CFMoto motorcycle CF650NK. Service Manual - part 29

12-14 BRAKES

Front Brake Pad Removal

●

 Remove the front caliper with the hose installed 

   (see Front Caliper Removal). 

●

 Draw out the holder shaft pin [A], and take off the 

   holder shaft [B]. 

●

 Remove the pad [C] on the piston side. 

●

 Push the holder [D] towards the piston, and 

   remove the pad of the other side [E] from the 
   holder shaft [F].

Front Brake Pad Installation 

●

 Push the caliper pistons in by hand as far as they 

   will go. 

●

 Install the anti-rattle spring in its correct position. 

●

 Install the pad on the piston side 

fi

 rst, then install 

   the other pad on the holder. 

●

 Install the front caliper (see Caliper Installation).

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 first 
application of the lever if this is not done.

Rear Brake Pad Removal 

●

 Remove the rear caliper with the hose installed 

   (see Rear Caliper Removal). 

●

 Draw out the holder shaft pin [A], and take off the 

   holder shaft [B]. 

●

 Remove the pad [C] on the piston side. 

●

 Push the holder [D] towards the piston, and 

   remove the pad of the other side [E] from the 
   holder shaft [F].

Rear Brake Pad Installation 

●

 Push the caliper piston in by hand as far as it will 

   go. 

●

 Install the anti-rattle spring in its correct position. 

●

 Install the pad on the piston side 

fi

 rst, then install 

   the other pad on the holder. 

●

 Install the rear caliper (see Caliper Installation).

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.

Brake Pad Wear Inspection 

●

 Refer to the Brake Pad Wear Inspection in the 

   Periodic Maintenance chapter.

!

!

BRAKES 12-15

Front Master Cylinder Removal 

●

 Remove the banjo bolt [A] to disconnect the 

   brake hose from themaster cylinder [B] (see 
   Brake Hose Removal/Installation).

●

 Disconnect the front brake light switch connectors 

   [A]. 

●

 Unscrew the clamp bolts [B], and take off the 

   master cylinder as an assembly with the 
   reservoir, brake lever and brake switch installed.

CAUTION

Immediately wash away any brake fl uid that 
spills.

●

 Remove:

   Brake Lever Pivot Bolt [A] and Locknut
   Brake Lever [B]
   Front Brake Light Switch [C]
   

Front Master Cylinder Installation 

●

 Install the front master cylinder so that the punch   

   mark [A] of the handlebar is aligned with the 
   mating surface [B] of the master cylinder clamp 
   to level the reservoir.

●

 The master cylinder clamp must be installed with 

   the arrow mark [A] upward. 

●

 Tighten the upper clamp bolt [B] 

fi

 rst, and then 

   the lower clamp bolt [C]. There will be a gap at 
   the lower part of the clamp after tightening.

   Torque - Front Master Cylinder Clamp Bolts: 
   8.8 N·m (0.90 kgf·m, 78 in·lb)

●

 Replace the washers on each side of the hose 

   

fi

 tting with new ones. 

●

 Tighten the brake hose banjo bolt.

   

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 

    kgf·m, 18 ft·lb)

●

 Bleed the brake line (see Brake Line Bleeding). 

●

 Check the brake for good braking power, no 

    brake drag, and no 

fl

 uid leakage.

12-16 BRAKES

Rear Master Cylinder Removal 

●

 Unscrew the brake hose banjo bolt [A] on 

    themaster cylinder (see Brake Hose Removal/
    Installation).

●

 Unscrew the master cylinder mounting bolts [A]. 

●

 Remove the cotter pin [B].

NOTE

○

 

Pull off the joint pin while pressing down the 

   brake pedal.

●

 Pull off the reservoir hose lower end [C], and 

   drain the brake 

fl

 uid into a container. •Remove 

   the master cylinder.

Rear Master Cylinder Installation 

●

 Replace the cotter pin [A] with a new one. 

●

 Replace the washers on each side of hose 

fi

 tting 

   with new ones. 

●

 Tighten the following bolts.

   Torque - Rear Master Cylinder Mounting 
   Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
   Brake Hose BanjoBolt: 25 N·m(2.5 kgf·m, 18 
   ft·lb)

●

 Bleed the brake line (see Brake Line Bleeding). 

●

 Check the brake for good braking power, no 

   brake drag, and no 

fl

 uid leakage.

Front Master Cylinder Disassembly 

●

 Refer to the Master Cylinder Rubber Parts 

   Replacement in the Periodic Maintenance 
   chapter.

Rear Master Cylinder Disassembly 

●

 Refer to the Master Cylinder Rubber Parts 

   Replacement in the Periodic Maintenance 
   chapter.

