Cfmoto

CF150-A Service
Manual
WWW.CFMOTO.COM
WWW.CFMOTO.COM
All rights reserved

Zhejiang CFMOTO Power Co., Ltd.
April. 2011
FORWORD
CONTENTS
Maintenance information 1
This manual introduces CF150-A maintenance
information, disassembly procedure, check & Vehicle body、Muffler 2
adjustment methods, troubleshooting and technical
specifications. There are illustrations, drawing to Checking& Adjustment 3
guide your operations. Cooling&Lubricating system 4
Chapter 1 mainly introduces general operation 5
information, tools, vehicle structure and basic Engine disassembly&assembly
specifications.
Chapter 2 mainly introduces check & adjustment Engine 6
methods and how to do vehicle maintenance.
disassembly,check&assembly
Chapter 3 mainly introduces disassembly,
installation, adjustment, maintenance and trouble- Front wheel、Brake、Suspension、 7
shooting information.
Steering system
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
Zhejiang CFMOTO Power Co., Ltd.
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.
Cautions The liquor (dilute sulfuric acid) in Battery is

Cautions The coolant is poisonous, please do not
strong corrosive; it may burn the skin and blind the eyes
drink it, do not let it contact the skin, eyes neither clothes.
when it contacts them. In case of contact, please wash it
In case it contacts the skin or clothes, please suds it
with a great deal of clear water immediately, and receive
immediately. When it contacts the eyes, please wash it
medical treatment in hospital. Besides, please also wash
thoroughly with a great deal of clear water immediately,
it by a great deal of clear when it contacts the clothes, for
and receive medical treatment in hospital. In case the
avoiding skin burn. The Battery and Battery liquor must
coolant is drunk by mistake, please try to vomit it out, and
be stored strictly, away from where children can touch.
receive medical treatment immediately after gargling. The
coolant must be stored strictly, away from where children
can touch.
Cautions Uniform (pilot uniform etc), cap, safety boots

suitable for the operation must be worn, and the safety Cautions: No smoking or naked fire is allowed at the
articles such as dustproof goggles, dustproof respirator operation site, for the gasoline is combustible. Not only
and gloves shall be worn for protection when necessary. flames, but electric sparks shall be avoided. Besides,
the vapored gasoline is explosive, please operate it in
the place with nice ventilation.
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.
Cautions The personnel shall make them be aware of

Cautions do not let the turning or movable pieces each other from time to time when operating, for safety
confirmation.
1-2
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 gasket, O-ring, piston pin retainer and split

pin must be renewed after disassembly.
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.
The parts shall be washed and the cleanser shall

be blown away by compressed air prior to deter- Inspect the necessary sites upon disassembly,
mination when they are disassembled and measure the relevant data, so that the original
inspected. The working surface shall be lubricated status can be resumed after assembly.
before assembly.
Insert and arrange the bolts one by one and make

sure the insertion volume of each bolt is equal The fasteners such as bolts, nuts and screws shall
before inserting them, when the bolt length is be pre-fastened, and then be fastened on the di-
unidentified. agonal according to regulated fastening torque in
the principle of from big to small, from inside to
outside.
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.
corrosion of gasoline or kerosene.
When disassembling the pressed ball bearing, the dis-

Proper special tools must be applied to the operations
assembled bearing must not be used again if the balls
which require special tools
are forced for disassembly.
The inside or outside track of ball bearing shall

be turned manually, for confirming the flexibility and
The installation direction of single-sided dustproof bear-
smoothness of turning.
ing shall be paid attention to upon disassembly. The sur-
The parts that are loose axially or radially shall be
face of open-type or dual-side dustproof bearing that is
renewed.
with the sign of manufacturer, dimensions shall face
The parts that are unsmooth shall be washed with
outside upon installation.
oil, and the parts that are not repaired after washing shall
be renewed (the dual-side dustproof type cannot be
washed)
Press it into the machine or axis, and the bearing
shall be renewed if the pressed part is not tight enough.
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
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.
Install oil seal with the side of manufacturer’s mark

outward.
.do not fold or scratch the oil seal lip.
When installing pipes, insert the pipe till the end. Fit the
.apply grease to the oil seal lip before assembling.
pipe clip, if any, into the groove. Replace the pipes or
hoses that cannot be tightened.
Do not mix mud or dust into engine or the hydraulic brake

system.
Clean the gaskets and washers of the engine cases
before assembling. Remove the scratches on the con-
tact surfaces by polishing evenly with an oilstone.
When assembling the parts of protection caps, insert the

Do not twist or bend the cables too much.Distorted or
caps to the grooves, if any.
damaged cables may cause poor operation.
1-5
Location of VIN No. and Engine No.
Model: CF150-A
VIN No.: LCEPDKL2XXXXXXX
Engine serial No.:157MJ-2A
1-6
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
Fuel capacity 15L

Fuel switch Flow rate：≥430mL/min
Fuel supply system
Carburetor Type: CPZ27
Idle speed 1500±150r/min
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
Lights, Dashboard, Switchs

I te m Sta nd a rd v al u e
Main 2 0A
Fuse
A u xi li a ry 1 0A
H ea d li g ht（ H i／ Lo ） 1 2V-3 5W /35 W
P o si ti on l ig h t 1 2V-5 W
B ra k e li gh t／ Ta il li g ht 1 2V-2 1W /5W
T urn l ig h t 1 2V-1 0W ×4
L i gh ts and D as h b oa rd l ig h t 1 2V-2 W ×2、 1 2V-3 W ×2
b u lb T urn i n di c at or li g ht 1 2V-2 W ×2
H ig h -b ea m i n di ca t or li gh t 1 2V-2 W
G ea rs h ift i nd i ca to r li gh t 1 2V-2 W ×5
N eu t ral i nd i c ato r li gh t 1 2V-2 W
W a ter te m p . a l arm li g ht 1 2V-2 W
1-8
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
P le as e a pp l y s ta nd ar d to rq ue to t i g ht en if t or que va lue is no t d ec rib ed at belo w t ab l e

N o te : 1 . C oa t e ng ine o il o n t hr ea ds and co nt ac t su rf ac e o f b olt s a nd n ut s.
2. Re pla ce ne w on e i f s e lf- l oc k i ng b olt i s r em o ve d.
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
Diagram of cables,pipes and wiring
1.Throttle cable 2.Harness,handlbar switch(RH) 3.harness dashboard

4.Ignition switch connector 5.Headlight connector 6.Harness,handlbar switch(LH)
7.Choke cable 8.Clutch cable 9.Turn light(L/R)10.Front brake hose
1-11
1-12
1-13
1-14
1 Maintenance information (Engine)
Maintenance information
General precaution information................................................... 1-16 1

Introduction of fuel, oil and coolant...............................................1-17
Engine break-in..............................................................................1-17
Engine picture & Location of engine serial No............................1-18
Engine specifications......................................................................1-19
Overhaul data...................................................................................1-20
Tightening torque data.....................................................................1-24
Tools................................................................................................... 1-25
Engine coolant,lubricants,grease and sealant................................1-27
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
with nice ventilation.
4. ·Do not use gasoline to wash or clean components or parts
·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
necessary to inspect its marking line or any leakage.
·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
screws, must clean it before assembly.
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
Introduction of fuel, engine oil and coolant

Fuel： Oct ane 90# or above, unleaded
Eng ine oil：O il type (SAE10W －40)
Oil grade :API (SF or SG ) 1

If abov e-mentioned oil is unav ailable, please choose
as right picture show s acc ording t o temperature.
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.
Caution： Do not mix other brand coolant to use.
Eng ine break-in
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
perform ance and reliability.
Rec omm ended break-in period is 1000Km.
Notes for break-in：
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.
3、 Keep oil path sm ooth.
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;
Av oid sudden acc elerat ion; Turn throttl e sl owly.
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.
· After break-i n, do a complete m aintenanc e and dri ve normall y.
1-17
Location of Engine serial Number
Left side view
Location of
engine serial number
Right side view
1-18
Engine technical specifications

Item I tem Specificat ions
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
3 Dis placem ent 144.9m l
4 Co mpres sion ratio 9.8：1
5 I dle spe ed 1500± 150r/min
6 Sta rting m ode Carburetor
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
Ty pe Pres sure s plash
Lu bricatio n O il pum p Rotor drive

