Cfmoto 675SS (2024+) - Workshop Repair Manual - Maintenance

CFMOTO 675SS (2024+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 675SS from 2024.
- Edition Item: CF650-10 (6GUH-00WX01-11) SM -20240630


CONTENTS:

01 SAFETY INFORMATION
- 1.1 About this Service Manual
- 1.2 Danger Levels and Symbols
- 1.3 General Precautions
- 1.4 Repair Precautions

02 GENERAL INFORMATION
- 2.1 Conversion Table
- 2.2 Number Engrave Place
- 2.3 Vehicle Specifications
- 2.4 Service Specification
- 2.5 Tighten Torque
- 2.5.1 Tighten Torque Table for Vehicle
- 2.5.2 Tighten Torque Table for Engine
- 2.6 Fuel, Oil and Coolant Recommendation
- 2.7 Service Offering Recommendation

03 MAINTENCE INFORMATION
- 3.1 Daily Maintenance Schedule
- 3.2 Maintenance Schedule During Break-in Period
- 3.3 Periodic Maintenance Schedule
- 3.4 Cylinder Compression and Leakdown Testing
- 3.4.1 Cylinder Compression Testing
- 3.4.2 Leakdown Testing
- 3.5 Throttle Control System Inspection

04 CLUTCH AND TRANSMISSION
- 4.1 Special Tool
- 4.2 Clutch System Description
- 4.3 How to Avoid Clutch Failure / Overheating and Diagnosis
- 4.4 Clutch Removal
- 4.5 Clutch-Inspection/Replacement
- 4.6 Clutch Installation
- 4.7 Transmission (Engine)
- 4.7.1 Exploded View
- 4.7.2 Transmission Overhaul
- 4.7.2.1 Main Shaft Assembly
- 4.7.2.2 Countershaft Assembly
- 4.7.2.3 Gearshift Fork Shaft and Fork
- 4.7.2.4 Shift Drum Assembly
- 4.7.2.5 Gearshift Positioning Swing Arm Sub Assembly
- 4.7.2.6 Gearshift Shaft Assembly
- 4.7.3 Gearshift Lever Assembly
- 4.7.3.1 Checking the Basic Position of Shift Lever
- 4.7.3.2 Adjusting the Basic Position of Shift Lever
- 4.7.3.3 Gearshift Lever Assembly Removal
- 4.7.3.4 Gearshift Lever Assembly Installation
- 4.8 Clutch Lever Clearance Inspection
- 4.9 Clutch Cable Free Play Adjustment

