CF MOTO X5 EFI 2009 User manual
WWW.CFMOTO.COM
CF500-5B
CF500-5C
Service
Manual
CFMOTO
All rights reserved
Zhejiang CFMOTO Power Co., Ltd.
Aug. 2009
WWW.CFMOTO.COM
FORWARD
This manual introduces X5 EFI version (CF500-
5B/5C) maintenance information, disassembly
procedure, check & adjustment methods, trouble-
shooting and technical specifications. There are
illustrations, drawing to guide your operations.
Chapter 1 mainly introduces general operation
information, tools, vehicle structure and basic
specifications.
Chapter 2 mainly introduces check & adjustment
methods and how to do vehicle maintenance.
Chapter 3 mainly introduces disassembly,
installation, adjustment, maintenance and trouble-
shooting information.
CFMOTO reserves right to make improve-
ments and modifications to the products
without prior notice. Overhaul and mainte-
nance should be done according to actual
condition of vehicle.
Zhejiang CFMOTO Power Co., Ltd.
Aug. 2009
CONTENTS
Maintenanceinformation 1
Vehiclebody!Muffler 2
Checking&Adjustment 3
Cooling&Lubricatingsystem 4
Engine disassembly&assembly 5
Engine disassembly,check&assembly
Fuel supply&Air intake system
Front wheel!Brake!Suspension!Steering system
Rear wheel!Brake!Suspensionsystem
6
7
8
9
Front &rear axle 10
Electricsystem
Lighting!Odometer!Switch
11
12
Troubleshooting 13
Conversion table
It
e
m
Ex
a
m
pl
e
C
onv
e
rsion
P
r
e
ssur
e
200
k
P
a
"2.00
k
gf /
c
m
2)1
k
gf /
c
m
2=98.0665
k
P
a
1
k
p
a
=1000
P
a
33
k
P
a
(250
mm
H
g)1
mm
H
g=133.322
P
a
=0.133322
k
P
s
Torqu
e
18
N
#
m
"1.8
k
gf -
m
)1
k
gf#
m
=9.80665
N
#
m
V
olu
m
e
419
m
l1
m
l=1
c
m
3=1
cc
1l=1000
c
m
3
F
or
ce
12
N
"1.2
k
gf$1
k
gf=9.80665
N
1-1
1.
M
a
int
e
n
a
n
ce
Infor
m
a
tion
1
Cautions
Safety Cautions
1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated place for long time.
2. Do not touch the engine or muffler with bare hands after the engine has just stopped to avoid scalding. Wear long-
sleeve work clothes and gloves for operation.
3.Battery liquid (dilute sulfuric acid) is highly caustic and may cause burns to skin and eyes. Flush with water if
splashed to skin and get immediate medical attention. Flush with water if splashed to clothes to avoid burns. Keep
battery and liquid away from reach of children
4.Coolant is poisonous. Do not drink or splash to skin, eyes or clothes. Flush with plenty of soap water if splashed to
skin. If splashed into eyes, flush with water and consult the doctor. If drinking the coolant, induce vomit and consult the
doctor. Keep coolant away from reach of children.
5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask.
6. Gasoline is highly flammable. No smoking or fire. Also keep against sparks. Vaporized
gasoline is also explosive. Operate in a well-ventilated place.
7.When charged, Battery may generate hydrogen which is explosive. Charge the battery in a well-ventilated place.
8. Be careful not to get clamped by the turning parts like wheels and clutch.
9. When more than two people are operating, keep reminding each other for safety purpose.
Cautions for Disassembling and Assembling
1. Use genuine CFMOTO parts, lubricants and grease
3. Clean the mud, dust before overhauling
2. Store the disassembled parts separately in order for correct assemble.
4. Replace the disassembled washers, o-rings, piston pin retainer, cotter pin with new ones.
5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers.
6. Clean and blow off the detergent after disassembling the parts. Apply lubricants on the surface of moving parts.
Measure the data during disassembly for correct assembling.
7.If you do not know the length of screws, install the screws one by one and make sure they are screwed in with same
depth.
8.Check if the disassembled rubber parts are aged and replace if necessary. Keep the
rubber parts away from grease.
9.Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque,
from big to small and from inner side to outer side.
10Replace aged latex parts before assembling. Do not mix volatile oil and grease on the surface,due to aggressivness
of fuel and oil.
