CFMoto CF625-C Spécifications

WWW.CFMOTO.COM CF625-B CF625-C Service Manual

Maintenance Parameters TableLubrication System Air Inlet SystemItem Standard Service Limit Engine Oil Capacity Volume when replacing 1900mL(2.01Q

CFMOTORemove nut and bolt of front axle from frame.Remove nut and bolt of rear axle from frame.Front DiffBoltsFront Drive ShaftFront DiffFront Drive S

5 Removal and Installation of Engine,Drive Train and Gearshift UnitRemove the 18 bolts for drive shafts and front and rearaxles(Refer to 5,bolt 3)Remo

6 Engine Removal, Inspection & Installation 6 Engine Removal, Inspection and Installation △Engine Removal/Installation Orders an

CFMOTOEngine RemovalPreparation before engine removalDrain coolant (3-15).Engine Periphery Water Hose/PipeRemove water hose clamp 1,2,Remove water hos

6 Engine Removal, Inspection & InstallationRemove valve adjusting covers.Remove cylinder head cover.Remove screw plug , insert a flat screwdrive

CFMOTORemove C-ring 1.Remove timing sprocket from camshaft, remove camshaft.Remove cam chain guide.Remove cylinder head bolts. Cylinder HeadRemove

6 Engine Removal, Inspection & InstallationRemove cylinder bolt.Remove cylinder.Remove dowel pin and cylinder gasket.Remove piston pin circlip 1w

CFMOTO Oil FilterRemove oil filter with special tools. Tool: Oil filter RemoverRemove bolt 1 of gearshift rocker arm.Sector GearRemove gasket 2 and g

6 Engine Removal, Inspection & InstallationRemove water pump screws.Remove water pump.Water PumpSheave DrumRemove the sheave drum by using a s

CFMOTORemove driven gear 1 and needle bearing.Starting Motor GearRemove idle gear and shaft 4.Remove dual gear and shaft 3. Oil Pump Sprocket and Cha

1. Maintenance InformationCooling SystemItem Standard/Parameter Service Limit Remark Full Capacity 2000m l 0.53Gallons Reservoir tank capacity

6 Engine Removal, Inspection & InstallationEngine Right Side CVT CoverRemove bolts from CVT cover.Remove CVT cover.Remove gasket and dowel pi

CFMOTOCVT CaseRemove bolts #1 from CVT case.Remove outer clutch face and CVT case. ClutchRemove clutch shoe fixing nut with special tool.Remove dowel

6 Engine Removal, Inspection & InstallationRemove left crankcase bolts.Remove right crankcase bolts.Separate right crankcase with special tool.Th

CFMOTORemove left crankcase from driven bevel gear.Shift Cam, Fork/Shaft Drive Bevel GearRemove Shift Cam Fork /Shaft Balancer ShaftRemove balancer

6 Engine Removal, Inspection & InstallationRemove oil pump and relief valve.Oil pump, Relief ValveSeparate crankshaft from left crankcase with

CFMOTOEngine Components InspectionCylinder Head CoverDisassemblyCAUTION:Each removed part should be identified to its location, and the parts should b

6 Engine Removal, Inspection & InstallationRocker ArmWhen checking the rocker arm, check the innerdiameter of the valve rocker arm and wear of th

CFMOTORemove thermostat.Compress the valve spring and remove valve re-tainers with tweezers.Remove valve spring upper seat and valve spring.Tools: Val

6 Engine Removal, Inspection & InstallationCylinder Head DistortionClean off carbon deposit from combustion chamber.Check the gasket surface of t

CFMOTOValve Stem Run-outSupport valve stem with V block as illustrated onthe right. Check the run-out with a dial gauge.Service Limit: 0.05mm

Front WheelRear WheelBrake System Item Standard Ope ration Lim it Front Wheel Play of wheel rim Vertical 1.0m m 2.0mm Horizontal 1.0mm 2.0mm Tire Gr

6 Engine Removal, Inspection & InstallationValve SpringValve Spring keeps valve and valve seat tight.Weakened spring results in reduced engine po

CFMOTOInstall valve spring with small-pitch end (b) facing cylinder head. Big-pitch end (a) is marked.Put on the valve spring retainer. Use the val

6 Engine Removal, Inspection & InstallationInstall thermostat.Install thermostat cover.Install water temperature sensor, apply thread locker t

CFMOTOAutomatic DecompressionMove the automatic decompression weight withhand and check if it is operating smoothly. If it isnot working smoothly, rep

6 Engine Removal, Inspection & InstallationCamshaft Journal O.D.Measure camshaft journal O.D. with a micrometer.If the O.D. is out of range, repl

6 Engine Removal,Inspection and InstallationChain TensionerInspectionInsert screw driver 1 into the slotted end of adjusting screw, turn it cloc

PistonPiston DiameterUse a micrometer to measure the diameter at the point 10mm above the piston end, as illustrated on the right. If the measuremen

6 Engine Removal,Inspection and InstallationPiston Ring Free End Gap and End GapBefore installing piston rings, use vernier caliper tomeasure the free

ConnectingRod/CrankshaftConnecting rod small end I.D.Use a dial gauge to measure the I.D. of connecting rod small end. If the measurement exceeds th

6 Engine Removal,Inspection and InstallationClutch InspectionCheck clutch for chipping, scrape, uneven wear or heat discoloration. At the same time

1. Maintenance Information Battery, Charging Device, Pickup CoilIgnition Device Item Standard Ignition ECU Ignition Spark Plug Type Resistance Sp

