Cfmoto 450MT Ibex450 from 2023 - Service Manual - Repair Manual

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CFMOTO 450MT IBEX450 (2023+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 450MT Ibex450 from 2023.


CONTENTS:

01 GENERAL INFORMATION
- 1.1 Operation Cautions
- 1.2 Disassembly and Assembly Cautions
- 1.3 Number Engrave Place
- 1.4 Fuel Evaporation System Diagram

02 MAINTENANCE INFORMATION
- 2.1 Maintenance Information
- 2.1.1 Daily Maintenance Schedule
- 2.1.2 Break-in Maintenance Schedule
- 2.1.3 Periodic Maintenance Schedule

03 TECHNICAL INFORMATION
- 3.1 General Specification
- 3.2 Engine Specification
- 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
- 3.3.5 Suspension
- 3.4 Service Specification
- 3.4.1 Valve Train+Cylinder Head
- 3.4.2 Lubrication System
- 3.4.3 Cylinder/Piston/Piston Ring/Connecting Rod
- 3.4.4 Clutch+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 Lubrication Requirements
- 3.6.1 Vehicle Consumption Materials
- 3.6.2 Engine Consumption 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 Handle Guard
- 5.3 Front Fender
- 5.4 Vehicle Panel Assembly
- 5.4.1 Radiator LH Panel and LH Turn Light
- 5.4.2 Radiator RH Panel and RH Turn Light
- 5.4.3 Fuel Tank Upper Panel
- 5.4.4 Vehicle LH Panel
- 5.4.5 Vehicle RH Panel
- 5.5 Headlight
- 5.6 Dashboard
- 5.7 Radiator Front Panel
- 5.8 Rear Rim Guard Assembly
- 5.8.1 Rear Armrest Cover
- 5.8.2 Rear Armrest
- 5.8.3 Rear LH Deco Plate
- 5.8.4 Rear RH Deco Plate
- 5.8.5 Tail Light Upper Guard
- 5.8.6 Rear Fender Assembly
- 5.9 Small Sprocket Guard
- 5.10 Engine Panel
- 5.10.1 Engine LH Panel
- 5.10.2 Engine RH Panel
- 5.10.3 Engine Lower Panel
- 5.11 Rear Fork Panel

06 FUEL SYSTEM
- 6.1 Fuel Evaporative System
- 6.2 Fuel Tank Removal
- 6.3 Fuel Pump
- 6.4Fuel Level Sensor Assembly

07 LIGHTS,DASHBOARD AND SWITCHES
- 7.1 Maintenance Information
- 7.1.1 Operation Caution
- 7.1.2 Maintenance Information
- 7.2 Trouble Shooting
- 7.3 Ignition Lock
- 7.4 Front Brake Light Switch
- 7.5 Handlebar Switch
- 7.5.1 Left Handlebar Switch
- 7.5.2 Right Handlebar Switch
- 7.5.3 ABS Switch
- 7.6 Dashboard
- 7.7 Battery
- 7.8 GND Cable
- 7.9 T-BOX

8 ELECTRICAL SYSTEM
- 8.1 Service Tool
- 8.2 Charging System
- 8.2.1 Magneto Coil Resistance
- 8.2.2 MAG Non-loaded Performance
- 8.2.3 Starter Relay
- 8.2.4 Regulator
- 8.3 EFI
- 8.3.1 EFI Structure
- 8.3.1.1 Sensors
- 8.3.1.2 ECU
- 8.3.1.3 Actuators
- 8.3.1.4 EFI System Maintenance Notice
- 8.3.2 Structure and Performance of EFI Parts
- 8.3.2.1 ECU
- 8.3.2.2 Throttle Body Assembly
- 8.3.2.3 Stepper Motor
- 8.3.2.4 Air Intake Pressure Temperature Sensor
- 8.3.2.5 Coolant Temperature Sensor
- 8.3.2.6 Oxygen Sensor
- 8.3.2.7 Trigger
- 8.3.2.8 Fuel Pump Assembly
- 8.3.2.9 Fuel Injector
- 8.3.2.10 Ignition Coil
- 8.3.3 UP6.0 Fault Code Table
- 8.4 Normal Troubles
- 8.5 Trouble Diagnosis In Accordance With Engine Error

09 COOLING SYSTEM
- 9.1 Cooling System Diagram
- 9.2 Cooling System Removal
- 9.3 Engine Coolant
- 9.3.1 Coolant Inspection
- 9.3.2 Coolant Addition
- 9.3.3 Coolant Replacement
- 9.4 Seal Inspection
- 9.5 Radiator and Water Pipes Inspection and Clean
- 9.6 Fan Motor Inspection

10 EXHAUST SYSTEM
- 10.1 Engine Panel, Exhaust Pipe and Muffler Assembly Removal
- 10.1.1 Engine Panel
- 10.1.2 Exhaust Pipe
- 10.1.3 Muffler Assembly
- 10.2 Exhaust Pipe Inspection

11 FRONT,REAR 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
- 11.5.1 Rear Brake Master Cylinder
- 11.5.2 Hand Brake Master Cylinder Assembly
- 11.6 ABS Execution Unit 
- 11.7 Tire Maintenance
- 11.7.1 Front Wheel
- 11.7.2 Rear Wheel
- 11.7.3 Spoke
- 11.7.4 Tire Pressure
- 11.7.5 Tire Appearance
- 11.7.6 Wheel Bearing
- 11.7.7 Rim
- 11.8 Brake System Maintenance
- 11.8.1 Hand Master Cylinder Maintenance
- 11.8.2 Rear Brake Master Cylinder Maintenance
- 11.8.3 Brake Hose Maintenance
- 11.8.4 Front/Rear Brake Caliper and Brake Pad Maintenance 
- 11.9 Free Play
- 11.9.1 Front Brake Lever Free Play
- 11.9.2 Rear Brake Pedal Free Play

