Cfmoto 800MT Ibex800 (2025+) - Workshop Repair Manual - Maintenance

CFMOTO 800MT IBEX800 (2025+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 800MT Ibex800 from 2025.


CONTENTS:

01 GENERAL INFORMATION
- 1.1 Operation Cautions
- 1.2 Disassembly and Assembly Cautions
- 1.3 VIN and EIN Location
- 1.4 Electrical Parts Routing
- 1.5 Fuel Evaporation System Diagram

2 MAINTENANCE INFORMATION
- 2.1 Reset Maintenance Interval
- 2.1.1 TFT Dashboard
- 2.1.2 MMI Dashboard
- 2.2 Maintenance Before Operation
- 2.3 Break-in Maintenance Schedule
- 2.4 Periodic Maintenance Schedule

03 TECHNICAL INFORMATION
- 3.1 General Specifications
- 3.2 Engine Specification
- 3.3 Maintenance Specifications
- 3.3.1 Front Wheel
- 3.3.2 Rear Wheel
- 3.3.3 Brake System
- 3.3.4 Light, Dashboard and Switch
- 3.4 Service Specification
- 3.4.1 Valve Train&Cylinder Head
- 3.4.2 Lubrication System
- 3.4.3 Cylinder, Piston, Piston Ring and Connecting Rod
- 3.4.4 Clutch and Transmission
- 3.4.5 Cooling System
- 3.4.6 Air Inlet System
- 3.4.7 Electrical System
- 3.5 Tighten Torque
- 3.5.1 Tighten Torque Table for Vehicle
- 3.6 Consumption Materials&Assembling Materials
- 3.6.1 Vehicle Consumption Materials
- 3.6.2 Engine Consumption Materials&Assembling Materials

04 SEAT
- 4.1 Seat Removal
- 4.2 Seat Installation

05 BODY COVERING PARTS
- 5.1 Windshield
- 5.2 LH&RH Steering Panels
- 5.3 LH&RH Fog Light Guards
- 5.4 Bumpers
- 5.5 Fuel Tank Lower Panels and Fog Light Assy
- 5.6 Fuel Tank LH&RH Front Panels
- 5.7 Fuel Tank Guard
- 5.8 Dashboard
- 5.9 Headlight Assy
- 5.10 Rear Armrest
- 5.11 Side Box Bracket
- 5.12 Tail Light LH&RH Panels
- 5.13 Tail Light Upper Cover

06 FUEL SYSTEM
- 6.1 Fuel Tank Removal
- 6.2 EVAP System
- 6.3 Fuel Pump
- 6.4 Floating Ball

07 LIGHTS, DASHBOARD AND SWITCHES
- 7.1 Maintenance Information
- 7.1.1 Operation Caution
- 7.1.2 Inspection Standard
- 7.2 Trouble Shooting
- 7.3 Turn Light
- 7.4 Tail Light/Brake Light
- 7.5 Dashboard
- 7.5.1 Dashboard(IMM)
- 7.6 Ignition Switch
- 7.7 Front Brake Light Switch
- 7.8 LH Handlebar Switch(Status 1)
- 7.9 LH Handlebar Switch(Status 2)
- 7.10 RH Handlebar Switch(Status 1)
- 7.11 RH Handlebar Switch(Status 2)
- 7.12 Fog Light
- 7.13 Horn
- 7.14 Fuel Level Sensor
- 7.15 Battery
- 7.16 Vehicle T-BOX
- 7.17 Ground Wire
- 7.18 Start Engine Stop Control Unit
- 7.19 Headlight Controller
- 7.20 Headlight Cable
- 7.21 Radar Sensor (Backward - Short-range ranging sensor)
- 7.22 Vehicle Control Unit
- 7.22.1 BCM Fault and Detection