Primary and Secondary Sheave(17)(16)(15)(14)(12)(13)(10)(11)(9)(8)(7)(6)(4)(2)(1)(5)(3)ABABCN m115115100

6 Engine Removal,Inspection and InstallationPrimary Sliding Sheave Remove spacerRemove Cam 1 roller 2Check each roller and sliding face for wear and

Primary Sliding Sheave and Fixed SheaveCheck the drive face for any abnormal conditions such as damage or stepped wearing.Replace if necessary.Ins

6 Engine Removal,Inspection and InstallationInstall Spacer Secondary SheaveUse special tool and holder to hold the secondarysheave. Remove secondary s

Remove spring 1.Remove spring seat 2.Remove guide pin and spacer.Remove secondary sliding sheave 3. O-ring and Oil Seal Check the O-ring and oil sea

6 Engine Removal,Inspection and InstallationInstall oil seal with special tool. Tool: Bearing install setUse vernier caliper to check the spring

Install guide pin and spacer 1.Install spring seat. Align hole A with hole B.Install spring and spring plate. Insert spring endinto the hole.Compress

6 Engine Removal,Inspection and Installation Tighten the ring nut with special tool to the specified torque. Tool: Ring nut wrench Sheave

TransmissionDisassemblyItem Description Qty Item Description Qty 1 MAINSHAFT. GEARSHIFT 1 10 DRIVENGEAR, HIGH RANG 1 2 SHIFT CAM 1 11 DRIVE

6 Engine Removal,Inspection and InstallationInspectionInspect drive bevel gear and sprocketfor stains, scratch or damage, replace if necessary.Inspect

Air Inlet Device+ Cylinder Head (mm) Item Standard Operation Limit Valve Diameter Intake 32.6 Exhau

Check the shift fork clearance with a thickness gauge in the groove of its gear.Replace if clearance exceeds the limit.Service Limit: 0.50mm Me

6 Engine Removal,Inspection and InstallationPut the guide bar on a flat place and roll it. In case of any bend, replace with a new one.NOTE:DO NOT

When assembling the guide bar, take care not to assemble the two shift forks and springs in the opposite direction.Guide bar; 2 Retainer 12;

6 Engine Removal,Inspection and InstallationOil Strainer InspectionCheck oil strainer 1and O-ring 2 for damage, re-place if necessary;Clean the surfac

Front Output ShaftDriven Bevel GearCheck bearing 7 for smooth turning and abnormal wear. Check oil seal 5 for damage. Replace if necessary;App

6 Engine Removal,Inspection and InstallationBevel GearNOTE:Proper bevel gear engagementdepends on that the gear backlash & tooth contact are withi

Tooth Contact InspectionAfter adjusting the backlash, checkthe tooth contact according to the followingproceduresRemove drive and driven bevelgear sha

6 Engine Removal,Inspection and InstallationBalance ShaftRemove starter clutch nut.Magneto RotorRemove the parts as illustrated on the right. Chec

Check starter clutch roller and holder for abnor-mal wear or damage,replace ifnecessary.NOTE:When install the starter clutch to the magneto rotor,

6 Engine Removal,Inspection & InstallationCheck the gear surface for nicks or damage, replace if necessary;Check magneto stator coil 2, pickup

1. Maintenance InformationCylinder + Piston + Piston Ring + Crankshaft (mm) Item Standard O peration Lim it Remar

1.Cap, handle 2.Handle 3.Friction plate 4.Spring clamp 5.Pawl 6.Spring 7.Sheave

6 Engine Removal,Inspection & InstallationAssemblyReverse the removal procedure for installation and payattention to the following:Install sheav

CVT COVERRemove screw 5, oil seal limitator 4 .Remove oilseal 3 with sepecial tool;Check bearing 2 for free turning. In case of anyabnormal, remove wi

6 Engine Removal,Inspection & InstallationCrankcase1-Right crankcase 2-Bearing 3-Bearing4-Bearing 5-Bearing 6-Bearing 7-Oilseal l8-Washer,r

Install reverse gear sensor 9 and tighten to thespecified torqueInstall speed sensor 24Install oil pipe and tighten the link bolt to the speci-fied to

6 Engine Removal,Inspection & InstallationCrankshaftInstall crankshaft to left crankcase with special tool. NOTE:Do not hammer the crankshaft in

Install shift cam 1 and shift fork 2.Check each part for smooth turning.Install low range driven gear to counter shaft 3.Install drive bevel gear and

Apply sealant 1 to the mating face of rightcrankcase;NOTE:Apply sealant evenly in a uninterrupted thin lineAssemble crankcase and tap slightly wi

CVT CasePrimary sheave,secondary sheave,driveBeltInstall drive belt on secondary sheave and tap witha plastic hammer to keep the belt as low as possib

6 Engine Removal,Inspection & InstallationTighten primary sheave nut with special tool to thespecified torque. Tool:CVT HolderTighten sec

Clutch + Transmission (mm) Item Standard Limit Remark Clutch Friction plate inner dia. 140.00

Engine leftDual gear/idler gearStarter driven gearInstall CVT case cover bolts and tighten diagonallyin several steps.Oil pump sprocket and chainInsta

6 Engine Removal,Inspection & InstallationMagneto rotorLeft crankcase coverNOTE:Use a new gasketRecoil starterzInstall recoil starter 1.zInstall

