CF MOTO CF400-A 2017 User manual

WWW.CFMOTO.COM
Service manual
CF400-A/CF650-7B

All right reserved
ZHEJIANG CFMOTO POWER CO.,LTD.
Sep/2017
WWW.CFMOTO.COM

FOREWORD
ThismanualintroducesCF400-A(CF650-7B/
CF400-Amodel)maintenanceinformation,disas-
semblyprocedure, check &adjustmentmethods,
troubleshooting andtechnicalspecifications.
Thereareillustrations,drawingstoguide your
operation.
CFMOTOhasfinal explanationstothismanual
information.Withoutourpriorwrittenapproval,
Anypartinthismanualisnotallowedtobe
copiedandtranslated.approval,themanual
cannotbedupliacted and disclosed.Donotuse
thismanualtomakethevideo.
CFMOTOtriedmanywaysandeffortstomake
thismanual perfectandaccurate. Butthis
manualisn tresponseforanydifferentand
missing.
CFMOTOreservesrightstomakeimprovements
andmodificationstotheproductswithoutprior
notice.Overhaulandmaintenanceshouldbe
doneaccordingtoactualconditionofvehicle.And
isn t responsefortheproduct. Thismanualonly
forreference. If anyproblemscomes.Please
connect toyourdealertogetthenewsfor
product.
Theinformationinthismanualrefertothe
newestproductwhencomesout.Thepictures,
drawingsand photosinthismanualdoesn tstand
forthereal model,assy and parts.
Thismanualiscompiledaccordingtostandard
GB/T9969-2008 and GB/T19678-2005.
CFMOTOreservesrightstomakeimprove-
mentsandmodificationstothe products
withoutpriornotice.Overhaulandmainte-
nanceshouldbedoneaccordingtoactual
conditionofvehicle.
CFMOTOCO.LTD
R&Ddepartment
Sep/20171stbrand
Contents
Maintenance Information 1
Periodic Maintenance 2
EFI system 3
Coolingsystem 4
Enginetop 5
Clutch 6
Enginelubricationsystem 7
Engineremovaland
installation
8
Crankshaftandtransmission 9
Wheelsandtires 10
Drivechain andsprocket 11
Breaking system 12
Suspensionsystem 13
Steering system 14
Vehiclebody 15
Electric system 16
PDA 17
Contentscanhelpyoufindoutthe
topicyouwantandthechapter
number. Usethepagelabeltosee the
chapterpage.Andfindmoreaccuratein
contentseachchapter.

Unitsform
A Ampere lb Pounds
ABDC
Afterbottomdeadcenter
m
Meter
AC Alternatingcurrent min Minutes
ATDC
Aftertopdeadcenter
N
Newton
BBDC Beforebottomdeadcenter Pa Pascal
BDC
Bottomdeadcenter
PS
Horsepower
BTDC
Beforetopdead center
psi
Pound
/
Squareinches
°C Celsius r Rounds
DC
D
irectcurrent
rpm
Roundsperminutes
F Farad TDC Top deadcenter
°F
Fahrenheit
TIR
Timesindicatorrecord
ft Feet V Volt
g
Gram
W
Watt
h
Hour
Ω
Ohm
L
liter
in
Inches
USgal USgallon USqt USquart
oz
O
unce
HP
Horsepower
cmHg Hgdeepnessincm pint Pint
cuin
Cubicalinches
mL
mililiter

