Cfmoto 450SS (2025+) - Workshop Repair Manual - Maintenance

CFMOTO 450SS (2025+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 450SS from 2025.
- Edition Item：CF400-6 (6AQV-00WX02-12) SM-20250122


CONTENTS:

01 GENERAL INFORMATION
- 1.1 Operational Precautions
- 1.2 Disassembly and Assembly Precautions
- 1.3 Location of VIN and EIN
- 1.4 Fuel Evaporation System Diagram

02 MAINTENANCE INFORMATION
- 2.1 Pre-Trip Maintenance Schedule
- 2.2 Break-In Maintenance Schedule
- 2.3 Periodic Maintenance Schedule

03 TECHNICAL INFORMATION
- 3.1 General Specifications
- 3.2 Engine Specifications
- 3.3 Vehicle Service Specifications
- 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 Suspension
- 3.4 Engine Service Specifications
- 3.4.1 Valve Train and 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 Torque Tables
- 3.5.1 Torque Table for Vehicle
- 3.6 Consumption and Assembly Materials
- 3.6.1 Vehicle Consumption Materials
- 3.6.2 Engine Consumption and Assembly Materials 

04 VEHICLE
- 4.1 Preparation Notes
- 4.2 Seat
- 4.2.1 Seat Removal
- 4.2.2 Seat Installation
- 4.3 Body Covering Parts
- 4.3.1 Headlight LH&RH Guards
- 4.3.2 Windshield and Rearview Mirrors
- 4.3.3 Engine Panel
- 4.3.4 Headlight Upper Press Cover
- 4.3.5 Wings
- 4.3.6 Dashboard
- 4.3.7 Fuel Tank Upper Guard
- 4.3.8 Radiator Guard Assembly
- 4.3.9 Rear Panel
- 4.3.10 Vehicle Cover
- 4.3.11 Front Fender
- 4.4 Fuel Tank
- 4.4.1 Depressurizing Fuel Hose 
- 4.4.2 Fuel Tank Removal
- 4.4.3 Fuel System Inspection
- 4.4.3.1 EFI Fuel Filter
- 4.4.3.2 Fuel Pump
- 4.4.3.3 Fuel Level Sensor
- 4.4.4 Fuel Tank Installation
- 4.5 Cooling System
- 4.5.1 Coolant Drain
- 4.5.2 Radiator Removal
- 4.5.3 Radiator Inspection
- 4.5.3.1 Radiator Fin Inspection
- 4.5.3.2 Filler Cap Pressure Inspection
- 4.5.3.3 Fan Inspection
- 4.5.3.4 Coolant Inspection, Addition and Replacement
- 4.6 Muffler Assembly
- 4.6.1 Muffler Removal
- 4.6.2 Muffler Inspection
- 4.6.3 Oxygen Sensor
- 4.7 Wheels, Brakes and Shock Absorbers
- 4.7.1 Front Brake Caliper and Front Wheel Removal
- 4.7.2 Rear Brake Caliper and Rear Wheel Removal
- 4.7.3 LH&RH Foot Pedal Removal
- 4.7.4 Rear Shock Absorber and Rear Fork Removal
- 4.7.5 Chain Removal
- 4.7.5.1 Chain Repairs
- 4.7.5.2 Chain Tension Inspection
- 4.7.5.3 Chain Cleaning and Maintenance
- 4.7.6 Rear Wheel Inspection
- 4.7.7 Tire Pressure
- 4.7.8 Tire Surface
- 4.7.9 Wheel Bearing
- 4.7.10 Front Shock Absorber Removal
- 4.7.11 Brake Master Cylinders
- 4.7.11.1 Brake Fluid Inspection
- 4.7.11.2 Brake Fluid Replacement
- 4.7.12 Brake Line
- 4.7.13 Brake Caliper and Brake Disc Inspection
- 4.7.14 Brake Free Play
- 4.7.15 MAB Execution Unit

05 ELECTRICAL SYSTEM
- 5.1 Diagnostic Tools
- 5.2 Preparation Notes
- 5.3 Battery
- 5.4 Dashboard
- 5.5 Headlight
- 5.5.1 Headlight Removal
- 5.5.2 Headlight Adjustment
- 5.6 Left Handlebar Switch
- 5.7 Right Handlebar Switch
- 5.8 Ignition Switch
- 5.9 Starter Relay
- 5.10 T-BOX
- 5.11 Relay Seat and Fuse Box
- 5.12 Regulator
- 5.13 Flasher
- 5.14 ECU
- 5.15 Taillights
- 5.16 Horn
- 5.17 MSE 6.0 Fault Codes
- 5.18 Fault Diagnosis
- 5.19 Fault Diagnosis by Engine Problem 

