Cfmoto 300SS (2019+) - Workshop Repair Manual - Maintenance

CFMOTO 300SS  (2019+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 300SS from 2019.
- Edition Item: CF300-3 / CF250-6 (6KM#-WX-01) SM-20191115


CONTENTS:

01 MAINTENANCE INFORMATION
- 1.1 Operation Cautions
- 1.2 Disassembly and Assembly Cautions
- 1.3 VIN and EIN Location: CF300/CF300-F
- 1.4 Main Specifications
- 1.5 Specifications for Maintenance
- 1.6 Tightening Torque
- 1.7 Lubricating Grease
- 1.8 Wires, Pipes and Cables Diagram

02 INSPECTION AND ADJUSTMENT
- 2.1 Overhaul Information
- 2.2 Maintenance Information
- 2.3 Fuel Filter
- 2.4 Throttle Cable
- 2.5 Chain
- 2.6 Clutch Cable
- 2.7 Front and Rear Brakes
- 2.8 Brake Fluid
- 2.9 Suspension
- 2.10 Bolts and Nuts
- 2.11 Wheel Axles and Handlebar
- 2.12 Engine Maintenance and Adjustment Process
- 2.13 Valve Clearance
- 2.14 Spark Plug 
- 2.15 Air Filter
- 2.16 Lubrication System Inspection
- 2.17 Cooling System Inspection
- 2.18 Engine Oil Pressure Test

03 VEHICLE BODY AND MUFFLER
- 3.1 Maintenance Information
- 3.2 Front Fender, Seat and Rear Handrest
- 3.3 License Plate Light
- 3.4 Tail Cover, Tail Light and Steering
- 3.5 Front Inner Side Plates and Fuel Tank Guard Removal
- 3.6 Fuel Tank
- 3.7 Engine Guard and Water Guard 
- 3.8 Headlight and Dashboard
- 3.9 Muffler Assembly
- 3.10 Body Covering Parts

04 COOLING AND LUBRICATING SYSTEMS
- 4.1 172MM-2 Engine Cooling System
- 4.2 Engine Coolant
- 4.3 Cooling Cycle Tightness Inspection
- 4.4 Radiator and Water Hoses Inspection and Clean
- 4.5 Fan Motor Inspection
- 4.6 Water Temperature Sensor Inspection
- 4.7 Inspection of Thermostat
- 4.8 Water Pump
- 4.8.1 Water Pump Assembly Inspection
- 4.8.2 Water Pump Assembly 
- 4.9 Lubrication System Drawing

