CF MOTO CFORCE 1000 2018

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CFMOTO

Edition No.:20180817

Edition item: CF1000AU(9AY0-WX-01-1)SM-20180817

Website:www.cfmoto.com

Main Page

Unit Conversion Table4
Danger/Warning/Caution4
Maintenance Information5
Safety Cautions5
Cautions for Removal and Installation5
Engine Break-In7
Recommended Break-In Period7
Operation Guide7
Main Specification8
Lubrication10
Light/Dashboard/Switch12
Tighten Torque12
Tightening Torque List13
Cable, Bearing and Other Moving Parts Lubrication14
Grease and Sealant14
Special Torque for Engine14
Engine Working Tool14
Cable, Brake System and Cooling System15
Wiring Identification15
Brake System Parts Diagram18
Brake System (EU 167 Left-Hand Park)19
Brake System (Right-Hand Park)20
Cooling System Parts Diagram21
Body Covering Parts22
Seat Assy, Air Filter Cover Assy24
Rear Seat24
Front Seat24
Air Filter Cover Assy24
Air Filter Upper Cover25
Air Filter Cover, LH25
Air Filter Cover, RH25
Gearshift Deco Cover26
Lock Cover26
Left Side Cover26
Side Cover, RH27
Seat Heat Insulator27
Rear Seat Bracket27
Right Cover28
Left Cover28
Front Rack28
Rear Rack Cover29
Rear Rack29
Hand Guard, LH/RH30
Handlebar Cover30
Hand Guard, RH31
Hand Guard, LH31
Handlebar Deco Cover, RH31
Dashboard Cover Assy31
Dashboard Cover, RH32
Dashboard Cover, LH32
Dashboard Lower Cover33
Dashboard Cover33
Front Dashboard Cover33
Front Licence Plate34
Front Lower Panel34
Front Bumper Block, RH34
Front Deco Cover, RH35
Front Bumper Cover, RH35
Front Bumper Cover, LH(EU)35
Bumper Assy35
Headlight Cover, RH36
Headlight Cover, LH36
Front Deco Plate36
Front Vent Cover, LH36
Headlight Cover37
Front Flare Fender, RH38
Front Inner Fender, RH38
Front Fender39
Engine Side Cover, LH40
Side Cover Bracket40
Rear Flare Fender, RH40
Rear Flare Fender, LH40
Tool Box Cover41
Rear License Plate41
Footrest, RH41
Footrest, LH41
Tool Box Locker42
Rear Plate42
Tool Box Locker Bracket42
Taillight Cover, RH43
Right Taillight43
Reflector43
Taillight Cover, LH43
Rear Fender44
Front Lower Plate45
Middle Lower Plate45
Rear Lower Plate45
Pipe Plug46
Front Suspension Cover, RH46
Rear Suspension Cover, LH46
Front Suspension Cover, LH46
Seat Belt(EU 167)47
Periodic Inspection and Adjustment48
Steering Column and Brake System52
Front Brake52
Clearance of the Front Brake Handle52
Front Brake Fluid Level53
Front Brake Disc&Brake Pads53
Brake Pad Wear53
Brake Disc Inspection & Replacement53
Rear Brake Fluid Level54
Brake Fluid Replacement54
Front Wheel Toe-In55
Front Wheel55
Tire Pressure56
Tire and Tire Pressure56
Tire Groove56
Wheel Nut and Axle57
Suspension System57
Shifting Mechanism58
Fuel System58
Inspect Fuel System Condition58
Throttle Inspection59
Speed Limiter59
Cooling System60
Coolant Level60
Coolant Leakage61
Coolant Gauge Inspection62
Headlight Beam Adjustment62
Selective Shock Absorber View63
Damping Force Knob for Compression63
Front Shock Absorber Adjustment64
Rear Shock Absorber Adjustment64
Front/Rear Shock Absorber Shape Selection65
Front Shock Absorber Spring Preload Adjustment66
Rear Shock Absorber Spring Preload Adjustment66
Alongside Engine67
Canister Removal (US)68
Intake System70
Exhaust System72
Engine Removal and Installation74
Table of Contents76
Maintenance Information77
- EIN Location81
- Engine Left Side81
- Engine Right Side81
- Engine Specification82
- Lubrication System83
- Service Data83
- Electrical System84
- Induction System84
- Valve Mechanism and Cylinder Head85
- Cvt87
- Engine Tighten Torque88
- Engine Service Tools90
- Measuring Tool90