10
syste m Filter elemen t Fu ll-f low pap er elem ent
O il grade SA E10W －40/ SF
Cooling Coo ling type Close-lo op recycle c ooling

11
syste m Coo lant typ e -3 5? ant i-freezing a nd anti-corrosive
Clutc h ty pe Wet a nd mu lti-disc ma nual clutch
Tra nsimission type Constant me sh
Num ber of g ears s hift 5 gea rs
Ty pe and order of gear shifting Mechanica l rec iprocatin g /1-0-2-3-4 -5-4-3-2-0-1
Transmis sion Prim ary ratio 3.471

12
syste m S econdary 1 gear 3
Tra nsimission ratio 2 gear 1.857
ratio 3 gear 1.368
4 gear 1.143
5 gear 0.957
13 Dime nsion L×W × H（m m）：386× 311× 439
14 Ne t weig ht 27.5k g
15 Drive m ode Chain drive
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)
Item Standard data Service data Remarks
IN. 27.5 —
Dia. Of valve stem
EX. 24 —
IN. 0.06-0.08 —
Valve clearance (cold engine)
EX. 0.1-0.13 —
Clearance between valve guide bush IN. 0.01-0.037 —
and valve stem EX. 0.03-0.057 —
Inner dia. Of valve guide bush IN. & EX 5-5.012 —
IN. 4.975-4.990 —
Outer dia. Of valve stem
EX. 4.955-4.970 —
Run-out of valve stem IN. & EX 0.03 0.05
Length of valve stem end IN. & EX 5.3-5.5/4.8-5.0 4.8/4.3
Thickness of valve head IN. & EX 0.5/0.8 —
Seal run-out of valve head IN. & EX 0.03 —
Seal width of valve seat IN. & EX 0.9-1.1 —
Inner spring 32.54 31

Free length of valve spring
Outer spring 34.98 32.5
Inner spring 33.7-44..3N when compressed to 26.78mm —

Elasticity of valve spring
Outer spring 88.6-104N when compressed to 29.78mm —
IN.
33.67 —
Height of cam.
EX
33.314 —
Clearance between outer dia. Of

φ22 0.032-0.066 0.150
camshaft and camshaft hole
Outer dia. Of camshaft φ22 21.959-21.980 —
Inner dia. Of camshaft hole φ22 22.012-22.025 —
Run-out of camshaft 0.008 —
Dia. Of rocker arm shaft IN. & EX 11.977-11.995 —
Inner dia. Of rocker arm shaft hole IN. & EX 12-12.018 —
Flatness of contact surface of cylinder

0.03 —
head
Flatness of contact surface of cylinder

0.03 —
head cover
1-20
Cylinder/Piston/Piston ring/Crankshaft (mm)

Item Stand ard data Service date Re marks
Cylind er pressure 12 00kPa —
Clea ra nce between piston a nd cylinde r 0.02-0.04 —
56 .97-56.9 9 1
Dia. Of piston shirt 7m m away from pisto n skirt end whe re —
m easure d
Inner dia. Of cylind er 57 -5 7.019 —
Flatn ess of cylin der con tact surface 0.02 —
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
1-rin g 0.9 7-0 .99 —

Th ickn ess of p ist on ring
2-rin g 0.9 7-0 .99 —
1-rin g 1.0 05-1.02 —
Width of piston groove 2-rin g 1.0 05-1.02 —
Oil ring 1.8 6-1 .96 —

—
Inner dia. Of pisto n pin hole 15 .002-15.008
—
Ou ter dia. Of piston pin 14 .994-15.000
—
Inner dia. Of connectin g rod sm all end 15 .006-15.014
—
Clea ra nce of connecting ro d big end 0.15-0.45
—
Th ickn ess of conne cting rod big en d 15 .95-16.0 0
—
Run-out o f crankshaft 0.04
Lubric ating sys te m
Item Standa rd data Se rvice da ta Re marks
Cle arance b etween oil pump inner 0.0 8mm-0.15m m

—
rotor and outer rotor
Cle arance be twe en oil p ump outer

0.1 5mm-0.19 3mm —
rotor and hole of oil pum p bod y
Oil pressure 10-30kP a when a t 3000 r/m in —
Oil typ e SA E1 0W－4 0，AP I Sf o r S G —
W hen chang e oil 1200m l —
Oil capa city W hen replace oil filter 1250m l —
W hen en gine ove rh aul 1450m l —
1-21
C lu tch + Tra nsi mi ssio n (m m )
Item Standa rd v alue Serv ic e limit R e marks
D riv e dis c of c lutc h 2.9 -3. 1 2.8
N umbe r o f driv e disc 5
D riv en disc of c lut ch 1.5 -1. 6 —
D is tortio n of driv en dis c 0.10
N umbe r o f driv en disc 4
Free len gth of c lutch sprin g 30. 4-3 1.6 29.5
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
Th ic kn ess of gear N o. 1 and N o. 2 gear 5-5.15 —
slot N o. 3 gear 5.5 -5. 65 —
Th ic kn ess of gear N o. 1 and N o. 2 gear 4.8 -4. 9 —
sh ifter fork N o. 3 gear 5.3 -5. 4 —
C oo lin g sys tem (m m )
Item Sta ndard v alue Lim it v alue R emark s
Te mperatu re of th erm ostat —

6 8-74℃
ope ning
Trav el o f thermos tat v alv e W hen 95℃ ， 3.5 -4. 5mm —
Pres su re of radiator c ov er —
1 08k Pa
ope ning
T ype 0 030-0226 00
Tem perature w hen

116℃ ~ 120℃
S w itc h “O N”
Alarm ing sw it ch of wate r
Tem perature w hen
tem perature 116℃ ~ 112℃
S w itc h “O FF ”
R e sistan ce （ w hen
≥ 1M Ω
2 5℃ ）
-30 ℃ an ti-freezing and ant i-corros iv e an d —

C o olan t typ e
h igh -bo iling p oint
1-22
Air intake system

Item Standard data Remarks
Carburetor type CPZ27
1
Choke size (mm) ø24
Idle speed（r/min） 1500 ±150
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）
Bolt, crankcase 12 M6 10～12
Bolt, oil pump 3 M6 10～12
Bolt plug, oil view hole 1 M12×1.25 18～25
Bolt cover, front left side cover 1 M26×1.5 28～32
Bolt, tensioner plate 1 M8 18～25
Bolt, overriding clutch 3 M8 28～32 Apply locking glues
Nut, flywheel 1 M10 65～75 Apply locking glues
Nut, crankshaft 1 M16×1.5（L） 85～95
Nut, clutch 1 M16 55～65 Apply locking glues
Bolt, flywheel stator 3 M6 16～20 Apply locking glues
Bolt, pick-up 2 M5 10～12
Drain bolt, crankcase 1 M14×1.25 25～30
Retainer bolt, crankcase 1 M14×1.25 25～30
Bolt, oil pass of right side cover 1 M14×1.25 25～30
Bolt, water pump 1 M6 10～12
Stud L (connecting crankcase) 2 YM8 7～11
Stud R (connecting crankcase) 2 YM8 7～11
Nut, cylinder head 4 M8 28～32
Switch, water temperature 1 R1/8 8～10 Apply locking glues
Spark plug 1 17～19
Stud, exhaust 2 M8 25～30
Bolt, timing sprocket 2 M6-10.9 15～18 Apply locking glues
Adjustable Nut, valve clrearance 2 M6×0.75 10～12
M5 6～8
Other bolts, screws and nuts M6 10～12
M8 18～25
1-24
157MJ -2 A E ngine repair tools
Mea uring gauges
Item Tool Name Specificat ion Purposes Rema rk
1 Vernier calip er 0-150m m Measure length and widt h.

