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CFORCE 1000 2018
CF MOTO CFORCE 1000 2018 User Manual
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CFMOT
O
SERVICE
MANUAL
CF1000AU
CF1000ATR
CFORCE
1000
2
Table of Contents
Unit Conversion Table
4
Danger/Warning/Caution
4
Maintenance Information
5
Safety Cautions
5
Cautions for Removal and Installation
5
Engine Break-In
7
Recommended Break-In Period
7
Operation Guide
7
Main Specification
8
Lubrication
10
Light/Dashboard/Switch
12
Tighten Torque
12
Tightening Torque List
13
Cable, Bearing and Other Moving Parts Lubrication
14
Grease and Sealant
14
Special Torque for Engine
14
Engine Working Tool
14
Cable, Brake System and Cooling System
15
Wiring Identification
15
Brake System Parts Diagram
18
Brake System (EU 167 Left-Hand Park)
19
Brake System (Right-Hand Park)
20
Cooling System Parts Diagram
21
Body Covering Parts
22
Seat Assy, Air Filter Cover Assy
24
Rear Seat
24
Front Seat
24
Air Filter Cover Assy
24
Air Filter Upper Cover
25
Air Filter Cover, LH
25
Air Filter Cover, RH
25
Gearshift Deco Cover
26
Lock Cover
26
Left Side Cover
26
Side Cover, RH
27
Seat Heat Insulator
27
Rear Seat Bracket
27
Right Cover
28
Left Cover
28
Front Rack
28
Rear Rack Cover
29
Rear Rack
29
Hand Guard, LH/RH
30
Handlebar Cover
30
Hand Guard, RH
31
Hand Guard, LH
31
Handlebar Deco Cover, RH
31
Dashboard Cover Assy
31
Dashboard Cover, RH
32
Dashboard Cover, LH
32
Dashboard Lower Cover
33
Dashboard Cover
33
Front Dashboard Cover
33
Front Licence Plate
34
Front Lower Panel
34
Front Bumper Block, RH
34
Front Deco Cover, RH
35
Front Bumper Cover, RH
35
Front Bumper Cover, LH(EU)
35
Bumper Assy
35
Headlight Cover, RH
36
Headlight Cover, LH
36
Front Deco Plate
36
Front Vent Cover, LH
36
Headlight Cover
37
Front Flare Fender, RH
38
Front Inner Fender, RH
38
Front Fender
39
Engine Side Cover, LH
40
Side Cover Bracket
40
Rear Flare Fender, RH
40
Rear Flare Fender, LH
40
Tool Box Cover
41
Rear License Plate
41
Footrest, RH
41
Footrest, LH
41
Tool Box Locker
42
Rear Plate
42
Tool Box Locker Bracket
42
Taillight Cover, RH
43
Right Taillight
43
Reflector
43
Taillight Cover, LH
43
Rear Fender
44
Front Lower Plate
45
Middle Lower Plate
45
Rear Lower Plate
45
Pipe Plug
46
Front Suspension Cover, RH
46
Rear Suspension Cover, LH
46
Front Suspension Cover, LH
46
Seat Belt(EU 167)
47
Periodic Inspection and Adjustment
48
Steering Column and Brake System
52
Front Brake
52
Clearance of the Front Brake Handle
52
Front Brake Fluid Level
53
Front Brake Disc&Brake Pads
53
Brake Pad Wear
53
Brake Disc Inspection & Replacement
53
Rear Brake Fluid Level
54
Brake Fluid Replacement
54
Front Wheel Toe-In
55
Front Wheel
55
Tire Pressure
56
Tire and Tire Pressure
56
Tire Groove
56
Wheel Nut and Axle
57
Suspension System
57
Shifting Mechanism
58
Fuel System
58
Inspect Fuel System Condition
58
Throttle Inspection
59
Speed Limiter
59
Cooling System
60
Coolant Level
60
Coolant Leakage
61
Coolant Gauge Inspection
62
Headlight Beam Adjustment
62
Selective Shock Absorber View
63
Damping Force Knob for Compression
63
Front Shock Absorber Adjustment
64
Rear Shock Absorber Adjustment
64
Front/Rear Shock Absorber Shape Selection
65
Front Shock Absorber Spring Preload Adjustment
66
Rear Shock Absorber Spring Preload Adjustment
66
Alongside Engine
67
Canister Removal (US)
68
Intake System
70
Exhaust System
72
Engine Removal and Installation
74
Table of Contents
76
Maintenance Information
77
EIN Location
81
Engine Left Side
81
Engine Right Side
81
Engine Specification
82
Lubrication System
83
Service Data
83
Electrical System