Master Cylinder Assembly 

●

 Refer to the Master Cylinder Rubber Parts 

   Replacement in the Periodic Maintenance 
   chapter.

BRAKES 12-17

Master Cylinder Inspection

●

 Remove the master cylinders (see Front/Rear  

   Master Cylinder Removal). 

●

 Disassemble the front and rear master cylinders. 

●

 Check that there are no scratches, rust or pitting   

   on the inner wall [A] of each master cylinder and 
   on the outside of each piston [B].
   If a master cylinder or piston shows any damage, 
   replace them. 

●

 Inspect the primary cup [C] and secondary cup 

   [D].
   If a cup is worn, damaged softened (rotted), or 
   swollen, the piston assembly should be replaced 
   to renew the cups.
   If 

fl

 uid leakage is noted at the brake lever, the 

   piston assembly should be replaced to renew the 
   cups.
   Front Master Cylinder [J]

●

 Check the dust covers [E] for damage.

   If they are damaged, replace them. 

●

 Check the piston return springs [F] for any 

   damage.
   If the springs are damaged, replace them. 

●

 Check that relief port [G] and supply port [H] are 

   not plugged.
   If the relief port becomes plugged, the brake 
   pads will drag on the disc. Blow the ports clean 
   with compressed air.
   Rear Master Cylinder [K]

12-18 BRAKES

Brake Disc Removal 

●

 Remove the wheel (see Front/Rear Wheel 

   Removal in the Wheels/Tires chapter). 

●

 Unscrew the mounting bolts, and take off the 

   disc. 

●

 Remove the gaskets.

Brake Disc Installation 

●

 Replace the gaskets with new ones. 

●

 Install the brake disc on the wheel so that the 

   marked side [A] faces out. 

●

 Apply a non-permanent locking agent to the 

   threads of the front and rear brake disc mounting 
   bolts [B]. 

●

 Tighten:

  

 Torque - Brake Disc Mounting Bolts: 27 N·m 

   (2.8 kgf·m, 20 ft·lb)

Brake Disc Wear 

●

 Measure the thickness of each disc [A] at the 

   point where it has worn the most.
   If the disc has worn past the service limit, replace   
   it.
   Measuring Area [B]
   

Brake Discs Thickness Standard:

   Front:
   4.3 ~ 4.7 mm (0.17 ~ 0.19 in.)
   Rear:
   4.8 ~ 5.2 mm (0.19 ~ 0.20 in.)
   Service Limit:
   Front:
   4.0 mm (0.16 in.)
   

Rear:

   

4.5 mm (0.18 in.)

Brake Disc Warp 

●

 Raise the wheel off the ground with jack (see 

   Front/Rear Wheel Removal in the Wheels/Tires 
   chapter).

   

Special Tools - Jack, Jack Attachment

○

 For front disc inspection, turn the handlebar fully 

   to one side. 

●

 Set up a dial gauge against the disc [A] as shown  

   and measure disc runout, while turning [B] the 
   wheel by hand.
   If runout exceeds the service limit, replace the 
   disc.

  

 Disc Runout

   Standard: 0.15 mm (0.006 in.) or less
   Service Limit: 0.3 mm (0.01 in.)

BRAKES 12-19

Brake Fluid Level Inspection 

●

 Refer to the Brake Fluid Level Inspection in the 

   Periodic Maintenance chapter.

   

Brake Fluid Change 

●

 Refer to the Brake Fluid Change in the Periodic 

   Maintenance chapter.

Brake Line Bleeding

  The brake fluid has a very low compression   
coef

fi

 cient so that almost all the movement of the 

brake lever or pedal is transmitted directly to the 
caliper for braking action. Air, however, is easily 
compressed. When air enters the brake lines, 
brake lever or pedal movement will be partially 
used in compressing the air. This will make the 
lever or pedal feel spongy, and there will be a loss 
in braking power.

WARNING

Be sure to bleed the air from the brake 
line whenever brake lever or pedal action 
feels soft or spongy after the brake fluid is 
changed, or whenever a brake line fi tting has 
been loosened for any reason.

NOTE

○

 

The procedure to bleed the front brake line is as 

   follows. Bleeding the rear brake line is the same 
   as for the front brake.

●

 Remove the reservoir cap [A] and diaphragm. 

●

 Fill the reservoir with fresh brake 

fl

 uid to the 

   upper level line in the reservoir. 

●

 Slowly pump the brake lever several times until 

   no air bubbles can be seen rising up through the 
   

fl

 uid from the holes at the bottom of the reservoir.

○

 Bleed the air completely from the master cylinder 

   by this operation.

●

 Remove the rubber cap from the bleed valve [A] 

   on the caliper. 

