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FOREWORD
This manual contains an introductory description of procedures for inspection maintenance,overhaul,disassembly & assembly,removal and installation of components and parts,troubleshooting and service data together with illustrations of our All Terrain Vehicle Model CF500-5 and CF500-5A Chapter 1 general service information, tools, vehicle structure and technical data. Chapter 2: key points for inspection and adjusting,service guide. Chapter 2 and after Chapter 3 disassembly of parts and components,installation,overhaul and troubleshooting. The manufacturer reserves the right to make improvements or modifications to the products without prior notice. Overhaul and maintenance should be done according to the actual state and condition of the ATV.
Converion table Item Example Conversion Pressure 200 kPa(2.00kgf/cm2)1kgf/cm2=98.0665kPa 1kpa=1000Pa 33kPa (250mmHg) 1mmHg=133.322Pa=0.133322kPs Torque 18N.m(1.8kgf-m) 1kgf.m=9.80665N.m Volume 419ml 1ml=1cm3=1cc 1l=1000cm3 Force 12N(1.2kgf) 1kgf=9.80665N
1 Maintenance Information
Cautions1-1 VIN Number & Engine Number1-3 Main Data Table1-4 Overhaul Data Table1-6 Tightening Torque1-13 Lubricant, Sealing Agent1-18 Cable Routing1-22
1-1
CFMOTO
14.Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly. Replace if the axial or radial play is too big. If the surface is uneven, clean with oil and replace if the cleaning does not help.When pressing the bearing into the machine or to the shaft
15. Install the one-side dust-proof bearing in the right direction. When assembling
the open type or double-side dustproof bearing, install with manufacturers mark outward. 16. Keep the bearing block still when blowing dry the bearing after washing clean. Apply oil or lubricant before assembling. 17. Install the elastic circlip properly. Turn the circlip after assembling to make sure is has been installed into the slot. 18. After assembling, check if all the tightened parts are properly tightened and can move smoothly. 19. Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these parts with water if splashed. 20. Install oil seal with the side of manufacturers mark outward. Do not fold or scratch the oil seal lip. Apply grease to the oil seal lip before assembling 21. When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if any, into the groove. Replace the pipes or hoses that cannot be tightened. 22. Do not mix mud or dust into engine and/or the hydraulic brake system. 23. Clean the gaskets and washers of the engine casing before assembling. Remove the scratches on the joint faces by polishing evenly with an oilstone. 24. Do not twist or bend the cables too much. Distorted or damaged cables may cause poor 25. When assembling the parts of protection caps, insert the caps to the grooves, if any.
1-2
1-3
CFMOTO
Main Data Table
Item Model Length Width Height Wheel base Engine type Displacement Fuel type Dry weight Number of Passengers Ma x. Load T ir e F ront Ti re Rear T ir e Mi n. Gr ound Clear ance T urni ng Di ameter Star ti ng E ngine Type Com bustion Cham ber Type Valve Dr iv ing Type B ore Str oke Com pres sion Ratio Lubr ic ation Type O il P ump Type Lubr ic ant Fi lter Type O il T ype Cool ing Type Cool ant T ype Par ameter CF500- 5/CF500- 5A CF500-5: 2100mm CF500-5A: 2300mm 1180m m 1230mm CF500-5: 1290mm CF500-5A: 1490mm CF188 3 493Cm Unle aded gasoli ne RQ- 90or above CF500-5: 344 kg CF500-5A: 358 kg CF500-5:2 Inc lude dr iver 210 kg 258-12 40J 185/80-12 40J 2510-12 47J 270/60-12 47J Mi n. Gr ound Clear ance Turnin g Di ameter Electrical starting, Manual Starting Single cylinder, 4-stroke, Liquid-cooled, 4 valves, OHC Triang le S OHC /Chain Dri ve 87.5m m82.0mm 10.2:1 P res sur e & Splash Rotor Full fl ow f ilter s cr een S AE15W -40/SF Clos ed cool ant cir cul ation - 35 anti- rus t c oolant
