Cfmoto
Cfmoto
Cfmoto
Manual
WWW.CFMOTO.COM
WWW.CFMOTO.COM
Rear wheel、Brake、Suspension 8
CFMOTO reserves right to make improve-
system
ments and modifications to the products
without prior notice. Overhaul and mainte- Electric system 9
nance should be done according to actual
condition of vehicle.
Lights、Instruments、Switches 10
Carburetor 11
Circuit diagram 12
Troubleshooting 13
April. 2011
Conversion table
Item Example Conversion
Pressure 200 kPa(2.00kgf/cm2) 1kgf/cm2=98.0665kPa 1kpa=1000Pa
33kPa (250mmHg) 1mmHg=133.322Pa=0.133322kPs
Torque 18N.m(1.8kgf-m) 1kgf.m=9.80665N.m
Volume 419ml 1ml=1cm3=1cc
1l=1000cm3
Force 12N(1.2kgf) 1kgf=9.80665N
1 Maintenance information (Chassis)
Notes during operation...........
........... 1-1 Table of maintenance parameters........1-8
Cautions to disassembly, assembly ... 1-3 Fastening torque...................... 1-9
Number marking position..............1-6 Grease, sealant...................... 1-10
Table of main parameters............ 1-7 Layout of cables, pipes and guy cable... 1-11
1
Notes during operation Cautions When the engine just stops, the tempera-
ture of engine, muffler is still high; please do not touch
Cautions Exhaust contains toxic ingredients. Do not
them with bare hands, for avoiding burn. Please wear
run the engine in closed places or places with poor ven-
uniform with long sleeves as well as gloves when
tilation for a long time.
maintaining.
1-1
Cautions The Battery may produce combustible and such as rear wheel, clutch etc clip your hands or
explosive hydrogen when it is being charged. So it clothes when maintaining.
may explode if there is flame or electric spark. So Cautions The asbestos dust on the brake drum is
please charge it in the place with nice ventilation. carcinogenic is breathed in. Do not clean off the dust
with compressed air. Use cleaning detergent to avoid
dust proliferation.
1-2
1 Maintenance information (Chassis)
Cautions to disassembly, assembly
The parts, lubricant and grease must adopt the Please clean the dirt, dusts on the vehicle before
pure parts of Chunfeng Brand or recommendation. maintenance.
The parts of each system shall be arranged and The elastic retainer will deform if it is opened too
stored separately, so that the parts can be as- wide upon disassembly, then it will easily fall off
sembled to the original places. when assembled again. Please do not use the
elastic retainer that is already loose and without
elasticity.
1-3
The rubber parts shall be checked whether they are
aged upon disassembly, renew them in advance when
The recommended lubricating grease must be applied
necessary. Besides, try not to make volatile oil, grease
etc attach on the rubber parts, for they are not resistant to or injected in the appointed positions.
Do not let the bearing race turn back when blowing the
The side with chamfer shall face the impact direction
ball bearing by compressed air after washing. If the bear-
when installing the circlip. The circlip that is loose al-
ing race turns back, its high back turning speed will be
ready or without elasticity shall not be used again. Rotate
beyond the limit that may result in damage of bearing.
the circlip after assembly, for confirming that it is installed
The bearing shall be lubricated with engine oil or grease
before assembly. in the groove properly.
1-4
1 Maintenance information (Chassis)
Each fastening part must be inspected whether they are
tightened and work well after assembly. Brake fluid and coolant may damage coating, plastic and
rubber parts. Flush these parts with water if splashed.
1-5
Location of VIN No. and Engine No.
Model: CF150-A
VIN No.: LCEPDKL2XXXXXXX
Engine serial No.:157MJ-2A
1-6
1 Maintenance information (Chassis)
Main specifications
Item Specifications
Model name and type Leader CF150-A
Length 2040mm
Width 750mm
Height 1070mm
1
Wheel base 1280mm
Engine model 157MJ-2A
Displacement 144.9ml
Fuel grade (Octane) 90# or above
Gross weight 128kg
Passengers 2 persons(including driver)
Load capacity 150kg
F/W 2.75-18 42P
Tire specifications
R/W 3.25-18 52P
Min. ground clearance 170mm
Min. turn radius 4.2m
Steering Right 42º
Turn angle
device Left 42º
Front Disc
Brake system
Rear Drum
Suspension Front wheel Telescopic fork
Suspension type
system Rear wheel Swingarm
Steel tube and
Frame type
plate
Item Standard
1-7
Maintenance data
Front wheel
Se rv ic e
I te m Sta n da rd v a lu e li m it
B e nd in g o f fro n t w he e l s h a ft - 0. 2m m
L on g it ud a l 0 . 8m m 2. 0m m
R im run -o u t
Ho ri z on ta l 0 . 8m m 2. 0m m
F ro n t
Re m a in in g
w he e l - 1. 6m m
g ro ov e
Ti re
Ai r 1 75 k P a ( 1.7 5kg f /
-
p re s su re c m 2)
Rear wheel
Se rv ic e
I te m Stan d a rd va l ue li m it
Rim L o ng i tu da l 0 .8m m 2. 0m m
ru n- ou t H or iz o nta l 0 .8m m 2. 0m m
R em a in i ng
- 1. 6m m
g ro o ve
R ea r wh ee l
Si ng l e p e rs o n: 20 0 k Pa
Tire -
A ir ( 2. 0k gf/ c m 2 )
p re s s ur e D o ub l e pe rs o n :
—
2 25 k Pa ( 2. 25 kg f/ cm 2 )
Brake system
Se rv ic e
I te m Sta nd a rd v a lu e li m it
Free play of front brake 10-20mm -
F ro n t b ra k e
Br ak e d is c w ea r 4mm 3m m
Free play of rear brake 10- 20mm -
R ea r b rak e Sta nd a rd d i am e te r :
Br ak e d ru m we a r 1 32 m m
1 3 0m m
1-8
1 Maintenance information (Chassis)
Tightening torque
To rq ue To rq ue
I t em N· m ( k gf ·m ) I t em N · m ( kg f· m )
5 m m B olt 、 Nu t 5( 0. 5) 5 m m S c re w 4 ( 0 . 4)
6 m m B olt 、 Nu t 10 ( 1 .0 ) 6 m m S c re w 9 ( 0 . 9)
8 m m B olt 、 Nu t 22 ( 2 .2 ) 8 m m S c re w 2 5 ( 2. 5)
1 0m m B o l t 、 N ut 34 ( 3 .5 )
6 m m S H B ol t wit h f l an ge
1 2 ( 1. 2) 1
6 m m B ol t an d nu t wi t h
1 2m m B o l t 、 N ut 5 4( 5. 5) 2 6 ( 2. 7)
f l a ng e
8 m m B ol t an d nu t wi t h 3 9 ( 4. 0)
f l a ng e
1 0m m B ol t a nd nu t wi t h
f l a ng e
T igh t en ing
D i am e t er
I t em Pcs t o rq ue R e m a rk s
( mm)
N ·m ( k gf · m )
D i s as s em b l y o f e ngin e
M ou n ti n g bo lt , e ng in e s us p ent i o n 8 8 3 0( 3. 1)
N ut , e ng ine s u sp en sio n s ha ft 1 14 1 00 ( 1 0. 1)
F ro nt wh eel , f ro nt su sp en sio n,
s t ee ri n g s ys t em 1 10 4 0( 4. 1)
N ut , s t ee ri n g c olum n
4 8 2 0( 2. 1)
S c re w, h and leb ar
N ut , f r on t w he el sh af t 1 12 6 5( 10 .1 )
Up p er B o l t, s hoc k a bs o rbe r 2 8 2 0( 2. 1)
L ow er b ol t , s h oc k a bs or be r
2 10 4 0( 4. 1)
R e ar w he el, re ar s u sp en sio n
N ut , r ea r w he el s haf t 1 14 1 00 ( 1 0. 1)
Up p er B o l t, s hoc k a bs o rbe r 2 10 4 0( 4. 1)
L ow er b ol t , s h oc k a bs or be r 2 10 4 0( 4. 1)
R et ai n er n ut , rea r b rak e
1 8 2 0( 2. 1)
B r ak e s y st em
M o un t ing b olt , f r on t b ra ke d isc 4 8 3 0( 3. 1)
M o un t ing b olt , f r on t b ra ke c a li per 2 8 3 0( 3. 1)
M u ff l e r
Nu t , e xh au st pi pe 2 8 2 6( 2. 7)
B olt , ex ha us t m u ff le r 1 10 4 0( 4. 1)
1-9
Lubricant grease & sealant
C o at ing are a Oi l o r Gr ea s e
R a ce , s t ee ring tu be
L ips of dus t pr oo f s ea l, f r on t w he el
R o ta tio n ar ea, re ar br ak e s us pe ns ion a rm
s h af t
C o nne c tio ns of da sh bo ar d c ab le
C o nne c tio ns of t hr ot t le c ab le a nd c h ok e
c a ble
Mu lti -pu rp os e g re as e
Th ro t tl e an d c hok e
R o ta tio n ar ea , r ea r lef t f o ot re s t
R o ta tio n ar ea , r ea r rig ht fo ot r es t
R o ra tio n ar ea , s ide s t an d
B u sh ing , r ea r s win g ar m
G ea r, c ou nt er
S h af t , ma in s ta nd
N u t th re ads and c on ta ct s ur f ac e, r ea r E n gine oil
w he el s ha ft
L ips of du st pr oo f s e al, fr on t s ho ck S h oc k a bs or be r oil # 5
a bs o rbe r
I n ne r ro un d su r fa ce , h an dle ba r E n gine oil
1-10
1 Maintenance information (Chassis)
Diagram of cables,pipes and wiring
1-11
1-12
1 Maintenance information (Chassis)
1-13
1-14
1 Maintenance information (Engine)
Maintenance information
1-15
General precautions
Caution:Proper repair and maintenance is very important not only to worker’s safety, but
also to engine reliability and safety.
