection
5
4
Inspect drive pinion gear and output driven gear teeth
3
for rusting,scratches,wear.Replace if necessary.
Inspect if bearing turns freely and smoothly.Replace if
necessary.
6
When replacing any of crankcase,drive pinion gear,
and drive pinion gear carrier,the adjustment shim should
7
be readjusted.Refer to the content further.
2
Drive Pinion Gear Installation
1
Reverse the removal procedure for installation.Oil bear-
8
ing and tighten nut to sepecified torque.
7
Tightening Torque:145N m.
Shim Adjustment Procedure
1.Drive Pinion Gear Carrier
5.Adjustment Shim
When crankcase and/or drive pinion gear and/or ring
2.Output Driven Gear
6.Drive Pinion Gear Shaft
gear and/or bearing carrier are replaced,the shim must
3.Drive Pinion Gear Nut
7.Bearing Retaining Plate
be adjusted.
4.Drive Pinion Gear
8.Ball Bearing
WARNING
Both gear backlash and tooth contact should
be in specification.
Gear Backlash
Install drive pinion gear and ring gear then install crank-
case gasket;
Close crankcase and install some screws;
To lock drive pinion gear,using a clean screwdriver,
reach the hole of drive pinion gear seat through speed
sensor hole,then pry output driven gear out of place in
its axial direction;
Install gear backlash measurement tools and dial
2
gauge;
Rotate ring gear shaft from engagement to engage-
ment to measure gear backlash.
NOTE:Measure the gear backlash at 4 positions.
Rotate the shaft 90
each time.
If gear backlash is out of specification,make the ad-
justment by adjusting the thickness of ring shim.
Gear Backlash:0.1-0.2mm(0.004-0.008in)
A
1
Adjustment Steps
Gear Backlash
Shim Adjustment
1.Backlash Measurement Tool
< 0.1mm
Increase shim thickness
2.Dial Gauge
A.46mm(1.81 in)
0.1-0.2mm
Correct
> 0.2mm
Reduce shim thickness
08-21
Tooth Contact
After backlash adjustment is carried out,the tooth
contact must be checked.Pay attention to the follow-
1
ing procedures:
Remove ring gear from crankcase;
Clean and degrease drive pinion gear and ring gear
teeth;
Apply a coating of machinist’s layout dye or paste to
several teeth of the driven gear;
Install ring gear;
Rotate the ring gear several turns in both directions;
Remove drive pinion gear and ring gear,then inspect
the the coated teeth of the drive pinion gear.The tooth
contact pattern should be as shown below;
2
Pattern 1
Contact at tooth top
Incorrect
Pattern 2
Contact at tooth middle
Correct
Pattern 3
Contact at tooth root
Incorrect
If gear tooth contact is found to be correct(pattern 2),
continue the next step.
If gear tooth contact is found to be incorrect(pattern 1
and pattern 3),the shim thickness between the drive
3
pinion gear and ring gear must be changed and the
tooth contact re-checked until correct.
NOTE:Clean the dye coated on the gear teeth after
the tooth contact adjustment is finished.
Adjustment Steps
Tooth Contact
Shim Adjustment
Pattern 1
Reduce shim thickness
Pattern 3
Increase shim thickness
CAUTION:Make sure to check the backlash af-
ter the tooth contact has been adjusted,since it
may have changed.Adjust the tooth contact and
backlash until they are both within specification.
If the correct tooth contact cannot be maintained
when adjusting the backlash,replace the drive
gear and ring gear.
08-22
08 CRANKCASE,CRANKSHAFT,GEARBOX
Shift Lever Assembly Removal
Remove shift lever cover screws;
Remove shift lever cover and gasket;
3
2
1
1.Screws
2.Shift Lever Cover
3.Shift Lever Gasket
Remove driven shift lever assembly;
Remove drive shift lever assembly.