- Engine Service Special Tools91
- Engine Service Materials93
- Engine Maintenance Schedule94
- Intake Pipe, Cylinder Head and Cylinder Body95
- Service Tool and Material96
Intake Pipe, Cylinder Head and Cylinder Body96
- Intake Pipe102
- Leakdown Test102
- Maintenance and Inspection102
- Valve Clearance Adjustment102
- Cylinder Head Cover103
  - Remove the Radiator Cap103
  - Leaking Reason105
  - Intake Pipe Assembly106
  - Intake Pipe Inspection106
  - Intake Pipe Removal106
  - Cylinder Head Assembly107
  - Cylinder Head Cover107
  - Cylinder Head Cover Inspection107
  - Tensioner Inspection108
  - Tensioner Removal108
  - Timing Chain Tensioner108
  - Tensioner Installation109
  - Camshaft Timing Sprocket110
  - Inspect the Timing Sprocket110
  - Removal the Timing Sprocket110
  - Installation the Timing Sprocket111
  - Install All the Removed Parts112
  - Remove the Rocker Arm113
  - Remove the Rocker Arm Shaft113
  - Inspection the Rocker Arm114
  - Remove the Thrust Washers114
  - Rocker Arm Inner Diameter114
  - Install the Rocker Arms115
  - Rocker Arm Shaft Inspection115
  - Timing Chain115
  - Remove the Cylinder Head116
  - Cylinder Head Inspection117
  - Cylinder Head Installation117
  - Camshaft118
  - Camshaft Timing119
  - Camshaft Timing Cylinder 2119
- Cylinder Head119
  - Camshaft Timing Cylinder123
  - Camshaft Removal124
  - Camshaft Inspection125
  - Remove Rocker Arms125
  - Camshaft Bearing Hole Diameter126
  - Camshaft Installation126
- Valve Spring127
  - Valve Spring Removal127
  - Remove Valve Cotters128
  - Valve Spring Inspection128
  - Valve Spring Installation128
  - Valve Removal129
- Cylinder Body130
  - Valve Inspection130
  - Valve Stem and Valve Guide Clearance130
  - Valve Stem Diameter130
  - Valve Stem Seal130
  - Valve Bevel and Valve Seat131
  - Valve Installation131
  - Cylinder Inspection132
  - Cylinder Removal132
  - Cylinder Taper132
  - Cylinder Installation133
  - Cylinder out of Round133
- Piston134
  - Piston Removal134
  - Piston Inspection135
  - Piston/Cylinder Body Clearance136
  - Piston/Cylinder Clearance136
  - Connecting Rod Small End Inner Diameter137
  - Connecting Rod/Piston Pin Clearance137
  - Piston Pin Diameter137
  - Piston Installation138
  - Piston Ring Gap Clearance140
  - Piston Ring/Groove Clearance140
  - Piston Rings140
- Piston Ring141
- Ring Installation141
- Crankcase, Crankshaft and Gears146
- Drive Gear147
- Timing Chain Installation148
- Crankcase149
- Crankcase Cover149
- Crankshaft149
  - Crankcase Cleaning151
  - Crankcase Inspection151
  - Crankcase Installation152
  - Crankshaft Locking Procedure153
  - Connecting Rod Big End Axial Play156
  - Crankshaft Axial Play156
  - Crankshaft Removal156
  - Connecting Joint Diameter157
  - Crankshaft Joint Clearance158
  - CVT Case Joint Clearance158
  - Inspection the Engine Front Output Shaft161
  - Installation the Engine Front Output Shaft161
- Driven Bevel Gear162
  - Removal the Driven Bevel Gear162
  - Clearance Adjustment163
  - Gear Inspection163
  - Gear Installation163
  - Drive Bevel Gear164
  - Drive Bevel Gear Inspection165
  - Drive Bevel Gear Installation165
  - Bevel Gear Clearance166
  - Shim Adjustment Procedure166
  - Tooth Contact167
  - Gearing Sector Gears Removal168
- Gearing System168
  - Mainshaft, Secondary Shaft, Shifting169
  - Bearing Removal in Crankcase171
  - Reverse Intermediate Gear Removal171
  - Measure Shift Fork Pins173
  - Shift Drum174
  - Parking Lever175
  - Shifting Main Shaft175
  - Gear176
  - Gearshift Driven Shaft Assy176