1. The personnel shall make them be aware of each other from time to time when operating, for safety
confirmation.
2.·Exhaust contains toxic ingredients. Do not run the engine in closed places or places with poor ventilation for
a long time.
3. ·No smoking or naked fire is allowed at the operation site, for the gasoline is combustible. Not only flames,
but electric sparks shall be avoided. Besides, the vapored gasoline is explosive, please operate it in the place
·5. When the engine just stops, the temperature of engine, muffler is still high; please do not touch them with
bare hands, for avoiding burn. Please wear uniform with long sleeves as well as gloves when maintaining.
· 6. In case fuel, lubricant system, cooling system or exhaust system has been repaired or maintained, it’s
·7. Place engine oil, coolant or waste components with proper way to protect environment.
Notes:
1.The parts, lubricant and grease must adopt the genuine parts of CFMOTO or recommendation.
2.·The parts of each system shall be arranged and stored separately, so that the parts can be assembled
to the original places.
3. ·Proper special tools must be applied to the operations which require special tools
4. Please clean the dirt, dusts on the vehicle before maintenance.
5. The recommended lubricating grease must be applied or injected in the appointed positions.
6. The fasteners such as bolts, nuts and screws shall be pre-fastened, and then be fastened on the
diagonal according to regulated fastening torque in the principle of from big to small, from inside to outside.
7. When bolts tightened by required torque with wrench, if there’re grease or oil on bolt threads and
8. The parts shall be washed and the cleanser shall be blown away by compressed air prior to
determination when they are disassembled and inspected. The working surface shall be lubricated before
assembly.
9. Inspect the necessary sites upon disassembly, measure the relevant data, so that the original status can
be resumed after assembly.
10. The gasket, O-ring, piston pin retainer and split pin must be renewed after disassembly.
1-16
1 Maintenance information (Engine)
Coolant: Coolant is anti-c orros ive and anti-rust and freez ing point s houl d be 5? low er than lowest surrounding temperature.
Recom mended co olant:- 35℃ , anti -froz en, anti-cor rosive and high-bo iling p oint
:Engine coolant is toxic, do NOT drink. Keep out of reach of children and store
Warning!
carefully.
There’re many moving parts inside engine, suc h as piston, piston ring, c ylinder, gears and so on. It’s very important to break -in during
initial driv e. Break-in c an make moving components matc h each other better, cont act bett er and adjust clearanc e to guarantee engine bett er
1、 Turn throttl e sl owly step by step after start engine. Do not turn faster and sl ower.
2、 Try to drive on a good road, do not driv e in up and down road for long time.
4、 Try to avoid sudden acc eleration or high RPM w ith no-load c ondition.
5、 Do regular repair and maintenanc e during break-in period. Remove it if any troul bes oc cur.
6、After break-in, please change engine oil, adjust elec tode of spark plug and valves clearance, inspec t oil path, and clean c arbon deposit on
head of piston and cylinder head if needed. D o a c om plete engine inspect and maintenanc e ac cording to service manual before norm al
driving.
0~ 500km : Do not run engine at ≥50% throttl e pos ition;do not change speed frequently; do not run engine at a fixed throttle position;
500~ 1000km : Do not run engine at ≥ 75% throt tle position for long tim e.
Attenion:· Do regular repair and maintenanc e during break-in period, if any troubles, please rem ov e it immedi at ely.
1-17
Location of Engine serial Number
Location of
engine serial number
1-18
1 Maintenance information (Engine)
No.
1 E ngine type Single cylinder, 4 -stroke ,wa ter-c oo led, 2 v alves and
SO HC 1
2 B ore× Stroke 57mm ×56. 8mm
Ig nition ty pe CDI
E lectric
7 Spark plu g & g ap CR9EP /0.8-0.9m m
syste m
Fly whee l 3-phas e A C (ro tor and s tator)
Ty pe Tria ngular
Combu stion
8 A ir filter Spong e elem ent
syste m
G asoline RQ-90
Valv es
9 Valve t ype SO HC/ Cha in d rive
syste m
4 gear 1.143
5 gear 0.957
14 Ne t weig ht 27.5k g
16 Ro tatio n direction of o utput shaft An ti-clockwise from le ft side view wh en goe s fo rward
1-19
Service data
Valves & cylinder head (mm)
IN. 27.5 —
Dia. Of valve stem
EX. 24 —
IN. 0.06-0.08 —
Valve clearance (cold engine)
EX. 0.1-0.13 —
IN. 4.975-4.990 —
Outer dia. Of valve stem
EX. 4.955-4.970 —
IN.
33.67 —
Height of cam.
EX
33.314 —
1-20
1 Maintenance information (Engine)
56 .97-56.9 9 1
Dia. Of piston shirt 7m m away from pisto n skirt end whe re —
m easure d
1-rin g R ≈7 —
Free open cut of piston ring
2-rin g R ≈7 —
—
1-rin g 0.1 5-0 .25
Close cle ara nce of piston ring
—
2-rin g 0.1 5-0 .25
—
Clea ra nce be twe en pisto n ring and 1-rin g 0.0 15-0.05
—
piston gro ove 2-rin g 0.0 15-0.05
—
Run-out o f crankshaft 0.04
1-21
C lu tch + Tra nsi mi ssio n (m m )
N ume r of spring 5
Adjus tm ent of c lutc h s crew Finish rotat ion o f sc rew and ret urn circ le of 1/4 -1/2
Pres su re of radiator c ov er —
1 08k Pa
ope ning
T ype 0 030-0226 00
R e sistan ce ( w hen
≥ 1M Ω
2 5℃ )
1-22
1 Maintenance information (Engine)
Electric system
Item Standard data Remarks
Type CR9EP
Spark plug
Gap 0.8-0.9
Charicteristic of spark plug >8mm,1 Mpa
Resistance of Primary 4±0.2 Ω
ignition coil Secondary 15±10 kΩ
Resistance of
Pick-up 110±11 Ω
flywheel coil
Voltage with no-load of
flywheel >50V(AC),5000 r/min
(cold engine)
Max. power of flywheel 140W ,6000 r/min
13.5V-15.0V , 5000
Voltage of regulator
r/min
Peak voltage of primary
12V
ignition coil
Peak voltage of pick-up coil >1.5V
Resistance of starter relay 3Ω-5Ω
1-23
157MJ-2A Engine tightening torque table
Dia. Of Torque
Item Qty Remarks
thread(mm) (N.m)
M5 6~8
M8 18~25
1-24
1 Maintenance information (Engine)
9 Feeler gau ge Measure surface flatness and adju st valve clrea rance
30 Straight screwdriver
32 Wre nch sle eve s One set Remove b olts and n uts
1-25
Special tools
No.