3
2
1
1.Screw
2.Driven Shift Lever Assembly
3.Drive Shift Lever Assembly
Main Shaft,Driven Shaft Assembly,Shift
Drum,Shift Fork/Shaft Removal
Remove gearshift limit spring seat;
Remove limit spring and steel ball;
4
3
2
1
1.Steel Ball
2.Spring
3.Washer
4.Spring Seat
08-23
Split crankcase(see CRANKCASE);
Remove gearshift driven shaft washer,driven lo range
1
gear;
2
1.Washer
2.Driven Lo Range Gear
Remove drive pinion gear assy;
Remove gearshift main shaft by shifting to lo gear
range;
1
1.Main Shaft
08-24
08 CRANKCASE,CRANKSHAFT,GEARBOX
Remove gearshift driven shaft assy,shift drum,shift
forks,parking lock lever;
2
1
4
3
1.Shift Drum
2.Shift Fork
3.Parking Lock Lever
4.Driven Shaft Assy
Reverse Intermediate Gear Removal
NOTE If reverse intermediate gear and needle
bearing turn freely and smoothly,and clearance of them
1
is normal,no need to remove them.
To remove reverse intermediate gear and needle
bearing,a proper service tool is required to press it out
of left crankcase.(Use care to protect reverse inter-
mediate gear and needle bearing from damage.)
1.Service Tool
08-25
Bearing Removal in Crankcase
If necessary,heat crankcase up to 100
(212
) be-
fore bearing removal.
WARNING
Clean oil,outside and inside,from crankcase
before heating.
CAUTION:Always support crankcase properly
1
when bearing is removed.Crankcase damages
may occur if this procedure is not performed
correctly.
To remove ball bearing in crankcase,use a blind hole
bearing puller.
Inspection
2
Always verify for the following when inspecting com-
ponents in crankcase:
gear teeth damage
1.Bearing Puller
worn or scoured bearing surface
2.Ball Bearing
excessively worn ,scoured,or bent shift fork
excessively worn ,scoured,or bent shift fork shaft
rounded engagament dogs and slots
1
excessively worn ,scoured parking lock lever
worn shift fork engagement pins
worn shift track on shift drum
worn or scoured shift fork claw
worn splines on shafts and gears
excessively worn and scoured parking cam
Bearing
Check if bearing turns freely and smoothly.If any bind-
ing or abnormal noise has been found,replace it with a
1.Bearing
new one.
Shift Fork/Shaft
Check both shift forks for excessice wear.Check shift
fork claw for bending.
A
Measure shift fork claw thickness.
Shift Fork Claw Thickness(both forks)
New
5.8-5.9mm(0.228-0.232in)
Service Limit
5.7mm(0.224in)
A.Shift Fork Claw
08-26
08 CRANKCASE,CRANKSHAFT,GEARBOX
Measure shift fork pins.
A
Shift Fork Pin Diameter(both)
New
7.9-7.95mm(0.311-0.313 in)
Service Limit
7.83mm(0.318 in)
A.Diameter of Shift Fork Pin
Fit shift fork onto the shift fork shaft,then move the
shaft as illustrated.Check if shift fork slides smoothly.
Replace if necessary.
Place shift fork shaft on a level surface and roll it.If
any bending has been found,replace it with a new one.
CAUTION: Do not try to correct the bend shift
fork pin.
08-27
Inspect shift fork springs for damages.Replace if
necessary.
Shift Drum
Inspect shift drum tracks for excessive wear and other
damages.
Inspect parking lock cam on shift drumfor excessive
wear and other damages.Replace if necessary.
Inspect limit washer for damages.
Replace if necessary.
Parking Lock Lever
Check parking lock lever for cracks or other damages.
1
1.Parking Lock Lever
08-28
08 CRANKCASE,CRANKSHAFT,GEARBOX
Gearshift Main Shaft
Check gearshift main shaft for damages.
Check gear teeth of gearshift main shaft for pittings,
scuffing and excessive wear.Replace if necessary.
Measure main shaft neck diameter of two ends as
shown.If the meassurements are less than the ser-
vice limit,replace.
Gearshift Main Shaft Neck Diameter
Service Limit
MAG Side
16.97mm(0.666 in)
A.MAG Side
CVT Side
29.97mm(1.178 in)
B.CVT Side
Gearshift Driven Shaft Assy
Disassemble gearshift driven shaft assy as shown.
6
Check teeth of each gear for fittings,scuffing and ex-
3
1
cessive wear.Check needle bearing and circlip for wear
and damages.Replace if necessary.
3
2
4
5
3
7
6
6
8
11
9
6
10
11
12
1.Washer 17.5x32x1
7.Driven Hi Range Gear
2.Driven Lo Range Gear
8.Driven Shaft
3.Needle Bearing
9.Driven Output Gear
4.Washer 24.5x33.5x1
10.Reverse Driven Gear
5.Gearshift Sliding Bushing
11.Circlip 29
6.Circlip 29
12.Parking Lock Gear
08-29
Gears
NOTE:Gears must be replaced in a pair.Always re-
place circlip after removal.
driven shaft output gear for reverse gear shifting
gearshift sliding sleeve for high and low gear shifting
A
Measure the width for engegement of shift fork.If the
width is out of specification,replace the gear.