Introduction
Thismanualisdesignedprimarilyforusebywell-trainedmechanicsinaproperlyequipped
workshop. Sotheoperatorshould havebasicand necessarymechanicalandelectrical
knowledge,aswellasknowledge ofproperuseoftools. Ifyoudon thaveenoughexperience,itis
bettertoaskqualifiedoperatortowork. Inordertoperformtheworkefficientlyandtoavoid costly
mistakes, itisimportanttoread themanual thoroughly. Forthewarrantyperiod, itisrecom-
mendedtorepairandmaintaincompletelyfollowingthisservicemanual.Anymaintenanceor
repairprocedurenotperformedinaccordancewiththismanualmayvoidwarranty.
To getthelongestlifeoutofyourvehicle.
●Followthemaintenanceschedule inthismanual.
●Bealertforproblemsandnon-scheduledmaintenance.
●Usegenuine CFMOTOpartsandpropertools.
Therearenecessaryinformation aboutgenuine partsandspecialtoolsinourpartscatalogueand
special toolslist.
●Followthe servicemanualproceduresstep bystep.Donottakeshortcuts.
●Remembertokeepcompleterecordsofmaintenanceand repairwithdatesandanynewparts
installed.
Howto Use This Manual
Thisproduction seperateintoseveral mainlysystemsin thismanual.Thesesystemsmakeup
eachchaptersinthismanual.The contentshasshownallthesystemin thisproduction and can
help you findout eachchapters.Eachchapteralsohasitsowncontents.Example£ŗIfyouwantto
find out theignition coilinformation.Findoutelectricalsystemchapterin contentsfirst.Thenfind
the ignition in electrical systemcontents.

Ifyouseethewarningsignal.Pleasepaymoreattention. And followthesafetyhandleand
servicemethod.
Danger
Thissignalshowsspecialindication.Itmaycauseinjuryordeathiftheinstructionnot
followed.
Warning
Thissignalshowsspecialindication.Itmaycausevehicledamagediftheinstruction not
fallowed.
Note
Thissignalshowsinformation abouthighlyefficiencyworkingway.
Thismanualhasalso3signalsbelow（Exceptthewarningsontop）.Theywillhelpyouseedifferentlevel
sign.
●Showsthejobneedstobedone
○Showsthejobsteporafterstepwork. It maybebeforethecautionnote.
★Showsthestep ssolution. Dependsonthestepfortestingorinspectionresult.Formost chapter
aftercontentsshowstheexplodedview.Intheview.Youcanseethetightentorque, lubricationoil,
greaseorglue.

1-1
1Maintenanceinformation
1
Saftypre-cautions…………………………………1-1
Beforeservicing……………………………………1-3
Serialnumberposition……………………………1-8
Generalspecification ……………………………1-9
Unitconvertiontable………………………………1-12
SafetyPrecautions
Exhaust containstoxicingredients. Donotrunthe
engineinenclosed orpoorly-ventilated areas.
Theliquor (dilutesulfuricacid) inBatteryisstrongly
corrosive; itmayburntheskinandblindtheeyes
whenit contactsthem. Incaseofcontact, please
washit withagreatdealofclearwater immediately,
andseekmedicaltreatment inhospital. Besides,
pleasealsowashit byagreatdealofclear water
whenit contactstheclothes, for avoidingskinburn.
TheBatteryandBatteryliquor mustbestored
strictlyout ofreachofchildren.
Uniform(pilotuniformetc),cap, safetybootssuit-
ablefor theoperationmust be worn,andthesafety
articlessuchasdustproofgoggles,dustproof
respirator andglovesshall beworn forprotection
whennecessary.
Whentheenginejust stops,thetemperature of
engine, muffler isstill high; pleasedo not touch
themwithbare hands,for avoidingburn. Please
wearuniformwithlongsleevesaswell asgloves
whenmaintaining.
Thecoolant ispoisonous, pleasedo not drinkit, do
notlet itcontacttheskin,eyesneither clothes.In
caseit contactstheskinor clothes,pleaserinseit
immediately. Whenit contactsthe eyes, please
washit thoroughlywithagreat dealofclear water
immediately, andseekmedicaltreatment in
hospital.Incasethecoolant isdrunkbymistake,
pleasetrytothrowit up,andseekmedicaltreat-
ment immediatelyafter gargling.Thecoolantmust
be stored strictlyoutofreachofchildren.

