Cfmoto 300SR 300SS (2023+) - Workshop Repair Manual - Maintenance

CFMOTO 300SR 300SS  (2023+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 300SR 300SS from 2023.
- Edition Item: 300SR 300SS (6KNV-00WX01-8100)SM-20230724.pdf
- 300SR:CF300-5 CF300-5B CF300-5F CF300-5BF
- 300SS:CF300-5US CF300-5BUS


CONTENTS:

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

02 MAINTENANCE INFORMATION
- 2.1 Maintenance before Operation
- 2.2 Break-in Maintenance Schedule
- 2.3 Periodic Maintenance Schedule

03 TECHNICAL INFORMATION
- 3.1 Main Parameters of the Vehicle
- 3.2 Engine Main Parameters
- 3.3 Maintenance Parameter Table
- 3.3.1 Front Wheel
- 3.3.2 Rear Wheel
- 3.3.3 Brake System
- 3.3.4 Lighting, Dashboard and Switches
- 3.3.5 Valve Train&Cylinder Head
- 3.3.6 Lubrication System
- 3.3.7 Cylinder, Piston, Piston Ring and Connecting Rod
- 3.3.8 Clutch and Transmission
- 3.3.9 Cooling System
- 3.3.10 Air Inlet System
- 3.3.11 Electrical System
- 3.4 Tighten Torque
- 3.4.1 Tighten Torque Table for Vehicle
- 3.4.2 Tighten Torque Table for Engine
- 3.5 Lubrication Requirements
- 3.5.1 Complete Vehicle Lubrication Requirements
- 3.5.2 Lubrication Requirements for Engine

04 SEAT
- 4.1 Seat

05 BODY COVERING PARTS
- 5.1 Rear View Mirror and Front Windshield
- 5.2 Fuel Tank Guard Assembly
- 5.2.1 Fuel Tank Guard Disassembly
- 5.3 LH Guard of Headlight
- 5.4 Front LH Panel and LH Spoiler Assembly
- 5.4.1 Front LH Panel and LH Spoiler Assembly Disassembly
- 5.5 Front RH Panel and RH Spoiler Assembly
- 5.5.1 Front RH Panel and RH Spoiler Assembly Disassembly
- 5.6 Seat Lower Deco Guard and Tail Guard Assembly
- 5.6.1 Seat Lower Deco Guard and Tail Guard Assembly Disassembly
- 5.7 LH Panel
- 5.8 RH Panel
- 5.9 Dashboard and Dashboard Guard Assembly
- 5.9.1 Dashboard and Dashboard Guard Assembly Disassembly
- 5.10 Fuel Tank LH Front Panel
- 5.11 LH Front Inner Panel
- 5.12 RH Front Inner Panel
- 5.13 Front Lower Fender
- 5.14 Engine Lower Guard 
- 5.14.1 Engine Lower Guard Disassembly
- 5.15 LH Middle Deco Cover
- 5.16 RH Middle Deco Cover
- 5.17 Small Sprocket Guard
- 5.18 Headlight Assembly
- 5.18.1 Headlight Assembly Disassembly
- 5.19 Rear Fender Upper and Lower Body Assembly
- 5.19.1 Rear Fender Upper and Lower Body Assembly Disassembly
- 5.20 Rear Fender and Tail Light Assembly
- 5.20.1 Rear Fender and Tail Light Assembly Disassembly
- 5.21 Frame Block
- 5.21.1 Frame LH Block
- 5.21.2 Frame RH Block
- 5.22 Front Fender Assembly
- 5.22.1 Front Fender Assembly Disassembly
- 5.23 Canister Deco Guard

06 FUEL TANK
- 6.1 Fuel Tank

07 LIGHTS, DASHBOARD AND SWITCHES
- 7.1 Maintenance Information
- 7.1.1 Operation Caution
- 7.1.2 Inspection Standard
- 7.2 Lights Troubleshooting
- 7.3 Ignition Lock Assembly
- 7.4 Front Brake Light Switch
- 7.5 Handlebar Switch
- 7.5.1 LH Handlebar Switch
- 7.5.2 RH Handlebar Switch
- 7.6 Fuel Level Sensor
- 7.7 Battery
- 7.8 Ground Wire
- 7.9 T-BOX

