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CFMoto ATV Terralander CF800-2. Service Manual - part 5

Oil Filter Element Installation

Install a NEW o-ring on oil filter cover;

2

Apply engine oil on o-ring and the end of filter;

Install the element into oil filter bore;

1

Install the oil filter cover on the engine.

1.Apply a light coating of oil here

Torque screws to 10N m(89Ibf in).

2.Apply a light coating of oil here

OIL PRESSURE REGULATOR VALVE

Engine oil pressure valve is located on engine PTO

side(under CVT air guide).

The oil pressure regulator valve works when the oil

pressure exceeds 450kPa(65PSI).

Removal

1

Remove screws no.1 and the holding strip;

Remove oil pressure regulator valve.

1.Engine Oil Pressure Regulator Valve

Inspection

Inspect oil pressure regulator valve no.4,spring seat

no.5,plunger no.7,o-ring no.8 for damages.Replace if

3

necessary.Circlip no.3 must be replaced.Check

2

spring no.6 for free length.If the length is out of the

following values,replace it.

1

8

7

6

5

4

Spr in g F ree Length

New Nominal

17mm

1.Bolt

2.Holding Strip

3.Circlip

Service Limit

16mm

4.Oil Pressure Regulator Valve

5.Spring Seat

6.Spring

7.Oil Plunger

8.O-ring

Installation

Reverse the removal procedure for installation.

10-8

10 ENGINE LUBRICATION SYSTEM

OIL PUMP

Oil pump is located on the engine MAG side(under

magneto cover).

1

1.Oil Pump

Removal

2

Remove magneto cover and related parts(see

4

3

Magneto Cover Removal);

Remove magneto rotor(see Rotor Removal);

Remove circlip,oil pump gear,needle pin,thrust

washer in turn;

1.Circlip

2.Oil Pump Gear

3.Needle Pin

4.Thrust Washer

Remove oil pump cover screws and oil pump cover;

2

Remove pump shaft with inner rotor and outer rotor.

1

1.Screws

2.Oil Pump Cover

10-9

Inspection

Inspect oil pump for marks or other damages.Check

for scratches in crankcase between outer rotor and

oil pump bore.If so,replace damaged parts;

4

1

3

5

2

1.Oil Pump Bore

2.Outer Rotor

3.Oil Pump Shaft

4.Needle Pin

5.Inner Rotor

Check inner rotor for corrosion pin holes or other

damages.If so,replace oil pump shaft assembly.

1

1.Pittings on the teeth

Using a feeler gauge,measure the clearance of inner

and outer rotors plus the clearance between outer

rotor and oil pump bore as shown.

2

1

If clearance between inner rotor and outer rotor

A

exceeds the tolerance,replace the inner and outer

rotor.

A

Ensure to also check oil pump cover,if damaged,

replace the oil pump cover.

1.Inner Rotor

2.Outer Rotor

A.Service Limit:0.25mm

10-10

10 ENGINE LUBRICATION SYSTEM

If clearance between outer rotor and its bore in

crankcase exceeds the tolerance,replace outer rotor

assembly and/or crankcase.

Using a depth gauge,measure the axial clearance of

the oil pump as shown.Difference between measure-

ments should not exceed 0.1mm(0.008in).If so,

replace the inner and outer rotor.

Measurement ”A”

Using a depth gauge,measure the axial depth of the

part that extends to oil pump bore as shown.

A-B

0.2mm

NOTE:When the axial clearance of the oil pump

shaft assembly increases,the oil pressure

decreases.

Measurement ”B”

Installation

Reverse the removal procedure for installation.

NOTE:No marks on inner and outer rotor.When

installating outer rotor,no secified direction for outer

rotor.

After installation,check for smooth operation of

the oil pump assembly.

Final Test

After engine is completely reassembled,start engine

and make sure oil pressure is within specifications

(refer to Engine Oil Pressure above.)

10-11

ENGINE OIL STRAINER

The engine oil strainer no.7 is located on the bottom

of left crankcase half.

Removal

Refer to Chapter 8.

1

Cleaning and Inspection

2

3

Clean engine oil strainer with a part cleaner then

use an air gun to dry it.

1.Oil Strainer

2.Retaining Plate

WARNING

3.Screws

Always wear eye protector.Chemicals can

cause a rash break out and injure your eyes.

Installation

Reverse the removal procedure for installation.

OIL DELIVERY PIPE AND OIL RADIATOR

1

4

2

1

4

3

2

1. Inlet Oil Delivery Pipe

2.Outlet oil Delivery Pipe

3.Oil Radiator

4.Oil Delivery Pipe Holding Screw

10-12

10 ENGINE LUBRICATION SYSTEM

Removal

1

Remove engine inlet and outlet oil delivery pipe

retaining screws;

Remove engine inlet and outlet oil delivery pipes.

3

2

1.Inlet Oil Delivery Pipe

2.Outlet Oil Delivery Pipe

3.Holding Screw

Remove the 4 mounting bolts then oil radiator;

CAUTION:Drain the oil in the oil delivery

1

pipe and oil radiator before removal.

1.Oil Radiator Mounting Bolts

Remove engine inlet and outlet union bolts no.1;

Remove inlet and outlet oil delivery pipes.