1
Measure oute r diamete r of rocker sha ft, valve stem a nd
2 M icrom eter 0-25mm
cam sh aft.
3 Dial indica tor 25-50m m Measure Ma x. lift travel of camshaft
4 Dial indica tor 75-100 mm Measure size of p iston skirt
5 Inside caliper Measure cylind er inne r d iame ter
Measure inner diameter o f rocker, pisto n pin hole

6 Int ernal quick calipe r 10-34m m
and sma ll end ho le of conn ecting rod
7 Dial indica tor 1/10 0 Measure run-out
8 Knife -e dge Stee l Ruler Measure surface flatness
9 Feeler gau ge Measure surface flatness and adju st valve clrea rance
10 Plastigauge Measure clea ra nce
11 Spring balance Measure spring elasticity
12 Tachometer Measure en gine RPM
13 Cylinder pressu re gauge 0-2MP a Measure cylind er pre ssure
14 Oil pressure g auge Measure oil p ressure
15 Baromete r Measure op en pressure of rad iato r cap
16 Ohmm eter Measure resistance and voltage
17 Amperem eter Measure curre nt/switch “ON” or “OFF”
18 Thermom eter Meau re coo lant temperatu re
19 Ig nition timing light Check ignitio n tim ing
20 Torquem easuring wrench One set Measure tighten ing torq ue
Common and auxilia ry tools
22 Alcohol burner Heating
23 M egnetic stand Install dia l indicato r
24 Fla t plate Help for measureme nt
25 V-blo ck Measure vibration
26 Twe ezers Install va lve clips
27 Circlip p lie rs Remove a nd in stall circlips
28 Nipper plie rs Remove a nd in stall circlips
29 Shock starter Remove cross bolts
30 Straight screwdriver
31 Cross scre wdrive r Remove cross screws
32 Wre nch sle eve s One set Remove b olts and n uts
33 Int ernal hexa gonal wre nch
1-25
Special tools
Item Tool name Specifications Purpose Remarks
No.
Special wrench for spark

1 Remove/install spark plug
plug
Rotation stopper wrench Remove/install nut of clutch or

2
for clutch nut of crankshaft
3 Remover for piston pin Remove piston pin
4 Puller for flywheel rotor Remove flywheel rotor
Compression tool for

5 Remove/install valve spring
valve spring
6 Grinder for valve Grind valve
7 Install tool for bearing One set Install bearing and oil seal
8 Remove tool for bearing One set Remove bearing
9 Remove tool for oil seal Remove oil seal
Stopper wrench for

10 Remove flywheel
flywheel
1-26
Engine lubricating materials and other materials
Th ere are lub rican ts (such as oil), greas e (bu tte r) , c o olan t, se ala nt and glue s.
Item S pecifications Ap plie d are as Re m a rks
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
# 3 grease w ith M oS 2 Se al lip s, o -ring an d o th er rubb er seals,

Gre ase/b utte r
lith iu m b ea rin g
Co ola nt - 35 ℃ a nti-fre ezing ,

Volu me de fined by
a nti-c o rro si ve a nd C oo ling sys te m
ra dia to r
h igh -b oiling p oin t
Se ala nts C on ta ct surfa ce b etwe en c rankc ase,
cylinde r a nd cylin de r he ad
Locking glue s So m e screw o r bo lt threa ds
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
2-2
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.
Middle guard board(left)

Remove
Remove seat
Opening fix point 1
Opening fix point 2
Pull back,up left middle guard board,
until break away from fix point 3,then remove
left middle guard board.
Installation
Reverse the removal procedures
for installation.
Middle guard board(right)

Remove
Remove seat
Opening fix point 1
Opening fix point 2

Pull back,up right middle guard board,
until break away from fix point 3,then remove
right middle guard board.
Installation
Reverse the removal procedure 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
FUEL TANK exploded view
2-4
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
installation.
Backpalte(LH&RH)
Remove
Remove seat,rear rack
Remove top cover of tail light
Loosen 2 bolts &2 nuts
Loosen 2 tapping screws
Pull back backplate(L&R)and tail light

Pull up connector of tail light cable
Loosen 4 tapping screws
Remove backplate(L&R)
Installation
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
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
installation.
FENDER exploded view (R)
2-6
Front fender
Remove
Loosen threaded sleeve(arrows of flexible shaft
,autometer),remove flexible shaft of autometer
Loosen 2 bolts 1 at left inboard of front fender
Loosen 2 bolts 2 at right inboard of front fender

remove front fender
Installation
installation.
Cover of chain
Loosen botl 1
Loosen botl 2
Pull it up ,remove chain cover
Installation
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
Pull up dragline of seat

Remove the dragline and lock of helmet
Installation
Large shade comp.

Remove
Loosen 2 bolts 1
Loosen 2 bolts 2
2-8
Loosen 1 bolt 3
Pull up connector of front turn light cable

and connector of head light cable
Remove large shade comp.
Installation
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
installation.
LARGE SHADE COMP. exploded view (R)
2-9
Muffler ,Triangular shield(R)
Remove
Remove clip
Remove outlet pipe of gulp valve
Remove 2 bolts in muffler
Loosen bolt 1 and nut ,remove muffler

Loosen bolt 2,remove triangular shield(R)
Installation
triangular shield (LH)
Lloosen bolt 1
Loosen bolt 2
Remove triangular shield(LH)
Installation
installation.
2-10
Cable
Remove
Loosen screw
Remove connector of choke cable out of
carburetor,then can remove choke cable
Remove top cover

2
Press spring of throttle valve
Remove throttle cable out of throttle valve,then
can Remove throttle cable
Installation
installation.
Attention
You must assemble throttle cable as shown on
the assembly
Make sure to protect needle vavle
Layout of Main parts
2-11
3 Inspection and Adjustment (vehicle body)
Maintenance information..................3-1 Rear drum brake, clutch, brake fluid.......3-5

Periodical replacing parts chart........3-2 Suspension, bolt, nut, tire.....................3-6
Fuel switch, throttle cable, chain......3-3 Front & rear axle, steering column.........3-6
Air filter..........................................3-4
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.
Fr eq u e n cy K ilom ete rs (km )（ Re m a rk 2 ）

In te rva l
Ir e m 1 0 0 0km 40 0 0 km 8 0 0 0km 1 20 0 0 km Re m a rk
*fu el ta n k, fu el D aily Tim e ly m a in tain o r r ep la ce, wh e n d am a ge ,
s witch , fu e l pip e a ge or b lo c kin g
*fu el t hr ottle I I I I b e fo re u se
*ca rb u re to r & id le I I I I
A ir filter & e le m e n t Re m a rk 1 C C R C
Sp ark p lu g I I R I
E n gin e lu b rica tio n o il N e w m otor cyc le m u s t r e place , wh e n k ilom e te rs o n o do m e ter 3 00 k m 、
6 0 0 km 、 10 0 0 km . Aft er fo rm er m a in te n a nce , d o re p la cem en t e ach 15 0 0
km
L u b rica tio n oil filter A n nu a l C C C C R
D rivin g cha in , Re m a rk 1 e a ch 5 00 km : I、 L
s p ro c ket
*b ra ke p a d ea c h 1 0 0 0km : I、 R
**b ra ke flu id e ve ry 2 yea rs: R
**fro n t & r ea r b ra ke R e m a rk 3 I I I I b e fo re u se
s yste m
*S witc h I I I I b e fo re u se
*lig h t, h o rn I I I I b e fo re u se
*b a tter y M o n th ly I I I I
F u s e o r o ve rlo a d I I I I
p ro te c to r
C on n e cting w ire I I I I
**th ro ttle a d ju s tm e n t R e m a rk 3 I I I I
*clu tc h I I I I b e fo re u se
*su sp en s ion system I I I I
*stre ng the n n u t an d I I I I b e fo re u se
b o lt
*w he e l I I I I b e fo re u se
**s tee r in g co lu m n R e m a rk 3 I I I I
b e a rin g
** e ng ine in s p ectio n R e m a rk 3 I I I I
R em ark 3： O nly C F M OT O m ainten anc e Tec hnic al per so n do m a inte nan ce an d a dju stm en t.
3-2
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
Turn adjustor to adjust throttle cable clearance
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
Remove 3 fixing bolts

