Cfmoto 800NK (2023+) - Workshop Repair Manual - Maintenance

CFMOTO 800NK (2023+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 800NK from 2023.
- Edition Item：800NK(6KWV-00WX01-2000)SM-20230403


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 Daily Maintenance Schedule
- 2.2 Break-in Maintenance Schedule
- 2.3 Periodic Maintenance Schedule

3 TECHNICAL INFORMATION
- 3.1 Main Parameters of the Vehicle
- 3.2 Main Parameters of Engine
- 3.3 Maintenance Parameter Table
- 3.3.1 Front Wheel
- 3.3.2 Rear Wheel
- 3.3.3 Brake System
- 3.3.4 Light, Dashboard and Switch
- 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
- 3.5 Running Materials & Assembling Materials
- 3.5.1 Vehicle Running Materials
- 3.5.2 Engine Running Materials & Assembling Materials

04 SEAT
- 4.1 Seat Removal
- 4.2 Seat Installation

05 BODY COVERING PARTS
- 5.1 Front Fender Assembly
- 5.1.1 Front Fender Deco Plate
- 5.2 Dashboard Lower Deco Guard (status 1)
- 5.2.1 Dashboard Lower Deco Guard (status 2)
- 5.3 Auxiliary Indicator Deco Guard (if equipped)
- 5.3.1 LH Auxiliary Indicator Deco Guard
- 5.4 Dashboard Assembly (status 1)
- 5.4.1 Dashboard Assembly Disassembly
- 5.5 Dashboard Assembly (status 2)
- 5.5.1 Dashboard Assembly Disassembly
- 5.6 Headlight Assembly
- 5.6.1 Headlight Assembly Disassembly
- 5.7 Radiator Deco Plate and Vehicle Front Deco Plate Assembly
- 5.7.1 Radiator LH Deco Plate and Vehicle LH Front Deco Plate Assembly
- 5.7.2 Radiator LH Deco Plate and Vehicle LH Front Deco Plate Assembly Disassembly
- 5.7.3 Radiator RH Deco Plate and Vehicle RH Front Deco Plate Assembly
- 5.7.4 Radiator RH Deco Plate and Vehicle RH Front Deco Plate Assembly Disassembly
- 5.8 LH/RH Rear Footrest Bracket
- 5.9 Vehicle LH/RH Lower Deco Plate
- 5.10 Rear Seat Front Deco Plate
- 5.11 Rear Seat Rear Deco Plate
- 5.12 Vehicle Rear Deco Plate
- 5.12.1 Vehicle LH Rear Deco Plate
- 5.12.2 Vehicle RH Rear Deco Plate
- 5.13 Tail Light Assembly
- 5.13.1 Tail Light Assembly Disassembly
- 5.14 Fuel Tank Deco Plate Assembly
- 5.14.1 Fuel Tank LH Front Deco Plate
- 5.14.2 Ignition Lock Deco Guard (state 1)
- 5.14.3 Ignition Lock Deco Guard (state 2)
- 5.14.4 Fuel Tank Lock Assembly
- 5.14.5 Fuel Tank Deco Plate Assembly Removal
- 5.14.6 Fuel Tank Deco Plate Assembly Disassembly
- 5.14.6.1 Fuel Tank LH+RH Deco Plate Assembly DIsassembly
- 5.15 Rear Fender Assembly
- 5.15.1 Rear Fender Assembly Disassembly(state 1)
- 5.15.1.1 Rear Reflector Assembly
- 5.15.1.2 Rear Fender Bracket
- 5.15.1.3 Rear Fender Inner Plate
- 5.15.1.4 LH and RH Rear Turn Light
- 5.15.1.5 Rear Reflector and License Light
- 5.15.1.6 Rear Fender and License Light
- 5.15.2 Rear Fender Assembly Disassembly(state 2)
- 5.15.2.1 Rear Fender Bracket
- 5.15.2.2 Rear Fender Inner Plate
- 5.15.2.3 LH and RH Rear Turn Light
- 5.15.2.4 Rear Reflector and License Light
- 5.15.2.5 Rear Fender and License Light
- 5.16 Rear Fork Panel
- 5.17 Battery Bracket
- 5.18 Rear Vehicle Base Panel

