Cfmoto 650NK (2023+) - Workshop Repair Manual - Maintenance

CFMOTO 650NK (2023+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 650NK from 2023.
- Edition Item: 400NK 650NK(6NQV-00WX02-B000)SM-20230208


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 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 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 Lighting, 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
-3.5.2 Tighten Torque Table for Engine
-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

05 BODY COVERING PARTS
-5.1 LH&RH Panel
-5.2 LH&RH Middle Panel
-5.3 Fuel Tank Panel
-5.4 Fuel Tank Front Panel
-5.5 LH&RH Rear Deco Plate
-5.6 LH&RH Engine Lower Panel
-5.7 Front Fender
-5.8 Rear Fender

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 Trouble Shooting
-7.3 Headlight
-7.3.1 Headlight Removal(CF400-B)
-7.3.2 Dashboard (CF400-B)
-7.4 Headlight
-7.4.1 Headlight Removal(CF650-7C)
-7.4.2 Dashboard (CF650-7C)
-7.5 Tail Light/Brake Light
-7.6 Rear License Light
-7.7 Ignition Switch
-7.8 Front Brake Light Switch
-7.9 Rear Brake Switch
-7.10 LH Handlebar Switch
-7.11 RH Handlebar Switch
-7.13 Instrument Switches(2022)
-7.12 Instrument
-7.12.1 400-B 650-7C 400-BF 650-7F
-7.13.1 400-BF 650-7F (2022)
-7.14 Horn
-7.15 Fuel Level Sensor
-7.16 Battery
-7.17 Vehicle Telematics (CN4)
-7.18 Ground Wire

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 Body
-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 Speed Sensor
-8.3.3.8 Fuel Pump
-8.3.3.9 Fuel Injector
-8.3.3.10 Idle stepping motor
-8.3.3.11 Ignition coil
-8.3.3.12 Roll-over Sensor
-8.3.4 Self-diagnosis
-8.3.4.1 Malfunction Indicating Lamp (MIL)
-8.3.4.2 PDA
-8.3.5 Fault Code
-8.4 Fault Diagnosis and Treatment
-8.5 Trouble Diagnosis In Accordance With 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 Inspection and Clean
-9.6 Fan Motor Inspection

10 MUFFLER
-10.1 LH Footrest
-10.2 RH Footrest
-10.3 Muffler
-10.3.1 Removal
-10.3.2 Inspection
-10.3.3 Installation

11 WHEELS AND BRAKE SYSTEM
-11.1 Front Wheel
-11.2 Rear Wheel
-11.3 Front Brake Caliper
-11.4 Rear Brake Caliper
-11.5 Rear Brake Master Cylinder
-11.6 Rear View Mirrors
-11.7 Hand Brake Master Cylinder Assy
-11.8 MAB Actuator
-11.9 Wheel Inspection
-11.9.1 Sprocket Seat
-11.9.2 Tire Pressure
-11.9.3 Tire Appearance
-11.9.4 Wheel Bearing
-11.9.5 Rim
-11.10 Brake System Inspection
-11.10.1 Hand Master Cylinder Inspection
-11.10.2 Brake Caliper and Brake disc Inspection
-11.10.3 Rear Master Cylinder Inspection
-11.10.4 Brake Hose Inspection
-11.11 Free Play
-11.11.1 Front Brake Lever Free Play
-11.11.2 Rear Brake Pedal Free Play