05 ENGINE
- 5.1 Maintenance Information
- 5.1.1 General Prevention Measures
- 5.1.2 Fuel and Engine Oil
- 5.1.3 Engine Break-In
- 5.1.4 EIN Location
- 5.1.5 Engine Technical Specifications
- 5.1.6 Service Specifications
- 5.1.7 Tighten Torque Chart
- 5.1.8 Special Tools
- 5.1.9 Engine Consumption Materials and Assembly Materials
- 5.2 Engine Disassembly
- 5.2.1 Preparation
- 5.2.2 Engine Timing Setup
- 5.2.3 Oil Filter Removal
- 5.2.4 Right Side Cover 
- 5.2.5 Water Pump Impeller
- 5.2.6 Clutch Removal
- 5.2.7 Output Gear Removal
- 5.2.8 Relief Valve Removal
- 5.2.9 Oil Pump Removal
- 5.2.10 Gearshift Lever and Gear Positioning Parts Removal
- 5.2.11 Starter Motor Removal
- 5.2.12 Left Side Cover
- 5.2.13 Dual Gear, Starter Middle Gear and Magneto Rotor Removal
- 5.2.14 Valve System Removal
- 5.2.15 Cylinder Head and Cylinder Body Removal
- 5.2.16 Piston and Piston Pin Removal
- 5.2.17 Gear Contactor, Oil Strainer and Speed Sensor Removal
- 5.2.18 Right Crankcase Removal
- 5.2.19 Gearshift Assembly Removal
- 5.2.20 Balance Shaft Removal
- 5.2.21 Crankshaft Removal
- 5.2.22 Bearing 6207 Removal
- 5.2.23 Cylinder Head Assembly Removal
- 5.2.24 Magneto Stator Removal
- 5.3 Inspection and Installation
- 5.3.1 Right Crankcase Inspection and Installation
- 5.3.2 Left Crankcase Inspection and Installation
- 5.3.2 Left Crankcase Inspection and Installation
- 5.3.3 Cylinder Head Assembly Inspection and Installation
- 5.3.4 Valve System Inspection and Installation
- 5.3.5 Cylinder Body Inspection and Installation
- 5.3.6 Crankshaft and Piston Inspection and Installation
- 5.3.7 Oil Pump Inspection and Installation
- 5.3.8 Water Pump Inspection and Installation
- 5.3.9 Clutch Release Shaft Inspection and Installation
- 5.3.10 Magneto Inspection and Installation
- 5.3.11 Starting System Inspection and Installation
- 5.3.12 Clutch Inspection and Installation
- 5.3.13 Gearshift Inspection and Installation
- 5.3.14 Main Shaft and Countershaft Inspection and Installation
- 5.4 Engine Assembly
- 5.4.1 Preparation
- 5.4.2 Crankshaft and Balance Shaft Assembly
- 5.4.3 Main Shaft and Countershaft Assembly
- 5.4.4 Shift Drum, Shift Fork and Shift Shaft Assembly
- 5.4.5 Right Crankcase Assembly
- 5.4.6 Oil Strainer, Gear Contactor and Speed Sensor Assembly
- 5.4.7 Gearshift Assembly
- 5.4.8 Piston Assembly
- 5.4.9 Cylinder Body Assembly
- 5.4.10 Timing Chain, Tensioner and Other Parts Assembly
- 5.4.11 Oil Pump Assembly
- 5.4.12 Relief Valve Assembly
- 5.4.13 Output Gear Assembly
- 5.4.14 Clutch Assembly
- 5.4.15 Magneto Rotor Assembly
- 5.4.16 Dual Gear and Starter Middle Gear Assembly
- 5.4.17 Left Side Cover Assembly
- 5.4.18 Cylinder Head Assembly
- 5.4.19 Starter Motor Assembly
- 5.4.20 Right Side Cover Assembly
- 5.4.21 Oil Filter Assembly
- 5.4.22 Cylinder Head Cover Assembly
- 5.5 Air Intake System
- 5.6 Lubrication System
- 5.7 Engine Oil Addition and Oil Pressure Measurement

06 ENGINE REMOVAL AND INSTALLATION
- 6.1 Maintenance Information
- 6.2 Engine Disassembly
- 6.3 Engine Installation

07 FRONT WHEEL, BRAKE, SUSPENSION AND STEERING
- 7.1 Maintenance Information
- 7.1 Maintenance Information
- 7.1.1 Operation Attention
- 7.1.2 Maintenance Specifications
- 7.1.3 Torque Specifications
- 7.2 Troubleshooting
- 7.2.1 Steering Is Too Tight
- 7.2.2 Handlebar Is Loose
- 7.2.3 Front Wheel Wobbles
- 7.2.4 Front Suspension Is Too Soft
- 7.2.5 Front Suspension Is Too Hard
- 7.2.6 Brake Lever Is Spongy
- 7.2.7 Braking Is Poor
- 7.2.8 Brakes Are Abnormally Noisy
- 7.2.9 Front Shocks Are Abnormally Noisy
- 7.3 Handlebar
- 7.4 Front Wheel
- 7.4.1 Front Wheel Inspection
- 7.4.2 Front Rim Inspection
- 7.5 Front Shock Absorbers
- 7.6 Steering Column
- 7.7 Front Brake Without ABS
- 7.7.1 Front Brake Master Cylinder Removal
- 7.7.2 Front Brake Caliper Removal
- 7.7.3 Front Brake Master Cylinder and Caliper Installation
- 7.7.4 Brake Fluid Replacement
- 7.7.5 Brake Pads and Discs
- 7.8 Front Brake With ABS
- 7.8.1 Front Brake Master Cylinder Removal
- 7.8.2 Front Brake Caliper Removal
- 7.8.3 Front Brake Master Cylinder and Caliper Installation
- 7.8.4 Brake Fluid Addition
- 7.8.5 Brake Pads and Discs