E ngine
1-4
1 Maintenance Information
It e m A ir Filter t ype F uel D e v ice Type Ca rb uretor Diame ter of m ixing valve W e t, A u t o -C e n t r if u g a l P a ra m e t e r Spon ge elem ent f ilter Vacu um Diap hragm typ e MIK UNI B SR 36-89 36m m
C l u tc h O p e r a t io n A u t o m a t ic C V T + P a rk in g & G e a r S h if t in g M ode G e a r s S h i ft L o w G e a r, H i g h Ge a r & R e ve r se G e a r S h if t M a n u a l /L - H - N -R M o d e / o rd e r C VT T ra n s m is sio 2 . 8 8 0 . 7 0 n R a t io F in a l R a t i o 1 . 3 3 3 2 4 / 1 8 B e v e l G e a r S e co n d a r y 1.952 41/21 R a t io G e a r in g L o w G e a r 2 . 2 5 (3 6 /1 6 ) H i g h G e a r G ear R a t io G e a rs 1.35 0( 27 /2 0) R e ve r se G ear 1.47 1( 25 /1 7) L o w G e a r 5 . 8 5 7 H ig h G e a r 3 . 5 1 4 To t a l R e ve r se G e a r 3 . 8 2 8 Front 33 / 9 = 3.6 67 A xle A xle Ra tio Re ar 33 / 9 = 3.6 67 A xle E n g in e O u tp u t M o d e F ro n t / R e a r S h a f t D i re c t io n of O utput C lo c kw is e o n f o rw a r d sh if t R o t a t io n S t e e r in g S t e e r in g In ne r 31 D e v ice A n g le O uter 31 F ro n t H y d ra u l ic D is c B ra k e Typ e Rear H y d ra u l ic D is c B umper S u sp e n s io n Sw i ng Ar m D e v ice F r a m e Typ e W e ld e d S t e e l T u b e a n d P la t e
1-5
Standard
Service Limit
Gap between Inner and Outer Rotors Gap between Outer rotor and boday Oil pressure
0.15mm 0.12mm
Fuel System
Item Fuel Tank Capacity Full capacity Type Jet Number Mi xing Valve Di ameter mm Main Jet Carburetor Main air Jet Needle Main Nozzle Idle Jet Idle Adjusting Screw Idle Speed Standard 19L MIKUNI BSR36-89 07G0 36mm N102221-130# MD13/24 -35# J8-5E26 785-401011-P-0M N224103-22.5# 604-16013-1A 1300100r / min
1-6
1 Maintenance Information
Cooling System
Item Full Capac ity Res erv oir tank c apaci ty Stan dard Dens ity O pening pr ess ur e of r adiator cap Ini tial Temper ature F ull openi ng Temper ature F ull opening l ift r ange Temperature Temper ature and Res is tanc e of W ater Temper ature S ensor 50 80 100 120 Cl ose- Open O pen- Close 722 88 3.5 4.5mm/95 ? Re sis tance 15416 524 273 162 8 8 Round 8 2 Round Standard/ Parameter 2000ml 30 0ml 50% S erv ice Lim it Rem ark
Coolant Capaci ty
Thermos tat
1-7
CFMOTO
Front Wheel
Item P la y o f w h e e l r im Fr o n t W h e e l T ir e Ve rt i ca l H o r izo n t a l G ro o ve P re s su r e Sta n d a rd 1 .0 m m 1 .0 m m 3 5 k Pa 0 . 3 5 k g f 2 cm Op e ra t io n L im it 2.0mm 2.0mm 3.0mm
Rear Wheel
It e m P la y o f w h e e l r im T ir e Ve rt i ca l H o r izo n t a l G ro o ve P re s su r e Sta n d a r d 1 .0 m m 1 .0 m m 2 3 0 kP a 0 .3 0 k g f cm O p e r a tio n L im it 2.0mm 2.0mm 3.0mm
R ear W heel
Brake System
I te m F r o n t Bra k e R e a r Br a ke Br a ke Br a ke Br a ke Br a ke Br a ke E n d Pla y D i sc T h ick n e ss E n d Pla y P e d a l Pla y D i sc T h ick n e ss 0 mm 3 .5 mm 5 -1 0 mm 0 mm 7 .5 mm St a n d a r d O p e ra ti o n L i m it 2 .5 mm 6 .5 mm
1-8
1 Maintenance Information
Battery, Charging Device, Pickup Coil
