Cfmoto 700CL-X and Sport (2021+) - Workshop Repair Manual - Maintenance

CFMOTO 700CL-X / SPORT (2021+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 700CL-X and Sport from 2021.
- Edition Item: CF700-2 / CF700-2A (6GU#-WX-01) SM-20200424


CONTENTS:

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

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

3 TECHNICAL INFORMATION
- 3.1 General Specifications
- 3.2 Engine Specification Table
- 3.3 Maintenance Specifications
- 3.3.1 Front Wheel
- 3.3.2 Rear Wheel
- 3.3.3 Brake System
- 3.3.4 Lights, Dashboard and Switches
- 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

4 SEAT
- 4.1 Seat Removal (Heritage, Adventure)
- 4.2 Seat Installation (Heritage, Adventure)
- 4.3 Seat Removal (Sport)
- 4.4 Seat Installation (Sport)

5 BODY COVERING PARTS
- 5.1 LH&RH Side Guards (Sport)
- 5.2 LH&RH Panels (Sport)
- 5.3 LH&RH Panels (Heritage, Adventure)
- 5.4 Fuel Tank LH&RH Panel Assembly
- 5.5 Vehicle LH&RH Deco Covers
- 5.6 Canister Deco Cover
- 5.7 Reservoir Tank Cap
- 5.8 Sprocket Guard (Heritage, Adventure)
- 5.9 Sprocket Guard (Sport)
- 5.10 Radiator LH&RH Guard Assembly
- 5.11 Front Fender
- 5.12 LH&RH Side Guards (Heritage, Sport)
- 5.13 LH / RH guard (Adventure)
- 5.14 Dust-proof Cover
- 5.15 Vice Frame
- 5.16 Front Windshield

6 FUEL SYSTEM
- 6.1 Fuel Tank Removal
- 6.2 Electric Fuel Filter
- 6.3 Fuel Pump
- 6.4 Floating Ball

7 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
- 7.4 Turn Light
- 7.5 Tail Light/Brake Light
- 7.6 Dashboard
- 7.7 Ignition Switch
- 7.8 Front Brake Light Switch
- 7.9 LH Handlebar Switch
- 7.10 RH Handlebar Switch
- 7.11 Horn
- 7.12 Fuel Level Sensor
- 7.13 Battery
- 7.14 Vehicle T-BOX (status 1)
- 7.15 T-BOX (status 2 )
- 7.16 Ground Wire

8 ELECTICAL 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 Assembly
- 8.3.3.3 Air Intake Pressure Sensor
- 8.3.3.4 T-MAP
- 8.3.3.5 Water Temperature Sensor
- 8.3.3.6 Oxygen Sensor
- 8.3.3.7 Trigger
- 8.3.3.8 Fuel Pump
- 8.3.3.9 Fuel Injector
- 8.3.3.10 E-throttle
- 8.3.3.11 Ignition Coil
- 8.4 Start Engine Stop (Sport, Adventure)
- 8.5 Vehicle Controller
- 8.5.1 Fault Code
- 8.6 Fault Diagnosis and Treatment
- 8.7 Trouble Diagnosis by Engine Error

9 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
- 9.6 Fan Motor Inspection
- 9.7 Coolant Inspection
- 9.8 Coolant Addition
- 9.9 Coolant Replacement

10 MUFFLER ASSEMBLY
- 10.1 Muffler Removal (status 1 )
- 10.2 Muffler Inspection
- 10.3 Muffler Installation
- 10.4 Muffler Removal ( status 2 )
- 10.5 Muffler Inspection
- 10.6 Muffler Installation

11 WHEELS AND BRAKE SYSTEM
- 11.1 Front Wheel
- 11.2 Rear Wheel
- 11.3 Front Brake Caliper (Heritage, Adventure)
- 11.4 Front Brake Caliper (Sport)
- 11.5 ABS Brake System Assembly
- 11.5.1 ECU
- 11.5.2 Air Filter Assembly
- 11.5.3 MAB Execution Unit
- 11.5.4 RH Footrest Bracket and Rear Brake Master Cylinder Assembly
- 11.5.4.1 Rear Brake Reservoir (Heritage,Adventure)
- 11.5.4.2 Rear Brake Reservoir(Sport)
- 11.5.4.3 RH Footrest Bracket
- 11.5.4.4 Rear Brake Master Cylinder Assembly
- 11.5.5 Rear Brake Caliper Assembly
- 11.5.6 Front Brake Master Cylinder Assembly(Heritage,Adventure)
- 11.5.7 Front Brake Master Cylinder Assembly(Sport)
- 11.5.8 Front LH Brake Caliper Assembly
- 11.6 LH Footrest Bracket
- 11.7 Wheel Inspection
- 11.7.1 Front Wheel (Heritage)
- 11.7.2 Front Wheel (Adventure)
- 11.7.4 Rear Wheel
- 11.7.5 Tire Pressure
- 11.7.6 Tire Appearance
- 11.7.7 Wheel Bearing
- 11.7.8 Rim
- 11.8 Brake System Inspection
- 11.8.1 Hand Master Cylinder Inspection
- 11.8.2 Rear Master Cylinder Inspection (Heritage, Adventure)
- 11.8.3 Rear Master Cylinder Inspection (Sport)
- 11.8.4 Brake Hose Inspection
- 11.8.5 Brake Calipers and Brake discs Inspection
- 11.9 Free Play
- 11.9.1 Front Brake Lever Free Play
- 11.9.2 Rear Brake Pedal Free Play

12 SHOCK ABSORBERS AND REAR FORK
- 12.1 Handlebar (Heritage, Adventure)
- 12.2 Handlebar (Sport)
- 12.3 Front Shock Absorbers
- 12.4 Chain
- 12.5 Rear Fork
- 12.6 Chain Inspection
- 12.6.1 Chain Looseness Adjustment
- 12.7 Front Shock Absorber 
- 12.8 Rear Shock Absorber