The width for engegement of shift fork on the gear should
be the same with the one on the sliding sleeve.
Width for Engagement of Shift Fork
New
6.1-6.2mm(0.240-0.244 in)
Service Limit
6.3mm(0.248 in)
A.Groove Width
Inspect reverse driven gear,high range gear,low range
gear for damages.Measure the gear inner diameter,if
it’s out of specification,replace the gear.
A
The inner diameter of reverse driven gear,high range
gear,low range gear is the same.
Inner Diameter
New
29-29.021mm(1.1417-1.1425 in)
Service Limit
29.025mm(1.1427 in)
A.Inner Diameter
Driven Shaft
Check driven shaft for damages.
Check driven shaft for pittings,scouring and exces-
sive wear.Replace if necessary.
Measure driven shaft neck diameter,f it’s out of
specification,replace it.
Driven Shaft
Service Limit
A
16.978(0.6684 in)
B
23.970(0.9437 in)
08-30
08 CRANKCASE,CRANKSHAFT,GEARBOX
Reverse Intermediate Gear
Check reverse intermediate gear for damages.Mea-
sure the inner diameter.If it’s out of specifiacation,re-
place it.
A
1
Reverse Intermediate Gear Inner Diameter
29.007-29.028 mm(1.1420-1.1428 in)
New
Service Limit
29.032 mm(1.1430 in)
1.Reverse Intermediate Gear
A.Inner Diameter
Reverse Intermediate Gear Shaft
Check reverse intermediate gear for damages.Mea-
1
sure reverse intermediate gear shaft neck diameter If
it’s out of specification,replace it.
Reverse Intermediate Gear Neck Diameter
New
24.980-24.993 mm(0.9834-0.984 in)
Service Limit
24.974 mm(0.9832)
1.Reverse Intermediate Gear Shaft
A.Reverse Intermediate Gear Shaft Neck Diameter
Shift Lever Assembly
Check shift lever cover for cracks,deformation and
1
other damages.Replace if necessary.
1.Shift Lever Cover
08-31
Check drive shift lever and driven shift lever for cracks,
deformation,wear and other damages.Replace if
necessary.
1
2
Assembly
Assembly procedure is the reverse of disassembly
1.Drive Shift Lever
procedure.Pay attention to the following details:
2.Driven Shift Lever
Always use a new circlip.Pay attention to the direc-
tion when installing a new circlip.Perform the installa-
tion as illustrated.
Lightly oil gears and shafts before assembly.
CAUTION:
Once circlip is removed,it has been damaged.
Round edge facing
Therefore,never use it for a second time.When
the gear
installing a new circlip,do not open the circlip
too much.
After circlip installation is finished,make sure the circlip
is in place.
When installing shift fork shaft,ensure shift forks and
shift fork springs are in correct locations as illustrated.
1.Shift Fork Shaft
2.Circlip 12;
3.Left Shift Fork
4 Shift Fork Spring(thin)
5.Right Shift Fork
6.Shift Fork Spring(thick)
7 .Spring Seat
08-32
08 CRANKCASE,CRANKSHAFT,GEARBOX
Installation
Crankcase installation procedure is the reverse to re-
moval installation procedure.However,pay attention to
the following details:
Do not use a hammer to install ball bearing unless its
structure is special.Only use a press tool to install a
bearing.
If necessary,heat crankcase up to 100
(212
) be-
2
fore removing ball bearing.
3
1
WARNING
Clean oil,inside and outside,from crankcase
before heating.
1.Reverse Intermediate Gear
2.Needle Bearing
ut a new ball bearing in an icebox or equivalent facil-
3.everse Intermediate Gear Shaft
ity to chill for 10 minutes before installation.
Using sevice tool,install the ball bearings in left crank-
case and right crankcase.
CAUTION:Always support crankcase properly
when installing ball bearings.
2
Perform the correct procedure when installing a
new oil seal(Refer to Oil Seal Installation above).
3
Other Parts in Crankcase
Fit needle bearing onto reverse intermediate gear shaft,
then install them together with reverse intermediate
gear.