●

 Attach a clear plastic hose [B] to the bleed valve, 

   and run the other end of the hose into a 
   container.

!

12-20 BRAKES

●

 Bleed the brake line and the caliper.

○

 Repeat this operation until no more air can be 

   seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and 
    apply the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while 
    holding the brake applied.
3. Release the brake [C].

NOTE

○

 

The 

fl

 uid level must be checked often during 

   the bleeding operation and replenished with
   fresh brake 

fl

 uid as necessary. If the 

fl

 uid in the  

   reservoir runs completely out any time during 
   bleeding, the bleeding operation must be done 
   over again from the beginning since air will have 
   entered the line.

○

 

Tap the brake hose lightly from the caliper to the 

    reservoir for more complete bleeding.

○

 

Front Brake: First bleeding the right caliper then 

   repeat the above steps for the left caliper.

●

 Remove the clear plastic hose. 

●

 Install the diaphragm and reservoir cap. 

●

 Tighten:

  

 Torque - Front Brake Reservoir Cap Screws: 

   1.0 N·m (0.10 kgf·m, 9 in·lb)

●

 Follow the procedure below to install the rear 

   brake 

fl

 uid reservoir cap correctly.

○

 First, tighten the rear brake 

fl

 uid reservoir cap [B] 

   clockwise [C] by hand until slight resistance is felt 
   indicating that the cap is seated on the reservoir 
   body, then tighten the cap an additional 1/6 turn 
   [D] while holding the brake 

fl

 uid reservoir body [A].

●

 Tighten the bleed valve, and install the rubber 

   cap.

   Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 
   in·lb)

●

 Check the 

fl

 uid level (see Brake Fluid Level 

   Inspection in the Periodic Maintenance chapter). 

●

 After bleeding is done, check the brake for good 

   braking power, no brake drag, and no 

fl

 uid 

   leakage.

BRAKES 12-21

WARNING

When working with the disc brake, observe 
the precautions listed below.
1. Never reuse old brake fl uid.
2. Do not use fl uid from a container that has 
    been left unsealed or that has been open 
    for a long time.
3. Do not mix two types and brands of fl uid for  
    use in the brake. This lowers the brake fl uid  
    boiling point and could cause the brake to  
    be ineffective. It may also cause the rubber 
    brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any  
    length of time to avoid moisture  
    contamination of the fl uid.
5. Don’t change the fl uid in the rain or when a 
    strong wind is blowing.
6. Except for the disc pads and disc, use only 
    disc brake fl uid, isopropyl alcohol, or ethyl 
    alcohol for cleaning of the brake parts. Do 
    not use any other fl uid for cleaning these 
    parts. Gasoline, engine oil, or any other 
    petroleum distillate will cause deterioration
    of the rubber parts. Oil spilled on any part 
    will be diffi cult to wash off completely and 
    will eventually deteriorate the rubber used 
    in the disc brake.
7. When handling the disc pads or disc, be 
    careful that no disc brake fl uid or any oil 
    gets on them. Clean off any fl uid or oil that 
    inadvertently gets on the pads or disc with 
    a high-fl ash point solvent. Do not use one
    which will leave an oily residue. Replace the 
    pads with new ones if they cannot be 
    cleaned satisfactorily.
8. Brake fl uid quickly ruins painted surfaces; 
    any spilled fl uid should be completely 
    wiped up immediately.
9. If any of the brake line fi ttings or 
    the bleed valve is opened at any time, the 
    AIRMUSTBEBLEDFROM THE BRAKE LINE.

Brake Hose Removal/Installation 

●

 Refer to the Brake Hose and Pipe Replacement 

   in the Periodic Maintenance chapter.

Brake Hose Inspection 

●

 Refer to the Brake Hose Damage and Installation 

   Condition Inspection in the Periodic Maintenance 
   chapter.

!

SUSPENSION 13-1

Suspension

Table of Contents

Front shock exploded View.........................................................................................................

13-2

Rear shock exploded View..........................................................................................................

13-4

Speci

fi

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

13-6

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

13-7

Front Fork....................................................................................................................................

13-8

Front Fork Removal.................................................................................................................

13-8

Front Fork Installation..............................................................................................................

13-8

Front Fork Oil Change.............................................................................................................