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 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 Bodyy
- 8.3.3.3 T-MAP
- 8.3.3.4 Water Temp. Sensor
- 8.3.3.5 Oxygen Sensor
- 8.3.3.6 Trigger
- 8.3.3.7 Fuel Pump
- 8.3.3.8 Fuel Injector
- 8.3.3.9 Idle Stepping Motor
- 8.3.3.10 Ignition coil
- 8.3.4 Self-diagnosis
- 8.3.4.1 MIL
- 8.3.4.2 Fault Code
- 8.4 Fault Diagnosis and Treatment
- 8.4.1 Engine Body
- 8.5 Trouble Diagnosis In Accordance With Engine Error

09 COOLING SYSTEM
- 9.1 Cooling System Diagram
- 9.2 Cooling System
- 9.2.1 Cooling Pipe
- 9.3 Coolant
- 9.4 Inspection for Cooling Cycle Seal
- 9.5 Fan Moto Assembly
- 9.6 Clean and Inspection for Radiator Assembly
- 9.6.1 Inspect Water Inlet Pipe and Outlet Pipe

10 MUFFLER
- 10.1 Muffler Assembly
- 10.1.1 Muffler Assembly Inspection and Repairment

11 WHEELS AND BRAKE SYSTEM
- 11.1 Front Wheel
- 11.2 Rear Wheel- Double Swing Arm
- 11.3 Rear Wheel- Single Swing Arm
- 11.3.1 Sliding Bearing Replacement
- 11.4 Footrest Bracket
- 11.4.1 LH Front Footrest Bracket
- 11.4.2 RH Front Footrest Bracket
- 11.5 MAB Hydraulic Brake Assembly- Double Swing Arm
- 11.5.1 Sprocket Guard
- 11.5.2 Rear Brake Master Cylinder Assembly
- 11.5.3 Remove MAB Hydraulic Brake Assembly
- 11.5.3.1 MAB Execution Unit
- 11.5.3.2 Rear Brake Pump and Rear Brake Caliper Assembly
- 11.5.3.3 Hand Brake Pump Assembly
- 11.5.3.4 Front Brake Caliper Assembly
- 11.6 MAB Hydraulic Brake Assembly- Single Swing Arm
- 11.6.1 Rear Brake Master Cylinder Assembly
- 11.6.2 Remove MAB Hydraulic Brake Assembly
- 11.6.2.1 MAB Execution Unit
- 11.6.2.2 Rear Brake Pump
- 11.6.2.3 Rear Brake Caliper
- 11.6.2.4 Hand Brake Pump Assembly
- 11.6.2.5 Front Brake Caliper
- 11.7 Wheel Inspection
- 11.7.1 Sprocket Seat (Double Swing Arm)
- 11.7.2 Tire Pressure
- 11.7.3 Tire Appearance
- 11.7.4 Wheel Bearing
- 11.7.5 Rim
- 11.8 Brake System Inspection
- 11.8.1 Front Master Cylinder Inspection
- 11.8.2 Brake Caliper and Brake Disc Inspection
- 11.8.3 Rear Brake Master Cylinder Inspection
- 11.8.4 Brake Hose Inspection
- 11.9 Free Play
- 11.9.1 Front Brake Lever Free Play
- 11.9.2 Rear Brake Pedal Free Play

12 SHOCK ABSORBER AND REAR FORK
- 12.1 Front Suspension Assembly Diagram
- 12.2 Front Shock Absorber
- 12.3 Chain
- 12.4 Rear Suspension Assembly Diagram- double swing arm
- 12.5 Rear Shock Absorber- Double Swing Arm
- 12.6 Rear Fork- Double Swing Arm
- 12.6.1 Chain Guard
- 12.7 Rear Suspension Assembly Diagram- single swing arm
- 12.8 Rear Shock Absorber- Single Swing Arm
- 12.9 Rear Fork- Single Swing Arm
- 12.9.1 Chain Guard
- 12.10 Drive Chain Inspection
- 12.10.1 Chain Looseness Adjustment - Double Swing Arm
- 12.10.2 Chain Looseness Adjustment - Single Swing Arm
- 12.11 Front Shock Absorber Inspection
- 12.12 Rear Shock Absorber Inspection
- 12.13 Rear Shock Absorber Adjustment