7 Install tool for bearing One set Install bearing and oil seal
1-26
1 Maintenance information (Engine)
Th ere are lub rican ts (such as oil), greas e (bu tte r) , c o olan t, se ala nt and glue s.
Oil Ca pacity
Mo vin g pa rts in sid e cylind er 1
12 00m L (C ha nge oil)
G ra de : Mo vin g pa rts in sid e cran kcase
En gin e oil 12 50 m L ( R epla ce oil
S AE 15 W -40 Mo vin g pa rts in sid e cylind er h ea d
fi lte r)
O r A PI: S F or S G L ub ricating d iag ra m p lea se see pag e 4-11
14 50 m L ( Eng ine
O il g ra de p leas e s ee p ag e 1-17
overha ul)
L ub rican t o il
Piston pin , va lve stem , v alve se al,
with
ca m sh aft
m o lyb de num
cylinde r a nd cylin de r he ad
of scre w
1-27
2 VEHICLE BODY & MUFFLER
Overhaul information............2-1 Front fenderchain cover..............................2-7
Seat,rear rack………………..2 -2 Lock seat,helmet lock…………………………….2-8
Front protective cover(LH&RH)、 Headlight cover……………………………………2-9
side cover(LH&RH)…… 2-3 Muffler,(L/R)triangular panel……………………2-10
Fuel tank ………………… 2-4 Cable,plastic parts………………………………..2-11
Top cover of tail Light ……2-5
Rear license bracket、rear flector、
rear mudguard……………2-6
2
Overhaul information
Caution
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.
Special attention should also be paid to sparks. Gasoline may also be explosive when it is
vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.
1.This chapter here introduce operation of disassemble and assemble for cover material
muffler and fuel tank .
2.Hoses, cables and wiring should be routed properly.
3.Replace the gasket with a new one after muffler is removed.
4.After muffler is installed, check if there is any exhaust leakage.
Tightening torque
Bolt of tailight/brake light cover 1.8N.m(0.18kgf.m)
Bolt of turning light cover 1.8N.m(0.18kgf.m)
Trouble shooting
Too big noise of muffler
1.Muffler breakage
2.Exhaust gas leakage
Not powerful
1.Muffler deformation
2.Exhaust gas leakage
3.Muffler blocked
2-1
Seat
Remove
Inset key to helmat lock
Turning the key 90 degrees in clockwise ,while
seat is broken away from seat lock ,pull out seat.
Installation
Reverse the removal procedures for installation.
Caution
Make sure there is no deviation of
the seat by shaking it after installation .
Rear rack
Remove
--two bolt 1
--one bolt 2
Remove rear rack
Installation
Reverse the removal procedures for installation.
2-2
2 VEHICLE BODY & MUFFLER
Left,Right front protect cover
Remove
--2 bolt
Pull along protect cover,until break away from
hanger of fuel tank ,then renmove left¡¢right front protect
cover .
Installation
Reverse the removal procedure for installation. 2
Caution
Adjusting front cover in perfect position
before installation.
Installation
Reverse the removal procedures
for installation.
2-3
Fuel tank
Remove
Remove seat,left&right front protect cover ,
left&right middle guard board
Loosen 2 hoops and remove fuel oil steam
pipe I and oil pipe.
Caution
Make sure fuel switch off before removing oil
pipe.
Loosen 2 bolts
Pull back fuel tank,until front supporter of fuel
tank is broken away from cushion rubbermat,
then lift front part of fuel tank up 30 degrees,
util it breaks away from frame.
Remove connection of oil line sensor
Remove fuel tank
Installation
Reverse the removal procedures for
installation.
Caution
Fixing connectors of fuel level sensor ,fuel
evaporated pipe and fuel pipe before fixing fuel
tank
2-4
2 VEHICLE BODY & MUFFLER
Top cover ,tail light
Remove
Remov seat,rear rack
Loosen tapping screw,pulling back tail light top
cover
Remove top cover of tail light
2
Installation
Reverse the removal procedures for
installation.
Backpalte(LH&RH)
Remove
Remove seat,rear rack
Remove top cover of tail light
Loosen 2 bolts &2 nuts
Installation
Reverse the removal procedures for
installation.
2-5
Rear license bracket&rear
reflector&rear fender
Remove
Remove seat,rack,top coverof tail light and
backplate(L&R) in turn.
Loosen 2 bolts (fix nut 1 at the back of fender
with spanner),remove rear license bracket
Loosen nut 2,remove rear reflector
Loosen 2 screws
Loosen 2 bolts
Loosen 2 screws
Pull up connector of rear turn light cable
Remove rear fender
Installation
Reverse the removal procedure for installation.
Rear innerfender
Remove
Remove seat,rack,top cover of tail light and
backplate(L&R) in turn .
rear fender
Loosen 2 bolts
Remove rear innerfender
Installation
Reverse the removal procedures for
installation.
2-6
2 VEHICLE BODY & MUFFLER
Front fender
Remove
Loosen threaded sleeve(arrows of flexible shaft
,autometer),remove flexible shaft of autometer
Installation
Reverse the removal procedures for
installation.
Cover of chain
Loosen botl 1
Loosen botl 2
Pull it up ,remove chain cover
Installation
Reverse the removal procedures for
installation.
2-7
lock bracket of seat, helmet
lock
Remove
Loosen 2 screw 1
Remove lock bracket
Remove dragline of seat
Loosen screw 2
Remove helmet lock
Installation
Reverse the removal procedure for installation.
Loosen 2 bolts 2
2-8
2 VEHICLE BODY & MUFFLER
Loosen 1 bolt 3
Installation
Reverse the removal procedures for
installation.
Headlight coverRemove
Remove headlight cover
Loosen 4 bolt ,remove front turn light
Loosen 5 tapping screw,5 screw ,remove head
light
Loosen 4 nut 1,renmove air deflector and front
cover of Headlight
Lloosen nut 2,remove front turn light
Installation
Reverse the removal procedures for
installation.
2-9
Muffler ,Triangular shield(R)
Remove
Remove clip
Remove outlet pipe of gulp valve
Installation
Reverse the removal procedure for installation.
Lloosen bolt 1
Loosen bolt 2
Remove triangular shield(LH)
Installation
Reverse the removal procedures for
installation.
2-10
2 VEHICLE BODY & MUFFLER
Cable
Remove
Loosen screw
Remove connector of choke cable out of
carburetor,then can remove choke cable
2-11
3 Inspection and Adjustment (vehicle body)
Maintenance information
3
Note:
zIt is forbidden to run the engine for long time in closed place or place without nice ventilation,
because the tail gas contains poisonous elements such as carbon monoxide (CO) etc.
zWhen the engine just stops, the temperature of muffler and engine is still high; they will
burn the skin if they touch it. Uniform with long sleeves and gloves must be worn for
operation when overhaul is necessary while the engine just stops.
z Gasoline is easily combustible, so no smoking or naked fire is allowed at the operation
site. Not only flames, but also electric sparks shall be avoided. Besides, the vapoured
gasoline is explosive, please operate it in the place with nice ventilation.
zPlease be cautious that do not let the turning pieces such as driving system etc as well as
movable pieces clip your hands or clothes.
Note:
The vehicle must be placed in an even and stable place, raise the vehicle properly with the main
support of the vehicle or maintenance bracket.
3-1
P e rio dica l rep la c in g parts ch a rt
T his m o torc ycle m us t d o pe riod ica l m ainte nanc e re gu larly. K e ep m o torc ycle b e c lea n b efo re do ing
m ain tena nc e.