Item M odel Output Charging Coi l Resis tance 20 ? P ick up Coil Res istanc e Magneto witho ut Loa d Vol tage/(Idle Speed) M ax. Output P owe r Rated Voltage P eak Voltage of Pic kup Coil Rec tifier Capacity Terminal Vol ta ge Point Full y Charged Insuffi cient Charged Standard Quick 3-phase A C 0.2 -0.3 110 -140 100V AC 5000r/m in 300W 5000r/mi n 13.5V-15.0V, 50 00r/mi n 120V Three-phase annular rectification, Silicon controlled parallel-connected regulated voltage Capaci ty 12.8V Stan dard
P e rm a n e n t m a g n e t A C Typ e
AC M agneto M otor
Battery
<11.8V
0.9A 5 10H 4A 1H
Chargi ng Current/time
Ignition Device
Item Stan dard
Ignition
Type Standard Spark Pl ug Opti onal Spark plug gap Spark
CDI ignition
Resistance Spark plug
Characteristic
Igni tion Tim ing Igni tion Coil Res is tance Initial Sec ondary Ignition Coil Peak Voltage Puls e Generator Starter Relay Coi l Resi stanc e Secondary Starte r Rel ay Coil Res is tance
1-9
CFMOTO
Valve System + Cylinder Head
(mm)
Standard 30.6 27.0 0.05-0.10 0.17-0.22 0.010-0.037 0.030-0.057 5.000-5.012 4.975-4.990 4.955-4.970
Operation Limit
Valve Clearance( Idle Speed) Fit Clearance between Valve Guide and Valve Stem Internal dia. of Valve Guide Exterior dia. of Valve Stem Valve Stem Run-out Length of Valve Stem End Thickness of Valve Head Valve Head Seal Run-out Width of Valve Seats Seal Length of Valve Spring Valve Spring Tension
Intake & Exhaust Intake Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake Exhaust
0.05 2.9-3.1 2.3 0.5 0.03 0.9-1.1 40 Tension182-210N /Length31.5mm 33.430-33.490 33.500-33.560 0.032-0.066 0.028-0.059 21.959-21.980 17.466-17.484 22.012-22.025 17.512-17.525 0.10 33.130 33.200 0.150 0.150 38.8
Cam Height Fit Clearance between Camshaft Exterior dia. &Bore. Camshaft Exterior dia.
22 17.5 22 17.5 22
Camshaft Bore Internal dia. Camshaft Run-out Rocker Arm Internal dia. Rocker Arm Shaft Exterior dia. Plainness of Cylinder Head Adjoining Plant Plainness of Cylinder Head Cover Adjoining Plant
17.5
0.03
0.05
1-10
1 Maintenance Information
C ylin de r + Pis to n + P is ton Rin g+ C ran k sh a ft Ite m C yli n de r Pre ssu r e F it C le a ra n ce be tw e en P isto n an d C ylin d e r Pi sto n S k ir t d i a. In ter n a l d ia . of C yli n de r Pla in n e ss o f Cyl in d e r Ad jo in in g Pla n t P isto n Ri ng Fr e e G ap P is ton R in g C lo se d G a p P isto n A n n u la r F it C le a ra n ce Th i ckn e ss P is ton R in g To p R in g 2
nd
(mm) Op er a tio n Li mi t R e ma r k
Stan d a rd 1 0 0 0 kPa 0 .0 3 0 -0 .05 1 8 7 .4 6 0 -8 7 .48 0 Tes ti n g th e p oi n t a w a y skir t e nd 10 m m 8 7 .5 0 0 -8 7 .52 2 0 .0 15 R R 11 .7 ro u n d 1 2 ro u n d 0 .15 - 0 .3 0 0 .15 - 0 .3 0 0 .04 - 0 .0 8
0.0 3- 0.07 0.9 7- 0.99 1.1 7- 1.19
0 .1 5
87 .3 8 0
0 .0 5 8 .9 9 .5 0 .6 0 0 .6 0 0 .1 8 0 0 .1 5 0
R in g
nd
Top R in g 2 2 2 2 R in g R in g R in g R in g Top R in g
nd
Top R in g
nd
Top R in g Pi sto n An nu l ar W id th
nd
1 .03 - 1 .0 5
1.2 2- 1.24
Oi l R in g Inte r na l di a . o f Pis to n Pin Bo re E xte ri o r d ia . Pisto n P in Ro d S m al l E n d In n e r d ia . R od Big End Gap Ro d Big End Th i ckn e ss Cr a nk sh aft R un - o ut
2 .51 - 2 .5 3
2 3.0 30 2 2.9 80 2 3.0 40 1.0
0 .0 8
1-11
CFMOTO
Clutch + Transmission
Item Clutch Friction plate inner dia. Clutch Joint Rotation Clutch lock-up R otation Drive Belt W idth Driven Disc Spring Free Length Shifter and fit flute gap Left Shifter Sliding Thickness Right Shifter Sliding Thickness Plunging Flute W idth Driven Output Gear Sliding W idth Standard 140.00-140.15 1800-2400r/min 3300-3900r/min 35.2 168 0.10-0.40 5.8-5.9 5.8-5.9 6.0-6.2 6.0-6.2 33.5 160 0.50 Limit 140.50