Take out air filter element
Take out and inspect sponge from air filter element:
1. If damaged, replace
2. If dusty or dirty, clean
3-4
Rear drum brake
When step rear brake pedal, mark needle point the

limit. It prove that brake shoes have weared
completely. Replace new brake shoes timely.
Brake clearance
Front(hand) brake clearance:10-20mm
Rear(foot) brake clearance: 10-20mm
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.
Appointed brake fluid:DOT3 or DOT4 brake fluid
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
Check the abradability of tire. If the abradability reach

the maximum(triangle), replace tire.
Check the tire pressure as right picture as right illus-

tration regulation.
Caution:
check tire pressure when tires are cooled.
Front & Rear axle

check if front axle loose. If loose, tighten it as ap-
pointed tourque.
Front axle nut tourque: 60-80N.m
check if rear axle loose. If loose, tighten it as ap-
pointed tourque.
Rear axle nut tourque: 80-100N.m
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
Inspection and Adjustment
Inspection Period.......................................... 3-8

Inspectionn and Adjustment process.............3-9
Valve clearance.............................................. 3-9
Engine idling.................................................. 3-10
Spark plug..................................................... 3-10 3
Air filter.......................................................... 3-11
Lubrication system inspection...................... 3-12
Cooling system inspection............................ 3-14
Cylinder pressure inspection....................... 3-15
Engine oil pressure inspection..................... 3-16
3-7
3-8
Inspection and Adjustment-process

Introduce detail inspection information base on
above item list.
Valve clearance
First inspection for every forty hours after twenty hours
running in.hereafter,check one time every forty hours or
every 1000km.Must to inspect after remove cylinder
cover.
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.
Loosen the adjustable bolt and nut of valve clearance,

the filler gauge mat between the top of valve (intake
valve:0.07mm thickness,exhaust valve:0.12mm) and
adjustable valve bolt.tighten the valve adjustable bolt,
make slight contact with filler gauge,tighten 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.
zRemove spark plug by special tools.
Spark plug Spec:CR9EP

zSpark plug inspection:if electrode excessive
damage.Insulator breakage or thread
damage.change spark plug as new one.
3-10
Check carbon deposition of spark plug.if

necessay,clear it by proper tools.
Spark plug clearance:check clearance by filler
gauge,if exceed limit,adjust it.
Spark plug clearance:0.8-0.9mm

Note
Check thread and extend distance of spark
plug after assembled if replace the spark plug.
if short.carbon deposition will be faced,even 3
damage the engine.
zSpark plug installation
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
Tool:Spark plug wrench,fitler gauge
Air filter
Check it every 2000km, clean and change it
if necessary.
if air filter jamed,less air into,power decrease

for engine,high fuel consumption. inspection
and clean air filler as follows:
zLoosen bolt 1.remove air inflow seat of air
filter 2.
zTake the filter element 3 from 2 .
Clean the filter.

Compress filter to wiping enough water by
hand.
Note:Don’t warp and damage the filter

Soakage the filter 3 by engine oil.proper crush
out enough engine oil and keep filter 3 as
slight oiling.
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.
Lubrication system inspection.

Change the engine oil and oil filter after
1000km.Check oil volume for every 1000km,
Change engine oil and oil filter for every
3000km.
Engine oil volume inspection.

1.oil level window 2.plug screw of oil
zHorizontal position for engine
filler
(Main stand to support the vehicle.)
zOil height should keep same level with F line
by oil level window.
3-12
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
Note: Lay engine at horizontal position.

Change engine oil and filter
zPut up vehicle by main stand;
zEngine prewarming by starting.

3
zRemove oil drain bolt;
zQuickly release all oil before engine cooled;
zRemove three nuts 1 of filter cover 2,remove
“O “seal ring 3,filter pressure spring 4,paper
filter 5,,from the right side cover 6.
zChange the paper filter 5.put peristome to
engine and install it on the right side cover.6.
zCheck “O “seal ring before install filter cover
2,whether it is damaged for “O “seal ring 3,
filter pressure spring 4 whether it is short
shipped,
zInstall filter cover and tighten nut,but don’t
more tighten.
zTighten up the oil outlet bolt,screw out plug
screw of oil filler.
zFill 1000ml engine oil by oil filler.
z Tighten up plug screw of oil filler.running
several seconds while engine starting.
z Check oil level after engine stopped one
minute,keep oil level in “F”if its low”F”,fill little
to “F”.Oil volume total 1250ml.
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
vapor and scalding cooling liquid.

zCooling liquid is poisonous,don’t drink it,don’t adhere to skin and eyes.just in case,wash it
by water at once,even,go to hospital to treat in time.

zTake care of cooling liquid.Must keep it in the safe place that child couldn’t take it.
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
Cylinder pressure inspection

It is important indicator for cylinder pressure
in cylinder that reflect the stand or fall of
engine.must to be checked the cylinder
pressure.
Cylinder pressure:1200kPa
Some reasons as follows if lower cylinder

pressure. 3
zCylinder overworn
zPiston or piston ring scuffing.
zPiston ring block in the piston ring slot.
zNot strictly closed for valve seat.

z Cylinder head gasket damaged or other
defects.
Note:check above situations if lower cylinder

pressure.
Note:Cylinder cover bolt whether it is tighten
base on special torque,Valve clearance
whether it is proper adjusted before check the
cylinder pressure..
zWarm up engine before inspection
zConfirm that it is fully-powered battery.

zRemove spark plug 1
Install cylinder pressure meter 2 below
spark plug hole and tighten nut.
zKeep open full for damper.

zTurning several seconds after engine started,
record the full-scale reading of cylinder
pressure.
Tool:cylinder pressure meter,

connector seat.
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
Abnormal situation will be caused dut to Higher

or lower engine oil pressure
zToo Lower engine oil pressure.
zOil pipe leakage

zOil pump defects.
zAbove-mentioned combination.
zHigh engine oil pressure.
zEngine oile viscosity too high.
zBlocking of vitta.
zBlocking of oil filter
zAbove-mentioned combination.
Engine oil pressure inspection process:

zRemove main vitta bolt.
contect tachometer and ignition coil

zInstall fuel pressure gauge and contacter
seat into main vitta hole.
zWarm up engine as follows
Summer: 10 minutes as 2000r/min
Winter: 20 minutes as 2000r/min
Increase engine speed to 3000r/min after
engine warmed,then record the oil pressure
reading.
zApply tighten glue on the bolt of main oil
pipe,then tighten the bolt into the screw hole
base on special torque.
Tighten torque:23N.m
Tool: Oil gauge, tachometer
3-16
4 Cooling and Lubricating System
Cooling and Lubrication System
Cooling system drawing.............................4-2

Engine coolant.....................................4-3
Inspection of coolant density.........................4-3
Inspection and cleaning of Radiator and hose...........4-4
Inspection of Fan COMP.............................4-5
Insepction of Water Temp. Alarm Swith ................4-6
Insepction of Thermostat.............................4-6
4
Water Pump.........................................4-7
Remove and Disassemble Water Pump..................4-7
Inspection of Water Pump..............................4-9
Assemble and Install Water Pump.......................4-10
Lubrication system drawing............................4-11
Inspection of Lubrication system........................4-12
Inspection of Oil Pump.................................4-12
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
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
Inspection of Cooling Cycle
zRemove radiator cap1 and connect tester2
NEVER open radiator cap when engine is still hot to

avoid hurt by scalding fluid or steam;
zApply pressure 105kPa and hold for 10 seconds.

zIf pressure drops in 10 seconds,which indicates leak-
age in cooling cycle.In this case,check the complete
system and replace parts when leakage found.
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
zSlowly apply pressure to 93.3~122.7kPa and

check if the cap can hold the pressure for at least
10 seconds
z If the cap can not meet the pressure
requirement,repalce with new one.
Radiator Cap Opening Pressure:

Standard:93.3~122.9kPa
Tool:Barometer
Inspection and Clean of Radiator
zRemove dirt or trash from radiator with com-

pressed air
zRepair radiator fins with a small screwdriver
Inspection of Waterhoses
zCheck radiator hoses for leakage or damage.If

any,replace with new one.
z Check water hose clamps.Replace with new

one if any looseness found.
zAfter inspection and clean of radiator and hoses,

check coolant level.Fill coolant if necessary
4-4
Inspection of Fan Motor
zRelease 2 bolts from Fan Motor with socket span-

ner 1.remove Fan motor from radiator 3 and
Thermoswitch 2
zTurn the vanes to check if they can turn smoothly
zCheck fan motor as the right chart: battery :12 volts