84
Induction System
84
Valve Mechanism and Cylinder Head
85
Cvt
87
Engine Tighten Torque
88
Engine Service Tools
90
Measuring Tool
90
Engine Service Special Tools
91
Engine Service Materials
93
Engine Maintenance Schedule
94
Intake Pipe, Cylinder Head and Cylinder Body
95
Service Tool and Material
96
Intake Pipe, Cylinder Head and Cylinder Body
96
Intake Pipe
102
Leakdown Test
102
Maintenance and Inspection
102
Valve Clearance Adjustment
102
Cylinder Head Cover
103
Remove the Radiator Cap
103
Leaking Reason
105
Intake Pipe Assembly
106
Intake Pipe Inspection
106
Intake Pipe Removal
106
Cylinder Head Assembly
107
Cylinder Head Cover
107
Cylinder Head Cover Inspection
107
Tensioner Inspection
108
Tensioner Removal
108
Timing Chain Tensioner
108
Tensioner Installation
109
Camshaft Timing Sprocket
110
Inspect the Timing Sprocket
110
Removal the Timing Sprocket
110
Installation the Timing Sprocket
111
Install All the Removed Parts
112
Remove the Rocker Arm
113
Remove the Rocker Arm Shaft
113
Inspection the Rocker Arm
114
Remove the Thrust Washers
114
Rocker Arm Inner Diameter
114
Install the Rocker Arms
115
Rocker Arm Shaft Inspection
115
Timing Chain
115
Remove the Cylinder Head
116
Cylinder Head Inspection
117
Cylinder Head Installation
117
Camshaft
118
Camshaft Timing
119
Camshaft Timing Cylinder 2
119
Cylinder Head
119
Camshaft Timing Cylinder
123
Camshaft Removal
124
Camshaft Inspection
125
Remove Rocker Arms
125
Camshaft Bearing Hole Diameter
126
Camshaft Installation
126
Valve Spring
127
Valve Spring Removal
127
Remove Valve Cotters
128
Valve Spring Inspection
128
Valve Spring Installation
128
Valve Removal
129
Cylinder Body
130
Valve Inspection
130
Valve Stem and Valve Guide Clearance
130
Valve Stem Diameter
130
Valve Stem Seal
130
Valve Bevel and Valve Seat
131
Valve Installation
131
Cylinder Inspection
132
Cylinder Removal
132
Cylinder Taper
132
Cylinder Installation
133
Cylinder out of Round
133
Piston
134
Piston Removal
134
Piston Inspection
135
Piston/Cylinder Body Clearance
136
Piston/Cylinder Clearance
136
Connecting Rod Small End Inner Diameter
137
Connecting Rod/Piston Pin Clearance
137
Piston Pin Diameter
137
Piston Installation
138
Piston Ring Gap Clearance
140
Piston Ring/Groove Clearance
140
Piston Rings
140
Piston Ring
141
Ring Installation
141
Crankcase, Crankshaft and Gears
146
Drive Gear
147
Timing Chain Installation
148
Crankcase
149
Crankcase Cover
149
Crankshaft
149
Crankcase Cleaning
151
Crankcase Inspection
151
Crankcase Installation
152
Crankshaft Locking Procedure
153
Connecting Rod Big End Axial Play
156
Crankshaft Axial Play
156
Crankshaft Removal
156
Connecting Joint Diameter
157
Crankshaft Joint Clearance
158
CVT Case Joint Clearance
158
Inspection the Engine Front Output Shaft
161
Installation the Engine Front Output Shaft
161
Driven Bevel Gear
162
Removal the Driven Bevel Gear
162
Clearance Adjustment
163
Gear Inspection
163
Gear Installation
163
Drive Bevel Gear
164
Drive Bevel Gear Inspection
165
Drive Bevel Gear Installation
165
Bevel Gear Clearance
166
Shim Adjustment Procedure
166
Tooth Contact
167
Gearing Sector Gears Removal
168
Gearing System
168
Mainshaft, Secondary Shaft, Shifting
169
Bearing Removal in Crankcase
171
Reverse Intermediate Gear Removal
171
Measure Shift Fork Pins
173
Shift Drum
174
Parking Lever
175
Shifting Main Shaft
175
Gear
176
Gearshift Driven Shaft Assy
176
Driven Shaft
177
Gear Inner Diameter
177
Reverse Intermediate Gear
177
Reverse Intermediate Gear Shaft
178
Shifting Sectors
178
Other Parts in Crankcase
180
CVT Drive
186
Service Tools, Material and View