13-8

Front Fork Disassembly........................................................................................................... 13-10
Front Fork Assembly................................................................................................................ 13-11
Inner Tube Inspection.............................................................................................................. 13-12
Dust Seal Inspection............................................................................................................... 13-12
Fork Spring Inspection............................................................................................................ 13-13

Rear Shock Absorber................................................................................................................... 13-14

Spring Preload Adjustment...................................................................................................... 13-14
Rear Shock Absorber Removal............................................................................................... 13-14
Rear Shock Absorber Installation............................................................................................ 13-15
Rear Shock Absorber Inspection............................................................................................. 13-15

Swingarm..................................................................................................................................... 13-16

Seingarm Removal.................................................................................................................. 13-16
Swingarm Installation.............................................................................................................. 13-16
Swingarm Bearing Removal.................................................................................................... 13-17
Swingarm Bearing Installation................................................................................................. 13-17
Swingarm Bearing, Sleeve Inspection..................................................................................... 13-18
Swingarm Bearing Lubrication................................................................................................ 13-19
Chain Guide Inspection........................................................................................................... 13-19

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

No

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

1

Front Axle Clamp Bolt

34

3.5

25

2

Front Fork Bottom Allen Bolts

30

3.1

22

L

3

Front Fork Clamp Bolts (Lower)

20

2.0

15

AL

4

Front Fork Clamp Bolts (Upper)

20

2.0

15

5

Front Fork Top Plugs

25

2.5

18

6.   Outer Tube

AL:   Tighten the two clamp bolts alternately two times to ensure even tightening torque..

G:   Apply grease.

L:   Apply a non-permanent locking agent.

R:   Replacement Parts

13-4 SUSPENSION

Exploded View

SUSPENSION 13-5

No.

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

1

Rear Shock Absorber Bolt

59

6.0

44

2

Rear Shock Absorber Nut

59

6.0

44

3

Swingarm Pivot Shaft Nut

108

11.0

80

G: Apply  grease.

R: Replacement Parts

13-6 SUSPENSION

Speci

fi

 cations

Item

Standard

Front Fork (Per One Unit)

Fork Inner Tube Outside Diameter

41 mm (1.6 in.)

Air Pressure

Atmospheric pressure (Non-adjustable)

Fork Spring Setting

Non-adjustable

Damper Setting

Non-adjustable

Fork Oil:

Viscosity

KAYABA KHL34-G10 or equivalent

Amount:

approx. 390 mL (13.2 US oz.) (when changing oil)
458 ±4 mL (15.5 ±0.14 US oz.)  (after disassembly and 
completely dry)

Fork Oil Level:

115 ± 2 mm (4.5 ±0.08 in.) (below from inner tube top with 
fully compressed, without fork spring)

Fork Spring Free Length

277.8 mm (10.94 in.) (Service limit 272 mm (10.7 in.))

Rear Shock Absorber

Spring Preload

3rd position (Adjustable Range: 1st ~ 7th position)

Gas Pressure

980 kPa (10 kgf/cm², 142 psi, Non-adjustable)

SUSPENSION 13-7

Special Tools

Inside Circlip Pliers

Jack

Fork Cylinder Holder Handle

Fork Oil Seal Driver, 

Φ

41

Fork Cylinder Holder Adapter

Fork Oil Level Gauge

Oil Seal & Bearing Remover

Jack Attachment

Bearing Driver Set

Stem Bearing Driver, 

Φ

28

Spacer, 

Φ

28

13-8 SUSPENSION

Front Fork Removal

●

 Remove:

   Front Wheel (see Front Wheel Removal in the
   Wheels/Tires chapter)
   Front Fender (see Front Fender Removal in the   
   Frame chapter)
   Loosen the upper fork clamp bolt [A] and fork top   
  plug [B]beforehand if the fork leg is to be   
   disassembled.

NOTE

○

 

Loosen the top plug after loosening the upper 

    forkclamp bolt.

●

 Loosen the upper fork clamp bolt and lower fork 

   clamp bolts [C].

●

 With a twisting motion, work the fork leg down 

   and out.

Front Fork Installation

●

 Install the fork with the upper end of the inner 

   tube 

fl

 ush [A] against the top surface of the stem 

   head [B]

●

 Tighten:

   

Torque - Front Fork Clamp Bolt (Upper): 

   20 N•m (2.0 kgf•m,15 ft•lb)

  

 Front Fork Top Plug: 25 N•m (2.5 kgf•m, 18 

    ft•lb)

NOTE

○

 

Tighten the top plug before tightening the upper  

    Fork clamp bolt.

○

  

Tighten the two clamp bolts alternately two times  

    to ensure even tightening torque.

●

 Tighten:

  

 Torque - Front Fork Clamp Bolt (Upper): 

   20 N•m (2.0 kgf•m,15 ft•lb):
   20N•m(2.0kgf•m,15ft•lb)

●

 Install the removed parts (see appropriate  

    chapters)

Front Fork Oil Change

●

 Remove the front fork (see Front Fork Removal).

●

 Remove:

   Top Plug [A] with O-ring Collar [B]
   Fork Spring Seat [C] Fork Spring [D]