05 ENGINE
- 5.1 Engine Special Tool
- 5.2 Engine Removal
- 5.3 Engine Disassembly
- 5.3.1 Engine Oil Drain
- 5.3.2 Oil Cooler and Water Pipe Assembly Removal
- 5.3.3 Oil Filter Removal
- 5.3.4 Output Sprocket Assembly Removal
- 5.3.5 Ignition Coil and Spark Plug Removal
- 5.3.6 Cylinder Head Cover Removal
- 5.3.7 Camshaft and Cylinder Head Removal
- 5.3.8 Water Pump Assembly and LH Side Cover Removal
- 5.3.9 Magneto Rotor and Starter Gear Removal
- 5.3.10 Stater Motor Assembly Removal
- 5.3.11 RH Side Cover Removal
- 5.3.12 Timing Chain and Chain Plate Removal
- 5.3.13 Clutch Removal
- 5.3.14 Oil Pump Removal
- 5.3.15 Oil Pan Removal
- 5.3.16 Oil Pressure Switch Removal
- 5.3.17 Lower Crankcase Removal
- 5.3.18 Balance Shaft Assembly and Crankshaft Assembly Removal
- 5.3.19 Shift Assembly Removal
- 5.3.20 Piston and Connecting Rod Removal
- 5.3.21 Cylinder Removal
- 5.4 Engine Parts Inspection
- 5.4.1 Crankshaft Main Plain Bearing and Balance Shaft Plain Bearing Radial Clearance Inspection
- 5.4.2 Selecting Main Plain Bearing and Balance Shaft Plain Bearing
- 5.4.3 Main Plain Bearing and Balance Shaft Plain Bearing Replacement
- 5.4.4 Lower Crankcase Operation
- 5.4.5 Upper Crankcase Operation
- 5.4.6 Oil Pan Inspection
- 5.4.7 LH Side Cover Operation
- 5.4.8 RH Side Cover Operation
- 5.4.9 Cylinder Head Cover Operation
- 5.4.10 Cylinder Head Disassembly
- 5.4.11 Cylinder Head Inspection
- 5.4.12 Cylinder Head Installation
- 5.4.13 Cylinder Body Inspection/Measurement
- 5.4.14 Piston Inspection/Measurement
- 5.4.15 Timing Assembly Inspection
- 5.4.16 Crankshaft Assembly and Connecting Rod Assembly Inspection
- 5.4.17 Oil Pump Inspection
- 5.4.17.1 Oil Pump Cover/Oil Pressure Relief Valve
- 5.4.18 Electric Starting Drive Inspection
- 5.4.18.1 Overriding Clutch Assembly
- 5.4.19 Oil Cooler and Water Pipe Inspection
- 5.5 Engine Assembly
- 5.5.1 Cylinder Installation
- 5.5.2 Piston and Connecting Rod Installation
- 5.5.3 Gearshift Assembly Installation
- 5.5.4 Crankshaft Assembly and Balance Shaft Assembly Installation
- 5.5.5 Lower Crankcase Installation
- 5.5.6 Oil Pressure Switch Installation
- 5.5.7 Oil Pan Installation
- 5.5.8 Oil Pump Installation
- 5.5.9 Clutch Installation
- 5.5.10 Timing Chain and Chain Plate Installation
- 5.5.11 RH Side Cover Installation
- 5.5.12 Starter Motor Assembly Installation
- 5.5.13 Magneto Rotor Installation
- 5.5.14 LH Side Cover and Water Pump Assembly Installation
- 5.5.15 Cylinder Head and Camshaft Installation
- 5.5.16 Cylinder Head Cover Installation
- 5.5.17 Spark Plug and Ignition Coil Installation
- 5.5.18 Output Sprocket Assembly Installation
- 5.5.19 Oil Filter Installation
- 5.5.20 Oil Cooler and Water Pipe Assembly Installation
- 5.5.21 Drain Bolt Installation and Oil Filling
- 5.6 Engine Installation
- 5.7 Engine Cooling System
- 5.7.1 Water Pump Assembly
- 5.7.1.1 Removal
- 5.7.1.2 Inspection
- 5.7.1.3 Installation
- 5.7.2 Thermostat
- 5.7.3 Oil Cooler
- 5.8 Engine Lubrication System
- 5.8.1 Lubricating Chart
- 5.8.2 Engine Oil Level Inspection
- 5.8.3 Engine Oil Replacement
- 5.8.4 Engine Oil Pressure Inspection
- 5.9 Air Intake System
- 5.9.1 Air Filter Element Maintenance
- 5.9.2 Air Filter Housing Assembly
- 5.9.2.1 Removal
- 5.9.2.2 Inspection
- 5.9.2.3 Installation
- 5.9.3 Throttle Body Assembly
- 5.9.3.1 Throttle Body Assembly Removal
- 5.9.3.2 Throttle Body Assembly Disassembly
- 5.9.3.3 Throttle Body Assembly Inspection
- 5.9.3.4 Throttle Body Assembly Assembly
- 5.9.3.5 Throttle Body Assembly Installation
- 5.10 Exhaust System
- 5.10.1 Removal
- 5.10.2 Inspection
- 5.10.3 Installation