11Apply or inject recommended lubricant to the specified parts
12Use special tools wherever necessary.
13 When ball bearing disassembled by pressing ball ring, it can not be reused.
Caution! ! ! ! ! ! ! ! !!1 - 1
Numbers Marking Locations
!!!!!1-3
Main Parameters Table!!!!!1-4
Maintenance Parameters Table!!!1-6
Tightening Torque!!!!!!!!1-
13
Grease & Seasant!!!!!!!!1-
18
Wiring, Pipe & Cables Layout!!!1-
19
Failure Indicator!!!!!!!!1-
23
1-2
C
F
M
O
T
O
14 .Turnth
e
i nn
e
r
a
nd out
e
r r i ngsof b
a
l l b
ea
r i ng to
m
ake
sur
e
th
e
b
ea
r i ng
w
i l l turn
s
m
oothly.
"
R
e
pl
ace
i f th
e
a
xi
a
l or r
a
di
a
l pl
a
yistoo big.
"If th
e
surf
ace
isun
e
v
e
n,
c
l
ea
n
w
ithoi l
a
nd r
e
pl
ace
i f th
e
c
l
ea
ning do
e
snot h
e
lp.
W
h
e
n
pr
e
ss ing th
e
b
ea
r ing i ntoth
e
m
ac
hin
e
or toth
e
sh
a
f t .
15. Inst
a
l l th
e
on
e
-sid
e
dust- proof b
ea
r ing inth
e
r ight di r
ec
t ion.
W
h
e
n
a
ss
e
m
bl ing th
e
op
e
n
typ
e
or doub l
e
-sid
e
dustproof b
ea
r i ng, i nst
a
l l
w
i th
m
a
nuf
ac
tur
e
r#s
m
a
r
k
out
w
a
rd.
16.
K
ee
pth
e
b
ea
r ing blo
ck
st i l l
w
h
e
nblo
w
ing dryth
e
b
ea
r ing
a
ft
e
r
w
a
shing
c
l
ea
n.
A
pp lyoi l
or lubr i
ca
nt b
e
for
e
a
ss
e
m
bl ing .
17 . Inst
a
l l th
e
e
l
a
st i
c
c
i r
c
l ipprop
e
r ly. Turnth
e
c
i r
c
l ip
a
ft
e
r
a
ss
e
m
bl ing to
m
ake
sur
e
i s
h
a
sb
ee
ninst
a
l l
e
dintoth
e
slot .
18 .
A
ft
e
r
a
ss
e
m
bl ing,
c
h
eck
i f
a
l l th
e
t ight
e
n
e
dp
a
rts
a
r
e
prop
e
r l yt ight
e
n
e
d
a
nd
ca
n
m
ov
e
s
m
oothly.
19 .
B
r
ake
f luid
a
nd
c
oo l
a
nt
m
a
yd
a
m
a
g
e
c
o
a
t ing, pl
a
st i
c
a
nd rubb
e
r p
a
rts.
F
lushth
e
s
e
p
a
rts
w
i th
w
a
t
e
r i f spl
a
sh
e
d.
20 . Inst
a
l l oi l s
ea
l
w
i thth
e
sid
e
of
m
a
nuf
ac
tur
e
r#s
m
a
r
k
out
w
a
rd.
"
D
onot foldor s
c
r
a
t
c
hth
e
oi l s
ea
l l ip.
"
A
pplygr
ea
s
e
toth
e
oi l s
ea
l l ipb
e
for
e
a
ss
e
m
bl ing
21.
W
h
e
ninst
a
lling pip
e
s, ins
e
rt th
e
pip
e
t i l l th
e
e
nd of joint .
F
it th
e
pip
e
c
l ip, i f
a
ny,
intoth
e
groov
e
.
R
e
pl
ace
th
e
pip
e
sor hos
e
sth
a
t
ca
nnot b
e
t i ght
e
n
e
d.
22 .
D
onot
m
ix
m
ud or dust into
e
ngin
e
a
nd /or th
e
hydr
a
ul i
c
br
ake
syst
e
m
.
23 .
C
l
ea
nth
e
g
a
s
ke
ts
a
nd
w
a
sh
e
rsof th
e
e
ng in
e
ca
sing b
e
for
e
a
ss
e
m
bl i ng .
