Cfmoto 450CL-C from 2025 - Service Manual - Repair Manual

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CFMOTO 450CL-C  (2025+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto 450CL-C from 2025.
- Edition Item: 450CL-C (6AQV-00WX01-11) SM-20250122
- 450CL-C: CF400-10


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
- 3.3 Maintenance Specifications
- 3.3.1 Front Wheel
- 3.3.2 Rear Wheel
- 3.3.3 Brake System
- 3.3.4 Light, Dashboard and Switch
- 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 Rear Seat (double seats)
- 4.1.1 Rear Seat Installation 
- 4.2 Front Seat(double seats)
- 4.2.1 Front Seat Installation
- 4.3 Seat Assembly (single seat)

5 BODY COVERING PARTS
- 5.1 Front Fender Assembly
- 5.1.1 Front shock absorber LH&RH deco guard
- 5.1.2 Disassemble the front fender assy
- 5.2 Instrument Assy
- 5.2.1 The rear cover of instrument
- 5.2.2 The seat cover of instrument
- 5.3 Headlight assy
- 5.3.1 Headlight seat 1
- 5.3.2 LH&RH headlight seat 2
- 5.4 Reservoir tank LH guard assy
- 5.4.1 Reservoir LH guard deco panel 
- 5.5 Reservoir tank RH guard assy
- 5.5.1 Reservoir RH guard deco panel
- 5.5.2 Battery box cover（Double Seats）
- 5.5.3 Battery Box Cover (Single Seat)
- 5.6 RH & LH guard
- 5.6.1 LH guard
- 5.6.2 RH guard
- 5.7 LH &RH guard deco cover
- 5.7.1 LH guard deco cover
- 5.7.2 RH guard deco cover
- 5.8 LH&RH guard base panel
- 5.8.1 LH guard base panel（Double Seats）
- 5.8.3 LH Panel Base Plate (Single Seat)
- 5.8.4 RH guard base panel（Double Seats）
- 5.8.6 RH Panel Base Plate (Single Seat)
- 5.9 Fuel tank LH&RH guard
- 5.9.1 Fuel tank LH guard
- 5.9.2 Fuel tank RH guard
- 5.10 Rear rim fender assy（Double Seats）
- 5.10.1 Rear fender LH&RH deco cover
- 5.10.2 Rear fender deco cover
- 5.11 Rear fender assy
- 5.11.1 License bracket
- 5.11.2 Rear reflecting plate
- 5.11.3 License light fixed plate
- 5.11.4 LH&RH rear turning light
- 5.11.5 Rear rim fender （Double seats）
- 5.11.5.1 Rear rim inner fender 
- 5.11.6 Rear fender outer plate assembly (Single Seat)
- 5.11.6.1 Welded Pipe Assembly
- 5.12 Front LH turning light mounting cover and assy
- 5.12.1 Front LH turning light mount seat
- 5.13 ll sprocket
- 5.14 Belt upper & lower guard
- 5.15 Carbon tank deco cover
- 5.16 Reservoir deco cover
- 5.17 Rear shock absorber fender（Double Seats）
- 5.18 Battery box and battery cartridge assy
- 5.18.2 Battery box cartridge
- 5.19 Fender（Double Seats）

6 FUEL SYSTEM
- 6.1 Fuel Tank Removal
- 6.2 Fuel Evaporation System
- 6.3 Fuel Pump
- 6.4 Fuel level sensor

7 LIGHTS, DASHBOARD AND SWITCHES
- 7.1 Maintenance Information
- 7.2 Operation Caution
- 7.2.1 Inspection Standard
- 7.3 Trouble Shooting
- 7.4 Ignition Switch
- 7.5 Front Brake Light Switch
- 7.6 Handlebar Switch
- 7.6.1 LH Handlebar Switch
- 7.6.2 RH Handlebar Switch
- 7.7 Battery
- 7.8 Ground Wire
- 7.9 Vehicle Telematics
- 7.10 Dashboard
- 7.10.1 Dashboard Pin Function

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 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
- 8.3.3.3 T-MAP
- 8.3.3.4 Idle Stepper Motor
- 8.3.3.5 Water Temp. 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 Ignition coil
- 8.3.4 UP6.0 Fault Code
- 8.4 Fault Diagnosis and Treatment
- 8.5 Trouble Diagnosis In Accordance With Engine Error

9 COOLING SYSTEM
- 9.1 Cooling System Diagram
- 9.2 Cooling System Assembly 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 Pipe Cleaning and Inspection
- 9.6 Fan Motor Inspection

10 EXHAUST SYSTEM
- 10.1 Muffler Removal
- 10.1.1 Muffler Pipe Assembly
- 10.1.2 Front Muffler
- 10.2 Exhaust Pipe Inspection

11 WHEELS AND BRAKE SYSTEM
- 11.1 Front Brake Caliper
- 11.2 Front Wheel
- 11.3 Rear Wheel（Double Seats）
- 11.4 Rear Wheel (Single Seat)
- 11.5 Rear Brake Caliper（Double Seats）
- 11.6 Rear Brake Caliper (Single Seat)
- 11.7 Brake Master Cylinder
- 11.7.4.1 Rear Brake Master Cylinder
- 11.7.1 Hand Brake Master Cylinder Assembly
- 11.8 ABS Execution Unit
- 11.9 Tire Inspection
- 11.9.1 Tire Pressure
- 11.9.2 Tire Appearance
- 11.9.3 Wheel Bearing
- 11.10 Brake System Inspection
- 11.10.1 Hand Brake Master Cylinder Inspection
- 11.10.2 Rear Brake Master Cylinder Inspection
- 11.10.3 Brake Hose Inspection
- 11.10.4 Brake Calipers and Brake Discs Inspection
- 11.11 Free Play
- 11.11.1 Front Brake Handle Free Play
- 11.11.2 Rear Brake Pedal Free Play

12 SHOCK ABSORBERS AND REAR FORK
- 12.1 LH and RH Front Shock 
- 12.2 Drive Belt
- 12.3 Rear Fork Assembly
- 12.3.1 Rear Shock Absorber
- 12.3.2 Rear Fork

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 Drive Pulley Removal
- 13.5.4 Starter Motor Removal
- 13.5.5 Thermostat Removal
- 13.5.6 Pump Removal
- 13.5.7 Cylinder Head Cover Removal
- 13.5.8 RH Cover Removal
- 13.5.9 Clutch Removal
- 13.5.10 Shift Lever Assembly, Shift Positioning Component and Positioning Star Wheel Removal
- 13.5.11 Oil Pump Removal
- 13.5.12 Cylinder Head Removal
- 13.5.13 Magneto and Double Gear Removal
- 13.5.14 Cylinder Body Removal
- 13.5.15 Piston Removal
- 13.5.16 Oil Pan Removal
- 13.5.17 Oil Rail Cover Plate Assembly Removal
- 13.5.18 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 Drive Pulley Installation
- 13.7.28 Oil Filling, Oil Level Inspection, Oil Pressure Inspection

14 HANDLEBAR AND TRIPLE CLAMPS
- 14.1 Handlebar Switch
- 14.1.1 LH Handlebar Switch
- 14.1.2 RH Handlebar Switch
- 14.2 Throttle Handle
- 14.3 Handlebar Inspection
- 14.3.1 Clutch Handle Play Inspection
- 14.3.2 Clutch Cable Free Play Adjustment
- 14.4 Handlebar Interference Inspection（Double Seats）
- 14.5 Handlebar Interference Inspection（Single Seats）
- 14.6 Handlebar Maintenance
- 14.6.1 Throttle Cable Free Play
- 14.7 Triple Clamps Front Fork Pipe