06 VEHICLE BODY AND FRAME
- 6.1 Preparation Before Maintenance
- 6.2 Seat
- 6.3 Rearview Mirrors
- 6.4 Front Plastics
- 6.4.1 Front Caliper LH/RH Ventilation Guard
- 6.4.2 Front Fender
- 6.4.3 Front Headlight LH/RH Deco Plate
- 6.4.4 Windshield
- 6.4.5 Engine LH Lower Guard
- 6.4.6 Vehicle LH Panel Assembly
- 6.4.6.1 Radiator LH Deco Plate Inner Plate
- 6.4.6.2 Vehicle Front LH Upper Deco Plate and Vehicle LH Wing
- 6.4.6.3 Radiator LH Deco Plate
- 6.4.7 Vehicle RH Panel Assembly
- 6.4.7.1 Radiator RH Windshield
- 6.4.7.2 Radiator RH Deco Plate Inner Plate
- 6.4.7.3 Vehicle Front RH Upper Deco Plate and Vehicle RH Wing
- 6.4.7.4 Radiator RH Deco Plate
- 6.4.8 Engine RH Lower Guard
- 6.5 Dashboard and Panels
- 6.5.1 Dashboard Mounting Plate
- 6.5.2 Dashboard
- 6.5.3 Dashboard Deco Plate
- 6.6 Middle Plastics
- 6.6.1 Fuel Tank Front LH Deco Plate
- 6.6.2 Fuel Tank Front RH Deco Plate
- 6.6.3 Fuel Tank Upper Guard
- 6.6.4 Small Sprocket Guard
- 6.6.5 Front LH Footrest Bracket
- 6.6.6 Rear LH Footrest Bracket Panel
- 6.6.7 Small Sprocket Deco Guard Mounting Bracket
- 6.6.8 Vehicle LH Middle Deco Plate
- 6.7 Headlight
- 6.8 Rear LH Footrest Bracket
- 6.9 Tail Plastic Parts Assembly
- 6.9.1 Rear Fork Panel
- 6.9.2 ECU Service Plate
- 6.9.3 Seat LH Lower Panel
- 6.9.4 Rear Tail Upper Deco Plate
- 6.9.5 Battery Box
- 6.9.6 Rear Fender and Taillight
- 6.9.7 Base Plate of Frame

07 POWERTRAIN SYSTEM
- 7.1 Maintenance Information
- 7.1.1 Operation Notice
- 7.1.2 Service Specification
- 7.1.3 Tighten Torque
- 7.2 Rear Wheel
- 7.2.1 Rear Wheel View
- 7.3 Front Wheel
- 7.3.1 Front Wheel Shaft Inspection
- 7.3.2 Front Wheel Rim Inspection
- 7.4 Chain and Sprocket Removal and Installation
- 7.4.1 Chain
- 7.4.2 Sprocket

08 BRAKE SYSTEM
- 8.1 Brake System View
- 8.2 Brake Noise Troubleshooting
- 8.3 Brake Caliper
- 8.3.1 Front Brake Caliper
- 8.3.2 Rear Brake Caliper and Rear Wheel
- 8.4 Brake Disc
- 8.4.1 Front Brake Disc
- 8.4.2 Rear Brake Disc
- 8.5 Brake Fluid
- 8.6 Handbrake Master Cylinder
- 8.7 Rear Brake Master Cylinder
- 8.8 ABS System Removal and Installation
- 8.9 Brake Hose and Pipe Inspections

09 SUSPENSION SYSTEM
- 9.1 Front Shock Absorber 
- 9.2 Rear Shock Absorber
- 9.3 Rear Fork
- 9.4 Steering Damper

10 STEERING SYSTEM
- 10.1 Explosed View
- 10.2 Triple Clamps Assembly Explosed View
- 10.3 Upper&Lower Triple Clamp Front Fork Pipes
- 10.4 Handlebar Service
- 10.4.1 Handlebar Interference Inspection

11 COOLING SYSTEM
- 11.1 Coolant Specification
- 11.2 Cooling System View
- 11.3 Cooling System Assembly Removal
- 11.4 Cooling Cycle Tightness Inspection
- 11.5 Radiator and Water Pipe Inspection and Cleaning
- 11.6 Fan Motor Inspection
- 11.7 Coolant Inspection
- 11.8 Coolant Addition
- 11.9 Coolant Replacement