T im ely Ins pec t, Clean , A d ju st, Lubr ica te o r R ep lac e M ark : “I”; Clean : “C ”; R ep lac e:” R”;
Lu bric ate :”L”
W ith o u t * m a rk ite m : us er do m ain tenan ce b y him se lf. O r go to C FM OT O m a in ten a n ce
stati o n to do m a in ten an ce .
W ith * m ark item : d o m ain t en an c e b y C F M OT O m ain ten ance tech n ica l p e rs o n. If u se r h as
sp ecia l too l, repl ace m en t p arts or m ai nten an ce kno w ledg e , h e can d o m a inte n an c e b y
h im sel f.
W ith ** m ark i tem : In ord e r to ens u re v eh ic le d ri vin g safe ty, o n ly C F M O TO m ain te n anc e
tec hn ic al p erso n d o m a in te n anc e.
R em ark 1:W he n driving th is m o torc yc le in d us t are a, m a inte nanc e period s ho w m ust be c ut s ho rt.
R em ark 2:K ilo m e ters on odo m e ter a re ov er t he m a xim al num be r, pe riod ic al m ainten an ce m u st b e
do ne as regu lat ed k ilom ete rs a s th e c hart.
3-2
3 Inspection and Adjustment (vehicle body)
Fuel switch
Check the oil pipe for any aging or damage.
In case of any aging or damage with the fuel pipes,
replace with new ones.
Check if there is cracks or bending with the vacuum
tube.
Replace it with a new one.
Torque:2.5N.m 3
Warning:
No smoking and fire
Throttle cable
Turn the throttle handle, and check if it can turn
smoothly.
Check the outer clearance of throttle cable.
clearance:2-6mm
Chain
Inspect transmission chain slackness
slackness:10-20mm
Chain adjustment:
1. loose nut of rear axle
2. loose nut of chain adjustor, adjust left and right
chain adjustors to same scale
3. turn rear wheel, check chain slackness
4. fasten adjustort nut, and then fasten rear axle nut
Caution:
After chain adjustment, must inspect clearance of
brake pedal.
3-3
Air filter
3-4
3 Inspection and Adjustment (vehicle body)
Rear drum brake
Brake clearance
Clutch
check clutch clearance:10-20mm
1. large adjustment: loose locking nut, turn large ad-
justment screw tube and adjust clearance.
2. slight adjustment: loose locking nut, turn slight
adjustment crew tube and adjust clearance
Brake fluid
keep steering handle straight, insepect brake fluid
level of up brake pump and ensure the level between
up limit and down limit.
3-5
Front suspension
Hold tight the front brake lever, press the front
suspension up and down several times.
Check front shock absorber for oil leakage,
damage or
looseness of the fastening parts.
Rear suspension
Press rear suspension up and dowm and check
if rear shock absorbers have big play and every part
has abnormal noise or loosen connection
press rear wheel and
move it side to side. And check if rear hanging
pivot has abnormal noise or loosen connection
Bolt, Nut
Check if bolts or nuts loosen. If loosen, tighten it as
appointed torque.
Tire
Inspect tire and check if it has crack or damage
Caution:
check tire pressure when tires are cooled.
Steering handle
Move steering handle side to side. and check if wires
have interference
Trun front wheel, check if front wheel has interference.
If front wheel does not move side to side smoothly,
check if steering axle tighten or not
3-6
3 Engine Inspection and Adjustment
3-7
3-8
3 Engine Inspection and Adjustment
3
Big noise if big valve clearance,power decrease if small
valve clearance.Check valve clearance based on in-
spection period. if necessary,need to adjust it .Proce-
dures as follows:
zRemove oilet plug screw 1.
zRemove the bolt of front cover(left)2.
zRemove valve cage cover 3.
zTurn crankshaft through the screw hold of the front
cover(left) ,then,adjust the TDC reticle of the flywheel
of magnetor to aim at the reticle of up oiletof front
cover(left).
zCheck the clearance between valve bottom and the
adjustable bolt of rocker .
Valve clearance
Cold state of engine
Intake valve:0.06-0.08
exhaust valve:0.10-0.13
Attention:Inspection and adjustment of valve
clearance should proceed in the cold state
of engine,and in the TDC of pistion by filler
gauge.
If valve clearance exceed specified valve,adjust it in
the prescribed limit by special tools. Process: loosen
adjustable bolt and nut.
3-9
zPull out the filler gauge and recheck the
valve clearance as prescribed limit.otherwise,
readjust the valve clearance conformance to
requirement.
Valve adjustalbe bolt fastening torque:
10-12N.m
Attention:fasten bolt after fully adjust it.
z Assemble the valve cover 3,bolt cover 2
and oilet bolt 1.
Tool: screwdriver,filter guage.
Engine Idle
First inspection after 20 hours opeation.then,
check one time after every 40 hours or every
1000km.
zStarting engine to fully warming.then,check
the engine idling during in 1350r/min-1650r/
min by tachometer.
Engine idling:1350r/min-1650r/min
Note:Adjust engine idling after engine
warming.
Tool:Tachometer
Spark plug
First inspection after 20 hours operated.then,
Check one time for every 80 hours or 2000km.
change it for every 6000km.
3-10
3 Engine Inspection and Adjustment
Note
Tighten the spark plug by hand avoid to dam-
age the thread of cylinder head.then,tighten
the spark plug by special tools.
Spark plug tighten torque:17-19N¡¤m
Air filter
Check it every 2000km, clean and change it
if necessary.
3-11
Warning:Don’t clean filter by gasoline and low
flash point of solvent cleaning
z Check filter of air filter whether it is
damaged,if damaged,change the filter.
Note:Keep clean for filter during
operation.
Quicken damage if without filter,dirty filter or
damanged for working.Frequently clean the
filter if working in the dirty situation.
z Check the air inlet,if dust in it,clean it by
cleanout fluid.
zCheck the oil storage pipe 4,if with oil.clear
the oil after take off strap and oil pipe.
lInstall the air filter as contrary process.to be
sure it is reliably for seal and filter element
fixed.
Accessories:cleanout fluid,SAE30 or
SAE10W/40 engine oil.
Tool:cross screwdriver,cleaning utensil.
3-12
3 Engine Inspection and Adjustment
zIf without engine oil,loosen the bolt 2,add en-
gine oil.keep oil as same level with F line.
Engine Oil:SAE10W/40 SF or SG
3-13
Note:Engine oil should change while heat engine.change oil filter,meanwhile change engine
oil.
Engine oil change volume
Only engine oil change: 1.2L
Meanwhile,change oil filter: 1.25L
Engine overhaul: 1.45L
Cooling system inspection
zCheck radiator,subsidiary water tank.,clamp situation,leaking situation of cooling liquid,if
damaged,change it as new parts.
¡ñcheck cooling liquid by observe the height of cooling liquid and up&down scribed line. if
below it,fill cooling liquid untill the top level.meanwhile,open the radiator cover,fill cooling liquied
into radiator.
Warning:
zDon’t open the radiator cover if engine is not cooled,otherwise,you will damaged by water
1.Engine assembly
2.Water pump
3.Water pump,outlet.
4.Outlet,Radiator
5.Radiator assembly
6.Fan motor element.
7.Inlet,radiator.
8.Reservoir tank
3-14
3 Engine Inspection and Adjustment
3-15
Engine oil pressure inspection
Engine oil pressure is important indicator to
show stand of fall for engine working.
Engine oil pressure:9.8~
~29.4kPa in 3000r/min
zAbove-mentioned combination.
zBlocking of vitta.
zAbove-mentioned combination.
3-16
4 Cooling and Lubricating System
4-1
157MJ-2A engine cooling system
1.Engine COMP.
2.Water Pump COMP.
3.Outlet hose of Water pump
4.Outlet hose of Radiator
5.Radiator Assy
6.Fan Comp.
7.Inlet hose of Radiator
8.Reservoir COMP.
4-2
4 Cooling and Lubricating System
Engine Coolant
zCoolant used in cooling system is mixture of 50%
distilled water and 50% ethylene glycol antifreeze. This
mixture ratio provides optimized corrosion resistance
and fine heat production.Coolant will protect t cooling
system from freezing at temperature above -30
degrees,celsius.Mixing ratio of coolant should be in-
creased to 55% or 60% according to the figure on the
right.