,motor runs at full speed with ampere not more then
3A indicating in ammeter.If the motor does not work of
the ampere exceeds the limit, replace the motor.
4
zInstallation:Apply a little thread locker to the bolts
and tighten to the specified torque .
Fan Motor Blot Tightening Torque:10N.m
Inspection of Thermoswitch
zRemove thermoswitch
zTest thermoswit opening and closing temperature

as illustrated on the right ,place thermoswitch “1” in a
vessel with engine oil above and alcohol burner.
zHeat engine oil to raise temperature slowly and take

the reading from thermometer “2” when opening and
closing thermoswithch
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.
z Installation: Change a new O-ring and tighten

thermoswitch to the specified torque:
Thermoswitch Tightening Torque:17N.m
zCheck coolant level after installation of thermoswitch,
Fill coolant if necessary.
4-5
Inspection of Water Temp.Alarm switch
zRemove Water Temp.Alarm switch
zCheck the resistance of Water Temp.Alarm switch

as illustrated on the right,Place Water Temp.Alarm
switch “2”in a vessel with engine oil above an alcohol
burner.
zHeat engine oil to raise temperature slowly and take

the reading from thermometer when it’s opening and
closing.
Tool:ohmmeter ,thermometer.
opening and closing table
zInstallation:Apply a little thread locker before assem-

bling it to the cylinder head by tightening to the speci-
fied torque.
Torque :10N. m
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
zremove 2bolts”1” from Thermostat cover Assy.

zRemove thermostat cover”2”
zRemove thermostat
4-6
zcheck the thermostat pellet “3”if any broken ,re-
place it.
ztest thermostat as the following steps:
1.Pass a string through thermostat flange as illustrated

on the right
2.Immerse thermostat in a beaker with water. Make

sure thermostat is in the suspensed position without
contact to the beaker.
Heat water with an alcohol burner and observe the
temp. rise on the thermometer.
5.If eigher of thermotat opening temperature or ther-

mostat valve lift does not reach the standards, replace
it .
zInstallation:Reverse the removal procedures for in-
stallation
Apply coolant to the rubber seal of thermostat before
assembling to the mounting hole.
Tighten to the specified torque to install thermostat
cover.
Tightening Torques:10N/m
Water Pump
Removal and Disassembly
zRelease hose clamp 1remove hose 2 to drain coolant.
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”
zRemove bolts”3”of water pump
zRemove Water Pump”4”
z Remove O-Ring”5” and checking,replace a

new one if broken.
zRelease water pump cover screws”6”
zRemove water pump gasket”8” and cover”9”

from water pump body”7”,check the gasket ,re-
place a new one if broken.
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.
z Release shaft clip “10” which on the water

pump shaft with Circlip pliers.
4-8
Note:shaft clipmust replaced with new one

after disassemble.
zRemove Water Pump Impeller Assy.11;
4
zRemove moving ring seal “12” from impeller.
zRemove stationary ring “13” with special tool.
Note: stationary ring does not need to be re-

moved if no abnormal condition
zRemove oil seal with special tool “14”

Note: Oil seal does not need to be removed if
no abnormal condition
z Inspect bearing of water pump if it can work

well. In case any problems like blocked, replace
it. When do replacement, use bearing puller tool
to remove bearing
Note: shaft must be replaced with a new one

after disassembly.
Inspection of Water Pump

Bearing:
z Check bearing clearance by hand while it is
still in the water pump body.
zTurn inner race of bearing to check for abnor-
mal noise and smooth rotation.
zRepalce bearing if any abnormal condition
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.
Moving seal Ring:

zCarefully check Moving seal for damage, especially
the seal face;
Water Pump Body:

zCheck the joint surface of water pump body with
bearing and seal ,if damage, replace it .
Water Pump Impeller:
zCheck impeller and shaft,if damage,replace with new
impeller.
zCheck O-ring carfully,if it’s damaged,replace it with

a new one.
Assembly and installation of water pump

zInstall Oil seal 5into water pump 4 with special
tool.
zInstall Stationary Seal 6 into water pump 4 with
special tool.
Note: Apply sealant to side “A ” of stationary seal.
zInstall bearing 2 into water pump 4.
zInstall moving seal 7 on the impeller 8.
Note:side “A”Moving seal is outward.
zApply grease to impeller shaft
zInstall impeller shaft which installed Stationary
Seal to water pump body
zInstall new ring to water pump shaft 1
zInstall new gasket 9 to water pump body
zInstall water pump cover 10 and tighten the bolts
11 and bleed bolt
zcheck impeller for smooth turning
zInstall new O-ring
Note:Apply engine Oil to the O-ring when install
water Pump.
zInstall water pump and joint waterhoses
4-10
Lubricant system drawing

157MJ-2A ENGINE LUBRICANT SYSTEM
DRAWING
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.
Inspection of Lubrication system

(see page3-12)
Inspection of engine oil pump

(see page 5-3)
4-12
5 ENGINE REMOVAL AND ASSEMBLY
Engine removal, inspection and assembly

△ Page location
Location PARTS REMOVAL INSPECTION ASSEMBLY REMARK
Engine CARBURETOR 5-2 — 5-38

outside WATER PUMP 5-2 — 5-37
LEFT SIDE COVER 5-2 — 5-38
MAIN CHAIN 5-2 — 5-38
ENGINE GEAR TOUCHER 5-2 — 5-38
LEFT DUAL GEAR CHAIN 5-2 — 5-38
STARTOR MOTOR 5-3 — 5-37
OIL FILTER COVER AND
5-3 — 5-34
ENGINE PAPER ELEMENT
RIGHT SIDE COVER 5-3 — 5-33
OIL PUMP SECONDARY
5-3 — 5-32
GEAR
OIL PUMP MAIN GEAR 5-3 — 5-32 5
CLUTCH 5-3 5-23 5-32
OIL PUMP 5-3 — 5-32
ENGINE TIMING SPROCKET
5-4 — 5-37
HEAD TENSIONER
SPARK PLUG 5-4 — 5-17
CYLINDER HEAD&COVER 5-4 5-10 5-36
CAMSHAFT 5-4 5-17 5-36
MAGNETO ROTOR 5-5 — 5-37
MAIN CHAIN 5-5 5-28 5-37
CYLINDER COVER 5-6 5-11 5-35
CYLINDER BODY 5-6 5-19 5-35
TIMING SPROCKET 5-7 — 5-36
PISTON 5-7 5-20 5-34
GEARSHIFT ROD 5-7 5-27 5-31
CAMSHAFT CHAIN 5-7 — 5-31
FILTER COVER 5-8 — 5-31
RIGHT CRANKSHAFT 5-8 — 5-30
CRANKSHAFT GEAR BOX,FORK,MAIN
5-8 5-25 5-29
SHAFT
CRANKSHAFT 5-9 5-22 5-29
REMARK:ARROW MEANS REMOVAL PROCEDURES AND
PROCEDURE IS REVERSE FOR 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
z Loosen clamp 2,remove water pipe

connection, loosen 3 pieces of bolt 1, and
take out water pump.
Engine left side

Left side cover
Remove 10 pieces of assembly bolts on left
side cover and remove left rear cover, left front
cover and left front mat.
Main drive chain

Loosen bolt 2, and remove main drive chain;
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
Engine right side

Starting motor
Loosen two pieces of bolt 1 and remove start-
ing motor 2.
Oil filter cover and element:

Loosen 3 pieces of assembly bolts 3, and
remove filter cover 4 then element and other
parts;
Right side cover
Loosen right side cover bolts 5 & 6, remove
right side cover 7 and right side cover mat.
Driven gear oil pump

5
Use special tool to remove clamp 1 and then
remove driven gear 2;
Main gear oil pump

Use chisel to loosen bolt 4 and remove
main gear 5;
Clutch
zLoosen 5 pieces of bolt 6 and remove clutch
plate 7, then take out clutch main plate and
driven plate;
zLoosen clutch tightening bolt 8, remove 9
and clutch gear 10 and then other parts;
zTake out clutch main driven gear 11.
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.
Note:Do not let dowel pin fall into

crankcase.
Camshaft
zRemove timing sprocket bolt 1;

zRemove camshaft spacer 3;
zRemove timing sprocket 2 from camshaft;
zTake out camshaft 1;
Note:Do not let spacer fall into

crankcase. Hook the timing sprocket
during removal to avoid drom into
crankcase.
5-4
MAGNETO ROTOR
zRemove tightening bolt 1;
zUse tool to fix on the outer thread and re-