1
1.Reverse Intermediate Gear
NOTE Reverse intermediate gear collar faces re-
2.Left Crankcase
verse intermediate gear shaft small end.
3.Bearing
NOTE:Press bearing no.3 before installing reverse
intermediate gear
Using press machine,press reverse intermediate gear
2
in the left crankcase.
Place parking lock lever in place in crankcase.
Engage shift fork assy with gearshift driven shaft assy,
1
then fit them in place in left crankcase.
NOTE:Do not install washer 17X32X1and reverse
3
range gear into gearshift driven shaft assy.
1.Shift Fork Assy
2.Driven Shaft Assy
3.Parking Lock Lever
08-33
Install drive pinion gear assy then tighten the 4 retain-
ing screws.
1
1
2
1.Screws
2.Drive Pinion Gear
Place parking lock lever in parking position,then align
shift drum tracks with shift forks and fit it in left
crankcase.Shift parking lock lever to parking position,
1
then align shift drum axial track with shift fork pin and
fit it in the left crankcase.
2
Using an appropriate tool,shift to low range,then in-
1.Shift Drum
stall gearshift main shaft.
2.Axial Track
Install washer and low range gear.
Using an appropriate tool,shift to neutral range.
Turn main shaft,check if gears rotate freely and
smoothly.
3
1
Rotate the main shaft,check if the corresponding mesh-
ing gears turn freely and smoothly.
2
NOTE:When installing rotational parts,equally oil
shaft necks.
1.Washer
2.Lo Range Gear
3.Main Shaft
08-34
08 CRANKCASE,CRANKSHAFT,GEARBOX
Install a new crankcase gasket
1
NOTE:Always use a new crankcase after splitting
crankcase.
Place the right crankcase on the left crankcase.In-
stall screws and torque to specifications.
WARNING
Do not turn shift drum before shift lever
installa tion is completed.
Install driven shift lever assy and drive shift lever assy.;
Torque driven shift lever screw to specified value;
1.Crankcase Gasket
NOTE:When installing driven shift lever assy and drive
shift lever assy,the marks on their teeth should be
1
aligned
2
4
1
3
Install shift lever cover gasket and cover;
1.Marks
Install shift lever cover screws and torque to specified
2.Screw
value;
3.Driven Shift Lever Assy
4.Drive Shift Lever Assy
Install other removed parts.
1.Screws
2.Shift Lever Cover
3.Shift Lever Cover Gasket
08-35
09 CVT AND CLUTCH
CVT AND CLUTCH
9
SERVICE TOOLS
Decription
P/N
Page
Split tool,drive&driven pulley
0800-052000-922-003
6
Drive pulley oil seal installer
0800-051204-923-001
8
Drive pulley holder
0180-051000-922-001
10
Driven pulley remover
0800-052000-922-002
11
Driven pulley holding wrench
0800-052000-922-001
14
Installer,clutch housing oil seal
0800-013104-923-001
16
Clutch housing damper
0180-053100-921-001
16
Clutch holding wrench
0180-054000-922-001
18
SERVICE PRODUCTS
Decription
P/N
Page
Engine oil
Threadlocker
09
Retaining Compound
09-1
Threadlocker
Retaining
Threadlocker
T3
LH Threads
Compound
Threadlocker
T2
Engine Oil
Engine Oil
Threadlocker
T3
Engine Oil
T1
Threadlocker
T1
T3
T1
115N m(85lbf ft)
T2
70N m(52lbf ft)
T3
10N m(89lbf in)
09-2
09 CVT AND CLUTCH
GENERAL
NOTE: For a better understanding, the following il-
lustrations are taken with engine out of vehicle.To
perform the following instructions,it is not necessary
to remove engine.
During assembly/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
beginning of this manual for complete procedure.
WARNING
Torque wrench tightening specifications must
strictly be adhered to.Locking devices(e.g.: lock-
ing tabs, elastic stop nuts,cotter pin,etc.)must be
replaced with new ones.
WARNING
Never touch CVT while engine is running.
09
Never drive vehicle when CVT cover is removed.
WARNING
Any drive pulley repairs must be performed by
an authorized CFMOTO dealer.Subcomponent
installation and assembly tolerances require strict
adherence to procedures detailed.
CAUTION: Never use any type of impact wrench
at drive pulley removal and installation.
WARNING
The clutch assembly is a precisely balanced
unit.Never replace parts with used parts from
another clutch assembly.
