CFMoto motorcycle CF650NK. Service Manual - part 26

9-36 CRANKSHAFT/TRANSMISSION

Transmission

Transmission Shaft Disassembly

●

 Remove the transmission assy (see Transmission   

   Assy Removal).

●

 Remove:

   Shift Rods [A]
   Shift Forks [B]
   Drive Shaft [C] and Output Shaft [D]

●

R e m o v e   t h e   c i r c l i p s ,   d i s a s s e m b l e   t h e 

   transmission shafts.

●

 Remove the 

fi

 fth 5th gear.

   

Transmission Shaft Assembly

●

 Apply engine oil to the collar, needle bearing 

   and the shaft.

●

 Install the collar to the shaft.

●

 Replace all the removed circlips.

●

 Install the circlips [A] so that the opening [B] is 

   aligned with a spline groove [C].

CRANKSHAFT/TRANSMISSION 9-37

Transmission

●

 The drive shaft gears can be recognized by size: 

   the gear with the smallest diameter is 1st gear, 
   and the largest one is 6th gear. Be sure that all 
   parts are put back in the correct sequence and all 
   circlips and washers are properly in place.

●

 Install the fifth gear and the bushing onto the 

   drive shaft.

●

 Install the 3rd/4th gear onto the drive shaft with 

   their oil holes aligned.

●

 Install the 6th gear and the bushing onto the 

   drive shaft with their oil holes aligned.

●

 The output shaft gears can be recognized by 

    size:  
   the gear with the largest diameter is 1st gear, 
    and the smallest one is 6th gear.  Be sure that all 
   parts are put back in the correct sequence and 
    all circlips and washers are properly in place.

●

 Install the 3rd/4th gear and the bushings onto the 

    output shaft with their oil holes aligned.

●

 Install the 

fi

 fth gear onto the output shaft.

●

 Check that each gear spins or slides freely on the 

  transmission shafts without binding after 
   assembly.

9-38 CRANKSHAFT/TRANSMISSION

Transmission

1.1st Gear   

8.Bushing

15.Oil Seal

22.Positioning Ring

2.2nd Gear 

9.Toothed Washer 

16.Collar

23.Washer 

Φ

38.5

3.3th Gear 

10.Circlip

17.Washer 

24.Bushing

4.4th Gear

11.Bushing

18. Nut

25.Toothed Washer

5.5th Gear

12.Thrust Washer

19.O-ring

26. Shim 

Φ

28

6.6th Gear

13.Needle Bearing

20.Ball Bearing

27.Circlip 

Φ

30

7.Ball Bearing

14. Circlip

21.Spacer

φ

39

28.Circlip 

Φ

30

         

CRANKSHAFT/TRANSMISSION 9-39

Transmission

Shift Fork Bending

●

 Visually inspect the shift forks, and replace any 

    fork that is bent. A bent fork could cause dif

fi

 culty 

   in shifting, or allow the transmission to jump out 
   of gear when under power.
   90° [A]

Shift Fork/Gear Groove Wear

●

 Measure the thickness of the shift fork ears [A], 

   and measure the width [B] of the gear grooves.
   If the thickness of a shift fork ear is less than the 
   service limit, the shift fork must be replaced.

   Shift Fork Ear Thickness
   Standard:  

5.9   6.0 mm (0.232   0.236 in.) 

   Service Limit:  5.8 mm (0.228 in.)

  If the gear groove is worn over the service limit, 
   the gear must be replaced.

  

 Gear Groove Width

   Standard: 

6.05   6.15 mm (0.238   0.242 in.) 

   Service Limit:  6.25 mm (0.246 in.)

Shift Fork Guide Pin/Drum Groove Wear

●

 Measure the diameter of each shift fork guide pin 

   [A], and measure the width [B] of each shift drum 
   groove.
   If the guide pin on any shift fork is less than the 
   service limit, the fork must be replaced.
   

   Shift Fork Guide Pin Diameter
   Standard:  

6.9   7.0 mm (0.272   0.276 in.) 

   Service Limit:  6.8 mm (0.268 in.)

9-40 CRANKSHAFT/TRANSMISSION

Transmission

   If any shift drum groove is worn over the service 
   limit, the drum must be replaced.

   

Shift Drum Groove Width

   Standard:  

7.10~7.15 mm 

   Service Limit:  7.30 mm (0.287 in.)