R
e
m
ov
e
th
e
s
c
r
a
t
c
h
e
son th
e
j oint f
ace
sbypol ishing
e
v
e
nly
w
i th
a
noi lston
e
.
24 .
D
onot t
w
ist or b
e
nd th
e
ca
bl
e
stoo
m
u
c
h.
D
istort
e
dor d
a
m
a
g
e
d
ca
bl
e
s
m
a
y
ca
us
e
poor
25 .
W
h
e
n
a
ss
e
m
bl ing th
e
p
a
rtsof prot
ec
t i on
ca
ps, ins
e
rt th
e
ca
pstoth
e
groov
e
s, i f
a
ny.
1-3
1.
M
a
int
e
n
a
n
ce
Infor
m
a
tion
1
N
u
m
b
e
rs
M
a
r
k
ing L o
ca
t i on
C
F
500 -5
B
/
C
F
500 -5
C
V
I
N
N
u
m
b
e
r!
!
L
C
EL
D
TS5"
"
/L
C
EL
D
TS6
Eng in
e
N
u
m
b
e
r!
!
C
F
188-
B
"
"
1-4
C
F
M
O
T
O
M
a
in
D
a
t
a
T
a
bl
e
Item
Parameter
Model CF500-5B/CF500-5C
Length
CF500
-
5B
: 2100mm
CF500
-
5
C
: 2300mm
Width 1180mm
Height 1230mm
Wheel base CF500-5B: 1290mm CF500-5C: 1490mm
Engine type CF188
Displacement 493Cm
3
Fuel type
Unleaded gasoline RQ
-
90or above
Dry weight CF500-5B: 344 kg CF500-5C: 358 kg
Number of Passengers CF500-5B:2 $Include driver%
Max. Load 210 kg
Tire
Front Tire 25!8-12 40J
185/80-12 40J
Rear Tire 25!10-12 47J
270/60-12 47J
Min. Ground Clearance
275
mm
Turning Diameter Turning Diameter
Engine
Starting Electrical starting, Manual Starting
Engine Type Single cylinder, 4-stroke, Liquid-cooled, 4
valves, OHC
Combustion Chamber Type Triangle
Valve Driving Type
SOH C /
Chain Drive
Bore !Stroke 87.5mm!82.0mm
Compression Ratio 10.2:1
Lubrication Type Pressure & Splash
Oil Pump Type Rotor
Lubricant Filter Type
Full flow filter screen
Oil Type SAE15W-40/SF
Cooling Type
Closed coolant circulati on
Coolant Type -35&anti-rust coolant
1-5
1.
M
a
int
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a
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ce
Infor
m
a
tion
1
Item
Parameter
Fuel
Device
Air Filter type Sponge element filter
Valve
Type Type: CF188-B-173000
Diameter of mixing
valve
36mm
Gearing
Clutch W et, Auto-Centrifugal
Operation
Mode Automatic$CVT%+P arking & Gear S hi fting
Gea
rs Shift
Low Gear, High Gear & Reverse Gear
Shift
Mode/order
Manual /L-H-N-R
$CVT %
Transmis sio
n Ratio
2.88'0.70
Gear
Ratio
Final Ratio 1.333$24/18(Bevel Gear%
Secondary
Ratio 1.952$41/21%
Gears
Low Gear )2.25(36/16) *High Gear )
1.350(27/20) *R ev erse Gear )
1.471(25/17)
Total Low Gear5.857 *High Gear )3.514 *
Reverse Gear)3.828
Axle Ratio
Front
Axle 33 / 9 = 3.667
Rear
Axle 33 / 9 = 3.667
Engine Output Mode Front/Rear Shaft
Direction of Output
Rotation Clockwise on forward shift
Steering
Device
Steering
Angle
Inner
31º
Outer 31º
Brak e Type Front Hydraulic D isc
Rear Hydraulic D isc
Bumper
Device Suspension
Swing Arm
Frame Type
Welded Steel Tube and Plate
1-6
C
F
M
O
T
O
M
a
int
e
n
a
n
ce
P
a
r
a
m
e
t
e
rsT
a
bl
e
Lubr i
ca
t i on Sys t
e
m
A
i r I nl
e
t Sys t
e
m
Item
Standard
Service Limit
Engine Oil
Capacity
Volume when
replacing
1900mL +
Volume when
replacing filter
2200mL +
Recommended Oil$See Original %
·Specially for 4-stroke motorcycle
SAE-15W-40
Substitutes must be used in the
following range.