1-2
The personnelshallmakethembeaware ofeach
other fromtimetotimewhenoperating,forsafety
confrmation.
TheBatterymayproducecombustibleandexplosive
hydrogenwhenit isbeingcharged.Soit may
explodeifthere isfameor electricspark.Soplease
charge it intheplacewithniceventilation.
Donot touchtheturningor movablepiecessuch
asrearwheel, clutch, etc.Payattentionnottoget
pinched whenservicing.
CFMTOTO

1-3
1Maintenanceinformation
1
Before Servicing
Before startingtoperformaninspectionserviceor carryoutdisassemblyandinstallationonamotorcycle,
read theprecautionsgivenbelow.Tofacilitateacutaloperations, notes,illustrations, photograghs, cautions
anddescriptionshavebeenincluded ineachchapterwherever necessary.Thissectionexplainstheitems
that requireparticular attentionsduringremovalandreassembly.
BatteryGround
Before completinganyserviceonthe motorcycle,
disconnect thebatterycablesfromthebatteryto
prevent the enginefrom accidentallyturningover.
Disconnect thegroundcable(-)first andthenthe
positive(+).Whenfinishing theservice,first connect
positive(+) cabletothepositive(+) terminalofthe
batteryandthen the negative(-)cabletothenega-
tive(-) terminal.
EdgesofParts
When servicepartswithedges,wearingglovesto
preventinjury.
Solvent
Useahigh-flushpointsolvent whencleaningparts.
High-flushpointsolventshouldbe used accordingto
directionsofsolventmanufacturer.
Cleaning VehicleBeforeDisassembly
Clean thevehiclecompletelybefore disassembly.
Dirt or other foreignmaterialsenteringintosealed
areasduringvehicledisassemblycancauseexces-
sivewearand reducevehicleperformance.
fixingtake down

1-4
Arrangement and Cleaning of Removed Parts
Disassembled partsare easy toconfuse.Arrange
thepartsaccordingtotheorder ofpartsdisas-
sembled and cleanthepartsinorder priorto
installation.
Storageof RemovedParts
After all the partsincludingsubassemblypartshave
beencleaned,store thepartsinacleanarea,put a
cleanclothor plasticsheet over thepartstoprotect
fromanyforeignmaterialsthatmaycollectbefore
reassembly.
Inspection
Reuseofworn ordamagedpartsmaylead to
seriousaccidents.Visuallyinspect removed partsfor
corrosion, discolorationorother damage.Referto
theappropriatesectionsofthismanualfor service
limitsonindividualparts. Replacethepartsifany
damage hasbeenfoundorifthepart beyondthe
servicelimits.
ReplacementParts
ReplacementpartsmustbeCFMOTOgenuineor
recommendedbyCFMOTO. Gaskets,O-rings, oil
seals, greaseseals,circlipsor cotter pinsmust be
replaced withnewoneswheneverdisassembled
AssemblyOrder
Inmostcasesassemblyorder isthereverseof
disassembly.However,ifassemblyorderisprovided
intheServiceManual,followtheproceduresgiven.
CFMTOTO

1-5
1Maintenanceinformation
1
TighteningSequence
Generally, wheninstallingapart withseveralbolts,
nutsor screws, start them all intheirholesand
tightentheminsnugfit. Thentightenthemaccord-
ing tospecifiedsequencetopreventcasewarpage
or deformation whichcanlead tomalfunction.
Converselywhenlooseningthebolts,nutsor
screws, firstloosenall ofthembyaquarterturnand
thenremovethem.Ifthespecified sequencesisnot
indicated,tightenthe fastenersalternating
diagnoally.
Tightening Torque
Incorrect torque applied toabolt, nut or screwmay
leadtoseriousdamage. Tightenfastenerstothe
specified torquebyusingagood qualitytorque
wrench.Often, thetightening sequenceisfollowed
twiceinitialtighteningandfinaltighteningtorque.
PorperForce
Usecommonsenseduringdisassemblyand
assembly.excessiveforcecancauseexpensiveor
hard torepairdamage.Whennecessary,remove
screwsthathavenon-permanent lockingagent
applied usinganimpactdriver.Useaplastic-faced
malletwhenevertapping isnecessary.
Gasket andO-ring
Hardening,shrinkage,ordamage ofbothgaskets
andO-ringafter disassemblycanreducesealing
performance.
LiquidGasket,Non-permanent Locking Agent
For applicationsthat require LiquidGasketor a
nonpermanentlockingagent, cleanthesurfacesso
thatnooil residueremainsbefore applyingliquid
gasketor non-permanentlockingagent. Donot
applythem excessively,excessiveapplicationcan
clog oil passagesandcausesseriousdamage.