Gear Dog and Gear Dog Hole Damage

●

 Visually inspect the gear dogs [A] and gear dog 

   holes [B].
   Replace any damaged gears or gears with 
   excessively worn dogs or dog holes.

Ball and Needle Bearing Replacement

●

 Using a press or puller, remove the ball bearing 

   and/or needle bearings.

●

 Using a press and the bearing driver set [A], 

   install the new ball bearing until it stops at the 
   bottom of its housing.

Ball and Needle Bearing Wear

●

 Spin [A] the bearing by hand to check its  

   condition.
   If the bearing is noisy, does not spin smoothly, or 
   has any rough spots, replace it.

WHEELS/TIRES 10-1

Wheels/Tires

Table of Contents

Explode View...............................................................................................................................

10-2

Speci

fi

 cations..............................................................................................................................

10-4

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

10-5

Wheel (Rims)...............................................................................................................................

10-6

Front Wheel Removal..............................................................................................................

10-6

Front Wheel Installation...........................................................................................................

10-6

Rear Wheel Removal..............................................................................................................

10-8

Rear Wheel Installation...........................................................................................................

10-8

Wheel Inspection..................................................................................................................... 10-10
 Axle Inspection....................................................................................................................... 10-10
Balance Inspection.................................................................................................................. 10-11

Balance Adjustment................................................................................................................ 10-11

Balance Weight Removal........................................................................................................ 10-11
Balance Weight Installation..................................................................................................... 10-11

Tire.............................................................................................................................................. 10-13

Air Pressure Inspection/Adjustment........................................................................................ 10-13
Tire Inspection......................................................................................................................... 10-13
Tire Removal........................................................................................................................... 10-13
Tire Installation........................................................................................................................ 10-13
Tire Repair............................................................................................................................... 10-15

Hub Bearing................................................................................................................................. 10-16

Hub Bearing Removal............................................................................................................. 10-16
Hub Bearing Installation.......................................................................................................... 10-16
Hub Bearing Inspection........................................................................................................... 10-16

WHEELS/TIRES 10-2

Exploded View

WHEELS/TIRES 10-3

Exploded View

No.

faster

Torque

Remarks

N·m

kgf·m

ft·lb

1

Front Axle

108

11.0

80

2

Front Axle Clamp Bolt

34

3.5

25

3

Rear Axle Nut

108

11.0

80

4.   Caliper Bracket 

G:   Apply grease.

HG:  Apply high-temperature grease. 

R:   Replacement Parts

WL:  Apply soap and water solution or rubber lubricant.

WHEELS/TIRES 10-4

Item

Standard

Service Limit

Wheels (Rims)

Rim Runout: 

Axial 

   Radial

Axle Runout/100 mm (3.94 in.) 

Wheel Balance

Balance Weights

Rim Size: 

Front

   

   Rear

TIR 0.5 mm (0.02 in.) or less
TIR 0.8 mm (0.03 in.) or less

TIR 0.03 mm (0.0012 in.) or less

10 g (0.35 oz.)  or less

10 g (0.35 oz.), 20 g (0.71 oz.), 30 g

(1.06 oz.)

17 × 3.50

 17 × 4.50

TIR 1.0 mm (0.04 in.)

TIR 1.0 mm (0.04 in.)

TIR 0.2 mm (0.008 in.)

– – – 

– – – 

– – – 

– – – 

Tires

Air Pressure (when Cold): 

Front

Rear

Tread Depth: 

Front

Rear

 

Up to 

236

 kg (

520.51 

lb) load: 2

80

 kPa

(2.

80

 kgf/cm², 3

9.8

 psi)

Up to 

325

 kg (

716.8

 lb) load: 2

80

 kPa

(2.

80

 kgf/cm², 3

9.8

 psi)

4

.5 mm (0.

18

 in.)

5.5 

mm (0.

22

 in.)

– – – 

– – – 

0.8~1mm

0.8~1mm

Standard Tires: 

Front

  Rear

Make,  Type

Size

CST TYRE

CST TYRE

120/70R17M/C(58H)

160/60R17M/C(69H)

WARNING

Use the same manufacturer’s tires on both front and rear wheels.

!

WHEELS/TIRES 10-5

Special Tools

Bearing Driver Set

Bearing Remover Shaft

Jack

Jack Attachment

Bearing Remover Head, 

Φ

20 × 

Φ

22

WHEELS/TIRES 10-6

Wheels (Rims)

Front Wheel Removal

●

 Remove:

   Brake Caliper Mounting Bolts [A]
   Front Brake Calipers [B]

●

 Loosen:

   Axle Clamp Bolt [A]

●

 Remove the front axle [B].