5
move the rotor and get off the woodruf key.
Tool: Rotor puller
Main gear
zRemove the main gear.
5-5
Cylinder tightening bolt
zLoosen 4 pieces of tightening bolts.
Cylinder head
zLoosen 4 pieces of cylinder cover bolts and
copper mat.
zRemove cylinder cover 1.
Cylinder body
zRemove pin 1;
zRemove gasket 2;
zRemove timing chain guide;
zRemove cylinder 4;
5-6
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
Tool:Piston pin removal tool
Engine crankcase
Gearshift rod unit

zRemove gearshift rod unit 1;
Gearshift camshaft driven gear

z Use a screwdriver to loosen 4 pieces of
bolts 2;
zRemove gearshift camshaft driver gear
Note:
During removal of driven gear 3, do not
loosen 4 and 5, spring 6 and pin 7.
5-7
zLoosen bolt 1 and take out spacer pin spring
and neutral spacer pin.
Filter element cover
zLoosen3 pieces of bolts 2;

zRemove cover 3.
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.
Gearbox,shifting fork axle and shifting

fork,main and driven axle
zRemove shifting fork axle 1;
zRemove shiting fork 2;
zRemove shifting fork axle 3;
zRemove shiting fork 4;
zRemove main gear 6 and driven gear 5;
zRemove gearbox.
5-8
Crankshaft
z Use tool to separate crankshaft from left
crankcase;
Tool: Crankshaft separating tool
5-9
Engine parts inspection
Cylinder head cover
Disassembly
Warning:during disassembly, make sure

each part position so assembly can be made
just same as done in factory.
zRemove 2 valve covers;

zDisassemble spacer 2;
zDisassemble two rocker arms 2;
zDisassemble two rocker arms 4.
Cylinder cover surface
Clean glue on cylinder cover and put it plain,

use a feeler gauge to check surface situation.
Touching surface of cylinder cover
Limit:0.05mm
Tool: feeler gauge.

Replace with new parts if limit is exceeded.
Note:Cylinder head and cover are an

assy,and should be replaced as a set.
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
Rocker arm
zDuring valve rocker arm, check also surface
1 and adjustment bolt for wearing ;
zValve rocker arm inner diameter:standard:

12.000¡«12.018mm
Tool:Innter diameter gauge
Assembly
zCoat rocker inner hole and rocker arm with

oil and assemble rocker arm as illustrated.
5
zInstall rocker arm O-ring, make sure rocker

arm surface in line with spacer position A.
Note:
Replace O-ring for every rocker arm inspec-

tion
Cylinder cover
Disassembly
zRemove air inlet pipe.
z Remove thermostat cover 1, water

temperature sensor 2 and chain tensioner 3.
5-11
zTake out thermostat;
zUse a special tool to compress valve spring

and then remove clamp 1.
Tool: Valve compress tool.
zTake out valve spring upper seat 2 and then

outer spring 3 and inner spring 4.
zRemove outlet valve 5 and inlet 6;
zTake out sealing 7.
zRemove seat valve spring.
5-12
Cylinder deformation
zClear burning room and touching surface.
zUse gauge to measure cylinder head and

touching deformation.Replace cylinder head
cover if necessary.
Cylinder head deforming limit:0.03mm

Tool: Feel gauge, kinfe feeler;
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.
Standard valve seat width.:0.9-1.1mm
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.
zRaise valve seat 10 mm higher from valve,

and use micrometer gauge to measure the
deviation at X and Y vertical position.Replace
valve or cylinder if limit is exceeded.
Deviation limit(Valve intake and exhaust)£º

0.25mm
Tools:Micrometer gauge and magnetic clock
seat.
5-13
External diameter of valve stem
zMeasure with a micrometergauge
Valve intake 4.975-4.990mm

Valve exhaust 4.955-4.970mm
Tool:Micrometer gauge(0-25mm)
Valve stem jump

zAs illustrated,use a V-shape to support valve,
use a micrometer to measure the jump.
Tool:micrometer and V-shape support
Valve head jump
zAs illustrated,use a micrometer gauge to

meausre valve head jump. If the jump is over
limit,replace valve.
Limit:0.03mm.
Tool:Megnetic clock seat, micrometer gauge

(1/100)and V-shape seat.
Valve head surface wearing
zCheck wearing of every valve head surface,
replace a new valve in case of wearing or
damage.Measure valve head width T, if valve
head depth is smaller than limit,replace
valve.
Valve head limit:0.5mm
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
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.
Valve spring length limit(valve intake and

valve exhaust):31mm
Valve external spring free travel limit(valve in-
take and valve exhaust):32.5mm
Tool:Feeler gauge.
5
zMeasure power of compressed spring and

replace standard limit of inner spring of valve
if the spring power out of limit.
Compressed from 26.8mmto 33.7N-44.3N
Valve external standard(valve intake and
exhaust):
Compress to 29.8mm is 88.6N-104N
Tool: Spring balance
zMeasure spring leaning,and replace spring

in case of leaning out of limit.
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
Warning: Valve step sealing can not be

re-used.
z Insertvalve 3 and 4, coat a layer of

molybdenum lubricant on valve step round
surface
Warning: Do not damage sealing
of valve step during valve installation
zInstall valve inner and external spring, little

end 6 close to cylinder head and big end with
mark upwards.
zPlace valve spring upper seat2 and com-

press spring with special tool. Put two valve
clamps1 at 3£¬and then release com-
pressed tool.
Note:Use a hammer slightly knocks

at valve end, and make sure valve clamp
is already fixed in valve groove.
5-16
Tool: Valve spring compressed tool, and

tweezers.
zCheck sealing of cylinder cover:inject clean-

ing liquid into air inlet ¢Ù and air outlet and
stop for a while,check valve seat ¢Ú for leak.
zInstall spark plug and water sensor,thermo-

stat and thermostat kit and cylinder cover re-
lated parts.
Camshaft
z Incase of abnormal noise or vibration or

power output too low from engine cylinder
cover,lift of camshaft or assembly must be
checked. Wearing of camshaft will also lead
to mentioned breakdown.
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
TENSIONER SET, CHAIN,GUIDE CHAIN.

zInspection
Check touching surface for wearing and
damage, replace if necessary.
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
Tool:knife straight edge and feeler gauge.
Cylinder body inner diameter inspection.
zCheck cylinder inner surface for scratch, or

any other damage and replace new parts if
necessary;
zMeasure inner diameter with spotted three
points, upper position,middle position and
bottom position, in vertical position between
each two points;
Cylinder body inner standard limit:57-57.
019mm
Tool:Cylinder body inner diameter gauge.
5-19
f
Piston:
:
Piston diameter.
.
Use a micrometer gauge to measured diam-
eter at position 7mm. Replace piston in case
of lower limit
Piston external standard:56.97-56.99mm

External diameter limit:56.94mm
Measure clearace between piston and cylin-

der body based on above measurement.
Repalce cylinder or piston or both if clearance
is exceeding 0.15mm.
Piston groove clearance
Use a feeler gauge to measure clerance be-

tween ring 1 and 2. And replace piston and
piston rings in case clearance exceeds the
limit.
First ring:0.15mm
Second ring: 0.13mm
Piston groove width standard:
First ring:1.005-1.02mm
Second ring: 1.005-1.02mm
Oil ring: 2.005-2.02mm
Piston ring thickness standard:

First ring:0.970-0.990mm
Second ring: 0.970-0.990mm
Tool; Feeler gauge

Micrometer gauge(0-25mm)
5-20
Piston free open and working open

Before piston ring assembly,use feelergauge
to measure free open of each ring and then
install pinton on cylinder body. Then measure
working open of each ring, replace piston ring
in case of incorrect limit.
First ring:7.5mm
Second ring:7.5mm
Piston ring working open limit:
First ring:0.25mm
Second ring:0.25mm
5
Tool:vernier cliper and feeler gauge
Piston pin and pin hole
zMeasure piston pin hole inner diameter with

a inner micrometer gauge, and mesaure ex-
ternal diameter with micrometer gauge. Re-
place piston and piston pin in case limit is
exceeded.
Piston pin hole limit:15.030mm
zUse a micrometer gauge to measure exter-

nal diameter at three points.
Piston pin external diameter limit: 14.980mm
5-21
Crankshaft
Crankshaft little end innerdiameter
z Replace crankshaft in case limit is

exceeded.
Little end limit : 15.014mm

Tool:percentile scale(0-18mm)
Crankshaft beat
zCrankshaft big end wearing can be checked
by checking little end beat. 2 ¼ì²é £º
Beat limit of little end :3mm .
Tool: percentile scale, magneto seat and V-

shape seat.
Crankshaft big end side clearance:

zPush big end to another end and use feeler
gauge to measure clearance£¨Standard:0.
10-0.45mm, limit:1.00mm);replace crank-
case if clearance is exceeding limit
Tool: Feeler gauge
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
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
zReplace two bearings in case of wearing or

damage.
zReplace two bearings in case of abnormal
noise.
FRICTION DISC, CLUTCH

z Use feeler gauge to measure clutch disc
thickness and replace friction disc clutch in
case limit is exceeded.
Thickness standard:2.9-3.1mm
Limit:2.8mm
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.
THRUST BEARING & BRACKET,CLUTCH

zCheck THRUST BEARING & BRACKET, CLUTCH
for abnormal status, such as broken, wearing
or damage, and replace if necessary.
Crankcase bearing.
zFeel clearance of crankshaft bearing inside,
and check for noise or smooth turn with hand,
replace bearing if necessary.
5-24
GEARSHIFTING
PART NO. PART NAME P/N PART NAME
1 SCREW M6×12 21 O-RING 26.2×2.4
2 RATCHETPLATE,GEAR SHIFT 22 SWITCHSEAT,GEAR POSITION
3 CAMSHAFT GUIDE, GEAR SHIFT 23 SCREW M5×20
4 RIGHT RATCHET 24 WASHER 6
5 RATCHET PIN, GEAR SHIFT 25 LIMIT, GEAR SHIFT DRUM
6 RATCHET SPRING 26 DOWEL SPRING, GEAR SHIFT
7 DRIVEN GEAR, GEAR SHIFT DRUM 27 BOLT
8 LEFT RATCHET 28 SHIFT FORK
9 CENTER SHAFT, SHIFT FORK 29 SHAFT, SHIFT FORK
10 SHIFT FORK (CENTER) 30 MAIN SHAFT
11 BOLT M14×1.25×12 31 COUNTERSHAFT
12 WASHER 14 32 DRIVE CHAIN SPROCKET
13 DOWEL SPRING, NUETRAL GEAR 33 LOCK WASHER, CHAIN
SPROCKET
14 STOP PIN, NUETRAL GEAR 34 NUT M16×1.5
15 PIN 4X6 35 ROD ASSY, GEAR SHIFT
16 HUB, GEAR SHIFT DRUM 36 ROD, GEAR SHIFT
17 CONTACT SPRING 37 RETURN SPRING
18 SWITCH CONTACT, GEAR POSITION 38 SHAFT COLLAR
19 WASHER 25×40×1 39 BUSH,DRIVECHAINSPROCKET
20 DOWEL PLATE, GEAR SHIFT DRUM 40 O-RING
5-25
Fork
zCheck position 1
z Check position2
Repalce in case of scrach, bending or
damage.
HUB, GEAR SHIFT DRUM

zCheck groove of HUB, GEAR SHIFT DRUM
z Check position A of HUB, GEAR SHIFT
DRUM
Replace in case of wearing or damage
Shift fork
zlCheck shift fork and 2
Replace in case scrach, wearing or damage.
zShift fork inspection:

In case not smooth, replace shift fork.
Note: Do not try to repair deformed
shiftfork.
zUse a slide caliper to measure thicknes of

shift fork composition.
Shift fork thickness standard:4.80-4.90mm

Fork(Middle)standard:5.30-5.40mm
5-26
Main,secondary shaft
zCheck main shaft 1 and secondary shaft 2.
Replace set in case of deforming, wearing or
damage.
zCheck bearing teeth

Replace bearing in case of blue points, wear-
ing or damage. 5
Replace in case of wearing, crack or

misplacement.
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.
DOWEL SPRING, GEAR SHIFT

zCheck DOWEL SPRING, GEAR SHIFT 4
and replace in case of wearing or damage.
Gearshift unit camshaft location

structure.
zCheck gearshift camshaft location structure
5 and replace in case of damage, wearing.
5-27
Starting driven bearing, dual gear and
dual shaft axle.
Inspection
l. Inspection driven bearing 1 for wearing or

damage.
2. Measure inner and external diameter s of
driven bearing 1.
Limit:
Inner;replace if over 22.10mm
External;replace if below 54.15mm
1. Check dual bearing 2 for wearing or

damage;
2.Check dual gear shaft axle 3 for wearing or
damage.
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
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
1.Use tool to pull rod into left crankcase

Note:
2.Do not let crankshaft by plastic hammer fall
into crankcase, tool must be used to keep left
and right crankcase in same concentric.
Tool: Crankshaft assembly tool.
Main, counter shaft

Assemble main, counter shaft as illustrated.
5-29
HUB, GEAR SHIFT DRUM AND SHIFT FORK
l. Assemble gear shft drum hub 1 onto

crankcase;
2.Install same two shift froks in correct posi-
tion and then install guide bar 3;
3.Install shift 4 in correct position and then in-
stall guide bar 5;
4.Install gear shift camshaft location structure
6;
5.Instll gearshift location spring 7;
6.Coat oil on surface of related parts;
7.Check if every bearing of each gear is work-
ing smoothly.
Note:Related parts must be cleaned and no
foreign matters or metallic fragments on
surface.
HUB, GEAR SHIFT DRUM AND SHIFT
FORK DRAWING
1.Coat left crankcase 1 with sealing glue and

install two pins 2 into location holes. Rake
crankcase3 and press properly left and right
crankcases.
5-30
2.Install assembly bolts and tighten bolts two

or three times as illustrated.
Torque:10N.m
Neutral gear stop pin and filter cover
1.Install stop pin and stop spring 2, gasket

and bolt 4;
5
Note: Do not mistake stop pin 1 assembly
direction;
2.Install filter cover as illustrated;
DRIVEN GEAR, GEAR SHIFT DRUM AND

GEARSHIFTING
DRIVEN GEAR, GEAR SHIFT DRUM
1. Install driven gear, gear shift drum into
driven bearing 1, plate 2 and camshaft guide.
Note: Assembly direction of ratchet plate,
gear shift and driven gear, gear shift drum
can’t be wrong.
Exploded drawing for driven gear,

geashift drum
1.DRIVEN GEAR, GEAR SHIFT DRUM
2.RATCHET PLATE, GEAR SHIFT
3.CAMSHAFT GUIDE, GEAR SHIFT 4. RIGHT
RATCHET 5. LEFT RATCHET;6. RATCHET
PIN, GEAR SHIFT;7.RATCHET SPRING
Note: Left ratchet and right ratchet can

not be installd in wrong direction.
Gearshift rod
1.Install gearshift rod as illustrated;
5-31
PRIMARY DRIVE GEAR AND OIL PUMP
PRIMARY DRIVE GEAR
Put dowel 1 into crankshaft groove and install

primary drive gear 2, oil pump drive gear 3,
tightening bolt 4 and bolt 5(Torque:85-90N.
m)
Note: Bolt 5 is with left-turning thread
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
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
Install clutch as illustrated;

Note:
1.Camshaft assembly groove shold be fac-
ing right right crankcase.
2.Coat 11 with oil before assembly;
3.Install part 8 longer end into main shaft fac-
ing left crankcase.
Clutch bolt adjustment

1.Loosen bolt 20 and install adjustment bolt
19 to touch slightly with clutch shaft
2.Remove clutch adjustment bolt 1/4-1/2 and
tighten tightening bolt 20.
Right side cover

Install right side cover as illustrated;
Note:Washer 6 and right side cover pater

must be new parts to avoid oil leak;
5-33
Paper element
1.Check O-ring and gasket 6 and replace if

necessary;
2. Clean paper element and replace if
necessary;
3.Install O-ring, gasket 6, paper element 5,
element spring 4 and O-ring 3, filter cover 2
and bolt 1 in order;
Piston ring assembly