(mm)
R emark
1-12
1 Maintenance Information
Tightening Torque
Torque Nm(kgfm) 5mm Bolt, nut 5(0.5) 5mm Screw 4(0.4) 6mm Bolt, nut 10(1.0) 6mm Screw 9(0.9) 8mm Bolt, nut 22(2.2) 6mmSH Bolt with flange, 10(1.0) 10mm Bolt, nut 34(3.5) 6mm Bolt with flange, nut 12(1.2) 12mm Bolt, nut 54(5.5) 8mm Bolt with flange, nut 26(2.7) 10mm Bolt with flange, nut 39(4.0) For others not lis ted in the chart, refer to the standard tightening torque. Notes: Appl y some engi ne oil on the part of s crew thread and adj oining surfac e. Item Torque Nm(kgfm) Item
Item
Quantity
Upper Front Mounting Bolt, Engine M860 Upper Rear Mounting Bolt, Engine M101.25110 Upper Rear Mounting Bracket Bolt, Engine M814 Upper Front Mounting Bracket Bolt, Engine M814 Low Mounting Bolt, Engine Bolt, Swing Arm Bolt, Rear Absorber Bolt, Front Absorber Bolt, Rear Wheel Shaft Holder Mounting Nut, Rim Nut, Rim Shaft Mounting Screw, Caliper M121.25140 M101.2570 M101.2550 M101.2550 M101.25100 901-07.00.02 M20 901-07.00.03 M10 Rear Brake M625 M101.2520 901-08.00.03 M8 M814 M855 M101.25 M141.5 M830 M814 M840 M101.25110 M101.2590 M101.2525 901-30.00.01 901-29.00.01 901-29.00.01 CF250T-420500 M814 M612 M814
1 1 1 1 2 16 4 4 4 16 4 2 2 8 4 4 4 1 1 1 1 2 1 2 6 4 8 1 2 2 4
3545 4050 3545 3545 5060 4050 4050 4050 4050 5060 110 130 1822 4050 2530 3545 2030 4050 100120 3035 3035 3035 4050 4050 4050 4050 3545 3545 912 3545 2530 3545
Bolt, Rear Brake Caliper Bolt, Front Brake Disc Bolt, Front Brake Caliper Locknut, Steering Stem Nut, Steering Stem Locknut, Steering Shaft Rear Mounting Bolt, Muffler Bolt, Exhaust Pipe Mounting Bolt, Exhaust Pipe Mounting Bolt, Rear Axle Mounting Bolt, Front Axle Mounting Bolt, Front Axle Back End Bolt, Rear Trans Shaft Front End Bolt, Rear Trans Shaft Bolt, Front Trans Shaft Thermo Switch Mounting Bolt 1, Front Rack Mounting Bolt 2, Front Rack Mounting Bolt , Rear Rack
1-13
CFMOTO
Engine Tightening Torque Table
Torque Item Qty Screw dia.mm N.m Sensor, Reverse Gear Spark Plug Water Temperature Sensor Valve Clearance Adjusting Nut Drive Disc Nut Driven Disc Nut Circle Nut, Driving Disc Nut, Front Output Shaft Nut, Drive Bevel Gear Nut, Driven Bevel Gear Fixing Nut, Clutch Limiting Nut, Driven Bevel Gear Shaft 1 1 1 4 1 1 1 1 1 1 1 1 M101.25 M121.25 Rc1/8 M5 M201.5 M201.5 M301 M141.5 M221 M161.5 M181.5 M60 20 18 8 10 115 115 100 97 145 150 70 110 Left handed Apply screw thread sealant Apply Limiting Nut, Front Output Shaft 1 M55 80 sealant, left handed Bolt, Swing Arm Shaft Drain Bolt Mounting Bolt, Overriding Clutch Mounting Bolt, Magneto Stator Bolt, CVT Windshield Link Bolt, Oil Pipe Mounting, Oil Pump Mounting Bolt, Pressure Limiting Valve Bolt, Drive Bevel Gear Cover Bolt, Driven Bevel Gear Cover Locating Bolt, Shift Flange Bolt, Fan 2 1 6 3 3 2 3 2 4 4 1 1 M141.25 M121.5 M8 M6 M6 M141.5 M6 M6 M8 M8 M141.5 M101.25 28 30 26 10 10 18 10 10 32 25 18 55 Apply screw thread sealant Apply screw thread sealant Apply screw thread sealant screw thread Apply screw thread sealant Remark
1-14
1 Maintenance Information 1