●

 Remove the lower fairing (see Lower Fairing  

    Removal in the Frame chapter).

●

  Raise the front wheel off the ground with jack.

    

Special Tools - Jack

    Jack Attachmen

●

 Pull out the axle to the right and drop the front 

    wheel out of the forks.

CAUTION

Do not lay the wheel on the ground with the 
discs facing down.  This can damage or warp 
the disc. Place wooden blocks under the 
wheel so that the disc does not touch the 
ground.

Front Wheel Installation

NOTE

○

 

The direction of the wheel rotation [A] is shown 

    by an arrow [B] on the wheel spoke.

●

 Check the wheel rotation mark on the front wheel 

   and install it.

WHEELS/TIRES 10-7

Wheels (Rims)

●

 Apply high-temperature grease to the grease 

   seal lips.

●

 Fit the collars [A] on the both sides of the hub.

●

 Insert the front axle, and tighten the axle.

  Torque - Front Axle: 108 N•m (11.0 kgf•m, 80 
   ft•lb)

●

 Before tightening the axle clamp bolt on the right 

   front fork leg, pump the front fork up and down 4 
   or 5 times to allow the right front fork leg to seat 
    on the front axle.

  

 NOTE

○

 

Put a block in front of the front wheel to stop 

    moving.

●

 Tighten the axle clamp bolt [A].

  

Torque - Front Axle Clamp Bolt: 34 N•m (3.5 

   kgf•m, 25 ft•lb)

●

 Install the lower fairing (see Lower Fairing 

    Installation in the Frame chapter).

●

 Install the front brake calipers (see Caliper 

    Installation in the Brakes chapter).

●

 Check the front brake effectiveness (see Brake 

   Operation Inspection in the Periodic Maintenance 
   chapter).

WARNING

Do not attempt to drive the motorcycle until 
a full brake lever is obtained by pumping the 
brake lever until the pads are against the 
disc.  The brake will not function on the 

fi

 rst 

application of the lever if this is not done.

!

WHEELS/TIRES 10-8

Rear Wheel Removal

●

 Raise the rear wheel off the ground with stand [A].

●

 Remove:

   Brake Caliper Mounting Bolts [A]
   Rear Brake Caliper [B]

●

 Remove:

   Cotter Pin [A]
   Axle Nut [B] Washer [C]
   Axle [D] with Washer

●

 Remove the drive chain [A] from the rear 

   sprocket toward the left.

●

 Move the rear wheel back and remove it.

CAUTION

Do not lay the wheel on the ground with the 
disc facing down.  This can damage or warp 
the disc. Place wooden blocks under the 
wheel so that the disc does not touch the 
ground.

Rear Wheel Installation

●

 Apply high-temperature grease to the grease 

   seal lips.

●

 Fit the collars [A] on the both sides of the hub.

WHEELS/TIRES 10-9

Wheels (Rims)

● Engage the drive chain with the rear sprocket.
● Install the caliper bracket [A] onto the swingarm  
   stop [B].
● Insert the axle from the right side of the wheel,  
   and tighten the axle nut.
  

Torque - Rear Axle Nut: 108 N•m (11.0 kgf•m, 80 

 

   ft•lb)

● Insert a new cotter pin [A].

NOTE

○ 

When inserting the cotter pin, if the slots in the  

    nut  do  not  align  with  the  cotter  pin  hole  in  
  the axle, tighten th nut clockwise [B] up to next  
   alignment.
○ 

It should be within 30°.

○ 

Loosen  once  and  tighten  again  when  the  slot  

    goes past the nearest hole.

●  Bend the cotter pin [A] over the nut [B].

WARNING

If the rear axle nut is not securely tightened or 

the cotter pin is not installed, an unsafe riding 

condition may result.

  

● Adjust  the  drive  chain  slack  after  installation  
   (see Drive Chain Slack Inspection in the Periodic  
   Maintenance chapter).
●  Install  the  rear  brake  caliper  (see  Caliper  
    Installation in the Brakes chapter).
● Install the rear wheel rotation sensor (see Rear  
   Wheel Rotation Sensor Installation in the Brakes  
   chapter).
● Check the rear brake effectiveness (see Brake  
   Operation Inspection in the Periodic Maintenance  
   chapter).