06 FUEL SYSTEM
- 6.1 Fuel Tank Removal
- 6.2 Fuel Evaporation System
- 6.3 Fuel Pump
- 6.4 Float Ball

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 Key Base Station
- 7.5 Front Brake Light Switch
- 7.6 Handlebar Switch
- 7.6.1 LH Handlebar Switch (state 1)
- 7.6.2 RH Handlebar Switch (state 1)
- 7.6.3 LH Handlebar Switch (state 2)
- 7.6.4 RH Handlebar Switch (state 2)
- 7.7 Fuel Level Sensor
- 7.8 Battery
- 7.9 Ground Wire
- 7.10 T-BOX
- 7.11 Horn
- 7.12 BCM

8 ELECTRICAL SYSTEM
- 8.1 Diagnostic Tools
- 8.2 Charging System
- 8.2.1 Magneto Coil Resistance
- 8.2.2 Magneto Non-loaded Performance
- 8.2.3 Starter Relay
- 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 Body Assembly
- 8.3.3.3 Air Intake Pressure Sensor
- 8.3.3.4 Air Intake Temperature Sensor
- 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
- 8.3.4 UP6.0 Fault Code
- 8.4 Fault Diagnosis
- 8.5 Fault Diagnosis by Engine Error

9 COOLING SYSTEM
- 9.2 Cooling System Assembly Removal
- 9.3 Engine Coolant
- 9.4 Inspection of Cooling Cycle Sealing
- 9.5 Radiator and Water Pipe Inspection and Cleaning
- 9.6 Fan Motor Inspection
- 9.7 Coolant Inspection
- 9.8 Coolant Addition
- 9.9 Coolant Replacement

10 EXHAUST SYSTEM
- 10.1 Muffler Disassembly
- 10.1.1 Exhaust Pipe
- 10.1.2 Rear Muffler Body
- 10.2 Exhauste Pipe Inspection

11 WHEELS AND BRAKE SYSTEM
- 11.1 Front Brake Caliper
- 11.2 Front Wheel
- 11.3 Rear Wheel
- 11.4 Rear Brake Caliper
- 11.5 Brake Master Cylinder
- 11.6 ABS Execution Unit
- 11.7 Hand Brake Master Cylinder Assembly
- 11.8 Wheel Inspection
- 11.8.1 Tire Pressure
- 11.8.2 Tire Appearance
- 11.8.3 Wheel Bearing
- 11.9 Brake System Inspection
- 11.9.1 Hand Master Cylinder Inspection
- 11.9.2 Rear Brake Master Cylinder Inspection
- 11.9.3 Brake Hose Inspection
- 11.9.4 Brake Caliper and Brake disc Inspection
- 11.10 Free Play
- 11.10.1 Front Brake Lever Free Play
- 11.10.2 Rear Brake Pedal Free Play

12 SHOCK ABSORBERS AND REAR FORK
- 12.1 Handlebar
- 12.2 LH+RH Front Shock Absorber
- 12.3 Chain
- 12.4 Rear Fork Assembly
- 12.5 Drive Chain Inspection
- 12.5.1 Chain Tightness Adjustment
- 12.6 Front Shock Absorber Inspection
- 12.7 Rear Shock Absorber Inspection