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

13 ENGINE ASSY (CF400-5)
-13.1 Engine Special Tool
-13.2 Engine Removal
-13.2.1 Engine Inlet&Outlet Water Pipe Removal 
-13.2.2 Air Filter Loose
-13.2.3 Clutch Cable Removal
-13.2.4 Gearshift Lever Assy Removal
-13.2.5 Sprocket Removal
-13.2.6 Engine Assy Removal
-13.3 Engine Air Intake System
-13.3.1 Throttle Valve Assy Disassembly
-13.3.2 Throttle Valve Assy Inspection
-13.3.2.1 Throttle Valve Body
-13.3.2.2 Fuel Rail Assy
-13.3.2.3 Air Intake Pipe 
-13.3.3 Throttle Valve Assy Assembly
-13.4 Engine Disassembly
-13.4.1 Engine Oil Drain
-13.4.2 Starter Motor Removal
-13.4.3 Magneto Rotor Removal
-13.4.4 Ignition Coil and Spark Plug Removal
-13.4.5 Cylinder Head Cover Removal
-13.4.6 Tensioner Removal
-13.4.7 Camshaft Removal 
-13.4.8 Cylinder Head Removal
-13.4.9 RH Side Cover Removal
-13.4.10 Clutch Removal
-13.4.11 Crankshaft Pulsing Rotor Removal
-13.4.12 Cylinder Body Removal
-13.4.13 Piston Removal
-13.4.14 Tensioner Plate Removal
-13.4.15 Water Pump Removal
-13.4.16 Gearshift Assy Removal
-13.4.17 Oil Pipe IV Removal
-13.4.18 Transmission Assy Removal
-13.4.19 Oil Pump Assy Removal 
-13.4.20 Oil Filter Removal
-13.4.21 Oil Pan Assy Removal
-13.4.22 Engine Case Removal
-13.4.23 Timing Chain Removal
-13.4.24 Crankshaft and Balance Shaft Removal
-13.5 Engine Parts Inspection
-13.5.1 Cylinder Head Cover Inspection
-13.5.2 Cylinder Head Inspection
-13.5.3 Camshaft Cover Inspection
-13.5.4 Camshaft Assy Inspection
-13.5.5 Cylinder Head Assy Inspection
-13.5.6 Valve Guide Pipe Removal 
-13.5.7 Cylinder Head Wear 
-13.5.8 Timing Tensioner Inspection 
-13.5.9 Cylinder Body Inspection
-13.5.10 Piston Assy Inspection 
-13.5.11 Camshaft Connecting Rod Assy Inspection
-13.5.12 Balance Shaft/Plain Bearing Wear 
-13.5.13 Overriding Clutch Inspection
-13.5.14 Magneto Rotor Inspection
-13.5.15 Starter Driven Gear, Dual Gear and Shaft Inspection
-13.5.16 Magneto Stater
-13.5.17 Clutch Assy Inspection
-13.5.18 Transmission Case Inspection
-13.5.19 Gearshift Assy Inspection
-13.5.20 Gearshift Cover Inspection
-13.5.21 Water Pump Assy Inspection 
-13.5.22 Crankcase Inspection 
-13.6 Engine Assembly 
-13.6.1 Crankshaft and Balance Shaft Installation
-13.6.2 Timing Chain Installation 
-13.6.3 Crankcase Installation
-13.6.4 Oil Pan Assy Installation
-13.6.5 Oil Filter Installation
-13.6.6 13.6.6 Oil Pump Installation
-13.6.7 Transmission Case Installation 
-13.6.8 Oil Pipe IV Assy Installation
-13.6.9 Gearshift Assy Installation 
-13.6.10 Water Pump Installation
-13.6.11 Tensioner Plate Installation
-13.6.12 Piston Installation 
-13.6.13 Crankshaft Pulsing Rotor Installation
-13.6.14 Cylinder Body Installation
-13.6.15 Clutch Assy Installation
-13.6.16 Cylinder Head Installation 
-13.6.17 Camshaft Installation
-13.6.18 Tensioner Installation
-13.6.19 RH Side Cover Installation
-13.6.20 Cylinder Head Cover Installation 
-13.6.21 Magneto Rotor Installation
-13.6.22 Starter Motor Installation
-13.6.23 Drain Bolt Installation
-13.7 Lubrication System
-13.7.1 Engine Oil Inspection
-13.7.2 Engine Oil Change
-13.7.3 Relief Valve 
-13.7.4 Engine Oil Pump
-13.7.5 Oil Pressure Measurement
-13.7.6 Oil Pressure Warning Switch
-13.8 Engine Installation
-13.8.1 Engine Installation
-13.8.2 Output Sprocket Installation
-13.8.3 Gearshift Lever Assy Installation 
-13.8.4 Clutch Cable Installation 
-13.8.5 Air Filter Connection
-13.8.6 Inlet/Outlet Pipe Installation
-13.9 External gear display