13 ENGINE
- 13.1 Special Tools
- 13.2 Engine Removal
- 13.3 Engine Air Intake System
- 13.3.1 Air Filter Assembly
- 13.3.2 Throttle Valve Assembly
- 13.4 Engine Disassembly
- 13.4.1 Engine Oil Drain
- 13.4.2 Output Sprocket Assembly Removal
- 13.4.3 Oil Filter Removal
- 13.4.4 Ignition Coil and Spark Plug Removal
- 13.4.5 Cylinder Head Cover Removal
- 13.4.6 Camshaft and Cylinder Head Removal
- 13.4.7 LH Side Cover Removal
- 13.4.8 Magneto Rotor and Starter Gear Removal
- 13.4.9 Stater Motor Assembly Removal
- 13.4.10 RH Side Cover Removal
- 13.4.11 Clutch Removal
- 13.4.12 Crankshaft Pulsing Rotor Removal
- 13.4.13 Tensioner Plate Removal
- 13.4.14 Cylinder Body and Piston Removal
- 13.4.15 Water Pump Removal
- 13.4.16 Transmission Assembly Removal
- 13.4.17 Oil Pump Assembly Removal
- 13.4.18 Oil Pan Removal
- 13.4.19 Lower Crankcase Removal
- 13.4.20 Balance Shaft Assembly and Crankshaft Assembly Removal
- 13.5 Engine Parts Inspection
- 13.5.1 Crankshaft Main Plain Bearing and Balance Shaft Plain Bearing Radial Clearance Inspection
- 13.5.2 Selecting Main Plain Bearing and Balance Shaft Plain Bearing
- 13.5.3 Main Plain Bearing and Balance Shaft Plain Bearing Replacement
- 13.5.4 Upper Crankcase Operation
- 13.5.5 Lower Crankcase Operation
- 13.5.6 Oil Pan Operation
- 13.5.7 LH Side Cover Operation
- 13.5.8 RH Side Cover Operation
- 13.5.9 Cylinder Head Cover Operation
- 13.5.10 Cylinder Head Disassembly
- 13.5.11 Cylinder Head Inspection
- 13.5.12 Cylinder Head Assembly
- 13.5.13 Cylinder Body Inspection/Measurement
- 13.5.14 Piston Inspection/Measurement
- 13.5.15 Timing Assembly Inspection
- 13.5.16 Crankshaft Connecting Rod Assembly Inspection
- 13.5.17 Oil Pump Inspection
- 13.5.18 Electric Starting Drive Inspection
- 13.5.18.1 Overriding Clutch Assembly
- 13.5.19 Clutch Inspection
- 13.5.20 Transmission Inspection 
- 13.5.20.1 Transmission Disassembly
- 13.5.20.2 Main Shaft Assembly
- 13.5.20.3 Countershaft Assembly
- 13.5.20.4 Gearshift Fork Shaft and Fork
- 13.5.20.5 Gearshift Drum and Gearshift Drum CAM
- 13.5.20.6 Gearshift Positioning Swing Arm Sub Assembly
- 13.5.20.7 Gearshift Cover
- 13.5.20.8 Gearshift Assembly Inspection
- 13.5.20.9 Transmission Assembly 
- 13.5.21 Water Pump Assembly Inspection
- 13.6 Engine Assembly
- 13.6.1 Crankshaft Assembly and Balance Shaft Assembly Installation
- 13.6.2 Lower Crankcase Installation
- 13.6.3 Oil Pan Installation
- 13.6.4 Oil Pump Assembly Installation
- 13.6.5 Transmission Assembly Installation
- 13.6.6 Water Pump Installation
- 13.6.7 Cylinder Body and Piston Installation
- 13.6.8 Tension Plate Installation
- 13.6.9 Crankshaft Pulsing Rotor Installation
- 13.6.10 Clutch Installation
- 13.6.11 Cylinder Head and Camshaft Installation
- 13.6.12 RH Side Cover Installation
- 13.6.13 Valve Clearance Inspection
- 13.6.14 Starter Motor Assembly Installation
- 13.6.15 Magneto Rotor and Starting Gear Installation
- 13.6.16 LH Side Cover Installation
- 13.6.17 Cylinder Head Cover Installation
- 13.6.18 Spark Plug and Ignition Coil Installation
- 13.6.19 Oil Filter Installation
- 13.6.20 Output Sprocket Assembly Installation
- 13.6.21 Drain Bolt Installation and Oil Filling
- 13.7 Engine Installation
- 13.8 Engine Lubrication System
- 13.8.1 Engine Oil Level Inspection
- 13.8.2 Engine Oil Replacement
- 13.8.3 Engine Oil Pressure Inspection

14 HANDLEBAR AND TRIPLE CLAMPS
- 14.1 Special Tools
- 14.2 Handlebar Switch (Heritage, Adventure)
- 14.2.1 LH Handlebar Switch
- 14.2.2 RH Handlebar Switch
- 14.3 Handlebar Switch (Sport)
- 14.3.1 LH Handlebar Switch
- 14.3.2 RH Handlebar Switch
- 14.4 Throttle Grip
- 14.5 Handlebar Inspection
- 14.5.1 Clutch Lever Free Play Inspection
- 14.5.2 Clutch Cable Free Play Adjustment
- 14.5.3 Handlebar Interference Inspection
- 14.6 Triple Clamps and Front Forks

15 CLEAN AND CONSERVATION
- 15.1 Motorcycle Clean
- 15.2 Inspection and Maintenance in Winter 

16 STORGE
- 16.1 Parking
- 16.2 Motorcycle Use after Storage