13 ENGINE
- 13.1 Preparation Instruction
- 13.2 Maintenance Information
- 13.2.1 Engine Appearance
- 13.2.2 General Prevention Measures
- 13.2.3 Fuel and Engine Oil Selection
- 13.2.4 Engine Break-in
- 13.2.5 Engine Technical Information
- 13.2.6 Service Information
- 13.2.7 Tighten Torque Chart
- 13.2.8 Service Tools
- 13.2.9 Engine Consumption Materials & Assembling Materials
- 13.3 Engine Removal
- 13.4 Engine Installation
- 13.5 Engine Disassembly
- 13.5.1 Engine Fixing
- 13.5.2 Draining the engine oil
- 13.5.3 Secondary Gulp Valve Removal (Euro 5 status)
- 13.5.4 Oil Filter Removal
- 13.5.5 RH Side Cover Removal
- 13.5.6 Water Pump Impeller Removal
- 13.5.7 TDC Adjustment
- 13.5.8 Clutch Removal
- 13.5.9 Output Gear Removal
- 13.5.10 Relief Valve Removal
- 13.5.11 Oil Pump Removal
- 13.5.12 Gearshift Lever, Gear Position Part and Shift Drum Cam Removal
- 13.5.13 Starter Motor Removal
- 13.5.14 LH Side Cover Removal
- 13.5.15 Dual Gear, Middle Gear and Magneto Rotor Removal
- 13.5.16 Valve System Removal
- 13.5.17 Cylinder Head, Cylinder Body Removal
- 13.5.18 Piston, Piston Pin Removal
- 13.5.19 Gear Contactor and Oil Strainer Removal
- 13.5.20 RH Crankcase Removal
- 13.5.21 Gearshift Assembly Removal
- 13.5.22 Crankshaft Removal
- 13.5.23 Bearing 6207 Removal
- 13.5.24 Cylinder Head Assembly Removal
- 13.5.25 Magneto Stator Removal
- 13.6 Inspection and Assembly
- 13.6.1 RH Crankcase
- 13.6.2 LH Crankcase
- 13.6.3 Cylinder Head Assembly
- 13.6.4 Valve System
- 13.6.5 Cylinder Body
- 13.6.6 Crankshaft and Piston
- 13.6.7 Oil Pump
- 13.6.8 Water Pump Assembly
- 13.6.9 Clutch Control Shaft Assembly 
- 13.6.10 Magneto Assembly
- 13.6.11 Start System
- 13.6.12 Clutch Assembly
- 13.6.13 Gearshift Assembly
- 13.6.14 Main Shaft, Counter Shaft
- 13.7 Engine Assembly
- 13.7.1 Preparation
- 13.7.2 Crankshaft, Balance Shaft Installation
- 13.7.3 Main Shaft and Counter Shaft Installation 
- 13.7.4 Shift Drum, Shift Fork and Shift Shaft Installation
- 13.7.5 RH Crankcase Installation
- 13.7.6 Oil Strainer and Gear Position Sensor Installation
- 13.7.7 Gearshift Assembly Installation
- 13.7.8 Piston Installation
- 13.7.9 Cylinder Body Installation
- 13.7.10 Timing Chain, Chain Guide, Tensioner Installation
- 13.7.11 Oil Pump Assembly Installation
- 13.7.12 Relief Valve Installation
- 13.7.13 Output Gear Installation
- 13.7.14 Clutch Assembly Installation
- 13.7.15 Magneto Rotor Installation
- 13.7.16 Dual Gear and Starter Middle Gear Installation
- 13.7.17 LH Side Cover Installation
- 13.7.18 Cylinder Head Installation
- 13.7.19 Starter Motor Installation
- 13.7.20 RH Side Cover Installation
- 13.7.21 Oil Filter Installation
- 13.7.22 Cylinder Head Cover Installation
- 13.7.23 Secondary Gulp Valve Installation (Euro 5 Status)
- 13.7.24 Drain Bolt Installation
- 13.8 Air Intake System
- 13.9 Air Intake System (Euro 5 Status)
- 13.10 Lubrication System
- 13.11 Engine Oil Addition and Oil Pressure Measurement

14 HANDLEBAR AND TRIPLE CLAMPS
- 14.1 Clutch Lever
- 14.2 LH Handlebar Switch
- 14.3 LH Balance Block, LH Hand Grip
- 14.4 RH Handlebar Switch
- 14.5 Throttle Cable
- 14.6 RH Balance Block, RH Hand Grip
- 14.7 Handlebar Inspection
- 14.7.1 Throttle Cable Free Play
- 14.7.2 Clutch Handle Clearance Inspection
- 14.7.3 Handlebar Interference Inspction
- 14.8 Front Suspension Assembly Diagram
- 14.9 Upper Triple Clamp Assembly
- 14.10 Lower Triple Clamp, Front Fork Pipe