13 ENGINE
- 13.1 Special Tools
- 13.2 Removing the Engine
- 13.3 Engine Installation
- 13.4 Engine Air Intake System
- 13.4.1 Air Filter Assembly
- 13.4.2 Throttle Body Assembly
- 13.5 Engine Disassembly
- 13.5.1 Draining the Engine Oil
- 13.5.2 Removing the Oil Filter
- 13.5.3 Removing the Starter Motor
- 13.5.4 Removing the Valve Cover
- 13.5.5 Removing Shift Shaft Sensor
- 13.5.6 Removing the Gear Position Sensor
- 13.5.7 Removing the Spacer
- 13.5.8 Removing the Alternator Cover
- 13.5.9 Removing the Torque Limiter and Starter Intermediate Gear
- 13.5.10 Removing the Ignition Pulse Generator
- 13.5.11 Removing the Heat Exchanger
- 13.5.12 Removing the Thermostat
- 13.5.13 Removing the Water Pump Impeller
- 13.5.14 Removing the Clutch Cover
- 13.5.15 Removing the Clutch Discs
- 13.5.16 Removing the Clutch Basket
- 13.5.17 Removing the Locking Lever
- 13.5.18 Removing the Shift Shaft
- 13.5.19 Removing the Spark Plugs
- 13.5.20 Removing the Camshafts
- 13.5.21 Removing the Cylinder Head
- 13.5.22 Removing the Timing Chain Rails
- 13.5.23 Removing the Rotor
- 13.5.24 Removing the Oil Pan
- 13.5.25 Removing the Oil Pump Unit
- 13.5.26 Removing the Engine Case Downwards
- 13.5.27 Removing the Transmission Shafts
- 13.5.28 Removing the Oil Spray Tube
- 13.5.29 Removing the Piston
- 13.6 Working on Individual Parts
- 13.6.1 Checking the Radial Clearance of Crankshaft Bearings
- 13.6.2 Changing the Main Bearing Shells
- 13.6.3 Checking the Balancer Shaft
- 13.6.4 Working on the Upper Section of the Engine Case
- 13.6.5 Working on the Lower Section of the Engine Case
- 13.6.6 Selecting the Main Bearing Shells
- 13.6.7 Installing the Primary Gear Wheel
- 13.6.8 Radial Shaft Seal Ring of Water Pump, Changing
- 13.6.9 Checking the Radial Clearance of Lower Conrod Bearing
- 13.6.10 Changing the Conrod Bearing
- 13.6.11 Checking/Measuring the Cylinder
- 13.6.12 Checking/Measuring the Piston
- 13.6.13 Checking the Piston Ring End Gap
- 13.6.14 Determining the Piston/Cylinder Mounting Clearance
- 13.6.15 Removing the Oil Pumps
- 13.6.16 Checking the Oil Pumps for Wear
- 13.6.17 Checking the Oil Pressure Control Valve
- 13.6.18 Installing the Oil Pumps
- 13.6.19 Preparing Timing Chain Tensioner for Installation
- 13.6.20 Checking the Timing Assembly
- 13.6.21 Working on the Camshaft Bearing Bridge
- 13.6.22 Working on the Cylinder Head
- 13.6.23 Checking the Cylinder Head
- 13.6.24 Checking the Clutch
- 13.6.25 Removing the Shift Drum Locating Unit
- 13.6.26 Checking the Shift Mechanism
- 13.6.27 Preassembling the Shift Shaft
- 13.6.28 Installing the shift drum locating unit
- 13.6.29 Disassembling the Main Shaft
- 13.6.30 Disassembling the Countershaft
- 13.6.31 Checking the Transmission
- 13.6.32 Assembling the Main Shaft
- 13.6.33 Assembling the Countershaft
- 13.6.34 Checking the Electric Starter Drive
- 13.6.35 Checking the Freewheel
- 13.6.36 Working on the Alternator Cover
- 13.7 Engine Assembly
- 13.7.1 Installing the Piston
- 13.7.2 Installing the Oil Spray Tube
- 13.7.3 Installing the Transmission Shafts
- 13.7.4 Installing the Lower Engine Case
- 13.7.5 Installing the Oil Pump Unit
- 13.7.6 Installing the Oil Pan
- 13.7.7 Installing the Rotor
- 13.7.8 Installing the Timing Chain Rails
- 13.7.9 Installing the Cylinder Head
- 13.7.10 Installing the Camshafts
- 13.7.11 Checking the Valve Clearance
- 13.7.12 Adjusting the Valve Clearance and Cleaning the Oil Screen
- 13.7.13 Installing the Spark Plugs
- 13.7.14 Installing the Shift Shaft
- 13.7.15 Installing the Locking Lever
- 13.7.16 Installing the Clutch Basket
- 13.7.17 Installing the Clutch Discs
- 13.7.18 Installing the Clutch Cover
- 13.7.19 Mounting the Water Pump Cover
- 13.7.20 Installing the Thermostat
- 13.7.21 Installing the Heat Exchanger
- 13.7.22 Installing the Crankshaft Speed Sensor
- 13.7.23 Installing the Torque Limiter and the Starter Intermediate Gear
- 13.7.24 Installing the Alternator Cover
- 13.7.25 Installing the Spacer
- 13.7.26 Installing the Gear Position Sensor
- 13.7.27 Installing the Shift Shaft Sensor
- 13.7.28 Installing the Valve Cover
- 13.7.29 Installing the Starter Motor
- 13.7.30 Installing the Oil Filter
- 13.7.31 Installing the Oil Drain Plug

14 HANDLEBAR AND TRIPLE CLAMPS
- 14.1 Handlebar Switches
- 14.1.1 LH Handlebar Switches
- 14.1.2 RH Handlebar Switches
- 14.2 Throttle Handle
- 14.3 Handlebar Inspection
- 14.3.1 Clutch Handle Clearance Inspection
- 14.3.2 Clutch Cable Free Play Adjustment
- 14.3.3 Handlebar Interference Inspection
- 14.4 Triple Clamps Front Fork Pipe