Water pumpzInstall water pump.Sector gear Install the parts as illustrated on the right.NOTE: Before tightening the bolts, be sure toinsert oil pump

6 Engine Removal,Inspection & InstallationOil filterTightening torque:63N m Tool:Oil filter wrenchStarting motorzInstall starting motor.Engine

zApply a light coat of moly oil to the piston pin.zInstall piston pin into holes of piston and conrod smallend.z1st and 2nd rings have letter R marked

6 Engine Removal,Inspection & InstallationNOTE: Use a new cylinder cover gasket toprevent oil leakage.Cylinder Cylinder head bolt tightening tor

CamshaftzInstall chain tensioner.zAlign mark A on magneto rotor with mark B oncrankcase.NOTE:While rotating crankshaft, pull the cam chainupward, or

6 Engine Removal,Inspection & InstallationCylinder head coverCylinder head cover bolt tightening torque:10N mNOTE: When tightening the cylinder

Chain tensionerzInsert (--) screwdriver into slotted end of chain ten-sion adjuster, turn it clockwise to lock the tensionerspring.zInstall the chain

6 Engine Removal,Inspection & InstallationChain tensioner screw tightening torque:8NmValve adjuster coverSpark plugSpark plug tightening torque:

1. Maintenance InformationTightening 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

zInstall left plastic cover 6.z Install water hose 5.z Install water hose 3.Left plastic coverWater pipe and hosez Install bolt 4.z Install clamp 1,2.

7 Fuel System, Air Intake SystemOverhaul InfoTroubleshootingHigh Pressure Fuel Line Disassembly/ InstallationTh

Overhaul InfoCAUTIONNOTEGasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.Special attention should also

7 Fuel System, Air Intake SystemHigh Pressure Fuel Line DisassemblyLoosen the special fuel line clamp on fuel in

Fuel Injector Assy RemovalUse thumbs of both hands to push two sides of fuelinjector cap snap spring, and then remove it.Seperate fuel injector cap an

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMOverhaulOperation NoticeAttention The frame must be hold up firmly when overhauling front wheel, suspen

Fault DiagnosisHandlebar Heavy Upper screw over tightened. Steering shaft worn or damaged. Bearing inner, external race destroy, worn, step. Steer

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMFront wheelDisassembleSet up front wheel with tool, ensure without any forceon the front wheel.Remove st

Brake SystemFront Brake CaliperDisassemblyRemove front wheel .Remove the 2pcs nuts installed on the armRemove brake caliper.InspectionCheck if the bra

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMBrake discDisassembleRemove front wheelRemove brake caliperTake away brake disc together with front whee

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 W

DisassemblyRemove foot restRemove front inner fender RHRemove bolt1, bolt2.Seperate pedal brake master cylinder from the body.AssemblyFor assembly,rev

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMAssemblyFor assembly,reverse the disassembly procedure.ATTENTION:Brake hose routing refers to section1 c

DisassemblyFront Shock AbsorberDisassemblyATTENTION:You do not need to remove any otherparts if you only replace the front suspension.Remove front lef

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMAssemblyFor assembly,reverse the diassembly procedure.Front left shock absorber disassembly, assembly, i

InspectionBall JointInspect if it can rotate flexibly between top ball joint 5and front left upper arm 22,bottom ball joint 13 andfront left lower 24.

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMFront AxlesAttention:For this vehicle, inspection,disassem-bling and assembling the front&rear axles

Steering SystemHandlebarDashboard coverDisassembyRemove dashboard cover bolt1.Remove dashboard cover.AssemblyFor assembly,reverse the disassembly proc

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMHandlebar Switch, LHDisassemblyRemove 2 screws.Remove LH handlebar switch connector.Remove handlebar swi

Handlebar PipeDisassemblyRemove the dashboard coverRemove RH&LH handlebar switchSeperate the right and left brake pump from thehanlebar pipe.Remov

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMInstall LH Handlebar SwitchPair the LH handlebar switch stopped onto the handlebarlocation hole.use bolt

1. Maintenance Information To be continued Item Quantity Diameter（mm） Torq

Install RH&LH GripClean inner LH grip and dry it. coat the connectionwith joint cement between handlebar and LH grip, putin the RH&LH grips.AT

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMSteering System211.Bolt1 21.Washer 22.Rubber Collar

Steering ColumnDisassemblyRemove dashboard front cover .Remove front wheel .Unhook handlebar switch connector.Use straight screwdriver and hammer ,ben

8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEMSteering Bearing, Oil SealDisassemblyRemove front wheelRemove steering columnRemove front ADWS arm assyU

9 Rear Wheel, Rear Brake, SuspensionOverhaul Info Rear Brake SystemTroubleshooting Rear Suspension SystemRear WheelOverhaul InformationOperating Notic

TroubleshootingRear Wheel Wobbles Rim bent Faulty Tire Tire Pressure Too Low Improper Wheel Balance Improper Tightening of Wheel Axle Nut Loosen

9 Rear Wheel, Rear Brake, SuspensionRear WheelRemovalRefer to Front Wheel RemovalInspectionRimDamage, bent, serious scrapesSlowly turn the wheel, meas

Rear BrakeRear Brake CaliperRemove:-Rear Left Wheel-2 Bolts from Arm.-Brake Caliper.nspectionBrake Caliper: Cracks, Oil Leakage: ReplaceInstallationRe

9 Rear Wheel, Rear Brake, SuspensionRear Suspension SystemRear Right SuspensionNOTE:DO NOT remove both left and right suspension at the same time to a