14 ENGINE ASSY (CF650-7)
-14.1 Engine Special Tool 
-14.2 Engine Removal
-14.2.1 Engine Inlet&Outlet Water Pipe Removal 
-14.2.2 Air Filter Loose
-14.2.3 Clutch Cable Removal
-14.2.4 Gearshift Lever Assy Removal
-14.2.5 14.2.5 Sprocket Removal
-14.2.6 Engine Assy Removal
-14.3 Engine Air Intake System
-14.3.1 Throttle Valve Assy Disassembly
-14.3.2 Throttle Valve Assy Inspection
-14.3.2.1 Throttle Valve Body
-14.3.2.2 Fuel Rail Assy
-14.3.2.3 Air Intake Pipe
-14.3.3 Throttle Valve Assy Assembly
-14.4 Engine Disassembly
-14.4.1 Engine Oil Drain
-14.4.2 Starter Motor Removal
-14.4.3 Magneto Rotor Removal
-14.4.4 Ignition Coil and Spark Plug Removal
-14.4.5 Cylinder Head Cover Removal
-14.4.6 Tensioner Removal
-14.4.7 Camshaft Removal 
-14.4.8 Cylinder Head Removal
-14.4.9 RH Side Cover Removal
-14.4.10 Clutch Removal
-14.4.11 Crankshaft Pulsing Rotor Removal
-14.4.12 Cylinder Body Removal
-14.4.13 Piston Removal
-14.4.14 Tensioner Plate Removal
-14.4.15 Water Pump Removal
-14.4.16 Gearshift Assy Removal
-14.4.17 Oil Pipe IV Removal
-14.4.18 Transmission Assy Removal
-14.4.19 Oil Pump Assy Removal 
-14.4.20 Oil Filter Removal
-14.4.21 Oil Pan Assy Removal
-14.4.22 Engine Case Removal
-14.4.23 Timing Chain Removal
-14.4.24 Crankshaft and Balance Shaft Removal
-14.5 Engine Parts Inspection
-14.5.1 Cylinder Head Cover Inspection
-14.5.2 Cylinder Head Inspection
-14.5.3 Camshaft Cover Inspection
-14.5.4 Camshaft Assy Inspection
-14.5.5 Cylinder Head Assy Inspection
-14.5.6 Valve Guide Pipe Removal
-14.5.7 Cylinder Head Wear
-14.5.8 Timing Tensioner Inspection
-14.5.9 Cylinder Body Inspection
-14.5.10 Piston Assy Inspection
-14.5.11 Camshaft Connecting Rod Assy Inspection
-14.5.12 Balance Shaft/Plain Bearing Wear
-14.5.13 Balance Shaft/Plain Bearing Wear
-14.5.14 Overriding Clutch Inspection
-14.5.15 Magneto Rotor Inspection
-14.5.16 Starter Driven Gear, Dual Gear and Shaft Inspection
-14.5.17 Magneto Stater
-14.5.18 Clutch Assy Inspection
-14.5.19 Transmission Case Inspection
-14.5.20 Gearshift Assy Inspection
-14.5.21 Gearshift Cover Inspection
-14.5.22 Water Pump Assy Inspection
-14.5.23 Crankcase Inspection
-14.6 Engine Assembly 
-14.6.1 Crankshaft and Balance Shaft Installation
-14.6.2 Timing Chain Installation 
-14.6.3 Crankcase Installation
-14.6.4 Oil Pan Assy Installation
-14.6.5 Oil Filter Installation
-14.6.6 Oil Pump Installation
-14.6.7 Transmission Case Installation
-14.6.8 Oil Pipe IV Assy Installation
-14.6.9 Gearshift Assy Installation
-14.6.10 Water Pump Installation
-14.6.11 Tensioner Plate Installation
-14.6.12 Piston Installation 
-14.6.13 Crankshaft Pulsing Rotor Installation
-14.6.14 Cylinder Body Installation
-14.6.15 Clutch Assy Installation
-14.6.16 Cylinder Head Installation
-14.6.17 Camshaft Installation
-14.6.18 Tensioner Installation
-14.6.19 RH Side Cover Installation
-14.6.20 Cylinder Head Cover Installation 
-14.6.21 Magneto Rotor Installation
-14.6.22 Starter Motor Installation
-14.6.23 Drain Bolt Installation
-14.7 Lubrication System
-14.7.1 Engine Oil Inspection
-14.7.2 Engine Oil Change
-14.7.3 Relief Valve 
-14.7.4 Engine Oil Pump
-14.7.5 Oil Pressure Measurement
-14.7.6 Oil Pressure Warning Switch
-14.8 Engine Installation
-14.8.1 Engine Installation
-14.8.2 Output Sprocket Installation
-14.8.3 Gearshift Lever Assy Installation
-14.8.4 Clutch Cable Installation
-14.8.5 Air Filter Connection
-14.8.6 Inlet/Outlet Pipe Installation
-14.9 External gear display

15.1 SPECIAL TOOLS

15.2 RH HANDLEBAR SWITCH

15.3 LH CLUTCH LEVER

15.4 LH HANDLEBAR SWITCH

15.5 HANDLEBAR 

15.6 INSTALLATION

15.7 HANDLEBAR INSPECTION
-15.7.1 Throttle Cable Free Play 
-15.7.2 Clutch Lever Free Play Inspection

15.8 HANDLEBAR INTERFERENCE INSPECTION

15.9 TRIPLE CLAMPS AND FRONT FORK