08 ELECTRICAL SYSTEM
- 8.1 Service Tool
- 8.2 Charging System
- 8.2.1 Charging Diagram
- 8.2.2 Magneto Coil Resistance
- 8.2.3 MAG Non-loaded Performance
- 8.2.4 Starter Relay
- 8.2.5 Regulator
- 8.3 EFI System
- 8.3.1 EFI Structure
- 8.3.1.1 Sensors
- 8.3.1.2 ECU
- 8.3.1.3 Actuators
- 8.3.2 EFI System Maintenance Notice
- 8.3.3 Structure and Performance of EFI Parts
- 8.3.3.1 ECU
- 8.3.3.2 Throttle Assy
- 8.3.3.3 Air Intake Pressure Sensor
- 8.3.3.4 Air Intake Temperature Sensor
- 8.3.3.5 Water Temp. Sensor
- 8.3.3.6 Oxygen Sensor
- 8.3.3.7 Trigger
- 8.3.3.8 Fuel Pump
- 8.3.3.9 Fuel Injector
- 8.3.3.10 E-throttle
- 8.3.3.11 Ignition coil
- 8.3.4 UP6.0 Fault Code
- 8.4 Fault Diagnosis and Treatment
- 8.5 Trouble Diagnosis by Engine Error

09 COOLING SYSTEM
- 9.1 Cooling System Diagram
- 9.2 Cooling System Removal
- 9.3 Coolant
- 9.4 Seal Inspection
- 9.5 Radiator and Water Pipes
- 9.6 Fan Motor Inspection
- 9.7 Coolant Inspection
- 9.8 Coolant Addition
- 9.9 Coolant Replacement

10 MUFFLER ASSY
- 10.1 Muffler Removal
- 10.1.1 Engine Panels
- 10.1.2 Exhaust Pipe
- 10.1.3 Rear Muffler Body
- 10.1.4 Front Muffler Body
- 10.2 Muffler Inspection

11 WHEELS AND BRAKE SYSTEM
- 11.1 Front Brake Caliper
- 11.2 Front Wheel
- 11.3 Rear Wheel
- 11.4 Rear Brake Caliper
- 11.5 Brake Master Cylinder 
- 11.6 ABS Actuator
- 11.7 Hand Brake Master Cylinder Assy
- 11.8 Wheel Inspection
- 11.8.1 Front Wheel
- 11.8.2 Rear Wheel
- 11.8.3 Tire Pressure
- 11.8.4 Tire Appearance
- 11.8.5 Wheel Bearing
- 11.8.6 Rim
- 11.9 Brake System Inspection
- 11.9.1 Hand Master Cylinder Inspection
- 11.9.2 Rear Master Cylinder Inspection 
- 11.9.3 Brake Hose Inspection
- 11.9.4 Brake Calipers and Brake discs Inspection
- 11.10 Free Play
- 11.10.1 Front Brake Lever Free Play
- 11.10.2 Rear Brake Pedal Free Play

12 SHOCK ABSORBERS AND REAR FORK
- 12.1 Handlebar
- 12.2 Front Shock Absorbers
- 12.3 Chain
- 12.4 Rear Fork
- 12.5 Chain Inspection
- 12.6 Front Shock Absorber
- 12.7 Rear Shock Absorber