186
Cvt(Exploded View)
187
General
188
Cvt
189
CVT Cover
189
CVT Case
189
CVT Cover Assy Inspection
190
CVT Cover Installation
190
Clutch Shoe Inspection
193
Drive Pulley Disassembly
193
Drive Pulley Inspection
193
Drive Pulley
193
Drive Pulley Assembly
194
Driven Pulley Disassembly
194
Driven Pulley Inspection
196
Driven Pulley Fixed Sheave Inspection
196
Driven Pulley Sliding Sheave Inspection
197
Spring Cam Seat Inspection
198
Driven Pulley Spring Inspection
198
Driven Pulley Assembly
198
Drive Belt
198
Drive/Driven Pulley and Belt Installation
199
CVT Case Removal
200
CVT Case Cleaning
201
CVT Case Assy Inspection
201
CVT Case Installation
202
Maintenance Tools, Material and View
204
Engine Lubrication System
204
Exploded View
205
Lubrication Line
206
Engine Oil Level Check
207
General
207
Engine Oil Replacement
208
Gear Box Oil Inspection
209
Gear Oil Replacement
209
Clean the Drain Plug up
210
Engine Oil Pressure
211
Oil Pressure Switch
211
Oil Pressure Switch Service Voltage
211
Oil Filter Element
212
Oil Filter Element Installation
213
Oil Pressure Limit Valve
213
Spring Free Length
213
Oil Pump
214
Final Test
216
Engine Oil Strainer
217
Oil Cooler
217
Strainer Cleaning and Inspection
217
Strainer Installation
217
Oil Cooler Inspection
218
Oil Cooler and Accessories Installation
219
Oil Cooler Cleaning
219
Oil Cooler Inlet/Outlet Pipe Inspection
219
Engine Start System
220
Service Tool, Material and View
221
General
223
Inspection and Cleaning
223
MAG-Side Crankcase Cover
223
Magneto Stator
225
Stator Installation
225
Magneto Rotor
226
Overriding Clutch
229
Driven Gear Removal
230
Start Gear Assy
231
Intake System
232
Service Material and Exploded View
233
Air Filter (Exploded View)
234
Cfmoto
235
Air Filter
235
Air Filter Installation
236
Air Filter Housing
236
Cooling System
238
Cooling System
240
Radiator (Exploded View)
240
Waterpump (Exploded View)
241
Cooling System Sealing Test
242
General
242
Inspection
242
Coolant Replacement
243
Maintenance
243
Draining the System
244
Refilling the System
244
Thermostat
245
Thermostat Removal
245
Radiator Cap
246
Thermostat Inspection
246
Thermostat Installation
246
Radiator Clean and Inspection
247
Radiator Removal
248
Radiator Installation
249
Reservoir
249
Reservoir Installation
249
Reservoir Removal
249
Cooling Fan Testing
250
Radiator Fan Relay
251
Relay Function Test
251
Relay Working Test
251
Remove the Relay
251
Thermoswitch Testing
252
Thermoswitch Working Temp
252
Water Pump Cover
253
Charging System
264
Charging Wire Diagram
264
Magneto Coil Resistance
264
Magneto with Non-Loaded
264
Electrical System
264
Voltage Regulator
265
Brush
266
Electrical Starting System
266
Starter Motor
266
Armature
267
Commutator
267
Oil Seal
267
Starter Relay
268
Auxiliary Starter Relay and Fuel Pump Relay
269
Engine Starting Notice
269
EFI Structure
270
EFI System
270
EFI System Maintenance Notice
271
Digital Multimeter
272
Service Tools
272
Vaccum Gauge
272
Compression Tester
273
Fuel Pressure Gauge
273
Timing Light
273
Ecu
274
EFI Components and Function
274
Limit Data
275
Pin Function
275
Throttle Body
275
Intake Temperature and Pressure Sensor
276
Absolute Pressure Pabs in KPA
277
Water Temperature Senser
278
Connection between Sensors and ECU
279
Oxygen Sensor
279
Mileage Sensor (Speed Sensor)
280
Gear Sensor
281
Reverse Pre-Caution
281
Fuel Pressure Test
282
Fuel Pump
282
Pressure Relief in Fuel System
282
Connection between Injectors and ECU
283
Fuel Injector
283
Fuel Injector Installation
283
Idle Stepping Motor
284
Connection between Ignition Coils and ECU.