1-6
Press
For itemssuchasbearingor oilsealsthatmust be
pressed intoplace, applysmall amountofoil on
contactarea.Besuretomaintainproper alignment
andusesmoothmovementswheninstalling.
Ball Bearing andNeedleBearing
Donotremoveball orneedleunlessremovalis
absolutelynecessary.Replacewithnewones
wheneverremoved.Pressbearingswithmanufac-
turer andsizemarksfacingout. Pressbearinginto
placebyputtingpressureonthecorrectbearing
raceasshown.
Oil seal&GreaseSeal
Donot removepressed oilor greasesealsunless
removalisabsolutelynecessary. Replacewithnew
oneswheneverremoved.Press newoilsealswith
manufacturerandsizemarksfacingout.Makesure
thesealisaligned properlywheninstalling.
Applyspecified greasetothelipofthesealbefore
installingtheseal.
Circlips, CotterPins
Replacecirclipsor cotter pinsthat were removed
withnewones.Takecare not toopentheclip
excessivelywheninstallingtoprevent deformation.
CFMTOTO

1-7
1Maintenanceinformation
1
Lubrication
It isimportant tolubricaterotatingorslidingparts
duringassemblytominimizewear duringinitial
operation.Lubricationpointsare calledoutthrough-
out thismanual.Applyspecificoil or greaseas
specified.
Direction of Engine Rotation
Whenrotatingcrankshaftbyhand, thefree playof
amountofrotatingdirectionwill affectadjustment.
Rotatethecrankshafttopositivedirection
(Clockwiseviewedfromoutputside)
ElectricalWires
Whenconnectingelectricalwires, first tocheck
color ofwiresandunless specialinstruction, same
colorofwiresshouldbe connected.
Instrument
Useameter that hasenoughaccuracyfor an
accuratemeasurement.Read the manufacturer ¯s
instructionscompletelybefore usingthemeter.
Incorrectvaluesmaylead toimproper adjustments.

1-8
Marking Locations
Model CF400-A ／ CF650-7B
VINNo. LCEPESL4～／ LCEPEVLB～
EngineserialNo 268MQ～／283MT～
①VIN
②Metal
③Engine No.
CFMTOTO

1-9
1Maintenanceinformation
1
Mainlyspecifications
Item CF400-A CF650-7B
Dimensions:
Overalllength 2114mm(83.2in.)
Overallwidth 757mm(29.8in.)
Overallheight 1100mm（43.3in.)
Wheelbase 1415mm(55.7in.)
Road clearance 150mm(5.9in.)
Seatheight 815mm(32.1in)
Dry mass 206kg(454.14lb)
Curbmass
Front: 105kg(231.48lb)
Rear: 101kg(222.66lb)
Fuel tankcapacity 17L(4.5USgal.)
Performance
Minimumturningradius(LH
or RH) 2.7m(8.9ft)
Engine
Type 2-cylinderinline,4-strokes,DOHC,8valvesandliquid
cooled
Coolingsystem liquid-cooled
Bore andstroke 68.4×54.5(2.7×2.1in)/83×60(3.3×2.4in)
Displacement 400.4 cm³(24.434cu in.)/649.3 cm³(39.60cuin.)
Compressionratio 11: 1／11.3: 1
Max. power 29.5kW(40.12ps)@9500r/min/45kW(61.2PS)@8750
r/min(rpm)
Max. torque 32N·m(3.26kgf·m,23.6ft·lb)@7750r/min/56N·m(5.7
kgf·m, 41.3ft·lb) @7000r/min(rpm)，
Carburetionsystem EFI
Startingsystem Electricstarter
Ignition system ECU
Timingadvance Controlled by ECU
Ignition timing From8°BTDC@1450r/minto40°BTDC@6000r/min
/From10°BTDC@1300r/min (rpm)to33°BTDC
@6000r/min (rpm)
Spark plug CR8EI
Cylindernumberingmethods lefttoright 1-2
Firing order 1-2
Valve timing
Intake
Open 37°BTDC/31°BTDC
Close 63°BTDC/61°ABDC
Duration 280°/272°