1

1.Union Bolt

10-13

1

Oil Delivery Pipe Inspection

1.Engine Oil Outlet Union Bolt

Inspect oil delivery pipe for leaks,cracks and other

damages.If so,replace it;

Always replace oil pipe clamp after removal.

Oil Radiator Inspection and Cleaning

Inspect radiator for deformation and bulge.If so,replace

1

it;

Use an air gun to clean the dirt on radiator fins;

2

1.Oil Radiator

2.Air Gun

Inspect radiator fins for deformation.If so,use a small

screw driver to repair the fins.

1

Oil Delivery Pipe and Oil Radiator Installa-

tion

2

1.Screw Driver

Reverse the removal procedure for installation.

2.Oil Radiator

Union bolt tightening torque

25N m

10-14

11 MAGNETO SYSTEM

MAGNETO SYSTEM

11

Description

P/N

Page

Magneto Rotor Remover

0800-031000-922-001

6

Description

P/N

Page

Engine Oil

Threadlocker

Loctite 5699(Silicone Sealant)

11

11-1

Engine Oil

T3

Loctite 5699

T4

Engine Oil

Threadlocker

T3

T2

T1

Engine Oil

T3

T1

105N m(78lbf ft)

T2

30N m(22lbf ft)

T3

10N m(89lbf in)

T4

4N m(36lbf in)

11-2

11 MAGNETO SYSTEM

GENERAL

Always perform the electric tests before removing or

installing whatever component.

During assembly/installation,use the torque values and

service products as in the exploded view. Clean

threads before applying threadlocker.Refer to LUBRI-

CANTS AND SERVICE PRODUCTS at the begining

of this manual for complete procedure.

WARNING

Torque wrench tightening specification must

strictly be adhered to.Locking devices.(e. g .:

locking tabs ,elastic stop nuts,cotter pins , etc.)

must be installed or replaced with new ones

where specified.If the efficiency of a locking

device is impaired ,it must be renewed.

MAGENTO COVER

Removal

3

1

Drain engine oil (refer to LUBRICATION SYSTEM

2

and cooling system) and coolant;

11

2

2

2

Remove crankshaft position sensor(CPS);

Disconnect magneto connector;

2

Remove magneto cover retaining screws;

2

Remove magneto cover.

2

1.Magneto Cover

2.Retaining screws

Inspection and Cleaning

3.CPS(crankshaft position sensor)

Check magneto cover for cracks or other damages.

Replace if necessary.

Check working condition of rolling bearing.Replace if

necessary.

11-3

NOTE:

Clean all metal components in a nonferrous metal

cleaner.Use suitable tool to remove gasket.

WARNING

Wear safety glasses and work in a well ventilated

area when working with strong chemical

products. Aslo wear suitable non-absorbent

gloves to protect your hands.

Installation

For installation, reverse the removal procedure.Pay

attention to the following.

1

NOTE:

At installation replace magneto cover gasket.

Apply sealing compound on startor cable grommet

as shown on the right.

apply grease on bearing

1.Apply Loctite 5699(Silicone Sealant)

17

1

16

5

Tightening sequence for screws on magneto cover is

15

6

4

as per following illustration.

14

3

7

13

12

8

Refill engine with recommended oil and coolant.

2

9

11

10

Tightening Sequence

11-4

11 MAGNETO SYSTEM

STATOR

1

Removal

3

Magneto Cover

Removal

4

Remove screws securing holding strip;

2

Remove stator retaining screws then the stator.

1.Stator

2.Stator retaining Screws

3.Holding Strip

4.Holding Strip screws

Inspection

Check stator condition, if damaged replace it.

Check if stator wires are brittle ,hard or otherwise

11

damaged.

Stator Installation

1.Stator

For installation, reverse the removal procedure.

CAUTION:

When installing the stator take care that the

cable is in place(guide for the wire).

1

NOTE:

There is only one position for the stator(notch in the

2

magneto housing cover )

1.Threads for cable holding strip

2.Notch for stator

11-5

ROTOR

Removal

1

2

Remove magneto cover.(Refer to MAGNETO

COVER above );

Remove screw and washer securing rotor to

3

crankshaft.

1.Bolt

2.Washer

3.Rotor

Install magneto puller and then remove rotor.

1.Magneto Puller

NOTE:

1

Use grease to magneto puller end prior to install rotor

puller in order to protect crankshaft.

Screw magneto puller bolt to remove rotor.

2

1.Rotor

2.Magneto Puller

11-6

11 MAGNETO SYSTEM

Inspection

Check inner side of rotor for scratches or other

damages.

Check keyway of rotor for wear or damages.

Check if trigger wheel teeth are bent or otherwise

damaged.

Check woodruff key and keyway on the crankshaft

1

for wear or damages.

1.Rotor with trigger wheel

Replace parts as necessary.

Installation

For installation,reverse the removal procedure.

Pay attention to the following.

Clean crankshaft taper and rotor with cleaner.

11

3

Oil sprag clutch in sprag clutch housing and install

sprag clutch gear.

Slide rotor onto crankshaft.The woodruff key and the

keyway must be aligned.

4

2

1

1.Sprag Clutch

2.Sprag clutch housing

3.Sprag clutch gear

4.Apply engine oil here

11-7

Slide spacer bush onto crankshaft and

1

4

torque the bolt to specified value.