Torque Item Quantity Diametermm N.m 14 Bolt, Crankcase 3 Bolt, Driven Sector Gear Mounting Bolt, Oil Filter Oil Filter Bolt, Starting Motor Bolt, Cylinder Head Bolt, Cylinder Head(2 sides) 1 1 1 2 4 2 1 Upper and Lower Bolt, Cylinder Bolt, Cylinder Head C over Bolt, Chain Tensioner Nut, Chain Tensioner Bolt, Radiator Fan Thermostat Bolt Bolt, Water Pump Cover Mounting Bolt, Water Pump Fixed Bolt, Timing Sprocket 4 12 2 1 3 2 3 2 2 M8 M6 M201.5 3 / 4 ? 1 6 / i n M6 M10 M6 M8 M6 M6 M6 M8 M6 M6 M6 M6 M6 M5 Bolt without remarks M6 M8 25 12 63 1820 10 38 10 25 10 10 10 8 10 10 6 10 15 4.5-6 8-12 18-25
A pply screw thread sealant
Remark
M6
10
1-15
CFMOTO
Engine Tools
Measuring Tools
No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Name Vernier Calipers Micrometers Dial gauge Dial gauge Inner dia. Gauge, Cylinder Inner dia. Gauge, Dial Test Indicator Knife Straight Edge Feeler Gauge Fuel Level Gauge Plastic gauge pull tension gauge Tachometer Cylinder Pressure Meter Oil Pressure Gage Barometer Ohmmeter Amperemeter Thermometer Timing Lights Torque Tester One Set 10-34mm 1/100 Type 0-150mm 0-25mm 25-50mm 75-100mm Function measure length and thickness measure the outer diameters of swing arm, valve rod and camshaft Measure max. lift range of camshaft Measure piston skirt Measure inner dia. of cylinder head Inner dia. of swing arm, piston pin hole, and rod head hole Run-out plainness Plainness, adjusting valve clearance Fuel level length of carburetor Fit clearance Spring bounce Engine rotation rate pressure in cyclinder Oil pressure Opening pressure of radiator cover Resistance and voltage Opening of currency / switch Liquid temperature Test spark timing Tightening torque Remark
Auxiliary Measuring Instrument 22 23 24 25 26 27 28 29 30 31 Alcohol Burner Magnet Stand Slab V-Block Forcep Plier Joint Plier Impact Driver Slot Type Driver Cross Type Driver Warming up Install dialgauge Auxiliary measure supplementary Run-out supplementary Install valve clip Disassemble and install circlip Disassemble and install flange Disassemble cross recessed bolt
1-16
1 Maintenance Information
Special Purpose Tools
No 1 Name Spark Plug Wrench Type 172MM-022400-922-004 Function Disassemble/ install spark plug CF188-051000-922-001 2 CVT Wrench CF188-052000-922-001 CF188-011300-922-001 CF188-040004-922-002 CF188-031000-922-001 Remover 6 7 Crankcase Dissociator Crank Remover from left crankcase Install crank shaft on left 8 Crank Tool crankcase Valve Spring 9 Compressor 10 11 Valve Former Circle Nut Wrench CF188-022004-922-001 CF188-052000-922-003 CF188-022006-922-001 spring Grind valve Disassemble CVT driven disc Disassemble CVT driven 12 Driven Disc Clamp CF188-052000-922-004 disc Disassemble CVT driven 13 Driven Disc Former CF188-052000-922-002 disc Disassemble driven bevel 14 15 16 17 18 Limiting nut Wrench Bearing Tool Bearing Remover Oil Ring Remover Limiting Nut Wrench CF188-060008-922-001 shaft bearing limiting nut Disassemble fan connector 19 Fixing Wrench CF188-A-180003-922-003 flange, adjust valve clearance CF188-062204-922-001 gear bearing limiting nut One full set One full set Install bearing and oil ring Disassemble bearing Disassemble bearing Disassemble front output Disassemble/ install valve stator Divide L/R crank case Disassemble crank shaft Disassemble/install CVT drive/driven disc nut Disassemble/ install oil filter Disassemble piston pin Disassemble magneto Remark
3 4 5
1-17
Operation Material and Installment Supplementary of Engine Engine op eration materials include lu bricant (oil), grease (lubricant g rease) and co olant, installm ent supp lementary inclu des plane sealant and screw thread sealant.