1-10
Item CF400-A ／ CF650-7B
Exhaust:
Open 53°BBDC／50°BBDC
Close 34°ATDC／30°ATDC
Keepingtime 267°／260°
Lubrication Pressure, Splash(Half dry oilpan)
Engineoil：
Model ELF10W-40/SJJASOMA2
Standard SAE10W-40
Capacity 2.6L(2.7USqt)
Drivesystem
Moderatelevel1:
Style Gear
ModerateRatio 2.146(88/41)／2.095(88/42)
Clutchstyle Oilcoolmultidiscclutch
Gearbox:
Style 6gears, Internationalseriesgear
Gearratio:
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
2.5／2.353
1.8／1.714
1.333
1.111
0.966
0.852
Main moderatesystem:
Style Chain drive
Ratio 3.857／3.067
Total ratio 7.052(Bottomgear)／5.474(Topgear)
Frame
Style WeldingSteelpipesandplates
Frontforkangle 24.5°
Dragdistance 102mm(4.0in.)
Fronttire:
Style No innertires
Size 120/70ZR17M/C(58W)
Rimsize 17×3.50
Rearwheel:
Style No innertires
Size 160/60ZR17M/C(69W)
Rimsize 17×4.50
Frontsuspension:
Style Flexible
Wheel clearance 120mm(4.7in.)
CFMTOTO

1-11
1Maintenanceinformation
1
Item CF400-A／CF650-7B
Rearsuspension：
Style Rockerarm
Wheelclearance 125mm(4.9in.)
Breakcaliper：
Front Dualdisc
Rear Singledisc
Electrical equipment
Battery 12V10Ah
Headlight：
Style Semi-closed
BulbCF400 Highbeam：HS135W×1；Lowbeam：HS135W×1
BulbCF650-7 Highbeam：LED×3；Lowbeam：LED×1
Taillight/ Breakinglight LED×13
ACmagneto：
Style 3phaseAC
Output 24A/14V @5000r/min
Astheorderchangesthespecificationsmaydifferentfromtherealvehicle.Thisspecifications
donot standforallmodelsforallareas.

1-12
Unit calculationform
Unitprefixion: Length:
Prefix Sign Counting km ×0.6214=mile
Mega M ×1000000
m
×
3.281
=
ft
Kilo k ×1000
mm
×
0.03937 =
in
Centi c ×0.01 Torque:
Mini m ×0.001 N·m×0.1020=kgf·m
Micro µ×0.000001
N
·
m
×
0.7376
=
ft
·
lb
Mass:
N·m×8.851 =in·lb
kgf·m×9.807=N·m
kg ×2.205=lb kgf·m×7.233=ft·lb
g ×0.03527=oz kgf·m×86.80=in·lb
Volume: Pressure:
L ×0.2642=gal（US）kPa ×0.01020=kgf/cm2
L ×0.2200=gal（imp）kPa×0.1450=psi
L×1.057=qt（US）kPa×0.7501=cmHg
L×0.8799=qt(imp)
kgf/cm
2
×98.07=kPa
L×2.113=pint（US）
kgf/cm
2
×14.22=psi
L×1.816=pint（imp）
cmHg×1.333 =kPa
mL ×0.03381=oz（US）
Velocity:
mL×0.02816=oz（imp）
mL×0.06102=cuin km/h×0.6214=mph
Force: Power:
N×0.1020=kg
kW ×1.360=PS
N×0.2248=lb
kW×1.341=HP
kg×9.807 =N
PS ×0.7355=kW
kg×2.205 =lb
PS ×0.9863=HP
Tempcalculation method
CFMTOTO