Bolt tightening torque:105N m

Rotate starter double gear counterclockwise to align

5

intermediate gear teeth with clutch sprag gear teeth.

2

6

NOTE:Breather shaft end with chamfer should

3

faces outside.

1.Double Gear

2.Breather Gear Shaft

3.Intermediate Gear 4.Sprag Clutch Gear

SPRAG CLUTCH

5.Spacer Bush

6.Bolt

NOTE:It is not necessary to remove if sprag clutch

has no problem.

2

3

4

Sprag Clutch Removal

1

Remove magneto cover (refer to MAGNETO

COVER above);

Remove rotor(refer to ROTOR above);

Remove sprag clutch gear;

1.Bolt

Remove sprag clutch housing screws and sprag

2.Rotor

clutch housing.

3.Sprag Clutch

4.Sprag Clutch Housing

Sprag Clutch Inspection

Perform a functional test of the sprag clutch.To do

so ,rotate driven gear in sprag clutch.

Inspect sprag clutch and sprag clutch housing for

1

wear and damage.

NOTE:

Sprag clutch must look in counterclockwise direction.

Sprag clutch,housing and gear must be replaced at

the same time ,if damaged.

Sprag Clutch Functional Test

1.Lock Direction

11-8

11 MAGNETO SYSTEM

Sprag Clutch Installation

For installation,reverse the removal procedure .

3

Pay attention to the following details.

Apply threadlocker on threads of sprag clutch

housing screws.

Install rotor then torque sprag clutch housing screws

2

4

to 30N m.

Apply engine oil on sprag clutch and inside sprag

1

clutch gear hole.

1.Sprag Clutch

2.Sprag Clutch Housing

3.Sprag Clutch Gear

4.Apply engine oil here

SPRAG CLUTCH GEAR

Removal

Remove rotor (refer to ROTOR above);

Pull sprag clutch gear from the rotor.

11

1

2

1.Rotor

Inspection

2.Sprag Clutch Gear

Inspect gear,especially teeth and sprag clutch

collar,for wear and other damages.

3

2

Check needle bearing condition;

Replace Drive Gear if necessary.

Installation

Reverse the removal procedure for installation.

1

NOTE:

Apply engine oil on needle bearing and collar of drive

INSPECT

gear.

1.Teeth

2.Collar

3.Needle Bearing

11-9

STARTER DRIVE GEARS

4

The starter gears are located on the engine MAG

side behind the magneto cover.

4

Removal

3

Remove magneto cover (refer to MAGNETO

2

COVER above);

1

Remove breather shafts,double gear,intermediate

1.Intermediate Gear

gear.

2.Starter Double Gear

3.Starter Gear

Inspection

4.Breather Shaft

Inspect gears and shafts for wear and damage.

Installation

Reverse the removal procedure for installation.

NOTE:

Apply engine oil on every gear shaft and teeth.

11-10

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

Check&repair information…………12-1

Brake system…………………………12-4

Troubleshooting………………………12-2

Front suspension………………… ……12-7

Front wheel……………………………12-3

Steeri ng system………… ……………12- 12

12

MAINTENANCE INFORMATION

Operation Cautions:

CAUTIONS:

z Securely support the vehicle when doing check and repair

z Do not overexert on the wheel, avoid any damage to the wheel.

z When removing tire, use the special tire lever and rim protector.

Maintenance Standard

Item

Standards

Service Limit

Radia l

0.8mm

2.0mm

Wheel Runout

Axial

0.8mm

2.0mm

Front Whee l

Tread Depth

-

3.0mm

Tire

Tire Pressure

45kPa

-

Front Brake

Brake Lever Free Play

0 mm

-

Tightening Torque

Nut, steering tie-rod

GB9457 M10x1.25

(30~40) Nz m

Lock nut, steering stem

GB6187 M14x1.5

(100~120) Nz m

Bolt, front brake disc

901-08.00.03

(25~35) Nz m

Bolt, front caliper

GB5789 M8x16

(15~25) Nz m

Axle nut

901-07.00.03

(15~25) Nz m

Bolt, front shock absorber

GB5789 M10x1.25x50,GB5789 M10x1.25x70

(15~25) Nz m

Wheel nut

901-07.00.02B

(70~80) Nz m

Bolt, A-arm

GB5789 M10X1.25X70

(40~50) Nz m

12-1

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

FRONT WHEEL

Removal

Securely support front wheels;

Remove wheel cap;

Remove the 4 wheel nuts no.1;

Remove front wheel.

Rim&Inspection

Check rim for damages,deformation,nicks.If any ab-

normal condition has been found,replace it.

Slowly turn wheel,use a dial gauge to measure the

rim runout

Service limit:

2.0mm (Axial)

2.0mm

(Radial)

Installation

Press rim into tire with special tool;

Fix wheel on the hub;

Wheel nuts tightening torque:70-80 N m

FRONT WHEEL HUB

Removal

Remove front wheel (

12-3);

Remove front brake caliper 5 (

12-4);

Remove rim axle nut no.2;

Remove brake disc and hub together;

Remove the 4 brake disc bolts no.6;

Remove front wheel hub no.4.

Installation

Reverse the removal procedure for installation.