API type: SE or SF grade
SAE type: Choose from the left
chart according to the
environmental temperature
Oil Pump Rotor
Gap between
Inner and Outer
Rotors
0.03'0.1mm 0.15mm
Gap between
Outer rotor and
body
0.03'0.1mm 0.12mm
Oil pressure 3000r / min ,130-170KPa
Item Standard
Fuel Tank Capacity
Full capacity 18L
Valve
CF188
-
B
-
173000
Inlet Pressure Sensor
CF188
-
B
-
175000
Inlet Temperature Sensor
CF188
-
B
-
177000
Air Bypass Valve CF188-B-172000
Injector CF188-B-171000
Idle Speed 1400±100r / min
1-7
1.
M
a
int
e
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a
n
ce
Infor
m
a
tion
1
C
oo l i ng Sys t
e
m
It em Standard/ Paramet er Ser vice
Li mit Remark
Ful l Cap acity 2000ml
Reservoir t an k capacity 300ml
Standard Densi ty 50%
Opening pressur e of radiator
cap 108kpa(1.1kgf/ cm2)
Thermostat
Init ial
Temperature 71±3&
Full opening
Temperature 88&
Ful l o pening lift
range 3.5'4.5mm/95?
Temperat ure
and
Resist ance of
Wat er
Temperat ure
Sensor
Temperat ur e(&)
End B
Resi stance(")
End A C
Resistance (k")
-20 ---- 13.71-16.94
25 ----- 1.825-2.155
50 176-280 ----
80 63.4-81.4 0.303-0.326
110 24.6-30.6 0.138-0.145
Temperat ure
of
Thermostat
Close -Open 88&Round 88&Round
Open-Close 82&Round 82&Round
Coolant Type
-35&anti-frozen, ant isepsi s, hi gh -boil co olant
1-8
C
F
M
O
T
O
F
ron t
W
h
ee
l
R
ea
r
W
h
ee
l
B
r
ak e
Sys t
e
m
Item Standard Operation
Lim it
Front W heel
Pl ay of wheel
rim
Ve rtical
1.0mm
2.0mm
H or izo ntal
1.0mm
2.0mm
Tire Groove +
3.0mm
P ressure 35kPa$0 .35kgf-cm2%
+
Item Standard Oper ati on
Limit
Rear W heel
Pl ay of wheel
rim
Ve rtical
1. 0mm
2.0mm
H or izo nta
l
1. 0mm 2.0mm
Tire Groove +3.0mm
P ressure 30kPa$0. 30kgf-cm
2%+
Item Standard Operation
Limit
Front B ra ke Brake En d P lay 0mm +
Brake Disc T hickness
3.5mm
2 .5mm
Rear Br ake
Brake End P lay 5-10 mm +
Brake Pedal P lay 0mm +
Brake Disc T h ickness
7.5mm
6 .5mm
1-9
1.