06 SELECT ENGINE TOPICS
- 6.1 Air Filter
- 6.2 Throttle Valve
- 6.2.1 Throttle Valve Body Removal
- 6.2.2 Throttle Body Cleaning
- 6.2.3 Fuel Injector
- 6.2.4 Intake Temperature Pressure Sensor
- 6.2.5 Throttle Position Sensor
- 6.2.6 Stepping Motor
- 6.3 Water Temperature Sensor
- 6.4 Trigger
- 6.5 Ignition Coil
- 6.6 Clutch Cable
- 6.7 Engine Removal
- 6.8 Throttle Cable Free Play

07 ENGINE
- 7.1 Preparation Notes
- 7.1.1 Unit Conversion Table
- 7.1.2 Warnings
- 7.2 Maintenance Information
- 7.2.1 Engine Appearance
- 7.2.2 General Precautions
- 7.2.3 Selection of Fuel and Oil
- 7.2.4 Engine Break-In
- 7.2.5 Special Engine Maintenance Tools
- 7.3 Engine Disassembly
- 7.3.1 Stabilize the Engine
- 7.3.2 Drain Engine Oil
- 7.3.3 Starter Motor Removal
- 7.3.4 Thermostat Removal
- 7.3.5 Pump Removal
- 7.3.6 Cylinder Head Cover Removal
- 7.3.7 RH Cover Removal
- 7.3.8 Clutch Removal
- 7.3.9 Shift Lever and Positioning Components Removal
- 7.3.10 Oil Pump Removal
- 7.3.11 Cylinder Head Removal
- 7.3.12 Magneto and Double Gear Removal
- 7.3.13 Cylinder Body Removal
- 7.3.14 Piston Removal
- 7.3.15 Oil Pan Removal
- 7.3.16 Oil Cooler Removal
- 7.3.17 Compartment
- 7.4 Engine Inspection
- 7.4.1 Crankcase
- 7.4.1.1 Selecting Plain Bearing
- 7.4.1.2 Crankcase
- 7.4.1.3 RH Side Cover
- 7.4.2 Cylinder Head Cover Assembly
- 7.4.3 Cylinder Head Assembly
- 7.4.4 Cylinder Body
- 7.4.5 Piston / Piston Ring / Piston Pin
- 7.4.6 Distribution Drive
- 7.4.7 Crankshaft Connecting Rod
- 7.4.8 Clutch
- 7.4.9 Shift Gear
- 7.4.9.1 Main Shaft
- 7.4.9.2 Countershaft
- 7.4.9.3 Shift Fork
- 7.4.9.4 Shift Drum
- 7.4.9.5 Gearshift Lever Assembly
- 7.4.10 Lubrication System
- 7.4.10.1 Lubricating Chart
- 7.4.10.2 Oil Pump
- 7.4.10.3 Oil Pressure Relief Valve
- 7.4.10.4 Oil Cooler
- 7.4.11 Water Pump Assembly
- 7.4.12 Electric Starter
- 7.4.13 Magneto Stator
- 7.4.14 Rear Balance Shaft Assembly
- 7.5 Engine Assembly
- 7.5.1 Rear Balance Shaft Assembly Installation
- 7.5.2 Shift Drum, Position Cam, and Position Swing Arm Installation
- 7.5.3 Countershaft Installation
- 7.5.4 Fork Shaft and Gearshift Fork Installation
- 7.5.5 Main Shaft Installation
- 7.5.6 Gearshift Lever Installation
- 7.5.7 Crankshaft Connecting Rod and Front Balance Shaft Installation
- 7.5.8 Crankcase Closing
- 7.5.9 Oil Pump and Oil Pressure Switch Installation
- 7.5.10 Water Pump Installation
- 7.5.11 Oil Pan Installation
- 7.5.12 Oil Cooler Installation
- 7.5.13 Oil Filter Installation
- 7.5.14 Cylinder Body and Piston Installation
- 7.5.15 Timing Chain Installation
- 7.5.16 Cylinder Head Installation
- 7.5.17 Magneto Rotor Assembly Installation
- 7.5.18 LH Side Cover Installation
- 7.5.19 Intake and Exhaust Camshaft Installation
- 7.5.20 Hydraulic Tensioner Installation
- 7.5.21 Cylinder Head Cover Installation
- 7.5.22 Starter Motor Installation
- 7.5.23 Clutch Installation
- 7.5.24 RH Side Cover Installation
- 7.5.25 Gear Sensor Installation
- 7.5.26 Oil Cooler Water Inlet and Outlet Hose Installation
- 7.5.27 Throttle and Fuel Pipe Assembly Installation
- 7.5.28 Output Sprocket Installation
- 7.5.29 Oil Filling, Oil Level Inspection, and Oil Pressure Inspection

08 CLEANING AND STORAGE
- 8.1 Motorcycle Cleaning
- 8.2 Inspection and Maintenance in Winter 
- 8.3 Parking
- 8.4 Motorcycle Use After Storage