Warning!
zUse high quality ethylene glycol base antifreeze
mixed with distilled water.Never mix alcohol base an-
tifreeze or other different brands of antifreeze
zThe ratio of mixture should not be more than 60% or
4
less than 50%
zDo not use anti-leak additive
Warning!
zNEVER open radiator cap when engine is still hot.
Or you may be injured by scalding fluid or steam;
zCoolant is harmful.DO NOT swallow or stain your
skin or eyes with coolant.In case of the above,flush
with plenty of water and consult a doctor if necessary;
zKeep coolant away from reach of children
Warning!
zWhen removing tester,put a rag on radiator filler to
prevent splash of coolant
zDO NOT allow testing pressure to exceed radiator
cap response pressure.
4-3
Inspection and Clean of Radiator and
Water Hoses
Inspection of Radiator
zRemove radiator cap1
zConnect radiator cap to barometer2
Inspection of Waterhoses
4-4
4 Cooling and Lubricating System
4
zInstallation:Apply a little thread locker to the bolts
and tighten to the specified torque .
Inspection of Thermoswitch
zRemove thermoswitch
Tool:Ammeter
Thermoswitch operating Temperature:
(OFF-ON):Approx.88degrees(C)
(ON-OFF):Approx.82degrees(C)
Note:
zAvoid sharp impact on thermoswitch.
zAvoid contact of the thermoswitch with thermom-
eter or vessel.
4-5
Inspection of Water Temp.Alarm switch
zRemove Water Temp.Alarm switch
Tool:ohmmeter ,thermometer.
Note
zAvoid sharp impact on water temp. Switch
zAvoid contact of water temp. Switch with thermom-
eter or vessel
zAfter installation ,check the coolant level, fill coolant
if necessary.
Inspection of Thermostat
4-6
4 Cooling and Lubricating System
zcheck the thermostat pellet “3”if any broken ,re-
place it.
ztest thermostat as the following steps:
Water Pump
Removal and Disassembly
Note
Before draining coolant,check water pump for oil or
coolant leakage.In case of oil leakage, check water
pump oil seal, O-ring, In case of coolant leakage ,
check water seal .
4-7
zRelease clamp”1”remove water hose “2”
z Note
It should be clean up the contact surface of wa-
ter pump body and cover ,in order to affect the
sealing of gasket.
4-8
4 Cooling and Lubricating System
4
zRemove moving ring seal “12” from impeller.
4-9
Stationary Seal Ring:
zCarefully check stationary seal for damage, espe-
cially the seal face.
zIN case of damage or leakage,replace the station-
ary seal ring,if necessary ,replace moving seal ring.
4-10
4 Cooling and Lubricating System
4-11
zSchematic diagram of engine lubrication system
1.crankcase oil tray 2.engine oil screen 3.Oil Strainer Cover
4.Oil Level Mirror 5.Oil drain plug 6.Oil Pump Assy
7.Oil Fiter Assy. 8.Clutch 9.Countershaft 10.Mainshaft 11.Crankshaft
12.Cylinder Assy. 13.Piston 14.Camshaft
zEngine lubrication system:most of parts inside engine which run at high speed,like
piston, Crankshaft,Camshaft all need great lubrication,the good lubrication is the base of
the good condition of engine working.
157MJ-2A engine is used pressure and splash lubrication system,Apply special engine oil for
4-Stroke engine,Engine Oil is not only used for lubrication,but also for clean rustproof,sealing
and cooling.
4-12
5 ENGINE REMOVAL AND ASSEMBLY
5-1
Engine removal
Preparations
zPrepare a plate for parts;
zPrepare tools;
zDrain all oil and coolant;
Engine outside
Carburetor
zLoosen two bolts 1, and remove
carburetor 2.
Water pump
Gear contactor
Use a screwdriver to loosen two pieces of
bolts 3, and remove gear contactor
DUAL GEAR
Take out dual gear axle and remove duel gear
4.
5-2
5 ENGINE REMOVAL AND ASSEMBLY
ing motor 2.
Oil pump
zLoosen 3 pieces of bolt 12, and then remove
oil pump 13.
5-3
Engine head
Timing sprocket tensoioner
zRemove bolt 1 and take out tensioner spring;
z Remove tensioner bolt and then the
tensioner.
Spark plug
zUse a special tool to remove spark plug 1.
Cylinder cover
zRemove valve room cover 1;
zRemove cover bolt;
zRemove cylinder cover;
zRemove cylinder cover pin.
Camshaft
5-4
5 ENGINE REMOVAL AND ASSEMBLY
MAGNETO ROTOR
Main gear
5-5
Cylinder tightening bolt
Cylinder head
zLoosen 4 pieces of cylinder cover bolts and
copper mat.
Cylinder body
zRemove pin 1;
zRemove gasket 2;
zRemove timing chain guide;
zRemove cylinder 4;
5-6
5 ENGINE REMOVAL AND ASSEMBLY
Timing chain
zRemove dowel pin;
zRemove gasket 2;
zRemove timing chain;
Piston
zUse clipper to remove piston pin 4;
zRemove pistion pin 5;
zRemove piston.
Note:
z Keep order with cylinder during piston
5
assembly;
zDuring piston removal, clear pin or groove
surface, and use too to remove piston if
necessary. Do not use knock out the piston
with hammer
Engine crankcase
5-7
zLoosen bolt 1 and take out spacer pin spring
and neutral spacer pin.
Right crankcase
zLoosen bolts on crankcase;
zPut left crankcase downwards and right one
upward, use tool to separate left and right
crankcases, then remove right crankcase.
5-8
5 ENGINE REMOVAL AND ASSEMBLY
Crankshaft
z Use tool to separate crankshaft from left
crankcase;
5-9
Engine parts inspection
Cylinder head cover
Disassembly
Limit:0.05mm
Rocker arm
z Use a micrometer to measure external
diameter.
External diameter:Rocker arm(air inlet and
outlet)
Standard: 11.977~11.995mm
Tool: Micrometer(0~ 25mm)
5-10
5 ENGINE REMOVAL AND ASSEMBLY
Rocker arm
zDuring valve rocker arm, check also surface
1 and adjustment bolt for wearing ;
Assembly
Cylinder cover
Disassembly
zRemove air inlet pipe.
5-11
zTake out thermostat;
5-12
5 ENGINE REMOVAL AND ASSEMBLY
Cylinder deformation
zClear burning room and touching surface.
Valve width:
:
zCoat a layer of color on A and then insert
valve and turn gently,in order to get clear trace
use tool to fix valve head.
5
zCoating trace on valve head must be con-
tinuous and strip width must be within follow
limit. Repair if nenessary.
Tool:Valve repair.
Va l v e s t e p a n d g u i d e b u s h i n g
composition.
5-13
External diameter of valve stem
zMeasure with a micrometergauge
Tool:Feeler gauge
Valve step end status
zCheck valve step end surface for corrosion
and wearing. If A is less than the limit,repair
it.
Valve stem length limit:4.5mm
Tool:feeler gauge;
5-14
5 ENGINE REMOVAL AND ASSEMBLY
Valve spring
Valve spring is for sealing between valve and
valve seat. Loss of spring power will cause
engine power output and lead to valve
mechanic nosie.
z Measure free travel and replace spring if
limit is below limit.
Tool:Feeler gauge.
5
5-15
Cylinder head assembly
zInstall all valve spring seat 1;
zCoat every valve step sealing with
lubricant and then install valve cap end.
Material:molybdenum lubricant
5-16
5 ENGINE REMOVAL AND ASSEMBLY
Camshaft
5-17
zWearing of camshaft
Wearing of camshaft will defect valve perfor-
mance and lower engine power output.Wear-
ing of inlet and outlet limit uses a to clarify.
And use a micrometer gauge for
measurement. Replace camshaft in case
over wearing;
The limit of camshaft travel
Inlet camshaft:5.6695mm
Valve exhaust camshaft:5.314mm
Tool: Micrometer gauge(0-25mm)
zCamshaft bearing wearing
During cam shaft assembly , measure clear-
ance between camshaft and bearing hole
tojudge if the cleearance is within the limit.