M
a
int
e
n
a
n
ce
Infor
m
a
tion
1
B
a
t t
e
ry,
C
h
a
rging
D
e
vi
ce
,
P
i
ck
up
C
oi l
Ign ition
D
e
vi
ce
Item Standard
Ignition ECU Ignition
Spark Plug
Type Resistance Spark plug
Standard
DPR7EA
-
9(NGK)
Optional DR8EA .D7RTC
Spark plug gap 0.8-0.9mm
Spark
Characteristic /8mm(1mpa
Ignition Timing
BTDC10ºCA 1500r/min
Ignition Coil
Resistance
Initial 0.740-0.780
Secondary 10.1k0-11.1 k0
Peak Voltage
Ignition Coil /150V
Pulse
Generator 2V
Starter Relay Coi l Resistance 3"-5"
Secondary Starter Relay Coil
Resistance 90"-100"
Item Standard
Fuse Main 20A
Auxiliary 10A!215A!2
Light, Bulb
Fuse
Head Light$Hi-Lo%12V—35W/35W
!2
Brake Light/ Tail Light 12V—5W!2
Turning Light 12V—21W/5W
Dashboard Indicator Light
12V
—
10W!4
Indicators #5 LED
Main LCD
Item Standard
AC
Magneto
Motor
Model
Permanentmagnet AC Type
Output 3-phase AC
Charging Coil Resistance$20?%0.2"-0.3"
Pickup Coil Resistance 110"-140"
Magneto without Load Voltage/(Idle
Speed) /100V$AC%( 5000r/min
Max. Output Power 300W(5000r/min
Rated Voltage 13.5V-15.0V, 5000r/min
Peak Voltage of Pickup Coil /120V
Rectifier
Three-phase annular rectification,
Silicon controlled parallel-connected
regulated voltage
Battery
Capacity
Capacity
Terminal Poi nt
Voltage
Fully
Charged
12.8V
Insufficient
Charged <11.8V
Charging
Current/time
Standard 0.9A-5'10H
Quick 4A -1H
Lights, I nst ru
m
e
nt , S
w
i t
c
h
e
s
1-10
C
F
M
O
T
O
A
ir Inl
e
t
D
e
vi
ce
+
C
yl i nd
e
r
H
ea
d(mm)
Item Standard Operation Limit
Intake 30.6
Valve Diameter
Exhaust 27.0
Intake 0.05-0.10
Valve Clearance( Idle Speed)
Exhaust 0.17-0.22
Intake 0.010-0.037Fit Clearance between Valve
Guide and Valve Stem Exhaust 0.030-0.057
Internal dia. of Valve Guide Intake & Exhaust
5.000-5.012
Intake 4.975-4.990
Exterior dia. of Valve Stem
Exhaust 4.955-4.970
Valve Stem Run-out Intake & Exhaust
0.05
Length of Valve Stem End Intake & Exhaust
2.9-3.1 2.3
Thickness of Valve Head Intake & Exhaust
0.5
Valve Head Seal Run-out Intake & Exhaust
0.03
Width of Valve Seats Seal Intake & Exhaust
0.9-1.1
Length of Valve Spring Intake & Exhaust
40 38.8
Valve Spring Tension Intake & Exhaust
Tension 182-210N
/Length31.5mm
Intake 33.430-33.490 33.130
Cam Height
Exhaust 33.500-33.560 33.200
#22 0.032-0.066 0.150Fit Clearance between
Camshaft Exterior dia. &Bore. #17.5 0.028-0.059 0.150
#22 21.959-21.980
Camshaft Exterior dia.
#17.5 17.466-17.484
#22 22.012-22.025
Camshaft Bore Internal dia.
#17.5 17.512-17.525
Camshaft Run-out 0.10
Rocker Arm Internal dia. Intake & Exhaust
12.000-12.018
Rocker Arm Shaft Exterior dia.
Intake & Exhaust
11.973-11.984
Plainness of Cylinder Head
Adjoining Plant
0.03 0.05
Plainness of Cylinder Head
Cover Adjoining Plant
0.03 0.05
1-11
1.
M
a
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ce
Infor
m
a
tion
1
C
yl in d
e
r +
P
isto n +
P
iston
R
ing +
C
r
a
n
k
sh
a
ft (mm)
Item Standard Operation
Limit R emark
Cylinder Pressure 1000kPa
F it Clearance betw een
P iston and C ylinder 0.030-0.051 0.15
Piston Sk irt di a.
87.460-87.480
Tes ting the point aw ay skirt end
10mm
87.380
Internal dia. of Cylinder 87.500-87.522
Plainness of Cylinder
Adjoining Plant 0.015 0.05
Top Ring R 11.7 round 8.9
Piston Ring Free Gap 2nd R ing R 12 round 9.5
Top Ring 0.15-0.30 0.60
Pis ton R ing Closed Gap 2nd
Ring 0.15 -0.30 0.60
Top Ring 0.04-0.08 0.180Piston Annular Fit
Clearance 2nd
Ring 0.03- 0.07 0.150
Top Ring 0.97- 0.99
Thickness Pis ton R ing 2nd
Ring 1.17- 1.19
Top Ring 1.03 -1.05
2nd
Ring 1.22- 1.24
Piston Annular Width
Oil R ing 2.51-2.53
Internal dia. of Pis ton Pin
Bore 23.002-23.008 2 3.0 30
Exterior dia. Piston Pin 22.995-23.000 2 2.9 80
Rod Small End Inner dia.