WARNING

Do not attempt to drive the motorcycle until 

a full brake pedal is obtained by pumping the 

brake pedal until the pads are against the 

disc.  The brake will not function on the first 

application of the pedal if this is not done.

!

!

WHEELS/TIRES 10-10

Wheel Inspection

●

 Raise the front/rear wheel off the ground with 

    jack.
   

Special Tools – Jack, Jack Attachment

●

 Spin the wheel lightly, and check for roughness 

   or binding. If roughness or binding is found, 
    replace the hub bearingWheel Inspection

●

 Raise the front/rear wheel off the ground with 

    jack.
  

 Special Tools – Jack, Jack Attachment

●

 Spin the wheel lightly, and check for roughness 

  or binding. If roughness or binding is found,   
   replace the hub bearings.

●

 Inspect the wheel for small cracks, dents, 

    bending, or warp.
   If there is any damage to the wheel, replace the  
   wheel.

●

 Remove the wheel, and support it without the tire 

   by the axle.

●

 Measure the rim runout, axial [A] and radial [B], 

   with a dial gauge.
   If rim runout exceeds the service limit, check the   
    hub bearings.
   If the problem is not due to the bearings, replace 
   the wheel.
   

Rim run out 

   Standard:
   Axial                TIR 0.5 mm (0.02 in.) or less
   Radial             TIR 0.8 mm (0.03 in.) or less
   Service Limit:
   Axial                TIR 1.0 mm (0.04 in.)
   Radial  

 TIR 1.0 mm (0.04 in.)

WARNING

Never attempt to repair a damaged wheel. If 
there is any damage besides wheel bearings, 
the wheel must be replaced to insure safe 
operational condition.

Axle Inspection

●

 Remove the front and rear axles (see Front/Rear 

   Wheel Removal).

●

 Visually inspect the front and rear axle for 

    damages.
    If the axle is damaged or bent, replace it.

●

 Place the axle in V blocks that are 100 mm (3.94 

   in.) [A]apart, and set a dial gauge [B] on the axle 
   at a point halfway between the blocks.Turn [C] 
   the axle to measure the runout. The difference 
   between the highest and lowest dial readings is 
    the amount of runout.
   If axle runout exceeds the service limit, replace 
    the axle.

    

Axle Runout/100 mm (3.94 in.)

    Standard: 

TIR 0.03 mm (0.0012 in.) or less

    Service Limit:     TIR 0.2 mm (0.008 in.)

!

WHEELS/TIRES 10-11

Balance Inspection

●

 Remove the front and rear wheels (see Front/

    Rear Wheel Removal).

●

 Support the wheel so that it can be spun freely.

●

 Spin the wheel lightly, and mark [A] the wheel at 

   the top when the wheel stops.

○

 Repeat this procedure several times. If the wheel 

   stops of its own accord in various positions, it is 
   well balanced.
   If the wheel always stops in one position, adjust 
   the wheel balance (see Balance Adjustment).

Balance Adjustment

●

 If the wheel always stops in one position, 

    provisionally attach a balance weight [A] on the 
    rim at the marking using adhesive tape.

●

 Rotate the wheel 1/4 turn [B], and see whether or 

   not the wheel stops in this position. If it does, the 
   correct balance weight is being used.
  If the wheel rotates and the weight goes up, 
  replace the weight with the next heavier size. 
  If the wheel rotates and the weight goes down, 
  replace the weight with the next lighter size. 

●

 Repeat these steps until the wheel remains at 

   rest after being rotated 1/4 turn.

●

 Rotate the wheel another 1/4 turn and then 

   another 1/4 turn to see if the wheel is correctly 
    balanced.

●

 Repeat the entire procedure as many times as 

    necessary to achieve correct wheel balance.

●

 Permanently install the balance weight.

Balance Weight Removal

●

 Insert a regular tip screwdrivers [A] [B] between 

   the rib [C] and the weight [D] as shown.

●

 Pry the balance weight with two screwdrivers and 

   remove the balance weight.

●

 Discard the used balance weight.

CAUTION

Do not tap the screwdrivers. The rim could be 
damaged.

Balance Weight Installation

●

 Check if the weight portion has any play on the 

   blade [A] and clip [B].
   If it does, discard it.

WARNING

If the balance weight has any play on the 
rib of the rim, the blade and/or clip have 
been stretched. Replace the loose balance 
weight. Do not reuse used balance weight. 
Unbalanced wheels can create an unsafe 
riding condition.

!