Tightening torque of axle nut : 110-130N.m

Tightening torque of brake disc bolts no.6: 25-35N. m

(apply threadlocker)

12-3

FRONT BRAKE SYSTEM

Front Brake Caliper

Removal

Remove front wheel(

12-3);

Remove the two bolts no.2;

Remove caliper no.1.

Inspection

Check any cracks of brake calipers and oil

leaks from tightening areas.Replace if necessary.

Installation

Tightening torque of brake caliper bolt: 15-25N.m

(Apply threadlocker)

BRAKE PADS

Removal

Remove brake caliper (

12-4);

Remove main sliding shaft of brake pads with allen

wrench;

Remove brake pads;

Measure thickness of brake pad friction surface no.4,

if it is less than 1mm, then replace both pads at the

same time.

12-4

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

BRAKE DISC

Removal

Remove front wheel (

12-3);

Remove brake calipers (

12-4);

Remove brake disc and wheel hub from vehicle

Remove the 4 brake disc bolts shown in the right

picture, then remove brake disc.

Inspection

Thickness of brake disc:

If less than 2.50mm,replace it.

Brake Disc

Bolts

Installation

Reverse the removal procedure for installation.

Tightening torque of brake disc bolts: 25-30N.m

FRONT BRAKE MASTER CYLINDER

Removal

Remove top cover of handlebar;

Remove right hand guard;

Remove bolt no.2;

Seperate master cylinder no.1 of front brake from

handlebar. It’s not necessary to remove it if replace-

ment is not required.

Attention:

Do not hang the master cylinder by brake line,

keep master cylinder in place (not inclined) while

installing it to avoid air entering brake line.

Keep brake line routed properly (refer to Chap-

ter 1) and ensure it is not kinked.

After installation of brake system, check brake

performance.

12-5

4-WHEEL MASTER CYLINDER

Revoval

Remove brake pedal (

2-11);

Remove bolts no.2;

Remove bolts no.4;

Remove cotter pin no.9;

Remove master cylinder no.1 from vehicle.

Installation

Reverse the removal procedure for installation.

Attention:

In order to avoid air entering 4-wheel master

cylinder, keep it in place while installing it.

Keep brake line routed properly (refer to Chap-

ter 1) and ensure it is not kinked.

After installation, check brake performance.

T-FITTING

Removal

Remove bolt no.6 and T-fitting.

Installation

Reverse the removal procedure for installation.

Attention: Keep brake line routed properly (refer

to Chapter 1) and ensure it is not kinked.

After installation, check if 4-wheel brake lever or

brake pedal can control front brake.

REAR BRAKE CALIPER

Disassembly

Remove bolt 7 and then disassemble rear brake cali-

per 8

Installation

Reverse the removal procedure for installation.

Attention: Keep brake line routed properly (refer

to Chapter 1) and ensure it is not kinked.

After installation, check if 4-wheel brake lever or

brake pedal can control front brake.

Mainten brake fluid level between “UPPER” and

“LOWER”, if necessary, add DOT 4 fluid (CFMOTO

recommended) into brake fluid reservoir. Check

brake light and switch.

12-6

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

FRONT SUSPENSION

Front LH Suspension

ATTENTION:Do not remove left and right suspen-

sion at the same time, otherwise vehicle may tip or

fall.

Removal

Park the vehicle on a level ground and securely sup-

port the front part of vehicle.

Remove LH front protector of suspension (

2-15);

Remove front wheel (

12-3);

Remove brake caliper (

12-4);

Remove front wheel hub (

12-3);

Remove bolts and nuts no.2 of front LH shock ab-

sorber and LH upper A-arm;

Remove front shock absorber no.1;

Remove bolts and nuts no.3 of LH front A-arm;

Remove cotter pin and nut no.5 assembled on left steer-

ing knuckle;

Remove front LH upper A-arm 4;

Remove cotter pin and locking nut no.8 of steering tie-

rod;

Remove bolts and nuts no.6 of LH front A-arm as-

sembled on frame;

Remove locking bolt no.9 of LH front A-arm;

Remove front LH lower A-arm no.7;

Remove steering knuckle from drive shaft;

There are optional shock absorbers available for differ-

ent markets.

The procedure above is for basic configuration. As for

other optional shock absorbers,refer to the procedure

above.

12-7

1.Front shock absorber 2.Nut 3. LH protector 4.Circlip

5. Top ball pin 6.LH front lower A-arm 7.Circlip 8.

Guard,brake disc 9.Bolt 10.Hub bearing 11.Washer 12.LH steering knuckle 13. Bottom ball pin 14.Buffering

collar 15.Cap, buffering collar 16.LH front upper A-arm 17.M6 Nut clip 18. Bolt 19. Slot nut 20. Cotter pin 21.

Bolt 22. Bearing kit, fixing end 23. Small clamp 24.Front LH drive shaft assy 25.Bearing kit,motion end 26.

Front LH drive shaft

FRONT SHOCK ABSORBER

Removal

NOTE: If only replacing front shock absorber,it’s not

necessary to remove other parts.

Remove bolt no.21 and nut no.2, then finally remove

front shock absorber (LH) no.1.

Inspection

Check shock absorber for oil leaks,oil seal aging and

other damages.Replace if necessary.