CAUTION: These pulleys have metric threads.
Do not use SAE threads puller.Always tighten
ouller by hand to ensure that the drive pulley has
the same type of threads(metric vs SAE) prior to
fully tightening.
09-3
CVT COVER
CVT Cover Removal
Remove CVT cover screws;
3
Remove CVT cover comp.;
Remove gasket.
2
1
1.Screw
2.CVT Cover
3.CVT Case
3
2
1
4
1.CVT Cover 2.Screw
3.Gasket
4.Dowel Pin
CVT Cover Inspection
Remove the bolts and retaining plate, the remove oil
seal;
Inspect bearing rotating condition.If any damage has
been found,replace the bearing;
1
2
3
4
Apply lubricant oil on bearing outer ring.Use special
5
tool to instrall the bearing and check it for smoothness;
6
Apply grease inside bearing;
7
Use a new seal and apply grease on seal lips.
1.CVT Cover 2.Bearing
3.Oil Seal
4.Retaining Plate
5.Screw
6.Washer
7.Screw
09-4
09 CVT AND CLUTCH
CVT Cover Installation
Reverse the removal procedure for CVT Cover
installation.
NOTE:
Tighten bolts in criss-cross sequence;
Replace new seal;
After Installing oil seal retaining plate, apply
threadlocker on screw threads.
DRIVE BELT
Drive Belt Removal
Remove CVT cover and gasket(Refer to CVT Cover);
Remove drive pulley (refer to Drive Pulley);
Remove driven pulley (refer to Driven Pulley);
09
1
2
3
1.Drive Pulley
2.Drive Belt
3.Driven Pulley
NOTE:
If no printed arrow mark has been left on drive belt,
remark the belt during removal to avoid incorrect
installation.
09-5
Drive Belt Inspection
Check belt for cracks,fraying or abnormal wear.
Replace if necessary.
1
Check drive belt width at cord level.
Replace if it is out of specification.
2
Belt Width Service Limit:33.0mm(1.181 in)
Tool:Vernire caliper
1.Drive Belt
2.Cord in Drive Belt
CAUTION: If belt surface is contaminated with
grease or oil, degrease the belt thoroughly.
1
2
3
Drive Belt Installation
Reverse the removal procedure for belt installation.
NOTE:
1.Using special tool,insert the threaded hole of driven
pulley and tighten to open the pulley.
1.Special Tool
2.Driven Pulley
2.No grease on belt and drive pulley
3.Drive Belt
3.Arrow printed on belt should point towards the front
of vehicle,viewed on top.
1
4
If no arrow on belt, install follow removal directly
remark.
4.Primary sheave should install corectly to avoid belt
against other parts and not well installed.
2
3
1.Printed Mark on Drive Belt
2.Drive Pulley(Front)
3.Driven Pulley(Rear)
4.Rotation Direction
09-6
09 CVT AND CLUTCH
DRIVE PULLEY
Drive Pulley Removal
8
6
7
Remove CVT Cover no.2 (refer to CVT Cover);
Remove drive pulley nut no.4 and drive pulley sliding
4
sheave no.6;
Remove driven pulley nut no.3 and driven pulley no.5;
Remove drive belt(refer to Drive Belt);
Remove drive pulley fixed sheave;
2
3
5
1
1.CVT Cover Screw
2.CVT Cover
3.Driven Pulley Nut
4.Drive Pulley Nut
5.Driven Pulley
6.Drive Pulley Sliding Sheave
7.Drive Belt
8.Drive Pulley Fixed Sheave
3
09
Drive Pulley Disassembly
Remove drive pulley shaft sleeve;
1
2
Remove cam and rollers;
4
1.Sleeve
2.Drive Pulley Sliding Sheave
3.Roller
4.Cam
2
1
1.Cam
2.Roller
09-7
Cam, Sliders and Rollers Inspection
2
Check Cam for wear and other damages. Replace if
3
necessary.
1
Check slider wear and other damages. Replace if
necesary.
Check each roller and sliding surface for wear and
other damages, if any damage has been found,replace
all rollers.
NOTE: Whenever replacing rollers and sliders,always
replace all rollers and sliders at the same time,or un-
1.Cam
balanced drive pulley will occur because of rollers or
2.Slider
sliders difference.
3.Roller
Oil Seal Inspection
1
NOTE:If no oil seal inside, It’s not necessary to per-
form this procedure.