Camshaft work-out clearance limit:0.15mm
Measurement method:
zClean cylinder head and cover.
zPut plastic clearance gauge external surface
of camshaft touching position and then as-
semble it with cylinder head cover;
zInstall cylinder head cover and tighten bolt
with proper torque
zDisassemble cylinder cover and then read
data on the gauge.
Tool: Plastic clerance gauge.
Tool:Plastic gauge
Note:Do not turn camshaft during plas-
tic gauge assembly.
If oil clerance exceeds the limit, measure di-
ameter of camshaft, replace camshaft in case
of over limit or replace cylinder head and head
cover.
zCamshaft assembly external diameter
Use a micrometer gauge to measure exter-
nal diameter A on camshaft assembly posi-
tion and replace camshaft in case of exceed-
ing limit.
Standard A limit:
21.959mm-21.98mm
Tool:micrometer gauge(0-25mm)
5-18
5 ENGINE REMOVAL AND ASSEMBLY
5
Cylinder body:
Cylinder body deformation:
z Use a knife straight ege and a feeler gauge
to inspect 7 points and read the limitdata and
replace cylinder body if limit is exceeded.
Limit: 0.02mm
5-19
f
Piston:
:
Piston diameter.
.
Use a micrometer gauge to measured diam-
eter at position 7mm. Replace piston in case
of lower limit
Tool:Micrometer gauge(50-75mm)
First ring:1.005-1.02mm
Second ring: 1.005-1.02mm
Oil ring: 2.005-2.02mm
5-20
5 ENGINE REMOVAL AND ASSEMBLY
First ring:7.5mm
Second ring:7.5mm
First ring:0.25mm
Second ring:0.25mm
5
Tool:vernier cliper and feeler gauge
Tool:Micrometer gauge(0-25mm)
5-21
Crankshaft
Crankshaft little end innerdiameter
Crankshaft beat
zCrankshaft big end wearing can be checked
by checking little end beat. 2 ¼ì²é £º
Crankshaft jump
zAs illustrated, put crankshaft on V-shape
support,turn slowly and use percentile scale
to measure jump, replace or repair crankshaft
if jump exceeds limit
Jump limit:0.04mm
Tool:Percentile gauge, magneto seat and V-
shape support
5-22
5 ENGINE REMOVAL AND ASSEMBLY
Clutch
Primary clutch:
zCheck bearing teeth and replace bearing A
in case of wearing or damage.
Secondary cltuch
zInner rubber wearing will cause movement
or noise between bearing and clutch. Replace
secondary B in case of serious movement 5
Plate clutch
z Use plain panel and thickess gauge1 to
measure deforming data(Limit 0.1mm),re-
place clutch plate if measurement exceeds
limit.
5-23
Clutch spring
zMeasure free travel of each spring with a
feeler gauge(Limit:29.5mm) Replace all
springs in case any length of spring is below
limit.
Crankcase bearing.
zFeel clearance of crankshaft bearing inside,
and check for noise or smooth turn with hand,
replace bearing if necessary.
5-24
5 ENGINE REMOVAL AND ASSEMBLY
GEARSHIFTING
SPROCKET
5-25
Fork
zCheck position 1
z Check position2
Repalce in case of scrach, bending or
damage.
Shift fork
zlCheck shift fork and 2
Replace in case scrach, wearing or damage.
5-26
5 ENGINE REMOVAL AND ASSEMBLY
Main,secondary shaft
zCheck main shaft 1 and secondary shaft 2.
Replace set in case of deforming, wearing or
damage.
Shift rod
zCheck 1 and replce in case of deforming,
wearing or damage.
Back spring
z Check spring 2 and replace in case of
damage, deforming.
Shaft collar
Check shaft collar 3 and replacein case
of damage or wearing.
5-27
Starting driven bearing, dual gear and
dual shaft axle.
Inspection
Overriding clutch
Inspection
l.Check working status of overriding cltuch
after installing starting driven gear onto over-
riding clutch as illustrated.
2.Hold flywheel, and status is good if starting
driven gear turns smoothly anti-clockwise.
5-28
5 ENGINE REMOVAL AND ASSEMBLY
Engine assembly
Assemble engine in reverse procedures of
assembly removal.and pay attention to follow-
ing points:
1.Clean related parts;
2.Every parts should be checked without no
damage.
3.Lubricate parts before assembly;
4.Oil lips and O-ring should be lubricated.
Crankcase assembly
Left crankcase
l.Clean oil and sealing glue on crankcase 5
sealing surface;
2.Lubricate oil seal lip;
Crankshaft rod
5-29
HUB, GEAR SHIFT DRUM AND SHIFT FORK
5-30
5 ENGINE REMOVAL AND ASSEMBLY
5-31
PRIMARY DRIVE GEAR AND OIL PUMP
Oil pump
1.Install poil pump 6 as illustrated and tighten
3 oil pump assembly bolts;
2.Install in procedures 7, 8 and 9.
Clutch
Exploded view:
5-32
5 ENGINE REMOVAL AND ASSEMBLY
PART PART NAME PART PART NAME
NO. NO.
1 CAMSHAFT, CLUTCH 14 WASHER
2 WASHER 10×20×1 15 NUT
3 OIL SEAL 10×20×6 16 FRICTION DIS C, CLUTCH
4 PLATE, OIL SEAL 17 PLATE, CLUTCH
5 BOLT M6×10 18 THRUS T ROD, CLUTCH
6 BOLT M6×16 19 ADJUST SCREW,CLUTCH
7 SEPARATE ROCKER 20 NUT M6
8 SHAFT, CLUTCH 21 THRUST BEARING & BRACKET,
CLUTCH
889102
9 WASHER20×34.5×2 22 WASHER AS152801
10 PRIMA RY DRIVEN GEA R 23 PRESSURE PLATE, CLUTCH
11 BUSHING, PRIMARY DRIVEN 24 SPRING,CLUTCH
GEAR
12 DAJUST WASHER 20 25 BOLT COMP. M5X16 5
13 HUB, CLUTCH 26
5-33
Paper element
Piston installaton
5-34
5 ENGINE REMOVAL AND ASSEMBLY
Cylinder body
Cylinder cover
5-35
Camshaft assembly and cylinder head
tightening
l.Install camshaft 1;
2.Install sprocket onto timing chain and install
timing chain sprocket on to camshaft.
Make sure marking line of timing chain in
paralle with cylinder cover connection
surface;
Note:Do not turn crankshaft during above
operation
1.Tighten cylinder cover bolt 3 and bolt 4, note
that position for both is right and do not miss
gasket;
2.Tighten camshaft timing chain sprocket bolt
5;
3.Install camshaft location washer;
4.Tighten 4 pieces of bolt 7;
Cylinder head cover
1.Clean oil on surface between cylinder head
cover and cylinder head;
2.Install dowel pins onto cylinder head;
3.Coat sealing glue on cylinder head cover
connection surface;
4.Install cylinder head cover 1 as illustraton;
5.Install two cover bolts onto rockerarm dowel
plate hole and then install onto cylinder head
cover;
6.Install rest bolts;
Note:Tightn cylinder head cover bolts two or
three times(Torque:10-12N.m);
7.Instal other assembly bolts;
5-36
5 ENGINE REMOVAL AND ASSEMBLY
Water pump
Tensioner
1.Remove bolt 8;
2.Press lock stop seat 2 and tensioner to bot-
tom as illustrated;
3.Install new tensioner 1 and then tighten bolt
4; 5
4. Install tensioner spring 6, O-ring 7 and
tighten bolt 8.
Starting motor
5-37
Dual gear
Gear connector
Carburetor
5-38
6 Engine Disassembly and Installation
Overhaul Information.................6-1 Engine Installation..................6-4
Disassembly of Engine................6-2
Overhaul Information
Operation Cautions:
-It requires an engine bench and coolant tube when installing and disassembling engine.
Do not damage frame, engine body, bolts and cables,etc.
