CFMoto motorcycle CF650NK. Service Manual - part 23

7-12 ENGINE LUBRICATION SYSTEM

Oil Pan

●

 Replace the oil pan gasket with a new one.

   When installing the oil pan, align [A] the damper 
   [B] on the breather pipe with the hollow [C] on the 
   oil pan.

●

 Tighten Oil Pan Bolts

  

 Torque: Oil Pan Bolts 12N·m

ENGINE LUBRICATION SYSTEM 7-13

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

●

 Refer to the Oil Pan Removal.

Oil Pressure Relief Valve Installation

●

 Refer to the Oil Pan Installation.

Oil Pressure Relief Valve Inspection

●

 Check to see if the valve [A] slides smoothly 

   when pushing it in with a wooden or other soft 
   rod, and see if it comes back to its seat by spring 
   [B] pressure.
                                  

NOTE

○

 

Inspect the valve in its assembled state. 

   Disassembly and assembly may change the 
   valve performance. 
  If any rough spots are found during above 
   inspection, wash the valve clean with a high-

fl

 ash 

  point solvent and blow out any foreign particles 
   that may be in the valve with compressed air.

 

WARNING

Clean the oil pressure relief valve in a well-
ventilated area, and take care that there is no 
spark or flame anywhere near the working 
a r e a .   B e c a u s e   o f   t h e   d a n g e r   o f   h i g h l y 
fl ammable liquids, do not use gasoline or low-
fl ash point solvent.

          

  If cleaning does no solve the problem, replace 
  the oil pressure relief valve as an accessory. The  
  oil pressure relief valve is precision made with no 
  allowance for replacement of individual parts.

!

7-14 ENGINE LUBRICATION SYSTEM

Oil Pump

Oil Pump Removal

●

 Drain:

  Engine Oil (see Engine Oil Change in the 
   Periodic Maintenance chapter)
   Remove:
  Clutch (see Clutch Removal in the Clutch 
   chapter)
   Oil Pump Cover Bolts [A]
   Oil Pump Cover [B]

●

 Remove:

   Inner Rotor [A] for Scavenge Pump
   Outer Rotor [B] for Scavenge Pump

●

 Remove:

   Dowel Pin [A]
   Pin [B]
   Oil Pump Body [C]

●

 Remove:

  Oil Pump Shaft [C] with Inner Rotor [A] and Pin 
   for Feed Pump
   Outer Rotor [B] for Feed Pump

ENGINE LUBRICATION SYSTEM 7-15

Oil Pump

Oil Pump Installation

●

 Apply molybdenum disul

fi

 de grease to the portion 

   [A] of the oil pump shaft as shown.

●

 Install:

   Outer Rotor [B] for Feed Pump
   Inner Rotor [C] for Feed Pump
   Oil Pump Shaft [D] and Pin [E]
   Dowel Pin [F]
   Oil Pump Body [G]
   Pin [H] and Inner Rotor [I] for Scavenge Pump
   Outer Rotor [J] for Scavenge Pump
   Oil Pump Cover [K]

                                   

NOTE

○

 

The scavenge pump rotors are wider than the 

    feed pump rotors

●

 Apply a non-permanent locking agent to the oil 

   pump cover bolts and tighten them.

  

 Torque: Oil Pump Cover Bolts 12N.m

7-16 ENGINE LUBRICATION SYSTEM

Oil Pressure Measurement

Oil Pressure Measurement

●

 Remove the lower fairing (see Lower Fairing 

    Removal in the Frame chapter)

●

 Remove the oil passage plug, and attach the 

    adapter [A] and gauge [B] to the plug hole.

    

Special Tools: 

    Oil Pressure Gauge 10kgf/cm2
    Oil Pressure Gauge Adapter, PT3/8

●

  Start the engine and warm up the engine.

●

  Run the engine at the speci

fi

 ed speed, and read 

     the oil pressure gauge.
   If the oil pressure is much lower than the 
    standard, check the oil pump, relief valve, and/
     or crankshaft bearing insert wear immediately.
    If the reading is much higher than the standard, 
     check the oil passages for clogging.

     

Oil Pressure

     Standard: at 4000r/min(rpm), oil temperature
         90 

O

C(194 

o

F)216~294kPa

         ( 2.2~3.0kgf/cm2,31~43psi)

●

  Stop the engine

●

  Remove the oil pressure gauge and adapter

WARNING

Takt care against burns form hot engine oil 
that will drain through the oil passage when 
the gauge adapter is removed.

                       

●

  Apply a non-permanent locking agent to the oil 

     passage plug, and install it.

     

Torque: Oil Passage Plug 20N·m

          

!

ENGINE LUBRICATION SYSTEM 7-17

Oil Pressure Switch

Oil Pressure Switch Removal

●

 Remove:

   Engine Oil (Drain, see Engine Oil Change in the 
    Periodic Maintenance chapter)
    Switch Cover [A]
    Switch Terminal Bolt [B]
    Oil Pressure Switch [C]

Oil Pressure Switch Installation

●

 Apply silicone sealant to the threads of the oil 

    pressure switch and tighten it.
    Sealant: Silicone Sealant

    

Torque: Oil Pressure Switch 15N·m

                        

●

  Tighten the terminal bolt securely.