2
Check oil seal lip for wear and other damages.Re-
place if necessary.
1.Oil Seal
2.Drive Pulley Sliding Sheave
2
Special tool is required to install the oil seal.
1
1.Drive Pulley Sliding Sheave
2.Special Tool
09-8
09 CVT AND CLUTCH
Primary sliding sheave and fixed sheave In-
1
spection
Check drive pulley faces for abnormal conditions.If any
wear and damage has been found,replace it.
2
1.Drive Pulley Sliding Sheave
2.Drive Pulley Fixed Sheave
Drive Pulley Sliding Sheave Installation
1
Install 8 rollers into sliding sheave;
09
2
1.Roller
2.Drive Pulley Sliding Sheave
Install 4 sliders on cam;
Install cam on sliding sheave;
Install shaft sleeve into sliding sheave.
2
3
1
1.Cam
2.Slider
NOTE: When installing shaft sleeve, hold the cam
3.Drive Pulley Shaft Sleeve
to avoid rollers coming out of place.
09-9
Drive Pulley Installation
Reverse the removal procedure for instrallation
NOTE:
1.If oil seal is inside the hole, apply grease inside the
hole and oil seal lip
CVT Drive Pulley Holder
2.If belt surface is stained with grease or oil, degrease
the belt thoroughly.
3.Using sepecial tool,tighten the drive pulley nut to
1
specified torque:
Drive Pulley Nut Tightening Torque:115N.m
2
Special tool:Drive Pulley Holder
2
1.Drive Pulley Holder
2.Locations to Place Drive Pulley Holder
DRIVEN PULLEY
8
7
6
4
Removal
Remove CVT case(refer to CVT COVER);
Remove drive pulley nut(refer to DRIVE PULLEY);
Remove driven pulley nut and driven pulley;
2
Remove drive belt(refer to DRIVE BELT);
3
5
1
Remove driven pulley;
1.CVT Cover Bolt
2.CVT Cover
3.Driven Pulley Nut 4.Driven Pulley Nut
5.Driven Pulley
6.Drive Pulley
7.Drive Belt
8.Drive pulley Fixed Sheave
09-10
09 CVT AND CLUTCH
DRIVEN PULLEY
Disassembly
1
2
NOTE:
Before disassembly, mark on the spring installation
holes and cam feet to sliders positions.
1.Cam and slider marks
2.Spring Installation Holes Marks
As the illustration shows, place driven pulley on the
1
special tool base.
2
Turn special tool handle to compress the cam and
09
1.Driven Pulley Remover
spring.Using a circlip remover(a plier),remove circlip.
2.Driven Pulley
1
2
3
1.Driven Pulley Remover
2.Circlip
3.Circlip Remover
09-11
Slowly loosen tool handle to release the spring tnesion
and remove the special tool;
Remove cam;
Remove guide pin;
Remove spring and sliding sheave of driven pulley.
3
1
2
4
1.Cam
2.Guide Pin
3.Spring
4.Sliding Sheave of Driven Pulley
Driven Pulley Inspection
Driven Pulley Fixed Sheave Inspection
Check driven pulley faces for any abnormal conditions,
such as heavy wear or visible damage. Replace if
necessary.
NOTE:Clean fixed sheave of driven pulley before
inspection.
1
1.Drive Face of Fixed Sheave
NOTE:Driven pulley assembly is precisely matched.
If only fixed sheave or sliding sheave is replaced,the
vibration may increase.It’s recommended to replace
both when necessary.
09-12
09 CVT AND CLUTCH
Driven Pulley Sliding Sheave Inspection
Inspect the drive face of sliding sheave for heavy wear
and damage.Replace if necesary.
1
1.Drive Face of Sliding Sheave
Inspect the 4 sliders on driven pulleyfor wear and
1
1
other damages.If the worn thickness is over the
measurement illustrated in the following figure,
replace all 4 sliders at the same time.
2
1
09
1.Slider
NOTE:Clean the sliding sheave before inspection.
2.Sliding Sleeve
A
1.5mm
A
09-13
Cam Inspection
2
Check spring cam sliding face for wear and other
damages. replace if necessary.
2
1
2
1.Cam
2.Sliding Face
A
Driven Pulley Spring Inspection
Check spring free length. If it is shorter than limit
length, replace it.
Spring free limit length A:214.0mm.
1.Spring
Driven Pulley Assembly
Reverse the disassembly procedure for driven pulley
assembly.