13 ENGINE
- 13.1 Special Tools
- 13.2 Removing the Engine
- 13.3 Engine Disassembly
- 13.3.1 Draining the Engine Oil
- 13.3.2 Removing the Oil Filter
- 13.3.3 Removing the Starter Motor
- 13.3.4 Removing the Valve Cover
- 13.3.5 Removing Shift Shaft Sensor
- 13.3.6 Removing the Gear Position Sensor
- 13.3.7 Removing the Spacer
- 13.3.8 Removing the Alternator Cover
- 13.3.9 Removing the Torque Limiter and Starter Intermediate Gear
- 13.3.10 Removing the Ignition Pulse Generator
- 13.3.11 Removing the Heat Exchanger
- 13.3.12 Removing the Thermostat
- 13.3.13 Removing the Water Pump Impeller
- 13.3.14 Removing the Clutch Cover
- 13.3.15 Removing the Clutch Discs
- 13.3.16 Removing the Clutch Basket
- 13.3.17 Removing Locking Lever
- 13.3.18 Removing the Shift Shaft
- 13.3.19 Removing the Spark Plugs
- 13.3.20 Removing the Camshafts
- 13.3.21 Removing the Cylinder Head
- 13.3.22 Removing the Timing Chain Rails
- 13.3.23 Removing the Rotor
- 13.3.24 Removing the Oil Pan
- 13.3.25 Removing the Oil Pump Unit
- 13.3.26 Removing the Engine Case Downwards
- 13.3.27 Removing the Transmission Shafts
- 13.3.28 Removing Oil Spray Tube
- 13.3.29 Removing the Piston
- 13.4 Working on Individual Parts
- 13.4.1 Checking the Radial Clearance of Crankshaft Bearings
- 13.4.2 Changing the Main Bearing Shells
- 13.4.3 Checking the Balancer Shaft
- 13.4.4 Working on the Upper Section of the Engine Case
- 13.4.5 Working on the Lower Section of the Engine Case
- 13.4.6 Selecting the Main Bearing Shells
- 13.4.7 Installing the Primary Gear Wheel
- 13.4.8 Radial Shaft Seal Ring of Water Pump, Changing
- 13.4.9 Checking the Radial Clearance of Lower Conrod Bearing
- 13.4.10 Changing the Conrod Bearing
- 13.4.11 Checking/Measuring the Cylinder
- 13.4.12 Checking/Measuring the Piston
- 13.4.13 Checking the Piston Ring End Gap
- 13.4.14 Determining the Piston/Cylinder Mounting Clearance
- 13.4.15 Removing the Oil Pumps
- 13.4.16 Checking the Oil Pumps for Wear
- 13.4.17 Checking the Oil Pressure Control Valve
- 13.4.18 Installing the Oil Pumps
- 13.4.19 Preparing Timing Chain Tensioner for Installation
- 13.4.20 Checking the Timing Assembly
- 13.4.21 Working on the Camshaft Bearing Bridge
- 13.4.22 Working on the Cylinder Head
- 13.4.23 Checking the Cylinder Head
- 13.4.24 Checking the Clutch
- 13.4.25 Removing the Shift Drum Locating Unit
- 13.4.26 Checking the Shift Mechanism
- 13.4.27 Preassembling the Shift Shaft
- 13.4.28 Installing the Shift Drum Locating Unit
- 13.4.29 Disassembling the Main Shaft
- 13.4.30 Disassembling the Countershaft
- 13.4.31 Checking the Transmission
- 13.4.32 Assembling the Main Shaft
- 13.4.33 Assembling the Countershaft
- 13.4.34 Checking the Electric Starter Drive
- 13.4.35 Checking the Freewheel
- 13.4.36 Working on the Alternator Cover
- 13.5 Engine Assembly
- 13.5.1 Installing the Piston
- 13.5.2 Installing the Oil Spray Tube
- 13.5.3 Installing the Transmission Shafts
- 13.5.4 Installing the Lower Engine Case
- 13.5.5 Installing the Oil Pump Unit
- 13.5.6 Installing the Oil Pan
- 13.5.7 Installing the Rotor
- 13.5.8 Installing the Timing Chain Rails
- 13.5.9 Installing the Cylinder Head
- 13.5.10 Installing the Camshafts
- 13.5.11 Checking the Valve Clearance
- 13.5.12 Adjusting the Valve Clearance and Cleaning the Oil Screen
- 13.5.13 Installing the Spark Plugs
- 13.5.14 Installing the Shift Shaft
- 13.5.15 Installing the Locking Lever
- 13.5.16 Installing the Clutch Basket
- 13.5.17 Installing the Clutch Discs
- 13.5.18 Installing the Clutch Cover
- 13.5.19 Mounting the Water Pump Cover
- 13.5.20 Installing the Thermostat
- 13.5.21 Installing the Heat 
- 13.5.22 Installing the Crankshaft Speed Sensor
- 13.5.23 Installing the Torque Limiter and the Starter Intermediate Gear
- 13.5.24 Installing the Alternator Cover
- 13.5.25 Installing the Spacer
- 13.5.26 Installing the Gear Position Sensor
- 13.5.27 Installing the Shift Shaft Sensor
- 13.5.28 Installing the Valve Cover
- 13.5.29 Installing the Starter Motor
- 13.5.30 Installing the Oil Filter
- 13.5.31 Installing the Oil Drain Plug

14 HANDLEBAR AND TRIPLE CLAMPS
- 14.1 Handlebar
- 14.1.1 LH Handlebar Switch
- 14.1.2 RH Handlebar Switch
- 14.2 Throttle Grip
- 14.3 Handlebar Inspection
- 14.3.1 Handlebar Interference Inspection
- 14.4 Triple Clamps and Front Forks