12-8

Inspection of upper A-arm

Remove front Upper A-arm (LH) no.3(

12-7);

Remove circlip no.2 (Type: GB894.1 34)

Remove top ball pin no.1;

Check top ball pin no.1 if it can move freely and also

check its clearance. If it cannot move frelly or too big

clearance, replace it. At the same time, check grease

inside top ball pin if it is deteroirated. Check dust boot

of ball pin if damaged or aging;

Remove bushing no.5 of front upper A-arm(LH);

Check bushing no.5 if damaged or aging, replace if

necessary.

Inspection of Lower A-arm

Remove front Lower A-arm (LH) no.3(

12-7);

Remove circlip no.2 (Type: GB894.1 34)

Remove top ball pin no.6;

Check top ball pin no.6 if it can move freely and also

check its clearance. If it cannot move frelly or too big

gap, replace it. At the same time, check grease in-

side top ball pin if it is deteroirated. Check dust boot

of ball pin if damaged or aging.

Remove bushing no.5 of front upper A-arm(LH)

Check bushing no.5 if damaged or aging, replace it if

necessary.

Installation

Use special tool to press ball pin into A-arm;

Install as reverse procedures of disassembly.

Attention: Upper and Lower A-arms should not

vibrate after installation, otherwise replace bush-

ing no.5.

Inspection of Left Steering Knuckle

Remove left steering knuckle no.10 (

12-7);

Remove circlip no.8 (Type: GB893.1 55);

Use special tool to remove hub bearing no.9 (Type:

DAC3055);

Check hub bearing if any damaged and move freely,

or big clearance.Replace it if necessary.

12-10

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

DRIVE SHAFT

NOTE:Method and procedure of removal, inspection

and installation between front and rear drive shafts

(LH &RH) are silimar,therefore only front drive shaft

(LH) is introduced.

Front LH Drive Shaft

Removal

NOTE: If only repairing front LH driveshaft, it’s not

necessary to remove front LH suspension from vehicle.

Remove front wheel(LH)(

12-3);

Remove front caliper (LH)(

12-4);

Remove front wheel hub (LH)(

12-3);

Remove front LH drive shaft no.3 from left side of front

differential;

Check dust boot if any damaged. If damaged, replace

it.

Check bearing kit of fixed and motion end if it can

move flexibly. Also check there is any clearance be-

tween universal joint and splines. If it cannot move

freely and there is noise, replace it.

CAUTION:Universal joint must move freely, oth-

erwise it can damage drive shaft and cause out

of control of tire and accident.

Installation

Reverse the removal procedure for installation.

12-11

STEERING

Handlebar

Master cylinderof front brake (

12-15);

Top cover of handlebar

Removal

Remove tapping screw no.1;

Remove top cover of handlebar.

Installation

Reverse the removal procedure for installation.

4-WHEEL HAND BRAKE LEVER

Removal

Remove bolts no.3;

Remove 4-wheel hand brake lever;

Installation

Reverse the removal procedure for installation.

WINCH CONTROL SWITCH

Removal

Remove bolt no.5;

Remove winch control switch no.6.

Installation

Reverse the removal procedure for installation.

LH HANDLEBAR SWITCHES

Removal

Remove bolts no.8;

Remove left handlebar switches no.7.

Installation

Reverse the removal procedure for installation.

12-12

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

RH HANDLEBAR SWITCHES

Removal

Remove bolts no.2;

Remove right handlebar switches no.1;

Unplug connector no.3 of left handlebar switches,

Unplug connector no.4 of right handlebar switches.

Installation

Reverse the removal procedure for installation.

REAR VIEW MIRROR

Removal

Slide sleeve no.6 out place and unscrew no.nut 7,

then remove rear view mirror no.5 in anti-clockwise

direction.

NOTE: As for rear view mirror (LH), the threads are

right hand, so remove it by turning it counter-clockwise.

Unscrew nut in clockwise direction and unscrew rear

view mirror (RH) to remove.

NOTE: As for rear view mirror (RH),the threads are

left hand, so remove it by turning it counter-clockwise.

Installation

Reverse the removal procedure for installation.

12-13

HANDLEBAR

Removal

Remove top cover of handlebar (

12-12);

Remove left and right handlebar switch (

12-12);

Remove left and right brake pump from handlebar;

Remove left and right hand protector;

Remove bolt 1 of handlebar cover;

Remove handlebar no.2.

Installation

Reverse the removal procedure for installation.

Handlebar cover bolt: GB5789 M8x55

Tightening torque: 15-25Nz m (1.5-2.5kgfz m)

ATTENTION:

Keep Main cable, throttle cable, brake line

properly routed.

Screws

RH Handlebar

Cover

Throttle Cable Installation

Remove the 3 screws illustrated in the right picture

and remove top cover of right handlebar;

Install throttle cable;

Install top cover of right handlebar.

Throttle Cable

12-14

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

STEERING EXPLODED VIEW

1.Bolt 2.Alum. cover, handlebar 3. Seal ring 4. Bolt 5.Lock clip 6.Adapter plate 7.Bush 8.Support bush,

steering bearing 9.Steering stem 10. Flange bolt M6x17 11. Steering bearing seat 12. Nut 13. Cotter pin

14.Nut 15. Washer 16. Steering tie-rod

12-15

STEERING COLUMN

Removal

Remove plastics( Chapter 2);

Remove upper cover of handlebar (

8-12);

Remove front wheel (

8-2);

Remove handlebar (

8-14);

Remove 4-wheel hand brake lever(

8-12);

Remove connector of handlebar switches;

Remove nut of steering tie-rod and steering column;

Use slotted screw driver and hammer to fix lock clip;

Remove bolt no.1;

Remove cotter pin;

Remove steering tie-rod nut and washer;

Press steering tie-rod away from steering column;

Remove bolt no.14;

Lift steering bearing away from steering stem;

Installation

Reverse the removal procedure for installation.