Rear Right AbsorberRemovalNOTE:Securely support the vehicle when remov-ing rear left and right absorbers. Suspend wheelsfrom ground.Maintenance of rea

All rights reservedZhejiang CFMOTO Power Co., Ltd.Aug. 2009

Engine Tools Measuring Tools No Name Type Function Remark 1 Vernier Calipers 0-150mm Measure length and thickness 2 Micrometers 0-25mm Meas ur

10 Front Differential/Rear GearcaseOverhaul informationStandardsLubricating PriodItemFront DiffTypeSAE15W/40 SF orSAE80W/90 GL-4CapacityInitial:

Inspection & OverhaulInspection and overhaul is needed if any of problems below happens to front diff and rear gearcase.Problem Descriptions Caus

10 Front Differential/Rear GearcaseFront Diff Drive Pinion Gear O-ring Bearing 6007 Adjust Washer Gear Motor Bolt M O

Inspection After Front Diff Disassembly Check if there is damage or cracks on the front diffrential gear case cover andbearing bore.Replace case cove

10 Front Differential/Rear GearcaseFront Diff Assembly And Adjustment Front Diff Case Cover AsselblyItem ”24 ”Tightening torque 62NmNOTE:Use engine o

 Front Diff Assembly And AdjustmentTightening torqueItem ”1 ” 25NmItem”25” 13NmBolt 25NmBolt 25NmItem ”30 ” 13

10 Front Differential/Rear Gearcase c Use special equipment or vehicle controlcircuit into 2WD position before gear motorassemblyd Make sure b and c i

Rear axle exploded view Item Part Name Qty Item Part Name Qty 1

10 Front Differential/Rear GearcaseRear Gearcase Inspection After Disas-sembly Check if there are cracks or damage in rear gearcase, check mounting h

Rear Gearcase Assembly And Adjust-ment IllustrationItem ”1” 40Nm Item ”2” 25Nm Item”12” 70Nm Item”15” 25Nm Item”20”

1. Maintenance Information Special Purpose Tools No Name Type Function Remark 1 Spark Plug Wrench 172MM-022400-922-004 Disassemble/ install spa

10 Front Differential/Rear Gearcase f Adjust item 29 as illustrated, and make sureits end and back clearance of drive gear is 0.3-0.6. Tighten item 31

11 Electric System CHARGING SYSTEMELECTRIC STARTING SYSTEM ELECTRICITY-SPRAYING SYSTEMELECTRICITY-SPRAYING SYSTEM STRUCTUREELECTRICITY-

MAGNETO COIL RESISTANCE MEASURE TRIPHASE MAGNETOR STATORCOIL RESISTANCE IF THE RESISTANCE VALUE OUT OF PRE-SCRIBED VALUE, REPLACE THE STATOR COIL.

11 Electric SystemUSE MULTIMETER MEASURE THE RESISTANCE BE TWEEN THE TERMINALS,AS BELOW FORM SHOWS, IF THERE IS ONE DATA OUT OF THE SETTIN

STARTING SYSTEMTRIGGER CIRCUIT DIAGRAM STARTING MOTORBattery 12VIgnition SwitchElectric Fuel PumpFuel Pump RelayAuxiliary RelayStart SwitchStart Motor

11 Electric SystemELECTRIC BRUSH CHECK IF THE ELECTRIC BRUSH PERMANENT SEAT ABNORMAL,CRACK,UNSMOOTH IF THERE IS ANY BROKEN, CHANGE THE WHO

INITIATING RELAY PUT 12V TO THE SMALL TERMINALS;THERE IS CONTINUITY BETWEEN THE LARGE TERMINALS. IF THE START RELAY CONTACTS,SHOULD MAKE

11 Electric SystemSTARTING ENGINE NOTICE JOINT LINES ACCORDING TO TRIGGERCIRCUIT. BEFORE STARTING, CHECK IF ALL THEPARTS ARE CORRECT JOINTED.ELECT

ELECTRONIC FUEL INJECTION SYS-TEMENGINE ELECTRONIC FUEL INJECTION SYSTEM INCLUD-ING THREE PARTS:(1)SENSOR: TRANSFORM THE ENGINE NON-ELECTRICITY PH

11 Electric SystemELECTRONIC FUEL INJECTION SYS-TEM DIAGRAMELECTRONIC FUEL INJECTION SYSTEM MAINTENANCENOTICEUSE QUALITY COMPONENTS FOR SERVICE, OR

Operation Material and Installment Supplementary of Engine Engine operation materials include lubricant (oil), grease (lubricant grease) and coolant,

SERVICE TOOLSTOOL NAME:DIAGNOSTIC EQUIPMENTFUNCTION:READ CLEAR ELECTRONIC FUEL INJECTION SYSTEMTROUBLE CODE,OBSERVE DATA STREAM,COMPONENETS MOTION TES

11 Electric SystemTOOL NAME:ELECTRONIC IGNITION TIMINGFUNCTION:INSPECT ENGINE ELECTRONIC SPARK TIMING.TOOL NAME:CYLINDER PRESSURE GAUGEFUNCTION:CHEC

ELECTRONIC FUEL INJECTION PARTS STRUC-TURE AND FUNCTION(1)ECU: ECU,IT IS THE BRAIN OF THE ENTIRE ELECTRONIC FUEL INJEC-TION SYSTEM. IT ANALYZE AND P