12 ELECTRICAL SYSTEM
- 12.1 Service Tool
- 12.1.1 Diagnostic Port
- 12.2 Lights
- 12.2.1 Lights View
- 12.2.2 Headlight Inspection
- 12.2.3 Tail Light Inspection
- 12.2.4 Brake Light Inspection
- 12.2.5 Turn Light Inspection
- 12.3 Fuse and Relay
- 12.3.1 Fuse and Relay Position
- 12.4 Switch
- 12.4.1 Switch Position
- 12.4.2 Ignition Lock
- 12.4.3 Front Brake Light Switch
- 12.4.4 Clutch Switch
- 12.4.5 Fan Relay Path Inspection
- 12.4.5.1 Fan Relay Operation Inspection
- 12.4.6 Handlebar Switch
- 12.4.6.1 LH/RH Handlebar Switch
- 12.5 Handlebar Switch
- 12.5.1 LH Handlebar Switch Assembly 
- 12.5.2 RH Handlebar Switch Assembly
- 12.5.3 10.2.3Throttle Grip
- 12.6 Charging System/Battery
- 12.6.1 Charging System Position
- 12.6.2 Regulator
- 12.6.3 Charging Voltage Inspection
- 12.6.4 Battery storage/recycling
- 12.6.5 Stator Path Inspection
- 12.6.6 Stator GND Inspection
- 12.6.7 Regulator Path Inspection
- 12.6.8 Regulator Input Voltage Test
- 12.6.9 Battery Leakage Inspection
- 12.6.10 Battery Inspection
- 12.7 Horn
- 12.8 Starting System
- 12.8.1 Starting System Position
- 12.8.2 Starter Relay
- 12.8.2.1 Starter Relay Path Inspection
- 12.8.2.2 Starter Relay Operation Inspection
- 12.8.3 Starting Switch
- 12.8.3.1 Starting Switch Path Inspection
- 12.8.4 Starter Motor
- 12.8.4.1 Starter Motor Appearance Inspection
- 12.8.4.2 Starter Motor Working Inspection
- 12.9 Tipping Sensor
- 12.9.1 Tipping Sensor Inspection
- 12.10 T-BOX
- 12.10.1 T-BOX Pin Function
- 12.10.2 T-BOX Fault Code
- 12.11 Dashboard
- 12.11.1 Dashboard Pin Function
- 12.12 Anti-lock Braking System (ABS)
- 12.12.1 Anti-lock Braking System (ABS) Position
- 12.12.2 ABS Diagram
- 12.12.3 ABS Fault Code
- 12.12.4 ABS Troubleshooting
- 12.13 Front/Rear Wheel Speed Sensor
- 12.13.1 Front Wheel Speed Sensor
- 12.13.2 Rear Wheel Speed Sensor
- 12.14 BCM
- 12.14.1 BCM Pin Function

13 FUEL SYSTEM
- 13.1 Service Tool
- 13.1.1 Diagnostic Port
- 13.2 EFI System
- 13.2.1 EFI System Location
- 13.2.1.1 Sensors
- 13.2.1.2 ECU
- 13.2.1.3 Actuators
- 13.3 Fuel Tank
- 13.4 Fuel Pump Assembly
- 13.4.1 Fuel Pump Pressure Test
- 13.4.2 Fuel Level Sensor Detection
- 13.4.3 Fuel Pump Relay
- 13.4.3.1 Fuel Pump Relay Operation Test
- 13.5 ECU
- 13.5.1 ECU Pin Function
- 13.5.2 EFI Fault Code Table
- 13.6 Oxygen Sensor
- 13.7 Ignition Coil
- 13.7.2.1 Ignition Coil Peak Voltage Inspection
- 13.7.2.2 Ignition Coil Resistance Inspection
- 13.8 Injector
- 13.8.1 Injector Resistance Detection
- 13.8.2 Injector Input Voltage Detection
- 13.9 Throttle Body Assembly
- 13.9.1 Idle Stepper Motor
- 13.9.1.1 Idle Stepper Motor Troubleshooting
- 13.9.2 Air Intake Pressure/Temperature Sensor
- 13.9.2.1 Air Intake Pressure/Temperature Sensor Troubleshooting
- 13.9.3 TPS
- 13.9.3.1 TPS Troubleshooting
- 13.10 Water Temperature Sensor
- 13.11 Trigger
- 13.11.3.1 Trigger Peak Voltage Inspection
- 13.11.3.2 Trigger Resistance Inspection
- 13.12 EVAP System Work Guide
- 13.12.1 Two-way Valve Test
- 13.12.2 Canister Test
- 13.12.3 Canister Magnetic Valve Test
- 13.13 Normal Troubles
- 13.14 Trouble Diagnosis In Accordance With Engine Error