12 SHOCK ABSORBER AND REAR FORK
- 12.1 Front Shock Absorbers
- 12.1.1 Front Shock Absorber Inspection
- 12.1.2 Recovery Damping Adjustment
- 12.1.3 Compression Damping Adjustment
- 12.2 Chain
- 12.2.1 Drive Chain Maintenance
- 12.2.2 Chain Looseness Adjustment
- 12.3 Rear Fork Assembly
- 12.4 Rear Shock Absorbers
- 12.4.1 Rear Shock Absorber Inspection

13 ENGINE
- 13.1 Preparation Instructions
- 13.1.1 Unit Conversion Table
- 13.1.2 Warnings
- 13.2 Maintenance Information
- 13.2.1 Engine Appearance
- 13.2.2 General Precautions
- 13.2.3 Selection of Fuel and Oil
- 13.2.4 Engine Break-in
- 13.2.5 Special engine maintenance tool
- 13.3 Engine Removal
- 13.4 Intake System
- 13.4.1 Air Filter Assembly
- 13.4.2 Throttle Valve Body Assembly
- 13.5 Engine Disassembly
- 13.5.1 Fix the Engine
- 13.5.2 Engine Oil Releasing
- 13.5.3 Starter Motor Removal
- 13.5.4 Thermostat Removal
- 13.5.5 Pump Removal
- 13.5.6 Cylinder Head Cover Removal
- 13.5.7 RH Cover Removal
- 13.5.8 Clutch Removal
- 13.5.9 Shift Lever Assembly, Shift Positioning Component and Positioning Star Wheel Removal
- 13.5.10 Oil Pump Removal
- 13.5.11 Cylinder Head Removal
- 13.5.12 Magneto and Double Gear Removal
- 13.5.13 Cylinder Body Removal
- 13.5.14 Piston Removal
- 13.5.15 Oil Pan Removal
- 13.5.16 Oil Rail Cover Plate Assembly Removal
- 13.5.17 Compartment
- 13.6 Engine Inspection
- 13.6.1 Crankcase
- 13.6.1.1 Selecting Plain Bearing
- 13.6.1.2 Crankcase
- 13.6.1.3 RH Side Cover
- 13.6.2 Cylinder Head Cover Assembly
- 13.6.3 Cylinder Head Assembly
- 13.6.4 Cylinder Body
- 13.6.5 Piston/Piston Ring/Piston Pin
- 13.6.6 Distribution Drive Sub-assembly
- 13.6.7 Crankshaft Connecting Rod
- 13.6.8 Clutch
- 13.6.9 Shift Gear
- 13.6.9.1 Main Shaft
- 13.6.9.2 Countershaft
- 13.6.10 Lubrication System
- 13.6.10.1 Lubricating Chart
- 13.6.10.2 Oil Pump
- 13.6.10.3 Oil Pressure Relief Valve
- 13.6.10.4 Oil Rail Cover Plate Assembly 
- 13.6.11 Water Pump Assembly
- 13.6.12 Electric Starter
- 13.6.13 Magneto Stator
- 13.6.14 Rear Balance Shaft Assembly
- 13.7 Engine Assembly
- 13.7.1 Rear Balance Shaft Assembly Installation
- 13.7.2 Shift Drum, Position Cam, Position Swing Arm Installation
- 13.7.3 Countershaft Installation
- 13.7.4 Fork Shaft and Gearshift Fork Installation
- 13.7.5 Main Shaft Installation
- 13.7.6 Gearshift Lever Installation
- 13.7.7 Crankshaft Connecting Rod and Front Balance Shaft Installation
- 13.7.8 Crankcase Closing
- 13.7.9 Oil Pump Sub-assembly and Oil Pressure Switch Installation
- 13.7.10 Water Pump Installation
- 13.7.11 Oil Pan Installation
- 13.7.12 Oil Rail Cover Plate Assembly Installation
- 13.7.13 Oil Filter Installation
- 13.7.14 Cylinder Body and Piston Parts Installation
- 13.7.15 Timing Chain Installation
- 13.7.16 Cylinder Head Installation
- 13.7.17 Magneto Rotor Assembly Installation
- 13.7.18 LH Side Cover Installation
- 13.7.19 Intake and Exhaust Camshaft Installation
- 13.7.20 Hydraulic Tensioner Installation
- 13.7.21 Cylinder Head Cover Installation
- 13.7.22 Starter Motor Installation
- 13.7.23 Clutch Installation
- 13.7.24 RH Side Cover Installation
- 13.7.25 Gear Sensor Installation
- 13.7.26 Throttle and Fuel Pipe Assembly Installation
- 13.7.27 Output Sprocket Installation
- 13.7.28 Oil Filling, Oil Level Inspection, Oil Pressure Inspection

14 HANDLEBAR,TRIPLE CLAMPS ASSEMBLY
- 14.1 Handlebar Assembly
- 14.1.1 Handlebar Switch
- 14.1.1.1 LH Handlebar Switch Assembly
- 14.1.1.2 RH Handlebar Switch Assembly
- 14.2 Throttle Grip
- 14.3 Handlebar Maintenance
- 14.3.1 Throttle Cable Free Play
- 14.3.2 Inspect Clutch Lever Clearance
- 14.3.3 Adjust Clutch Cable Free Play
- 14.3.4 Inspect Handlebar Interference
- 14.4 Upper and Lower Triple Clamp Assembly
- 14.4.1 Upper Triple Clamp Assembly
- 14.4.2 Front Fork Pipe and Lower Triple Clamp Assembly