11 Electric System(2)THROTTLE VALVE ASSY: JOIN THE AIR CLEANER AND ENGINE,CONTROLTHROTTLE VALVE OFF AND ON ANGLE THROUGHTHROTTLE CABLE. AIR DAMPER

(3)MAP Sensor:MONITOR AIR PRESSURE IN MANIFOLD,PROVIDE EN-GINE LOAD INFORMATION TO ECU.EACH STITCH FUNCTION:1.CONNECT 5V POWER2.GROUNDING3.OUTPUT VOLT

11 Electric System(4)INTAKE AIR TEMPERATURE SENSOR(IATSensor):THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFI-CIENT (NTC) THERMISTANCE,IT’S RESISTANCE V

(5)WATER TEMPERATURE SENSOR:THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFI-CIENT (NTC) THERMISTANCE,IT’S RESISTANCE VALUEDECREASE WHEN THE COOLANT TEMPER

11 Electric System(6)OXYGEN SENSOR:THIS SENSOR USED IN ELECTRONIC CONTROL FUELINJECTION EQUIPMENT FEEDBACK SYSTEM,TO RE-ALIZE CLOSED-LOOP CONTROL,RA

(7)TRIGGER: PROVIDE ENGINE ROTATE SPEED INFORMATION TO ECU,ECU DETERMINE IGNITION ANGLE,FUEL IN JECTION ANGLE ACCORDING TO THIS INFORMATION.THE

11 Electric System(8)ODOMETER SENSOR:PROVIDE ENGINE OUTPUT SHAFT SPEED TO ECU,ECU JUDGE VEHICLE SPEED ACCORDING TO THISINFORMATION.IT IS A KIND OF H

1. Maintenance Information Wiring, Pipes, Cable Layout234Picture 1123456789101112131415161.Plug-in on Front Fender(See Pic 1)12.Wirings in Middle S

(9)GEAR SENSOR CLUSTER:PROVIDE GEAR INFORMATION TO THE METER,SO AS TOFUNCTIONS OF THE FOOTS:YELLOW/BLUE-L(UNDERDRIVE)ORANGE/BLUE-H(HIGH POSITION)YELL

11 Electric System(11)FUEL PUMP ASSY: THE OIL FUEL PUMP ASSY COMBINED OF FUEL PUMP,PLASTICBRACKET,PREFILTRATION,PRES SURE REGULATING VALVE.IT D

(12)FUEL INJECTOR:FUEL INJECTOR ONE END INSTALLED IN SEAT,THE OTHER END CONNECT WITH THE FUEL PIPE VIA FUEL INJECTOR CAP.ACCORDING TO THE ECU I

11 Electric System(13)IDLE SPEED CONTROL VALVE(CARBON TANK CONTROL VALVE):CONTROL PASS-BY AIR FLOW. ECU CONTROL THEIDLE SPEED VALVE ACCORDING TO THE

(14)IGNITION COIL: IGNITION COIL CHANGE THE PRIMARY WIND ING LOW VOLTAGE INTO SECONDARY WINDING HIGH VOLTAGE,THROUGH SPARK PLUG DISCHARGE TO CREA

11 Electric SystemELECTRONIC FUEL INJECTION SYSTEMFAULT SELF-DIAGNOSISECU CONTINUOUSLY MONITOR THE SENSOR,ACTUATOR,RELEVENT CIRCUIT,TROUBLE LAMP,BAT

(2)DIAGNOSTIC EQUIPMENT:IT HAVE THREE PINS,POWER,GROUNDWIRE AND DATA K LINE,CONNECTWITH THE CORRESPONDING PINS IN ECU.THE RIGHT IS THE DIAGNOSTIC EQUI

11 Electric System TROUBLE CODE LIST: REF TROUBLE C OD E INSTR UCTION 1 P0030 OXYGEN SENSOR HEA TING CONTROL CIR CUITOPEN CIRCUIT 2 P0031 OXYG

13 Lights,Instrument,SwitchesOverhaul Info HornTroubleshooting DashboardBulb replacement Fuel SensorHeadlight WaterTemperature sensorIgnition

13 Lights,Instrument,SwitchesReplacing BulbHeadlight BulbCautionsHeadlight bulb will be very hot when it is turned on.Do not touch it after it is just

Picture 21234123413121110987651.Fan Plug-in 2.Headlight Plug-in 3.Start Servo- Relay 4.Start Relay 5.Parking Brake Plug-in 6.Battery7.Clock Setti

13 Lights,Instrument,SwitchesNOTE:Main cable,wiring and tube shouldbe routed properly( chapter 1)Dashboard Light BulbRemove dashboardRemove dashboard

13 Lights,Instrument,SwitchesCheck according to the following table ifthe connector terminals are in continuity.ContinuityDisassemble:Remove front cov

13 Lights,Instrument,SwitchesDisassembleDisconnect horn connector.Remove bolt.Remove horn.Reverse the removal procedure forinstallation.DashboardRun t

13 Lights,Instrument,SwitchesInstallationPut fuel sensor into installation hole of fuel tank.Fuel sensor should be fitted properly.Check for fuel leak

13 Troubleshooting1. Engine troubleshooting...13-2 2. Diag

1.Engine troubleshooting Complaint Symptom and Possible Causes RemedyEngine will not startor is hard to startComp

13 TroubleshootingComplaint Symptom and Possible Causes Remedy Poor engine running in high-speed range. 1. Weak valve spring 2. Worn camshaft 3. Fo

Complaint Symptom and Possible Causes Remedy Engine is noisy Valve Chatter 1. Excessive valve clearance 2. Worn or broken valve spring 3.