  - Driven Shaft177
  - Gear Inner Diameter177
  - Reverse Intermediate Gear177
  - Reverse Intermediate Gear Shaft178
  - Shifting Sectors178
  - Other Parts in Crankcase180
- CVT Drive186
- Service Tools, Material and View186
- Cvt(Exploded View)187
- General188
Cvt189
- CVT Cover189
- CVT Case189
- CVT Cover Assy Inspection190
- CVT Cover Installation190
- Clutch Shoe Inspection193
- Drive Pulley Disassembly193
- Drive Pulley Inspection193
- Drive Pulley193
- Drive Pulley Assembly194
- Driven Pulley Disassembly194
- Driven Pulley Inspection196
- Driven Pulley Fixed Sheave Inspection196
- Driven Pulley Sliding Sheave Inspection197
- Spring Cam Seat Inspection198
- Driven Pulley Spring Inspection198
- Driven Pulley Assembly198
- Drive Belt198
- Drive/Driven Pulley and Belt Installation199
- CVT Case Removal200
- CVT Case Cleaning201
- CVT Case Assy Inspection201
- CVT Case Installation202
- Maintenance Tools, Material and View204
Engine Lubrication System204
- Exploded View205
- Lubrication Line206
- Engine Oil Level Check207
- General207
- Engine Oil Replacement208
- Gear Box Oil Inspection209
- Gear Oil Replacement209
- Oil Pump214
  - Final Test216
  - Engine Oil Strainer217
- Oil Cooler217
- General223
- Inspection and Cleaning223
- MAG-Side Crankcase Cover223
- Magneto Stator225
- Stator Installation225
- Magneto Rotor226
- Overriding Clutch229
- Driven Gear Removal230
- Start Gear Assy231
Intake System232
- Service Material and Exploded View233
- Air Filter (Exploded View)234
- Cfmoto235
- Air Filter235
- Air Filter Installation236
- Air Filter Housing236
Cooling System238
- Cooling System240
- General242
- Inspection242
- Coolant Replacement243
- Maintenance243
  - Draining the System244
  - Refilling the System244
- Thermostat245
- Charging System264
- Charging Wire Diagram264
- Magneto Coil Resistance264
- Magneto with Non-Loaded264
Electrical System264
- Voltage Regulator265
- Brush266
- Electrical Starting System266
- Starter Motor266
- Armature267
- Commutator267
- Oil Seal267
- Starter Relay268
- Auxiliary Starter Relay and Fuel Pump Relay269
- Engine Starting Notice269
- EFI Structure270
- EFI System270
- EFI System Maintenance Notice271
- Digital Multimeter272
- Service Tools272
  - Vaccum Gauge272
  - Compression Tester273
  - Fuel Pressure Gauge273
  - Timing Light273
- Ecu274
- EFI Components and Function274
  - Limit Data275
  - Pin Function275
- Throttle Body275
- Intake Temperature and Pressure Sensor276
  - Absolute Pressure Pabs in KPA277
  - Water Temperature Senser278
  - Connection between Sensors and ECU279
- Oxygen Sensor279
- Mileage Sensor (Speed Sensor)280
  - Gear Sensor281
  - Reverse Pre-Caution281
  - Fuel Pressure Test282
- Fuel Pump282
  - Pressure Relief in Fuel System282
  - Connection between Injectors and ECU283
- Fuel Injector283
- Fuel Injector Installation283
- Idle Stepping Motor284
- Connection between Ignition Coils and ECU.285
- Ignition Coil285
  - Ignition Coil Parameters286
  - Secondary Ignition Voltage Test286
- EFI Self-Diagnosis287
- Mil287
- MIL Flash Principles287
- PDA Function288
- Version Infomation Display288
- Fault Display288
Troubleshooting290
- EFI Trouble Codes294
- Help295
- Instruction295
- Trouble Code Diagnosing295
- Trouble Code P0107:Intake Pressure Sensor Low Voltage or Open297
- Trouble Code P0108:Intake Pressure Sensor High Voltage297
- Trouble Code P0112: Intake Temp. Sensor Low Voltage297
- Trouble Code P0117:Thermo Sensor Low Voltage297
- Trouble Code P0122:TPS Low Voltage or Open298