NOTE: After installation, be sure to check steering

agility.

12-16

12 FRONT WHEELS,BRAKE,SUSPENSION,STEERING

STEERING BEARING & OIL SEAL

Removal

Remove steering bearing (

8-16);

Steering bearing and oil seal are pressed onto steer-

ing column, check if any damaged. If damaged, please

replace it.

Installation

Reverse the removal procedure for installation.

NOTE: After installation, it is necessary to check

steering agility.

12-17

13 REAR WHEELS,BRAKE,SUSPENSION

Maintenance Information

13-1

Rear Brake System

13-4

Troubleshooting

13-2

Rear Suspension

13-5

Rear Wheels

13-3

MAINTENANCE INFORMATION

Operation Cautions

13

CAUTION:

z When performing rim,suspension maintenance,jack or other suitable stand is required to raise the

vehicle body off the ground.

z Rim,suspension mounting bolts,nuts should be genuine parts.

z Never exert an excess force on the wheels.Be careful not to damage wheels.

z when removing tires from wheels,use special tools,such as tire removal rod and tire protector to

avoid damages to rims.

Maintenance Specifications:

Item

Standards

Service Limit

Radia l

-

2.0mm

Wheel Runout

Axial

-

2.0mm

Rear Whee l

Tread Depth

-

3.0mm

Tire

Tire Pressure

45kPa

-

Rear Brake

Brake Lever Free Play

10-20mm

-

Tightening Torque:

Axle Nuts:

110-130N m

Wheel Nuts:

70-80N m

Upper Shock Mounting Bolts&Nuts:

40-50 N m

Lower Shock Mounting Bolts&Nuts:

40-50 N m

13-1

13 REAR WHEELS,BRAKE,SUSPENSION

REAR WHEEL

Removal

See the front wheel removal.(

12-3)

RIM&CHECK

Check rim for damages,deformation,nicks.If any abnormal condition has been found,replce it.

Slowly turn wheel,use a dial gauge to measure the rim runout

Service Limit:

Radial:2.0mm

Axle:2.0mm

Installation

See front wheel installation(

12-3).

WHEEL HUB

Removal

Remove rear wheel(

13-3);

Remove rear axle nut;

Remove wheel hub.

Installation

Reverse the removal procedure for installation.

Axle Nut Tightening Torque:110-130N m

Hub

Axle Nut

13-3

REAR BRAKE SYSTEM

Rear Brake Caliper

Removal

Remove rear wheel,LH(

);

Remove the 2 bolts fitted on A-arm;

Remove brake caliper.

Bolts

Inspection

Visually inspect caliper for cracks and brake fluid leaks.

Replace the part if any damage has been found.

Installation

Reverse the removal procedure for installation.

NOTE:Refer to Chapter 1 for brake line routing.

Rear Brake Disc

Brake Disc

Chapter 1

Remove the drive shaft;

Remove rear caliper(

3-4);

Remove the 6 rear brake disc mounting 6 bolts ;

Bolts

Remove brake disc(

13-3 .

Rear Propshaft

Inspection

Replace the brake disc if it’s thickness is less than 6.

5mm.

Measuring Rear Brake Pads no.1

If the brake pad friction surface no.2

1mm,replace

the 2 brake pads no.1 as an assembly.

Installation

Reverse the removal procedure for installation.

NOTE:Refer to Chapter 1 for brake line routing.

A whole brake system replacement:( Chapter 12,

Brake System)

13-4

13 REAR WHEELS,BRAKE,SUSPENSION

REAR SUSPENSION

Rear Suspension,LH

NOTE:When servicing suspension,don’t remove LH suspension and RH suspension at the same time.

Otherwise,vehicle may tip or fall.

1.Bolts 2.Gland Cover 3.Rubber Support 4.Bolt 5.Self-locking Nut 6.Bolt 7.Rear Shock,LH 8.Stabilizer

Bar 9.Rear LH Ball Pin 10.Real LH A-arm 11.Rear Upper A-arm,LH 12.Rear Lower A-arm,LH 13.Bolt

14.Bushing 15.Bearing 16.Circlip 17.Grease Fittings 18.Bearing Carrier 19.Rear RH Ball Pin 20.Rear LH

Suspension protector 21.Buffering Collar 22.Cap,Buffering Collar 23.Bolt 24.Bearing Kit,Fixed End

25.Small Clamp,Fixed End 26.Rear LH Axle 27.Rear Bell Boot,Motion End,LH 28.Front Axle,LH

Disassembly

STABILIZER BAR

Removal

Remove bolt no.1;Remove gland cover no.2 and rub-

ber support no.3;Remove self-locking nut no.2;Remove

LH ball pin no.9 and RH ball pin no.26;Remove stabi-

lizer bar.

Installation

Reverse the removal procedure for installation.