ENGINE REMOVAL/INSTALLATION 8-1

Engine Removal/Installation

Table of Contents

Exploded View.............................................................................................................................

8-2

Engine removal/installation..........................................................................................................

8-4

Engine removal.......................................................................................................................

8-4

Engine installation...................................................................................................................

8-7

ENGINE REMOVAL/INSTALLATION 8-2

Exploded View

ENGINE REMOVAL/INSTALLATION 8-3

Exploded View

No.

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

1

Rear Engine Mounting Nuts

44

4.5

32

S

2

Front Engine Mounting Bolts

44

4.5

32

S

3

Engine Mounting Bracket Bolts

25

2.5

18

S

    4. Engine Mounting Brackets

    5. Collar

    S: Follow the speci

fi

 ed tightening sequence.

ENGINE REMOVAL/INSTALLATION 8-4

Engine Removal/Installation

Engine Removal

●

 Support the rear part of the swingarm with a 

    stand.

●

 Squeeze the brake lever slowly and hold it with a 

    band [A].

WARNING

Be sure to hold the front brake when removing 
the engine, or the motorcycle may fall over.  It 
could cause an accident and injury.

CAUTION

Be sure to hold the front brake when 
removing the engine, or the motorcycle 
m a y   f a l l   o v e r.   T h e   e n g i n e   o r   t h e 
motorcycle could be damaged.

●

 Drain:

  Engine Oil (see Engine Oil Change in the 
   Periodic Maintenance chapter)
  Coolant (see Coolant Change in the Periodic 
   Maintenance chapter)

●

 Remove:

   Seat (see Seat Removal in the Frame chapter)
  Lower Fairing and Center Fairings (see Fairing 
   section in the Frame chapter)
  Side Covers (see Side Cover Removal in the 
   Frame chapter)
   Frame Covers (see Frame Cover Removal in the   
   Frame chapter)
  Radiator and Hoses (see Radiator and Radiator 
   Fan Removal in the Cooling System chapter)

●

 Unscrew the lower fairing bracket bolts (both 

   sides) [A] and remove the brackets (both sides) 
    [B].

●

  Disconnect the oil pressure switch terminal [A].

!

ENGINE REMOVAL/INSTALLATION 8-5

●

 Disconnect the crankshaft sensor lead connector 

   [A].

●

 Remove:

  Exhaust Pipe (see Exhaust Pipe Removal in the  
   Engine Top End chapter)
  Muffler Body (see Muffler Body Removal in the 
   Engine Top End chapter)
  Fuel Tank (see Fuel Tank Removal in the Fuel   
   System (EFI) chapter)
  Air Filter Housing (see Air Filter Housing    
   Removal in the Fuel System (EFI) chapter)
  Throttle Body Assy (see Throttle Body Assy   
   Removal in the Fuel System (EFI) chapter)
  Clutch Cable (see Clutch Cable Removal in the  
   Clutch chapter)

●

 Remove:

   Stick Coils [A]
   Baf

fl

 e Plate [B]

●

 Remove or Disconnect:

   Coolant Temperature Sensor Lead Connector [A]
   Starter Motor Cable [B]
   Engine Ground Cable Terminal Bolt [C]
   Alternator Lead Connector [D]
   Sidestand Switch Lead Connector [E]
   Speed Sensor Lead Connector [F]

ENGINE REMOVAL/INSTALLATION 8-6

Engine Removal/Installation

●

 Remove the engine sprocket cover (see Engine 

   Sprocket Removal in the Final Drive chapter).

●

 Remove the shift pedal [A] (see Shift Pedal 

  Removal in the Crankshaft/Transmission 
   chapter).

●

  Disconnect:

    Oxygen Sensor Lead Connector [B]     
    Neutral Switch Lead Terminal [C]

●

  Remove the bracket [D] and the engine sprocket 

   [E] (see Engine Sprocket Removal in the Final 
    Drive chapter).

●

  Remove:

    Horn Leads [A] (Disconnect)
    Horn Bolt [B] 
    Horn [C]

●

  Support the engine with a stand or jack [A].

●

  Put a wooden board [B] on the suitable stand.

●

  Remove the engine mounting bolts [C].

●

  Remove the engine mounting bracket bolts (both 

    sides) [D] and remove the brackets [E].

●

  Remove the engine [F].

ENGINE REMOVAL/INSTALLATION 8-7

Engine Installation

●

 Firstly, insert the rear engine mounting bolts [A] 

   from the left side of the engine.

●

 Secondly, temporally tighten the right engine  

   mounting bracket bolts [B] and then the right front 
   engine mounting bolt [C].

●

 Position the collar [D] as shown.