2-1
2Periodicmaintenance
2
Contents
PeriodicMaintenanceChart………………………………………………………………………………………2-3
TorqueSpecifications………………………………………………………………………………………………2-6
SpecificationsandServiceLimit…………………………………………………………………………………2-11
SpecialTools………………………………………………………………………………………………………2-13
FuelSystem(EFI) ………………………………………………………………………………………………2-14
AirFilterElementCleaning……………………………………………………………………………………2-14
ThrottleControlSystemInspection …………………………………………………………………………2-15
IdleSpeedInspection …………………………………………………………………………………………2-16
FuelLineInspection(fuelleak,damage, installation condition) …………………………………………2-17
CoolingSystem……………………………………………………………………………………………………2-18
CoolantLevelInspection………………………………………………………………………………………2-18
Radiator HoseDamage andInstallationConditionInspection ……………………………………………2-18
Cylinderhead………………………………………………………………………………………………………2-19
ValveClearanceInspection……………………………………………………………………………………2-19
Clutch………………………………………………………………………………………………………………2-25
ClutchOperationInspection …………………………………………………………………………………2-25
Wheels/Tires………………………………………………………………………………………………………2-26
AirPressureInspection ………………………………………………………………………………………2-26
Wheel/TireDamage Inspection ………………………………………………………………………………2-26
Tire Tread Wear,AbnormalWearInspection ………………………………………………………………2-26
WheelBearingDamageInspection …………………………………………………………………………2-27
Drivechain…………………………………………………………………………………………………………2-27
DriveChainLubricationCondition Inspection ………………………………………………………………2-27
DriveChainSlackInspection…………………………………………………………………………………2-28
DriveChainSlackAdjustment ………………………………………………………………………………2-28
WheelAlignment Inspection ……………………………………………………………………………………2-29
DriveChainWearInspection ……………………………………………………………………………………2-30
ChainGuideInspection …………………………………………………………………………………………2-30
BrakeSystem ……………………………………………………………………………………………………2-31
BrakeFluidLeak(BrakeHoseandPipe) Inspection………………………………………………………2-31
BrakeHoseand Pipe DamageandInstallationConditionInspection…………………………………… 2-31
BrakeOperationInspection ………………………………………………………………………………… 2-32
BrakeFluidLevelInspection………………………………………………………………………………… 2-32
BrakePadWearInspection ………………………………………………………………………………… 2-33
BrakeLightSwitchOperation Inspection…………………………………………………………………… 2-33

2-2
CFMOTO
Suspensions……………………………………………………………………………………………………2-34
Front Forks/Rear ShockAbsorberOperation Inspection ………………………………………………2-34
FrontForkOilLeakInspection ……………………………………………………………………………2-34
RearShockAbsorber OilLeakInspection ………………………………………………………………2-34
SteeringSystem………………………………………………………………………………………………2-35
Steering PlayInspection……………………………………………………………………………………2-35
SteeringPlayAdjustment……………………………………………………………………………………2-33
SteeringStemBearingLubrication…………………………………………………………………………2-36
ElectricalSystem………………………………………………………………………………………………2-36
SparkPlugConditionInspection……………………………………………………………………………2-36
Lightsand SwitchesOperation Inspection ………………………………………………………………2-37
HeadlightAimingInspection…………………………………………………………………………………2-39
SidestandSwitchOperationInspection……………………………………………………………………2-40
EngineStopSwitchOperation Inspection ………………………………………………………………2-41
Others …………………………………………………………………………………………………………2-42
ChassisPartsLubrication……………………………………………………………………………………2-42
Bolts,NutsandFastenersTightness Inspection………………………………………………………2-43
ReplacementParts……………………………………………………………………………………………2-44
AirFilterElementReplacement……………………………………………………………………………2-44
FuelLine Replacement………………………………………………………………………………………2-44
CoolantChange………………………………………………………………………………………………2-45
RadiatorHoseand O-ringReplacement…………………………………………………………………2-47
EngineOil Change……………………………………………………………………………………………2-48
OilFilterReplacement………………………………………………………………………………………2-48
BrakeHoseand PipeReplacement………………………………………………………………………2-49
BrakeFluidChange…………………………………………………………………………………………2-49
MasterCylinder Rubber PartsReplacement ……………………………………………………………2-50
CaliperRubberPartsReplacement ………………………………………………………………………2-52
SparkPlugReplacement……………………………………………………………………………………2-54