- Trouble Code P0123:TPS Voltage High298
- Trouble Code P0201/ P0202: Cylinder 1/2 Injector Coil Trouble298
- Trouble Code P0562:Battery Voltage Low299
- Trouble Code P0563:Battery Voltage High299
- Trouble Code P0627: Fuel Pump Relay Coil Open299
- Trouble Code P0629: Fuel Pump Relay Coil Short to Power299
- Common Troubles List300
- Diagnosis Tips300
- Starting Failure/Hard Starting301
- When Starting, Engine Can Rotate but Cannot Start301
- Difficult to Start Cold Engine302
- Difficult to Start Hot Engine302
- Difficult to Start in any Conditions303
- Normal Starting,But Unstable Idle Speed304
- Normal Starting, but Unstable Idle Speed During Engine Warming305
- Engine Starts Normally, but Idle Speed Is too High307
- RPM Cannot Increase or Engine Stops When Accelerating308
- ) Difficult to Accelerate and Bad Performance309
- Low Acceleration309
- General Diagnostic Procedures310
- Vehicle Chassis311
- Maintenance Specifications312
- Tools312
- Excessive Handlebar Free Play313
- Heavy Steering313
- Suspension too Soft313
- Wheel Cannot Turn Freely313
- Brake Pad Removal314
- Front Brake Caliper314
- Reverse the Removal Procedure for Installation314
- Wheel Hub and Brake Disc314
- Front Brake Master Cylinder315
- Front Suspension System316
- Pcv316
- Rear Brake Caliper316
- Rear Suspension System317
- Front Upper A-Arm318
- Front Lower A-Arm319
- Rear Suspension Arm319
- Steering Knuckle319
- Loose the Connector320
- Right Handlebar Switch320
- Steering System320
  - Winch Control Switch320
  - Handlebar Pipe321
  - Rear View Mirror321
  - Throttle Cable321
  - Non-EPS Steering Shaft322
  - EPS Motor324
  - Remove Body Covering Parts324
  - EPS Controller325
  - EPS Steering System Diagnostic325
  - EPS System Fault Code Table325
  - EPS Trouble Analyze and Solution326
- Front and Rear Gear Case327
  - Gear Case Maintenance Information327
  - Maintenance Schedule327
  - Gear Case Inspection and Maintenance328
  - Inspect and Analyze328
- Front and Rear Gear Case Removal and Installation329
- Front/Rear Gear Case Oil Replacement330
- Front Gear Case Disassembly331
- Front Gear Case Service331
  - Front Gear Case Disassembly and Inspection332
  - Differential Assy Assembly333
  - Front Axle Drive Bevel Gear Assembly333
- Front Gear Case Assembly and Adjustment333
  - Rear Gear Case Disassembly (No-Spin Differential)336
  - Rear Gear Case Service336
  - Rear Axle Inspection after Disassembly337
  - Differential Lock338
  - Rear Axel Drive Bevel Gear Assembly338
- Rear Gear Case Assembly and Adjustment338
  - Rear Gear Case Adjustment339
  - Rear Gear Case Disassembly (Non-Differential)340
  - Rear Gear Case Inspection after Disassembly341
  - Driven Bevel Gear Assembly342
  - Rear Axle Assemble and Adjustment342
  - Rear Gear Case Disassembly (Automatic Lock Differential)344
  - Differential Assembly346
- Drive Shaft348
  - Maintenance Information of CV Shaft and Driveshaft348
  - CV Shaft and Drive Shafts Removal and Installation349
  - CV Shaft Removal349
  - Rear Drive Shaft Removal350
  - Front and Rear CV Shaft Disassemble View351
- Front and Rear CV Shaft Inspection352
- Front Drive Shaft Disassemble and Inspection353
- Rear Drive Shaft Disassemble and Inspection354
- Signal and Lighting System355
- Front Turn Signal Light356
- Indicator Light356
- Bulb Replacement356
- Head Light Cannot Turn on356
- Tail Light Replacement357
- Ignition Switch358
- Handle Bar Switch358
- 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 Switch360
- Horn361

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