285
Ignition Coil
285
Ignition Coil Parameters
286
Secondary Ignition Voltage Test
286
EFI Self-Diagnosis
287
Mil
287
MIL Flash Principles
287
PDA Function
288
Version Infomation Display
288
Fault Display
288
Troubleshooting
290
EFI Trouble Codes
294
Help
295
Instruction
295
Trouble Code Diagnosing
295
Trouble Code P0107:Intake Pressure Sensor Low Voltage or Open
297
Trouble Code P0108:Intake Pressure Sensor High Voltage
297
Trouble Code P0112: Intake Temp. Sensor Low Voltage
297
Trouble Code P0117:Thermo Sensor Low Voltage
297
Trouble Code P0122:TPS Low Voltage or Open
298
Trouble Code P0123:TPS Voltage High
298
Trouble Code P0201/ P0202: Cylinder 1/2 Injector Coil Trouble
298
Trouble Code P0562:Battery Voltage Low
299
Trouble Code P0563:Battery Voltage High
299
Trouble Code P0627: Fuel Pump Relay Coil Open
299
Trouble Code P0629: Fuel Pump Relay Coil Short to Power
299
Common Troubles List
300
Diagnosis Tips
300
Starting Failure/Hard Starting
301
When Starting, Engine Can Rotate but Cannot Start
301
Difficult to Start Cold Engine
302
Difficult to Start Hot Engine
302
Difficult to Start in any Conditions
303
Normal Starting,But Unstable Idle Speed
304
Normal Starting, but Unstable Idle Speed During Engine Warming
305
Engine Starts Normally, but Idle Speed Is too High
307
RPM Cannot Increase or Engine Stops When Accelerating
308
) Difficult to Accelerate and Bad Performance
309
Low Acceleration
309
General Diagnostic Procedures
310
Vehicle Chassis
311
Maintenance Specifications
312
Tools
312
Excessive Handlebar Free Play
313
Heavy Steering
313
Suspension too Soft
313
Wheel Cannot Turn Freely
313
Brake Pad Removal
314
Front Brake Caliper
314
Reverse the Removal Procedure for Installation
314
Wheel Hub and Brake Disc
314
Front Brake Master Cylinder
315
Front Suspension System
316
Pcv
316
Rear Brake Caliper
316
Rear Suspension System
317
Front Upper A-Arm
318
Front Lower A-Arm
319
Rear Suspension Arm
319
Steering Knuckle
319
Loose the Connector
320
Right Handlebar Switch
320
Steering System
320
Winch Control Switch
320
Handlebar Pipe
321
Rear View Mirror
321
Throttle Cable
321
Non-EPS Steering Shaft
322
EPS Motor
324
Remove Body Covering Parts
324
EPS Controller
325
EPS Steering System Diagnostic
325
EPS System Fault Code Table
325
EPS Trouble Analyze and Solution
326
Front and Rear Gear Case
327
Gear Case Maintenance Information
327
Maintenance Schedule
327
Gear Case Inspection and Maintenance
328
Inspect and Analyze
328
Front and Rear Gear Case Removal and Installation
329
Front/Rear Gear Case Oil Replacement
330
Front Gear Case Disassembly
331
Front Gear Case Service
331
Front Gear Case Disassembly and Inspection
332
Differential Assy Assembly
333
Front Axle Drive Bevel Gear Assembly
333
Front Gear Case Assembly and Adjustment
333
Rear Gear Case Disassembly (No-Spin Differential)
336
Rear Gear Case Service
336
Rear Axle Inspection after Disassembly
337
Differential Lock
338
Rear Axel Drive Bevel Gear Assembly
338
Rear Gear Case Assembly and Adjustment
338
Rear Gear Case Adjustment
339
Rear Gear Case Disassembly (Non-Differential)
340
Rear Gear Case Inspection after Disassembly
341
Driven Bevel Gear Assembly
342
Rear Axle Assemble and Adjustment
342
Rear Gear Case Disassembly (Automatic Lock Differential)
344
Differential Assembly
346
Drive Shaft
348
Maintenance Information of CV Shaft and Driveshaft
348
CV Shaft and Drive Shafts Removal and Installation
349
CV Shaft Removal
349
Rear Drive Shaft Removal
350
Front and Rear CV Shaft Disassemble View
351
Front and Rear CV Shaft Inspection
352
Front Drive Shaft Disassemble and Inspection
353
Rear Drive Shaft Disassemble and Inspection
354
Signal and Lighting System
355
Front Turn Signal Light
356
Indicator Light
356
Bulb Replacement
356
Head Light Cannot Turn on
356
Tail Light Replacement
357
Ignition Switch
358
Handle Bar Switch
358
Handle Bar Switch(US)
358
Light Switch (No.1)
359
Emergency Switch (No.2)
359
Engine Stop Switch (No.3)
359
Engine Start Switch (No.4)
359
Steering Signal Switch (No.1)
360
Horn Switch (No.2)
360
Brake Light Switch
360
Horn
361
4
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CF MOTO CFORCE 1000 2018 Specifications
General
Brand
CF MOTO
Model
CFORCE 1000 2018
Category
Offroad Vehicle
Language
English
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