13 Troubleshooting 2 Diagnosis troubles according to EFI system Trouble Code NOTE: 1. Only start inspection and fixation when trouble is steady-stat

Trouble Code: P0030 Oxygen Sensor Heating Control Circuit Broken Note Possible Troubles are as below 1）Circuit broken between ECU Pin and Oxygen Senso

1. Maintenance Information123456789101112131234561.Gear Shift Mechanism 2.Oxygen Sensor Plug-in 3.Water Temp Sensor 4.Throttle Body5.MAP Sensor 6.

13 TroubleshootingTrouble Code：P0106 Air Inlet Pressure Sensor Signal irrationally failure Note Possible Troubles are as below 1）Air leakage of Air I

Trouble Code：P0117 Engine Water Temperature Sensor Circuit Voltage low. Note Possible Troubles are as below 1）Circuit between ECU Pin and ground short

13 TroubleshootingTrouble Code：P0132 Oxygen Sensor Circuit Voltage High Explanation： When engine starts, ECU check the Oxygen Sensor Circuit Voltage;

Errors coding: P0261 Control circuit of single cylinder injector short to ground Maintenance Tips： The possible faults may exists as follow: 1）All dri

13 TroubleshootingErrors coding: P0458 Control circuit voltage of idle air control valve too low Maintenance Tips： The possible faults may exists as

Errors coding: P0507 Rotate speed of idle speed control valve faster than target idle speed Introduction of theory and fault reason: Engine rotate s

13 TroubleshootingErrors coding: P2177 Self-learning value of air-fuel ratio, closed-loop control exceeds upper limit Errors coding: P2178 Self-le

3.Diagnosis troubles according to engine fault phenomena Before start to diagnosis fault, please take the primary inspection first: 1.Engine failure i

13 Troubleshooting（ 1） Starting Failure/Hard Starting Possible defective part： 1.Battery； 2.Starter motor； 3.Wiring harness or ignition switch;4.engi

4 Check compression of cylinder and observe the pressure if is disc re pa ntl y. yes Eliminate engine mechanism fault no next 5 C ontact EFI co mm uta

1234561.Rear Brake Hose 2.Master Cylinder 3.Brake Fluid Reservoir 4.Brake Cable 5.Four-way Connector 6.Front Brake Hose1.Ignition Switch 2.Back

13 TroubleshootingRef no Operation Test result Next Steps 1 Contact fuel pressure meter(contact front point of oil input pipe of injector), start

2 Contact fuel pressure meter(contact front point of oil input pipe of injector), starting engine, check the fuel pressure whether is around 300kPa o

13 Troubleshooting2 Check idle speed valve whether clogged or not. Yes Clean or replace no next 3 Check spark plug, look its type and gap if accord

6 Check fuel and observe the faul t if caused after fueling Yes Replace fuel no next 7 Check compression of cylinder and observe the pressure. yes E

13 TroubleshootingPossible defective part：1、idle speed valve；2、injector Overhaul: Ref no Operation Test result Next Steps 1 Disassembly idle speed

6 Contact with EFI commutator, open ignition switch, check ECU5#、10#、23# stitch, the power whether supply normal or not, check 2#、21# stitch whether i

13 Troubleshooting（ 12）Reaction slowly when in acceleration. Possible defective part：1、fuel containing water； 2、air intake pressure sensor and thro

Overhaul： Ref no Operation Test result Next Steps 1 Check the faults if exist clutch skid, low tyre pressure, lagged brake, improper tyre size etc

1. Maintenance Information1231.Parking Cable 2.Throttle Cable 3.Choke Cable121.Rear Turn Lights 2.Taillight

12ECU1.Front Turn Lights 2.Headlights

1. Maintenance InformationFailure IndicatorFailure Indiactor is located on the left top”1”ofinstrument.While the indicator flashing is faulty, failur

FORWARD This manual introduces X6 EFI version( CF625-B/CF625-C) maintenance information, disassemblyprocedure, check & adjustment methods, tro

2 Vehicle Body and MufflerOverhaul Info………………………………………2-1 Troubleshooting…………………………………… 2-1 Front Rack, Bolt Cap…………………………… …2-2 Seat, Seat Support &

Front Rack, Bolt CapRemove:Remove bolt caps;Front rack bolts can now be seen.Remove fixing Bolt 1.(one for each on the left and right.)Remove fixing B

2 Vehicle Body and MufflerSeatRemove:Pull upward seat latch;Lift and push seat backward.Installation:Press upward seat latch;Press seat forward and d

Front Top CoverRemove:Front Rack6 nuts;Front Top Cover.Assemble:Reverse the removal process and direction.Dashboard CoverRemove:--2 pieces Bolt 1--2 p

2 Vehicle Body and MufflerFront Side Support(Left)Remove:Bolt 1;Front Side Support.Assemble:Reverse the removal process and direction.Front Side Supp

Rear Top CoverRemove:Rear RackSeperate clasps of rear top cover from rearfender;Remove Rear Top CoverInstallation:Reverse the remove procedure anddire

2 Vehicle Body and MufflerLeft Side CoverRemove:SeatLeft Side Cover BoltLeft Side CoverInstallation:Reverse the remove procedure anddirection for ins