NOTE:Special tool is also required in driven pulley
assembly.
1
Driven Pulley Installation
Reverse the removal procedure for driven pulley
installtion.
2
NOTE:
Torque driven pulley nut to specified value.
Driven Pulley Nut Tightening Torque:115N.m.
1.CVT Driven Pulley Holder
09-14
09 CVT AND CLUTCH
CVT AIR GUIDE
3
CVT Air Guide Removal
4
Remove CVT cover(refer to CVT COVER);
5
Remove drive pulley(refer to DRIVE PULLEY)
1
6
2
Remove driven pulley(refer to DRIVEN PULLEY);
1.Screws
2.Air Guide Plate
Remove drive belt(refer to DRIVE BELT);
3.Screw
4.Clutch Housing
5.Nut
6.Air Guide
Remove air guide plate;
Remove CVT case screws and nuts;
Remove clutch housing and CVT Case;
3
Remove dowel pin(or not) and gaskets;
Remove one-way clutch.
09
2
1
1.Dowel Pin
2.Gasket(front)
Clutch Housing Disassembly
3.Gasket(rear)
Remove oil seal;
Remove retaining ring;
Use press machine to press clutch housing out of
CVT air guide.
NOTE: If bearing or oil seal is not suspected to be
damaged, it’s not necessary to perform the disassem-
bly procedure.
09-15
CVT Air Guide and Clutch Inspection
Check bearing for rotation condition,if any abnormal
condition has been found, remove bolt and bearing
5
plate to replace the bearing.
Check oil sea,if any damage has been found, replace
2
it;
Check one-way clutch for wear and damage.Replace
4
if necessary;
3
1
Check clutch housing innner side if color changes into
blue and for scratches, cracks or uneven wear, if
1.Screws
2.Bearing Plate
3.Bearing
4.CVT Air Guide
serious damage has been found, replace it.
5.Oil Seal
NOTE:If bearing is checked to be ok,it’s not neces-
sary to replace it.However,whenever disassembling
clutch housing,oil seal must be replaced.
1
2
CVT Air Guide and Clutch Housing Assembly
1.One-way Clutch
2.Clutch Housing
Apply grease on bearing and install it in place by
special tool.Check the rotation condition;
Install CVT bearing plate and screws;
Using hydraulic press machine and special press tool,
install the clutch housing into CVT air guide.
NOTE: When pressing clutch housing, it’s required
to put a special holding tool on clutch shaft end to
support bearing inner ring.
Apply grease on oil seal lip and install it with a special
tool;
Install one-way clutch into clutch housing;
NOTE:The marked side of one-way clutch should
point outside.
09-16
09 CVT AND CLUTCH
CVT Air Guide and Clutch Housing Installa-
tion
Reverse the removal procedure for CVT air guide and
clutch housing installation.
NOTE:
1.Use new front and rear gasket.Keep them even on
bases .
2.Fasten screws/nuts in criss-cross sequence.
CLUTCH
Removal
Remove CVT cover (refer to CVT COVER);
Remove drive pulley(refer to DRIVE PULLEY);
Remove driven pulley(refer to DRIVEN PULLEY);
Remove drive belt(refer to DRIVE BELT);
Remove CVT air guide and clutch housing (refer to
CVT AIR GUIDE and CLUTCH HOUSING);
2
1
09
Use special tool to remove clutch nut and remove
clutch.
1.Clutch Nut
2.Clutch
NOTE: Clutch nut threads is left hand oriented.
09-17
Clutch Inspection
1
Check clutch for debris,scratches, uneven wear and
discolouration.Meanwhile,check clutch shoe depth, if
no groove remains on any brake shoe, replace the
clutch.
Check one-way clutch for wear, if any damage has been
found,replace it.
2
NOTE:Clutch must be replaced as an assembly.
1.Clutch Shoe
2.Clutch Collar
Clutch Installation
Reverse the removal procedure for clutch installation.
Use special tool to hold clutch and then tighten nut.
1
2
NOTE: Apply threadlocker on nut threads.Torque it
to specified torque value.The threads are left hand
oriented.
1.Clutch Holding Tool
Nut tightenning Torque Value:105N m.