23.006-23.014 2 3.0 40
Rod Big End Gap 0.10-0.55 1.0
Rod Big End Thi ckness 24.95-25.00
Crank shaft Run-out 0.03 0 .08
1-12
C
F
M
O
T
O
Clutch + Transmission
(mm)
Item Standard Limit Remark
Clutch Friction plate inner dia. 140.00-140.15 140.50
Clutch Joint Rotation 1800-2400r/min
Clutch lock-up Rotation 3300-3900r/min
Drive Belt Width 35.2 33.5
Driven Disc Spring Free Length 168 160
Shifter and fit flute gap 0.10-0.40 0.50
Left Shifter Sliding Thickness 5.8-5.9
Right Shifter Sliding Thickness 5.8-5.9
Plunging Flute Width 6.0-6.2
Driven Output Gear Sliding Width
6.0-6.2
1-13
1.
M
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Tightening Torque
Item Torque N·m(kgf·m) Item Torque N·m(kgf·m)
5mm Bolt, nut 5(0.5) 5mm Screw 4(0.4)
6mm Bolt, nut 10(1.0) 6mm Screw 9(0.9)
8mm Bolt, nut
22(2.2)
6mmSH Bolt with flange,
10(1.0)
10mm Bolt, nut 34(3.5) 6mm Bolt with flange, nut 12(1.2)
12mm Bolt, nut 54(5.5) 8mm Bolt with flange, nut
26(2.7)
10mm Bolt with flange, nut
39(4.0)
For o thers not listed in the chart, refe r to t he standard tightening torque.
Notes: Apply some engine oil on the part of screw thre ad and adjo ining surface
Item Thread Dia.
(mm)
Quantity
Torque
N·m(kgf·m) Remark
Upper Front Mounting Bolt, Engine
M8!60
1
16'20
Upper Rear Mounting Bolt, Engine
M10!1.25!110 1 40'50
Upper Rear Mounting Bracket Bolt,
Engine M8!14 1 16'20
Upper Front Mounting Brac
ket Bolt,
Engine
M8!14
1
16'20
Low Mounting Bolt, Engine M12!1.25!140 2 50'60
Bolt, Swing Arm M10!1.25!70 16 40'50
Bolt, Rear Absorber M10!1.25!50 4 40'50
Bolt, Front Absorber
M10!1.25!50
4
40'50
Bolt, Rear Wheel ShaftHolder M10!1.25!100 4 40'50
Mounting Nut, Rim 901-07.00.02 M20 16 50'60
Nut, Rim Shaft
901
-
07.00.03 M10
4
110'130
Mounting Screw, Rear Brake
Caliper
M6!25
2
18'22
Bolt, Rear Brake Caliper M10!1.25!20 2 40'50
Bolt, Front Brake Disc 901-08.00.03 M8 !8 25'30
Bolt, Front Bra
ke Caliper
M8!14
4
16'20
Locknut, Steering Stem M8!55 4 16'20
Nut, Steering Stem M10!1.25 4 40'50
Locknut, Steering Shaft M14!1.5 1 100'120
Rear Mounting Bolt, Muffler
M8!30
1
16'20
Bolt, Exhaust Pipe M8!14 1 16'20
Mounting Bolt, Exhaust Pipe M8!40 1 16'20
Mounting Bolt, Rear Axle
M10!1.25!110
2
40'50
Mounting Bolt, Front Axle M10!1.25!90 1 40'50
Mounting Bolt, Front Axle
M10!1.25!25
2
40'50
Back End Bolt, Rear Trans Shaft 901-30.00.01 6 40'50
Front End Bolt, Rear Trans Shaft
901
-
29.00
.01
4
35'45
Bolt, Front Trans Shaft 901-29.00.01 8 35'45
Thermo Switch CF250T-420500 1 9'12
Mounting Bolt 1, FrontRack
M8!14
2
35'45
Mounting Bolt 2, FrontRack M6!12 2 25'30
Mounting Bolt , Rear Rack M8!14 4 16'20
1-14
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Engine Tightening Torque Table
Item Q’ty Screw dia.$mm%
Torque
$N.m%
Remark
Sensor, Reverse Gear 1 M10!1.25 20
Spark Plug 1 M12!1.25 18
Water Temperature Sensor 1 Rc1/8 8 Apply screw thread sealant
Valve Clearance Adjusting Nut 4 M5 10
Drive Disc Nut 1 M20!1.5 115
Driven Disc Nut 1 M20!1.5 115
CircleNut, Driving Disc 1 M30!1 100
Nut, FrontOutput Shaft 1 M14!1.5 97
Nut, Drive BevelGear 1 M22!1 145