Rear Side PanelRemove:SeatRight Side Cover Fixing BoltRemove connecting Bolt 1 between RightSide Panel and Front Fender at bottomof Front Fender;Remov

2 Vehicle Body and MufflerTop Cover, Fuel TankRemove:SeatFront RackFront Top CoverLeft Side Panel-Right Side PanelBolt 1, 2Bolt 3, 4Fuel Tank CapRemo

Footrest,Left SideRemove:Left Side PanelRemove three Bolt 1 and 3 nuts connectingwith Front Fender.Remove three Bolt 2 and 3 nuts connectingwith Rear

Conversion TableItem Example ConversionPressure 200 kPa(2.00kgf/cm2 ) 1kgf/cm2=98.0665kPa 1kpa=1000Pa33kPa (250mmHg) 1mmHg=133.322

2 Vehicle Body and MufflerRear FenderRemove:--Seat--Rear Rack--Rear Top Cover--Left,Right Side Panel--Lef,RightSide Support--Rear ProtectorRemove Bat

DisasemblyNOTE:Side skid Plate(Front,Middle, Rear)and Double Seat Protection are locatedat bottom of vehicle. The mainteanaceperson should work under

2 Vehicle Body and MufflerRight Front Inner FenderRemoval:Remove Bolt 1 ,and remove Right Front InnerFender.Installation:Reverse the remove procedure

Front Left Inner FenderRemoval:Remove Bolt 1 and 2;Remove Front Left Inner FenderInstallation:Reverse the remove procedure for InstallationFront Right

2 Vehicle Body and MufflerBumper ProtectorRemove:--Loosen Front Turning Light Connector.--Remove Bumper and Bumper Protector.Remove tapping screw 1 f

Front Vent GrillRemove:--Loosen Connector of Front Head Light--Remove Front Fender--Remove Bumper--Remove Bolt 1, 2 and 3--Remove Vent GrillNOTE: For

2 Vehicle Body and MufflerRemove Fuel Line 1 and Circlip;Remove Fuel Tank.Installation:Reverse the removal procedure for installation.NOTE:Be careful

MufflerCaution: Perform disassembly onlyafter the muffler is cooled down.Remove:--Seat (2-3)--Right side panel (2-8)--Nut1, Nut 2 for exhaust pipe elb

2 Vehicle Body and MufflerVisible Parts:4567891011121314151617181920211231.Front Suspension Protector,LH 2.Front Rack 3.Front Top Cover 4.Dashb

3.Checks & AdjustmentOverhaul InfoOperation CautionsNOTE:-DO NOT keep the engine running for long time in a poorly ventilated or enclosed place b

1. Maintenance InformationCautionsSafety Cautions1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated place fo

Maintenance Interval The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the engine at

3.Checks & AdjustmentInspection & Maintenance ○: Interval Item Intervals Standard Part Item Daily 1/2 Year Annual Steering System H

Item Intervals Standard Part Item Daily 1/2 Year Annual Drive train Final shaft (Drive shaft) Looseness of joint parts O O Sway of Spline O

3.Checks & AdjustmentItem Intervals Part Item Daily 1/2 Year Annual Standard Lighting device and turning indictors Function ○ ○ Alarm and lo

Steering ColumnPark the vehicle on level place, hold steering handlebar,and shake in the direction as illustrated on the rightand see if there is any

3.Checks & AdjustmentMaster Cylinder<Fluid level>Check the Brake Fluid LevelWhen the brake fluid level is near to the lower limitline, chec

WheelsLift front wheel on level place, and make sure there isno loading on the wheels.Shake the front wheel left and right to check whetherthe joint o

3.Checks & Adjustment Tire Pressure Check the pressure of the tires with a pressure gauge. NOTE: Check the tire pressure after tires are cooled.

Wheel Nut and Wheel AxleCheck front and rear wheel axle nuts for looseness;Loosened axle nuts TightenTightening Torque:Front wheel axle nut:110-130N.m

3.Checks & AdjustmentAdjusting the Shock AbsorberUse special tools to adjust the length ofshock absorber spring according to loading requirement;

14.Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly. Replace if any axial or radial play is found. If the

Checking the Throttle LeverCheck the free play of throttle leverFree play: 3-5mmOut of range: AdjustLoosen locknut of throttle cableturn the adjustor

3.Checks & AdjustmentCooling SystemNOTE:Check coolant level from reservoir tank.Do not check from radiator.If the radiator cap is opened while th

When the coolant level is below the LOWER limit,remove reservoir tank cap and add coolant till upperlimit.(Add coolant or diluted original liquid).Rec

3.Checks & AdjustmentInspection of Cooling SystemCheck initially at 50 hours or 500km, replace coolantannually.Check radiator, reservoir tank and

Check Water Temperature GaugeWhen engine is not working, the water temperatureshould be in the position. Start the engine tocheck if the indicator wo

3.Checks & AdjustmentVALVE CLEARANCEInspect initially at 20-hour break-in and every 100 hoursor every 1000km thereafter. Inspect the clearance af

Take out the feeler gauge, measure the clearance.If the clearance is incorrect, repeat the above stepsuntil the proper clearance is obtained.Locknut:

3.Checks & AdjustmentIn case of carbon deposit, clean with a proper tool.SPARK PLUG GAPMeasure the spark plug gap with a feeler gauge.Out of spec

A--Non-flammable cleaning solventB Engine oil SAE#30 or SAE15W/40.Never use with gasoline or low flash pointsolvents to clean the filter elementInspec