Tightening Torque:
Engine suspension tightening nut: M8: 20-30N.m M10: 30-40N.m
Rear arm shaft tightening nut: 80-100N.m
Rear wheel axle tightening nut: 80-100N.m
6-1
CFMOTO
Disassembly of Engine
Remove:
-Seat
Front protection cover(LH&RH)
-Middle protection plate(LH&RH)
Fuel tank
-Air pipe,fuel pipe water pipe and cables
connected with engine
-Wirings connected with engine
-Muffler
-2 water pipe clamps,drain coolant.
6-2
6 Engine Disassembly and Installation
Loosen:
-Clamp to seperate carburetor and air filter.
-Clutch cable and throttle cable
Loosen:
-gear shift rod bolt
-1pc engine mounting nut
-rear arm shaft nut
Remove engine
6-3
CFMOTO
Engine installation
Note:
Do not damage bolt thread, wirings and
flexibale cables,etc.when connecting
engine with frame,
6-4
7 Front wheel,Braking,Suspension and Steering System
Overhaul information.................7-1 Front shock absorber..................7-9
Troubleshooting......................7-2 Steering column......................7-10
Handle bar...........................7-3 Front brake...........................7-12
Front wheel..........................7-6
Overhaul Information
Note
1.Securely support the scooter when overhauling front wheel and suspension system.
2.Do not overexert on the wheel. Avoid any damage to the wheels.
3.When removing tire, use the special tire lever and rim protector.
Overhaul Standard
Se r vic e
Ite m Sta nd a rd
limit
Ca mbe r o f f ro nt w h e el 7
- 0. 2m m
sh af t
Fro nt Rim Lon gitu da l 0. 8 mm 2. 0m m
wh ee l ru n- ou t Ho riz on ta l 0. 8 mm 2. 0m m
Gr oo ve lef t - 1. 6m m
Tire
Air p re su re 1 75 kPa ( 1. 75 kg f/ c m 2 ) -
Fro nt
Fr ee pla y of b ra ke le ve r 10 - 20 mm -
bra k e
Tightening Torque
7-1
CFMOTO
Troubleshooting
7-2
7 Front wheel,Braking,Suspension and Steering System
Steering bar
Disassembly
7-3
CFMOTO
Installation
reverse the disassembly procedure for installation.
7-4
7 Front wheel,Braking,Suspension and Steering System
7-5
CFMOTO
Front Wheel
7-6
7 Front wheel,Braking,Suspension and Steering System
Disassembly
Remove counter from right side of front wheel
Remove:
-sleeve, front wheel shaft
-4pcs fising bolt
-brake disc
-front disc brake disc
-dust seal
7
thickness service llimit, front disc brake disc: 3mm
7-7
CFMOTO
Installation
NOTE
Press fitting right bearing,front wheel before left breaing.
NOTE
Make sure cable is in line with counter when assem-
bling cable, speedometer..
7-8
7 Front wheel,Braking,Suspension and Steering System
Front shock absorber
Remove
front fender-(2-7)
big light cover-(¨2-8)
front wheel-(7-6)
Loosen
-2 pcs fixing bolt
-2pcs fixing screw 1
7
Installation
7-9
CFMOTO
Steering Column
Remove:
front fender-(2-7)
big light cover-(2-8)
front wheel-(7-6)
handlebar(LH&RH)-(7-9)
front shock absorber-(7-9)
2 pcs bolt, loosen dashboard
7-10
7 Front wheel,Braking,Suspension and Steering System
Installation
7
Install lower joint plate to frame riser,
insert top bearing race and dust cover.
Lock up lower jont plate with nut, adjust tightness to
proper position(standard:plate do not move up and
down, flexible move left and right)
lock up nut tightening torque:60-90N.m
7-11
CFMOTO
Front Brake
Installation
Reverse removal procedure for installation of fluid res-
ervoir and master cylinder.
NOTE
.Do bot hang brake pump on brake hose.
1.
2.Remove master cylinder first before fluid reservoir;
install fluid reservoir first before master cylinder,
do not reverse the procedure in case air enter into
hydraulic system.
3.Do not pinch front brake lever after removal of brake
pump.
7-12
7 Front wheel,Braking,Suspension and Steering System
NOTE
Cover coating and plastic parts with cloth to avoid
brake fluid.
Inject brake oil into fluid cup,suck out air with injec-
tion tube until no air in the hose, lock up relief valve.
NOTE
1.Oil level in fluid cup should keep at least half when
sucking in case of sucking in air.
2.Use recommended brake oil(DOT3 or DOT4 non-
petroleum base brake fluid)
7-13
CFMOTO
Brake Disc/Front
Brake Disc
Replace
Remove brake disc
Pres bracket, brake disc until inner pads can be get
as illustrated.
NOTE
Brake disc must be adjustmented after installing
before usage.
7-14
8 Rear Wheel,Rear Brake&Suspension
Overhaul information...............................................8-1
Troubleshooting...........................................8-2
Rear Wheel..................................................8-3
Rear arm & Rear brake.............................8-5
Overhaul info
Note
Securely support the scooter when overhauling the front wheel and suspension system.
1.Assemble the fender driving chain, make gap to the opposite way from the wheel.
2.Adjust the driving chain, double confirm the brake if need to do adjustment accordinglly.
Overhaul standard
S e r v ic e
I te m S ta n d a rd
l im i t
Camber of re a r w h e el
- 0 .2 m m
s h af t
R im L o n g it u d a l - 2 .0 m m
Rear ru n -o u t H o ri z o n ta l - 2 .0 m m
w h ee l S in g l e p e r s o n : 2 0 0 k P a
-
( 2 .0 k gf / c m 2 )
T ire p res s u re
Tw o p e rs o n: 2 25 k P a
( 2 .2 5 kg f/ c m 2 )
8
Rear T hic k ne s s o f re a r br ak e
s h oe s 4mm 2m m
br ak e
Tightening torque
8-1
Troubleshooting
Heavy steering
1.Warped rim
Poor Brake
1.Improper brake adjust-
ment
2.Stained or damaged brake disc
3.Worn brake shoe
4.brake shoes assembled imporperly
5.Worn axle arm
8-2
8 Rear Wheel,Rear Brake&Suspension
Rear wheel
Removal
Support the frame with jack, lift the front wheel,
remove
rear wheel chain adjusting nut.
Remove:
COTTER PIN . nut 1
Rear wheel axle nut, take out rear wheel axle
Front wheel
Inspection
Wheel axle
Set axle on a V block, measure axle vibration
with centesimal gauge.
8
Set rear wheel on the rotating stage,
check the rims vibration
Service Limit:
Horizontal:2.0mm
Vertical :2.0mm
8-3
Dissemble rear wheel
Assemble
Follow the opposite way of dissemble when As-
semble rear wheel
Note;
Assemble the rear axle bearing first, then press
the rear axle to assemble
8-4
Rear Arm
Disassembly
8 Rear Wheel,Rear Brake&Suspension
Remove
Rear wheel-(8-3)
Loose 2 nuts, remove rear right absorber
Loose rear armer nut
Assemble
Follow the opposite way of dissembly when asemble
Rear brake
INSPECTION
Check thickness of rear brake shoes
Using limit: to replace when below 2.00mm
Dissembly 8
Remove spring, brake shoe and rear brake shoes
Loosen brake rocker arm nut, remove rocker
arm, indicator and O ring, remove rocker
arm axle.
Installation
Spread with butter on oil groove of the rear brake
rocker arm and on picture indicating part.
Arrow on the indicator alignment with arrow on
the picture to install.Install rear brake rocker arm,
fasten with bolts
Note
Installed rear wheel, check driving chain, rear
wheel position, brake drum and brake pedal clearance .
8-5
9 ELECTRIC SYSTEM
Electric Apparatuses
9-1
Charging System
Charging Diagram
9-2
9 ELECTRIC SYSTEM
Regulator
Caution:
When Multimeter probe is unconnceted,
Multimeter voltage is below than 1.4V,
Please replace Multimeter Battery.
9-3
Starting system
Starting system Diagram
Starting Motor
9-4
9 ELECTRIC SYSTEM
Idle speed:1350-1650rpm
9-5
Ignition system
Ignition system Diagram
Ignition coil
Ignition coil primary voltage
1.Keep spark plug in the cylinder head, install quali-
fied spark plug on the spark plug cap and earth the
engine.