13-5

14 FRONT DIFFERENTIAL/REAR GEARCASE

MAINTENANCE INFORMATION

Standards

Lubricating Period

Interval

14

Item

Type

Capacity

Initial

Next

Front Differential

SAE15W/40 SG

Initial:0.33L /Replace:0.28L

350km

5000km

or

Rear Gearcase

SAE80W/90 GL-4

Initial:0.30L/Replace:0.25L

Item

Qty

Specification

Toque(N.m)

Remark

Bolt,F/D

6

M8X28

25

Motor Screw ,F/D

4

M8X20

13

Bolt,Shift Fork Rack Stopper

1

M8X10

13

Apply threadlocker

Nut,F/D

1

M14X1.5

62

Bolt,R/G

6

M10X1.25X22

45

Fill Bolt,F/D

1

M10X1.25X12

25

Drain Bolt,F/D

1

M10X1.25

25

Retainer,F/D

1

M64X1.5X7

80

Bolt,R/G

2

M10X1.25X25

40

Bolt,R/G

6

M8X25

25

Nut,Drive Pinion Gear Shaft,R/G

1

M12X1.25

70

Bolt,Bearing Carrier,R/G

4

M8X30

25

Retainer,R/G

1

M65X1.5X10

70

Nut

1

M8

16

Fill Bolt,R/G

1

M20X1.5X12

25

Drain Bolt,R/G

1

M14X1.25X12

25

F=Front,D=Differential,G=Gearcase,R=Rear

14-1

Inspection & Maintenance

Inspection and maintenance is required if any of problems below happened to front differential and rear gearcase.

Problem Description

Possible Causes

1.A pronounced hesitation or “jerky” movement during

A.Bearing damage;

acceleration,deceleration,or sustained speed.

B.Improper gear lash;

C.Gear severely worn;

2. Abnormal noise in front differential and/or rear

D.Gear blocked

gearcase.

E.Drive shaft broken

F.lack of lubrication

3.No power transmitted from the engine to the front and/

G.Foreiggn objects in the front differential and/or rear

or rear wheel.

gearcase

NOTE: Problems A,B and C above may be difficult to diagnose.The symptoms are quite subtle and

difficult to distinguish from normal machine operating noise.If there is reason to believe these components

are damaged,remove the components and inspect them.

Obsernvation and Judgement

1.Investigate any unusual noises:

a. Unstable noise during acceleration or deceleration.The noise increases with front and/or rear

wheel speed,but it does not increase with higher engine or transmission speed.

Diagnosis:Possible wheel bearing damage.

b. Constant abnormal noise during acceleration or deceleration might be caused by improper gear lash

during assembly.

NOTE:Improper assembly or adjustment of the front differential and/or rear gearcase will aggravate gear

wear and block;

c.Slight noise would be noticed during low-speed driving, while may not be heard during high-speed driving.

This symptom might be caused by gear block.

WARNING:In case of above mentioned itmes, stop riding immediately for inspection and fix the

problem before successive use.otherwise it will cause loss of control of the machine and possible

injury to the rider.

2.Check lubrication condition;

Often check if the consumption of lubricant is normal and the metal particles in lubricant is normal.

3.Chcek lubricant leakage;

a.Check front differential and rear gearcase housing for oil residue throughly;

b.Oil residue on ground on the parking lot;

c.Lubricant splash inspection.Check if there is gear case or oil seal leakage. Replace broken parts if

necessary.

14-2

14 FRONT DIFFERENTIAL/REAR GEARCASE

FRONT DIFFERENTIAL EXPLODED VIEW

24

23

22

21

9

8

7

25

12

Item

Part Name

QTY

Item

Part Name

QTY

1

Bolt M8X28

6

17

Bearing F1512

1

2

Differential Gear Case,LH

1

18

Drive Pinion Gear

1

3

O-ring 141X2.4

1

19

Bearing 6007

1

4

Bearing 16007

1

20

Oil Seal 48X65X9

1

5

Circlip 62

1

21

Coupler

1

6

Drive Clutch Cover

1

22

O-ring 14X6.8

1

7

Drive Clutch

1

23

Nut Washer

1

8

Shimφ83X71

1-2

24

Nut M14X1.5

1

9

Differential Gear Assembly

1

25

Screw M8X20

4

10

Shim φ61X48

2-4

26

Gear Motor

1

11

Drain Bolt M10X1.25

1

27

O-ring 81.2X1.9

1

12

Washer 10,Drain Bolt

1

28

Shift Fork Rack

1

13

Washer 14,Fill Bolt

1

29

Stopper Shaft

1

14

Bolt M14X1.25

1

30

Screw M8X10

1

15

Oil Seal 24X38X8

2

31

Retainer M64x1.5X7

1

16

Differential Gear Case,RH

1

32

14-3

14 FRONT DIFFERENTIAL/REAR GEARCASE

Front Differential Assembly and Adjust-

ment

16

Front RH Differential Gear Case Assembly

Item “31” tightening torque: 80N m

Item “24” tightening torque 62N m

NOTE: Apply engine oil on oil seal, bearing and drive

clutch assembly;

10

23 24

Apply threadlocker on item “24” .

Front LH Differential Gear Case Assembly

NOTE:Use engine oil for oil seal or bearing

assembly.