08 REAR WHEEL, BRAKE AND SUSPENSION
- 8.1 Maintenance Information
- 8.1 Maintenance Information
- 8.1.1 Operation Attention
- 8.1.2 Maintenance Specifications
- 8.1.3 Torque Specifications
- 8.2 Rear Wheel
- 8.2.1 Rear Wheel Removal
- 8.2.2 Rear Wheel Inspection
- 8.3 Rear Swing Arm
- 8.3 Rear Swing Arm
- 8.3.1 Rear Swing Arm Removal
- 8.3.2 Rear Swing Arm Inspection
- 8.4 Rear Brake Without ABS
- 8.4.1 Brake Removal
- 8.4.2 Brake Installation
- 8.4.3 Brake Pad Inspection
- 8.4.4 Brake Disc Measurement
- 8.4.5 Brake Fluid Replacement
- 8.5 Rear Brake With ABS
- 8.5.1 Brake Removal
- 8.5.2 Brake Installation
- 8.5.3 Brake Pad Inspection
- 8.5.4 Brake Disc Measurement
- 8.5.5 Brake Fluid Addition

09 ELECTRICAL SYSTEM
- 9.1 Service Tools
- 9.2 Charging System
- 9.2.1 Charging Diagram
- 9.2.2 Magneto Coil Resistance
- 9.2.3 Magneto Non-Loaded Performance
- 9.2.4 Voltage Regulator / Rectifier
- 9.3 Starting System
- 9.3.1 Starter Relay
- 9.3.2 Auxiliary Relay
- 9.3.3 Engine Starting Notice
- 9.4 EFI System
- 9.4.1 EFI Structure
- 9.4.2 EFI Subsystems
- 9.4.2.1 Sensors
- 9.4.2.2 Electronic Control Unit
- 9.4.2.3 Actuators
- 9.4.3 EFI System Maintenance Notice
- 9.4.4 EFI Components and Function
- 9.4.4.1 Electronic Control Unit
- 9.4.4.2 Throttle Body
- 9.4.4.3 T-MAP Sensor
- 9.4.4.4 Coolant Temperature Sensor
- 9.4.4.5 Oxygen Sensor
- 9.4.4.6 Crankshaft Position Sensor
- 9.4.4.7 Speed Sensor
- 9.4.4.8 Gear Sensor
- 9.4.4.9 Fuel Pump
- 9.4.4.10 Fuel Injector
- 9.4.4.11 Idle Air Control Valve
- 9.4.4.12 Ignition Coil
- 9.4.4.13 Rollover Sensor
- 9.4.5 EFI Self-Diagnosis
- 9.4.5.1 Malfunction Indicator Lamp
- 9.4.5.2 PDA
- 9.4.5.3 Fault Code Table

10 LIGHTS, DASHBOARD AND SWITCHES
- 10.1 Maintenance Information
- 10.1.1 Operation Instructions
- 10.1.2 Standard Value
- 10.2 Headlight
- 10.2.1 Troubleshooting
- 10.3 Dashboard-Low Configuration
- 10.4 Dashboard-High Configuration
- 10.5 Turning Light
- 10.6 Tail Light / Brake Light
- 10.7 Rear License Light
- 10.8 Ignition Switch
- 10.9 Front Brake Switch
- 10.10 Rear Brake Switch
- 10.11 Handlebar Switch, LH
- 10.12 Handlebar Switch, RH
- 10.13 Horn
- 10.14 Instrument Switches (2019)
- 10.15 Fuel Level Sensor

11 TROUBLESHOOTING
- 11.1 Engine Body
- 11.2 Diagnose In Accordance With Engine Error