Name Type Parts Rotati ng section and carriage in cylinder, Rotati ng section and carriage in crankcase Rotati ng secti on and carriage in cylinder head See Lubrication Systems Diagram5-14 capacity 2200m Lreplace oil 2300 m Lreplace oil filter 2600 m Lengine overhaul Remark
for
4-stroke
motorcycle SAE-10W-4020W-50 Substitutes must be used in the following range. API type: SE or S G grade Replacement see 1-3
Lubricant with molybdenum Grease/lubricant grease Coolant # 3 MoS2 l ithium based grease -35 anti-frozen, anti-rust,
Piston pin, valve rod part, valve ring, cam shaft Oil seal lip, O ring and other latex sealing, bearing with seals, and CVT bearing/housing Capacity based on radiator Cool ing system, water seals high boiled coolant pi pe system Coupl ing surfaces of cases, cases and cylinder, cylinder head and cylinder head cover
Plane sealant
Screw sealant
thread
1-18
1-19
CFMOTO
1-20
1 Maintenance Information 1
1-21
CFMOTO
1-22
CFMOTO
Valve System + Cylinder Head
(mm)
Standard 30.6 27.0 0.05-0.10 0.17-0.22 0.010-0.037 0.030-0.057 5.000-5.012 4.975-4.990 4.955-4.970
Operation Limit
Valve Clearance( Idle Speed) Fit Clearance between Valve Guide and Valve Stem Internal dia. of Valve Guide Exterior dia. of Valve Stem Valve Stem Run-out Length of Valve Stem End Thickness of Valve Head Valve Head Seal Run-out Width of Valve Seats Seal Length of Valve Spring Valve Spring Tension
Intake & Exhaust Intake Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake & Exhaust Intake Exhaust
0.05 2.9-3.1 2.3 0.5 0.03 0.9-1.1 40 Tension182-210N /Length31.5mm 33.430-33.490 33.500-33.560 0.032-0.066 0.028-0.059 21.959-21.980 17.466-17.484 22.012-22.025 17.512-17.525 0.10 33.130 33.200 0.150 0.150 38.8
Cam Height Fit Clearance between Camshaft Exterior dia. &Bore. Camshaft Exterior dia.
22 17.5 22 17.5 22
Camshaft Bore Internal dia. Camshaft Run-out Rocker Arm Internal dia. Rocker Arm Shaft Exterior dia. Plainness of Cylinder Head Adjoining Plant Plainness of Cylinder Head Cover Adjoining Plant
17.5
0.03
0.05
1-10
CFMOTO
Engine Tightening Torque Table
Torque Item Qty Screw dia.mm N.m Sensor, Reverse Gear Spark Plug Water Temperature Sensor Valve Clearance Adjusting Nut Drive Disc Nut Driven Disc Nut Circle Nut, Driving Disc Nut, Front Output Shaft Nut, Drive Bevel Gear Nut, Driven Bevel Gear Fixing Nut, Clutch Limiting Nut, Driven Bevel Gear Shaft 1 1 1 4 1 1 1 1 1 1 1 1 M101.25 M121.25 Rc1/8 M5 M201.5 M201.5 M301 M141.5 M221 M161.5 M181.5 M60 20 18 8 10 115 115 100 97 145 150 70 110 Left handed Apply screw thread sealant Apply Limiting Nut, Front Output Shaft 1 M55 80 sealant, left handed Bolt, Swing Arm Shaft Drain Bolt Mounting Bolt, Overriding Clutch Mounting Bolt, Magneto Stator Bolt, CVT Windshield Link Bolt, Oil Pipe Mounting, Oil Pump Mounting Bolt, Pressure Limiting Valve Bolt, Drive Bevel Gear Cover Bolt, Driven Bevel Gear Cover Locating Bolt, Shift Flange Bolt, Fan 2 1 6 3 3 2 3 2 4 4 1 1 M141.25 M121.5 M8 M6 M6 M141.5 M6 M6 M8 M8 M141.5 M101.25 28 30 26 10 10 18 10 10 32 25 18 55 Apply screw thread sealant Apply screw thread sealant Apply screw thread sealant screw thread Apply screw thread sealant Remark
1-14
Bumper Cap 2-15 Front Vent Grille, Fuel Tank2-16 Bottom Plate, Fuel Tank 2-17 Muffler 2-18 Description of Visible Parts2-19
Overhaul Information Operation Cautions Warning Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should be done in a well-ventilated place. Remove and Install muffler after it is fully cold.