Differential Gear Assembly

Spider Gear Pin

Spider Gear

Locking Pin

Bolt M10 X 1.25 X 22 tightening torque 45N m

Bearing 61912

Adjustment Shim

Gear Carrier

Washer

NOTE: Use engine oil for bearing and differential gear;

Use proper shim to make gear work freely;

Washer

Driven Gear

Drive Gear

Bearing 6007

Upper Gear Carrier

Washer

Shim

0.1 0.2 0.3 0.4

Bolt M10X1.25X22

Ring Gear

thickness

0.5 1.0

14-5

Front Differential Assembly and Adjustment

1

3

8

Assemble front differential as illustrated:

7

10

Tightening Torque

Item “1”

25Nz m

28

29

Item “25”

13Nz m

30

Item “30”

13Nz m

27

Fill Bolt

25Nz m

25

Drain Bolt

25Nz m

26

Use threadlocker for item “30” assembly.

a Use proper shim no.8 and no.10 to adjust gear lash

between drive pinion gear and ring gear.

1

2

Measure the lash between drive bevel gear and driven

bevel gear as inllutrated: Install gear lash measure-

ment tool no.1,locking bolt(M10X1.25X60) no.2.Using

a dial gauge, make sure the measuring point is 21mm

(0.83 in).Rotate gear lash measurement tool from en-

gagement to engagement.

Standard: 0.10 ~ 0.25

Shim

0.1 0.2 0.3 0.4

thickness

0.5

1.0

b When assembling front differential gear motor,shift

fork rack and drive clutch should be against tightly as

the arrow points.

14-6

14 FRONT DIFFERENTIAL/REAR GEARCASE

c Using special equipment or vehicle control circuit,

1

switch diff. motor to 2WD before assembly.

d Make sure b and c is assembled properly and use

illustrated position screw M8X100 no.1 to assemble

differential gear motor and front differential.

14-7

14 FRONT DIFFERENTIAL/REAR GEARCASE

FRONT DIFFERENTIAL EXPLODED VIEW

24

23

22

21

9

8

7

25

12

Ite m

P/N

Qty

Item

P/N

Qty

1

Bolt M8X28

6

17

Bearing F1512

1

2

Differential Gear Case,LH

1

18

Drive Pinion Gear

1

3

O-ring 141X24

1

19

Bearing 6007

1

4

Bearing 16007

1

20

Oil Seal 48X65X9

1

5

Circlip 62

1

21

Coupler

1

6

Driver Clutch Cover

1

22

O-ring 14X6.8

1

7

Driver Clutch

1

23

Nut Washer

1

8

Shim

83X71

1-2

24

Nut M14X1.5

1

9

Differential Gear Assy

1

25

Screw M8X20

4

10

Shim

61X48

2-4

26

Gear Motor

1

11

Drain Bolt M10X1.25

1

27

O-ring 81.2X1.9

1

12

Washer 10,Drain Bolt

1

28

Shift Fork Rack

1

13

Washer 14,Fill Bolt

1

29

Stopper Shaft

1

14

Bolt M14X1.25

1

30

Screw M8X10

1

15

Oil Seal 24X38X8

2

31

Retainer M64X1.5X7

1

16

Differential Gear Case,RH

1

32

14-3

14 FRONT DIFFERENTIAL/REAR GEARCASE

Bearing Disassembly

a Disassemble needle bearing 55BTM6720 as shown

when necessary.

b When replacing needle bearing NA5903, rear

gearcase should be heated to 150

before

replacement.

Rear Gearcase Inspection after Disas-

sembly

Check if there is damage or cracks on the rear gear case and the condition of bearing seats.Replace if

necessary.

Check rear gearcase bearing free play,rotation,bearing cage,steel balls,needles conditions. Replace if

necessary(Using special tools).

Check teeth of gearcase drive pinion gear and ring gear. Replace if necessary.

Check if oil seal lips and O-ring shape are normal. Replace if necessary.

Check cylndrical surface that contacts oil seal lips.Replace if necessary.

Check gearcase inside and outside splines for wears. Replace if necessary.

Check other parts. Replace if necessary.

14-9

Rear Gearcase Assembly and Adjustment

Illustration

Tightening Torque

Item “1”

40Nz m

Item “2”

25Nz m

Item “12”

70Nz m

Item “15”

25Nz m

Item “20”

70Nz m

Item “31”

16Nz m

Bolt

25Nz m

Bolt

25Nz m

Use threadlocker for Item “29” assembly.

Assembly and gear lash adjustment between drive

pinion gear and ring gear of rear gearcase.

a Adjust installation gear lash by choosing “24”washer.

b Adjust gear lash by choosing “6” washer.

c Check tooth contact between drive pinion gear and

1

ring gear by coloring.

d Measure installation gear lash between drive pinion

gear and ring gear as illustrated: Install gear lash

measurement tool no.1,locking bolt(M14X1.25X60) no.

2.Using a dial gauge,make sure the measuring point

is 22mm.Turn gear lash measurement tool from en-

gagement to engagement.

Standard: 0.1~0.2

2

e Keep the axial gear lash within 0.1~0.2 by choosing

washer “8” .

Washer

0.2 0.3 0.4

“6”

Washer

1.0 1.2 1.4 1.6 1.8

“8”

Washer

0.4 0.5 0.6

“24”

14-10

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