3.Checks & AdjustmentInspection:Inspect drive belt for wear and damage.If any cracks or damages are found,replace drive belt with a new one.Inspe

1. Maintenance InformationNumbers Marking Location CF625-B/CF625-CVIN Number: LCELDUS1~/LCELDUS2~Engine Number:196S-B~Engine Number Locatio

Inspection of Lubrication SystemReplace engine oil and oil filter initially at 20 hours or250km and every 100 hours or 1000km thereafter.Inspect the e

3.Checks & Adjustment-Install oil dip rod, start the engine and allow it to runfor several minutes at idling speed.-Turn off the engine and wait

Inspection of cylinder pressureCheck cylinder pressure is necessary.Cylinder Pressure: 1000kpa/145PsiA lower cylinder pressure may be caused by:-Exces

3.Checks & AdjustmentInspection of Oil PressureOil Pressure: 18.5-25Psi at 3000 Rpm;Lower or higher oil pressure may be caused by:Oil pressure is

Inspection of Clutch Engagement and Lock-upCF196-S engine is equipped with a centrifugal typeautomatic clutch.Before checking the initial engagement a

4-14 Cooling and Lubrication System Overhaul InfoTrouble ShootingPerformance OverhaulReservoir Tank Adding CoolantCooling system chart Engine Cool

4-2Trouble ShootingWater Temperature Rises Too FastImproper radiator cap.Air in the cooling system.Malfunction of water pump.Malfunction of thermostat

4-34 Cooling and Lubrication SystemPerformance OverhaulInspection of coolant densityCaution:Be sure to open the radiator cap after coolant is cooled.R

4-4Pressure testing of cooling systemApply the specified pressure(radiator cap openingpressure) for 6 seconds and make sure that there isdrop in press

4-54 Cooling and Lubrication SystemRemove Drain BoltRemove drain bolt, seal gasket from waterpump, drain coolant.After drainage, assemble new seal gas

Main Data TableItem Parameter Model CF625- B/CF625- C Length CF625-B:2100mm CF625-C: 2300mm Width 1180m m Height 1230mm Whe el base CF625-B: 1290mm

4-6Adding CoolantAdd coolant through filling portStart the engine and discharge air from coolingsystem. Check from filling port that air is fullydisch

4-74 Cooling and Lubrication SystemCooling System1612151189 10761423131451.Water Inlet Hose 2.LH Crankcase 3.LH Sidecover 4.Water Pump2.Water Pipe 6.

4-8Engine CoolantThe cooling used in cooling system is mixture f 50%distilled water and 50% ethylene glycol antifreeze. This50:50 mixture provides th

4-94 Cooling and Lubrication SystemInspection and Cleaning of Radiator andWater HosesRadiator CapzRemove radiator cap zInstall radiator cap to cap tes

4-10Inspection of Fan MotorzRemove fan motor from radiator.zTurn the vanes and check if they can turn smoothly.zCheck fan motor.Make sure that the bat

4-114 Cooling and Lubrication SystemInspection of Water Temperature SensorzPlcae a rag under water temperature sensor 1 andremove it from cyclinder he

4-12zCheck thermostat pellet for cracks.If necessary, re-place it.zTest the thermostat according to the following steps:Pass a string between thermost

4-134 Cooling and Lubrication SystemzRemove clamps and water hoses.zRemove bolts and remove water pump.zRemove O-ring.NOTE:Do not reuse the O-ring.zRe

4-14zRemove mechanical seal with special tool. NOTE:The mechanical seal does not need to be moved,if there is no abnormal condition. NOTE:Do not reus

4-154 Cooling and Lubrication SystemOil SealzCheck oil seal for damaged. Pay attention to the oilseal lip.zIn case of damage or leakage, replace the o

1. Maintenance Information Item Param eter Fuel Device Air Filter t ype Sponge element filter Val ve Type Type: C F188-B-173000 Diameter of mixing

4-16zInstall mechanical seal with a suitable socket wrench.NOTE:Apply sealant to side ”A” of mechanical seal.zInstall bearing with special tool.Tool:B

4-174 Cooling and Lubrication SystemzInstall ring to water pump shaft.zInstall new gasket to water pump body.zInstall water pump cover and tighten the

4-18zInstall water pump and tighten the bolts to the speci-fied torque.Water pump bolts tightening torque: 10N.mNOTE:Set the water pump

4-194 Cooling and Lubrication SystemIllustration of CF188 Engine Lubrication System1.Oil Drain Bolt2.Washer,Oil Drain Bolt3.Oil Pump4.Oil Bypass Valve

4-20Add oil to the engine parts(piston,cylinder body,cam-shaft and so on) which run at high speedEngine lubrication should be special oil. Engine oil

5 Removal and Installation of Engine,Drive Train and Gearshift UnitOverhaul InfoOperation CautionsSecurely support the ATV with bracket when removing

CFMOTOEngine RemovalRemove:—Plastic(-Chapter 2)—Air Filter(-Engine service chapter)—Throttle body (-Engine service chapter)—Clamp—Water Inlet HoseRemo

5 Removal and Installation of Engine,Drive Train and Gearshift UnitRemove spark plug cap from spark plug.Remove protection sleeve of starter relay.Rem

CFMOTORemove engine mounting bolts 4 locations.Bolts

5 Removal and Installation of Engine,Drive Train and Gearshift UnitEngine InstallationPut engine onto the frame,install the two lower mount-ing bolts