Nut, Driven Bevel Gear 1 M16!1.5 150
Fixing Nut, Clutch 1 M18!1.5 70 Left handed
Limiting Nut, Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant
Limiting Nut, Front Output Shaft 1 M55 80
Apply screw thread
sealant, left handed
Bolt, Swing Arm Shaft 2 M14!1.25 28
Drain Bolt 1 M12!1.5 30
Mounting Bolt, Overriding Clutch 6 M8 26 Apply screw thread sealant
Mounting Bolt, Magneto Stator 3 M6 10 Apply screw thread sealant
Bolt, CVT Windshield 3 M6 10 Apply screw thread sealant
Link Bolt, Oil Pipe 2 M14!1.5 18
Mounting, Oil Pump 3 M6 10
Mounting Bolt, PressureLimiting Valve 2 M6 10
Bolt, Drive Bevel Gear Cover 4 M8 32
Bolt, Driven Bevel Gear Cover 4 M8 25
Locating Bolt, Shift 1 M14!1.5 18
Flange Bolt, Fan 1 M10!1.25 55
1-15
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To be continued
Item Quantity
Diameter$mm%
Torque
$N.m%
Remark
Bolt, Crankcase
14 M6 10
3 M8 25
Bolt, Driven Sector Gear 1 M6 12
Mounting Bolt, Oil Filter 1 M20!1.5 63
Oil Filter 1
3/4 ?
$
16 /
in
18'20
Bolt, Starting Motor 2 M6 10
Bolt, Cylinder Head 4 M10 38
Bolt, Cylinder Head(2 sides) 2 M6 10
1 M8 25
Upper and Lower Bolt, Cylinder 4 M6 10
Bolt, Cylinder Head Cover 12 M6 10
Bolt, Chain Tensioner 2 M6 10
Nut, Chain Tensioner 1 M8 8
Bolt, Radiator Fan 3 M6 10
Thermostat Bolt 2 M6 10
Bolt, Water Pump Cover 3 M6 6
Mounting Bolt, Water Pump 2 M6 10
Fixed Bolt, Timing Sprocket 2 M6 15 Apply screw thread sealant
Bolt without remarks
M5 4.5-6
M6 8-12
M8 18-25
1-16
C
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Engine Tools
Measuring Tools
No Name Type Function Remark
1 Vernier Calipers 0-150mm Measure length and thickness
2 Micrometers 0-25mm
Measure the outer diameters of swing
arm, valve rod andcamshaft
3 Dial gauge 25-50mm Measure max. lift range of camshaft
4 Dial gauge 75-100mm Measure piston skirt
5 Inner dia. Gauge, Cylinder Measure inner dia. of cylinder head
6 Inner dia. Gauge, 10-34mm
Inner dia. of swing arm, piston pin hole,
and rod head hole
7 Dial Test Indicator 1/100 Run-out
8 Knife Straight Edge plainness
9 Feeler Gauge Plainness, adjusting valve clearance
10 Fuel LevelGauge Fuel level length of carburetor
11 Plastic gauge Fit clearance
12 pull tension gauge Spring bounce
13 Tachometer Engine rotation rate
14 Cylinder Pressure Meter pressure in cyclinder
15 Oil Pressure Gage Oil pressure
16 Barometer Opening pressure of radiator cover
17 Ohmmeter Resistance and voltage
18 Amperemeter Opening of currency / switch
19 Thermometer Liquid temperature
20 Timing Lights Test spark timing
21 Torque Tester One Set Tightening torque
Auxiliary Measuring Instrument
22 Alcohol Burner Warming up
23 Magnet Stand Install dialgauge
24 Slab Auxiliary measure supplementary
25 V-Block Run-out supplementary
26 Forcep Install valve clip
27 Plier Disassemble and install circlip
28 Joint Plier Disassemble and install flange
29 Impact Driver Disassemble cross recessed bolt
30 Slot Type Driver
31 Cross Type Driver
This manual suits for next models
2
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