2. Measure the primary voltage of Ignition coil by
multimeter.
3.Connect multimeter and peak value voltage adapter
as follow:
+ Probe: Green Downlead/Ground
- Probe: Black/Yello Downlead
Notice:
Confirm the voltage of battery 12V
Downlead of Ignition coil is connected.
Refer to User Guide when using Multimeter
and Peak value voltage adapter
Warnning
When measuring the voltage, do not touch the termi-
nal with finger to avoid electric shock.
9-6
9 ELECTRIC SYSTEM
6. Refer to Troubleshooting and check all the items
when the measured value is lower than the specified
value.
9-7
10 Lights&instruments&switches
Overhaul information................10-1 Handlebar switch..................10-5
Troubleshooting.....................10-2 Electrical horn.................. 10-5
Bulb replacement....................10-3 Fuel sensor.....................10-6
Odometer Bulb......................10-3
Ignition switch .......................10-4
Brake light switch....................10-5
Overhaul information
Notice
1.Headlight bulb has larger power and the temperature is very high when it is turned on. Do not touch it
immediately after it is just turned off. Operation should be done when the bulb is cooled down.
2.The temperature of headlight is quite high when turned on. Replacing with bare hand or stained glove will
cause oil stains on the glass cover which may form heat points and cause deformation of glass face and
damage to bulb.
3.Pay attention to the following points when replacing the bulb.
£-Do not replace the bulb when it is turned on. Keep ignition switch in the “OFF”position, and replace after the
bulb is cooled down.
£-Replace the bulb with hands in clean gloves.
4.Clean the glass with a piece of clean cloth dipped in alcohol in case of any oil stains on the surface.
5.If the Inspection has to be done with battery, check if the battery is normal.
6.Inspection of switches can be done without removing the switches from the vehicle.
7.After the inspecting and overhauling of each part, routing of cables and wires should pass through the
proper positions.
Overhaul standard
10
I t em s Standard
Main 20A
Fuse
Auxiliary 10A
Headlamp( Hi / Lo ) 1 2 V- 35 /3 5W
Position light 1 2 V- 5W
Brake light/Taillight 1 2 V- 21 W /5 W
Turning light 1 2 V- 10 W × 4
Light、bulb Odometer Bulb 1 2 V- 2W × 2 、 1 2V -3 W × 2
Turning indicator 1 2 V- 2W × 2
H i gh b ea m in di ca to r 1 2 V- 2W
G e ar i nd ic at or 1 2 V- 2W × 5
N e ut ra l in di ca to r 1 2 V- 2W
10-1
Troubleshooting
Head light cannot turn on.
Hi/Lo beam can not be transfered.
1.Fuse blown
2.Switch damaged
3.Bulb burnt
4.Dead battery
5.Poor connections
10-2
10 Lights&instruments&switches
Replacing bulb
Head light bulb
Notice
Headlight bulb has larger power and the tem-
perature is very high when it is turned on. Do
not touch it after it is just turned off. Operation
should be done when the bulb is cooled down.
Remove handlebar front cover-(2-8)
Remove waterproof cover, push the Jump sring
Remove headlight bulb
Remove position bulb
Inspect the bulb. replace the bulb with a new one
if it was damaged
Position Bulb specification:12V 5W
Headlight Bulb specification:12V 35/35W
Installation
Reverse the removal procedure for installation.
Odometer Bulb
Remove handlebar front cover-(2-8)
Remove the connecter of flexible cable for odometer.
Loosen 3 pieces of screw. Remove the rear cover
of odometer.
Remove odometer bulb,
Replace with a new bulb if it was damaged
Installation
Reverse the removal procedure for installation.
Turnning light 10
Remove the screws
Take out the ligh seat,remove the bulb.
Replace with a new bulb if it was damaged
Bulb specification:12V R10W
Installation
Reverse the removal procedures for installation.
10-3
Brake light/Tail light bulb
Remove
Remove the seat.
Unscrew the tail light holder
Ignition Switch
Remove
Remove the 2 pieces of screw.
Take off the ignition switch lock.
Inspection:
Check if the coupler terminals are connected.
10-4
10 Lights&instruments&switches
Rear brake switch
Disassemble rear brake switch wire, inspect the
connection of wire.
Inspection
Push brake pedal: rear brake light works.
Release brake pedal: rear brake light doesn’t work.
Horn
Connected with a fully charged 12V battery
and check if the horn can make sounds.
if dumb, replace the horn with a new one.
If it sounds bad, turn the adjusting screw to adjust
the sound quality .
10-5
Fuel sensor
Disassembly
Remove the seat-(2-2)
Remove the front protective cover and middle protective
cover-(2-3)
Remove the fuel tank-(2-4)
Remoce the 4 pieces of nut and take out the fuel sensor.
Notice
Remove the fuel sensor fixing plate with a flat
screwdriver by turning it counter clockwise
and remove fuel sensor.
Inspection
Installation
Reverse the removal procedures for installation.
Caution:
Install the fuel sensor properly into fuel tank hole.
There should be no fuel leakage.
10-6
11 Carburetor
Carburetor
Overhaul information........................................11-2
Trouble shooting................................................11-2
Carburetor disassembly/assembly................11-3
11
11-1
Overhaul information
Caution
Note
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work
place. Special attention should also be paid to sparks. Gasoline may also be explosive
when it is vaporized, so operation should be done in a well-ventilated place.
1.Do not over twist or bend the cables. The twisted cables may cause poor operation.
2.To prevent impurities from entering into the engine after the carburetor is removed, cover the
engine air intake opening with a piece of cloth or packing tape.
Overhail Info
11-2
11 Carburetor
Carburetor removal
Carburetor
Unscrew two blolts 1, remove carburetor 2
Carburetor Assembly
Reverse the removal procedures for assembly
11
11-3
(17) Electric diagram
Start relay& Fuse
Battery
Llumination switch Hand light relpay Fan&Motor relpay Rear brake switch
Front brake switch
Kill switch Start switch
CDI
Flasher relay Fuel sensor
Turning indicator(RH)
Turning indicator(LH)
Starting Motor
Instrumert indicator
Fuel indicator
Tail light/ brake light
12v 21/5w
Water temperature indicator
water Thermostat
Fan motor
Head light
Horn
Position light
R-Red Br-Brown
B-Black O-Orange
G-Green P-Pale
Y-Yellow LR-Light red
L-Blue Sb-Light Blue
W-White Lg-light green
Gr-Grey
-49-
13 Troubleshooting
Troubleshooting
13
13-1
1.Engine part
Troubles Possible causes Countermeasures
Cylinder pressure too low
1.Cylinder wear Replace
2.Piston ring wear Replace
3.Air leakage of cylinder gasket Replace
4.Valve stem wear or unsuitable valve seat Replace or repair
5.Spark plug loosen Tighten
6.Starting motor rotate too slowly Check electric parts
7.Improper valve timing Adjust
8.Improper valve clearance Adjust
Spark plug cannot ignite or weak ignition
Cannot start or 1. Improper spark plug clearance Replace or adjust
difficult to start 2. Spark plug dirty or wet Clean and dry or repair
3.Defect ignition coil Replace
4.Pick up short circuit or open circuit Replace
5.Defect flywheel Replace
6. CDI defect Replace
Insufficient fuel inside carburetor
1.Breather hole blocked Clean or Replace
2.Fuel switch failure or blocked Clean or Replace
3. Valve needle failure Replace
4.Fuel tank blocked Replace
5.Carburetor blocked Clean or Replace
13-2
13 Troubleshooting
Troubles Possible causes Solutions
13-3
Troubles Possible causes Solutions
13-4
13 Troubleshooting
Troubles Possible causes Solutions
2.Carburetor
13
1.Needle valve worn or damaged Replace
2.Needle valve spring damaged Replace
Overflow or fuel
3.Float work failure Adjust or Replace
level fluctuation
4.Needle valve dirty or blocked Clean
13-5
3.Cooling system/Radiator
Troubles Possible causes Solutions
4.Ignition system
Troubles Possible causes Solutions
13-6
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