2.Clutch
09-18
10 ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
10
SERVICE TOOLS
Description
P/N
Page
Oil Pressure Gauge
6
Adapter Hose
6
SERVICE PRODUCTS
Description
P/N
Page
Engine Oil
Threadlocker
10-1
COMPONENTS
NEW
Engine Oil
T2
Threadlocker
T3
Threadlocker
T4
Engine Oil
Engine Oil
Engine Oil
M12X1.5
T1
Threadlocker
NEW
T4
Threadlocker
T3
T1
20N m(15lbf in)
T2
12N m(107lbf in)
T3
10N m(89lbf in)
T4
6N m(15lbf in)
10-2
10 ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION
1
1
8
2
7
3
4
7
6
5
1
1
2
3
8
7
4
6
5
1.Camshaft Bearings
5.Oil Strainer
2.Oil Pressure Switch
6.Oil Pump
3.Oil Filter
7.Crankshaft Main Bearings
4.Oil Pressure Regulator Valve
8.Connecting Rod Bearing
10-3
GENERAL
Lubrication is employed to reduce the wear of some
components,such as piston,crankshaft,camshaft,etc,
which moves relative against other parts.Proper lubri-
cation is the basis for engine normal operation.
Recommended engine oil is required for this engine.
Engine oil has cleaning,anti-rust,sealing,cooling and
other functions besides lubrication.
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.
Engine Oil Level Check
Start the engine and allow it to idle for a few minutes,
then shut it off.Wait a few minutes to allow oil flow
down to crankcase then check oil level;
1
2
Ensure vehicle is on a level surface;
Unscrew dipstick and wipe the oil residue off,then put
dipstick in the hole.Don’t screw in dipstick to read oil
Oil Level Mark:1.Upper 2.Lower
level,just make dipstick threads contact the hole
surface;
Remove dipstick and read oil level;
Engine oil level must be between “upper” and “lower”
marks;
If oil level is below “lower”,refill.
NOTE:
Strictly follow the procedure above,otherwise wrong
oil level may be indicated;
Vehicle must be placed on a level surface;
Don’t screw in dipstick to read oil level.
10-4
10 ENGINE LUBRICATION SYSTEM
Engine Oil Change
Replace engine oil and filter element at the same
time when engine is warm.
WARNING
The engine oil can be very hot.Wait until engine
oil is warm.
Place a drain pan under the engine oil drain plug
area;
Clean the drain plug area;
1
2
Unscrew oil dipstick,drain plug and discard the
gasket ring;
Allow oil to drain completely from crankcase;
1.Drain Plug
Intall washer and drain plug;
2.Washer
Drain plug tightening torque:20N m
Replace oil filter element,refer to OIL FILTER further
in this section;
Refill engine with about 3.4 L recommended engine
oil through dipstick hole;
Install dipstick.Run the engine to ensure oil filter and
drain plug areas are not leaking;
After filling,check engine oil level with dipstick.
Refer to Engine Oil Level Check above.
NOTE:
Oil condition gives information about the engine
condition.See TROUBLESHOOTING section.
Check the drained engine oil for engine shavings
and residue.Presence of debris indicates a failure
inside the engine.Check engine to correct the
proplem.
10-5
ENGINE OIL PRESSURE
The engine oil pressure test should be done with a
warm engine 90
( 194
) and the recommended
engine oil.
Remove engine oil pressure switch;
Install engine oil pressure gauge and adapter hose.
The engine oil pressure should be within the follow-
ing values:
Engine Oil Pressure Gauge
O il Pr ess ur e
1250 RPM
6000RPM
Min im a l
70 KPa
350 KPa
Nominal
180 KPa
420 KPa
M axi ma l
300 KPa
550 KPa
If the engine oil is out of specifications,check the
points described in THROUBLESHOOTING section.
Remove engine oil pressure gauge and adapter
hose.
Reinstall the engine oil pressure switch.
Adapter Hose
NOTE:To remove adapter hose from engine oil
pressure gauge,use the service tool.
10-6
10 ENGINE LUBRICATION SYSTEM
OIL FILTER ELEMENT
Removal
Remove oil filter cover screws;
2
Remove oil filter cover;
1
Remove o-ring;
Remove oil filter element.
4
3
1.Screw
2.Oil Filter Cover
3.O-ring
4.Oil Filter Element
Oil Filter Element Inspection
Check and clean the engine oil filter inlet and outlet
area for dirt and other contaminations.
1
2
1.Inlet bore from the oil pump to the oil pump
2.Outlet to the engine oil providing system
10-7

 

 

 

 

 

 

 

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