●

 Thirdly, temporally  tighten  the  left  engine  

    mounting bracket bolts [E] and then the left front 
    engine mounting bolt [F].

●

 Fourthly, temporally tighten the rear engine 

    mounting nuts[G].

●

  Fifthly, tighten the rear engine mounting nuts.

Torque - Rear Engine Mounting Nuts: 44 N·m 
(4.5 kgf·m, 32 ft·lb)

●

 Sixthly, tighten the right engine mounting bracket 

    bolts.

   Torque - Engine  Mounting   Bracket Bolts:  
   25  N·m  (2.5 kgf·m, 18 ft·lb)

●

 Seventhly, tighten the right front engine mounting 

   bolt.

  Torque - Front Engine Mounting Bolt: 44 N·m  
   (4.5 kgf·m, 32 ft·lb)

●

 Eighthly, tighten the left engine mounting bracket 

   bolts.

   Torque - Engine  Mounting   Bracket  Bolts:  
   25  N·m  (2.5 kgf·m, 18 ft·lb)

●

 Lastly, tighten the left front engine mounting bolt.

   

Torque - Front Engine Mounting Bolt: 44 N·m 

    (4.5 kgf·m, 32 ft·lb)

●

 Install the engine sprocket (see Engine Sprocket 

   Installation in the Final Drive chapter).

●

 Run the leads, cables, and hoses correctly.

CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission

Table of Contents

Exploded View............................................

9-2

Specifications..............................................

9-6

Special Tools...............................................

9-9

Crankcase Splitting.....................................

9-10

Crankcase Splitting................................

9-10

Crankcase Assembly..............................

9-12

Crankshaft and Connecting Rods...............

9-18

Crankshaft Removal...............................

9-18

Crankshaft Installation............................

9-18

Connecting Rod Removal.......................

9-19

Connecting Rod Installation....................

9-19

Connecting Rod Bend............................

9-22

Connecting Rod Twist.............................

9-22

Connecting Rod Big End Side  

9-22

Clearance...............................................
Connecting Rod Big End Bearing Insert/          

9-23

Crankpin Wear.......................................
Crankshaft Side Clearance.....................

9-24

Crankshaft Runout.................................

9-25

Crankshaft Main Bearing Insert/Journal 

9-25

Wear.......................................................

Balancer......................................................

9-27

Balancer Removal..................................

9-27

Balancer Installation...............................

9-27

Insert/Journal Clearance........................

9-27

Transmission...............................................

9-29

Shift Pedal Removal............................

9-29

Shift Pedal Installation............................

9-29

External Shift Mechanism Removal........

9-29

External Shift Mechanism Installation.....

9-30

External Shift Mechanism Inspection......

9-31

Transmission Assy Removal...................

9-32

Transmission Assy Disassembly.............

9-33

Transmission Assy Assembly..................

9-34

Transmission Assy Installatiion...............

9-35

Transmission Shaft Disassembly............

9-36

Transmission Shaft Assembly.................

9-36

Shift Fork Bending..................................

9-39

Shift Fork/Gear Groove Wear.................

9-39

Shift Fork Guide Pin/Drum Groove   

9-39

Wear.......................................................
Gear Dog and Gear Dog Hole Damage..

9-40

Ball and Needle Bearing Replacement...

9-40

Ball and Needle Bearing Wear................

9-40

9-2 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 9-3

Exploded View

No.

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

1

Connecting Rod Big End Nuts

See Text

---

---

MO

2

Timing Rotor Bolt

40

4.1

30

3

Oil Plate Bolts

10

1.0

87in·lb

L

4

Breather Plate Bolts

10

2.0

87in·lb

L

5

Shift Shaft Return Spring Pin

29

2.9

22

L

6

Oil Plate Bolts

10

1.0

87in·lb

L

7

Crankcase Bolts (M9,L=113mm)

44

4.5

32

MO,S

8

Crankcase Bolts (M9,L=83mm)

44

4.5

32

MO,S

9

Crankcase Bolts (M8,L=73mm)

35

3.6

26

MO,S

10

Crankcase Bolts (M8,L=60mm)

35

3.6

26

MO,S

11

Crankcase Bolts (M8,L=110mm)

27.5

2.8

20

S

12

Crankcase Bolts (M8,L=50mm)

27.5

2.8

20

S

13

Crankcase Bolts (M7)

20

2.0

15

S

14

Upper Crankcase Bolts

27.5

2.8

20

S

  15. 

Do not apply any grease or oil. 

   G:   Apply grease.

   L:  

Apply a non-permanent locking agent.

   LG:  Apply liquid gasket.

   M: 

Apply molybdenum disul

fi

 de grease. 

   MO:  Apply molybdenum disul

fi

 de oil solution.

            (mixture of the engine oil and molybdenum disul

fi

 de grease in a weight ratio 10 : 1) 

   R:   Replacement Parts

   S:  

Follow the speci

fi

 ed tightening sequence.

   SS:   Apply silicone sealant.