1.Install piston ring onto piston;
2.Coat pistons rings with oil;
3.Do not damage piston;
4.Put piston ring with mark upside;
5.After assembly, make sure piston ring
can turn freely and make first ring open
mouth facing air inlet.
Piston installaton
1.Install piston 1, piston pin 2 and dowel pin

3.
2.Put piston end with arrow mark towards to

exhuast port.
5-34
Cylinder body
1.Install dowel pin 1 and new cylinder body

gasket 2.
2.Coat cylinder inner surface, piston and pis-

ton ring with clean engine oil;
3.Press piston ring, and install piston into cyl- 5
inder 1 and then install cyliner onto crankcase;
Note:Do not damage piston or piston ring;
Note piston ring open not facing piston pin
with angle of 120 degrees.
1.Install timing chain sprocket 2;
2.Install guide chain 3;
3.Intall dowel pin and new cylinder gasket 4;
4.Turn crankcase, make piston to to stop
point.
Cylinder cover
Install cylinder cover as illustrated.
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;
Valve clearance adjustment

1.Turn crankshaft and make pstion to stop
point. Adjust air intake and exhaust valve and
tighten clearance adjustment bolts.
Air inlet clearance:0.06-0.08mm
Exhaust valve clerance:0.10-0.13mm
2.Intall valve room cover.
5-36
Water pump
1.Install water pump 1 as illustrated;

2.Intall water pipe joint 3;
3.Install water outlet pipe;
Do not forget to assemly O-ring during water
inlet pipe assembly;
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
Install starting motor as illustrated
Starting gear and magneto rotor
1.Put 1 into grrove;

2.Install starting gear 1 onto crankshaft;
3.Install magneto rotor;
4.Coat thread glue on crankshaft and then
tighten bolt 4.
5-37
Dual gear
Install dual gear 1, axle sleeve 2 and dual gear

axle 3.
Gear connector
1.Install spring 1 into gearsift durm hub;

2.Install gear contact into hole of the hub;
3.Install O-ring 3 and gear contact terminal 4 and
tighten bolt 5.
Front side cover and drive chain;

1.Install dowel pin into left crankscase pin
hole;
2.Install new left side cover gasket onto left
crankcase;
3.Install front left cover onto left crankcase;
Note: Gasket must be clean and withou
foreign fragments. Dowel pin must not be
hit
Install drive chain sprocket;
Carburetor
Install carburetor as illustrated.
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.
-Following operation doesn’t require engine removed from vehicle.
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.
Remove ignition coil high tension cap from spark

plug.
Loosen rear wheel shaft nut
Loosen chain snaps with pliers and remove

chain
6-2
6 Engine Disassembly and Installation
Loosen:
-Clamp to seperate carburetor and air filter.
-Clutch cable and throttle cable
Loosen 4 pcs engine mounting nut
Loosen 3 pcs engine mounting nut
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,
Make sure gear shift rod installed to

a comfortable position for usage,
Use recommended coolant,drain out air

in engine cooling pipe.
Check clutch and chain free clearance

after installation.
Reverse the disassembly procedure for

engine instalation.
Carefully install engine to the original position

by jack or other tools to support engine.
Add coolant before fuel tank installation.

(refer to Chapter 4)
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
Mounting nut, steering bar 10-14 N.m

Nut, front wheel shaft 60-80N.m
Upper fixing nut, front shock absorber 20-30 N.m
Lower fixing bolt, front shock absorber 30-40 N.m
7-1
CFMOTO
Troubleshooting
Heavy steering(steering too tight

·Upper thread is over tightened.
·Steering bearing is damaged or worn out.
·Inner & outer bearing seats are damaged,
worn out or stepped.
·Steering column is distorted
·Tire pressure is too low.
·Worn tire
Spongy brake lever

Loosened Handlebar
· air enter into brake system

·Front right and left shock absorbers are not matched.
· brake oil level too low
·Front shock absorbers are distorted
· oil leakage in brake system
·Front wheel shaft is distorted,
wrong assembly of front wheel
Front wheel wobbles Poor brake

·Deformed rim
·Faulty wheel bearing · dirty brake disc
·Faulty tire · brake disc unparalle with wheels
·Improper tightening of wheel shaft
Front suspension too soft Abnormal noise with disc brake
· Loosened spring,front shock absorber · dirty brake disc

· oil insufficiency,front shock absorber · eccentri disc brake disc
· disc brake pump wrong assembly
Front suspension too hard · brake disc unparalle with wheels
· improper oil,front shock absorber

· front shock absorber deformed
· oil channel blocked,front shock absorber
Abnormal noise with Front absorber
·slipping parts distorted

·oil insufficiency,front shock absorber
·outer oil seal broken
·steering bearing worn out
·oil insufficiency,counter gear
7-2
Steering bar
Disassembly
Remove 2 pcs mounting nut, right handlebar switch
Remove throttle cable and throttle grip,

remove right handlebar switch
Loosen fixing screw, balance block,

remove balance block and throttle grip.
Loosen 2pcs half cover bolt, fluid reservoir,

remove fluid reservoir
7-3
CFMOTO
Loosen 2 pcs mounting screw,

Seperate choke cable and choke lever,
remove left handlebar switch
Loosen 2 pcs briquetting bolt,clutch lever,

remove clutch lever
Loosen 4pcs decorative screw cap(disposable items)

with straight screwdriver,remove 4 pcs fixing screw
and left handlebar.
Installation
reverse the disassembly procedure for installation.
Insert dowel pin into position hole when assembling

left handlebar.
7-4
When assembling right handlebar switch,

insert throttle grip into right handlebar,
install throttle cable.
Insert dowel pin into position hole, assemble

right handlebar.
7-5
CFMOTO
Front Wheel
Support main stand,put a jack under engine or put a

heavy thing on rack, raise front wheel.
Loosen
-cable, speedometer
-nut, front wheel shaft
Remove
-front wheel shaft
-front wheel
Front wheel shaft inspection

Put front wheel shaft on V block,
check curvature.
service limit: >0.2mm¡úreplace
Front rim inspection
Put front wheel on turntable, turn wheel to check wheel

beating with dial indicator..
Service limit:
Axial direction: 2.0mm
Radial direction: 2.0mm
Check wheel bearing for looseness; turn bearing inner

ring to check for flexible rotation; Check if any loose-
ness when assembled on rim.
If any above problem, replace with a new bearing.
7-6
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
Push out wheel bearing and wheel shaft sleeve
7-7
CFMOTO
Installation
Apply grease to bearing inner ring,

press fitting bearing and shaft sleeve.
NOTE
Press fitting right bearing,front wheel before left breaing.
Install front brake disc,lock up bolt with retainer,

apply grease to dust seal before intalling to
brake disc side of front wheel,
install sleeve, front wheel shaft.
Install counter to wheel,

set jag into groove.
Install front wheel to front shock absorber,

insert front wheel shaft from left to right
with nut,install speedometer cable to
counter through cable clip.
UP in counter points to lock nut,front wheel
shaft in shock absorber direction.
tightening nut£¬front wheel shaft£º60-80N¡¤m
NOTE
Make sure cable is in line with counter when assem-
bling cable, speedometer..
7-8
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
Loosen 4 pcs fixing screw, remove handlebar(LH&RH).

Loosen 2 pcs fixing bolt, brake disc
Remove front shock absorber(LH&RH).

NOTE
Do not put the shock absorber upside down in
case of oil leakage from inner absorber.
Inspection:
Oil leakage, aged or damaged oil seal -Replace
7
Installation
Reverse removal procedure for

installation.
Set brake hose into brake clipper, apply
thread glue to fixing bolt,brake disc, tight-
ening torque:30-40N .m
Fastening screw 1: 20-30N.m

Fixing bolt: 30-40 N.m
Fastening screw: 10-14N.m
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
Loosen fixing bolt
Loosen nut with wrench, remove dust cover and lower

joint plate, front fork.
Remove circlip, upper bearing, top and bottom ball.
Remove top and bottom bearing race with impact tool.
7-10
Installation
Put bottom ball into lower joint plate, front fork.
Install top and bottom bearing race to frame riser with

impact tool, apply enough grease.
Put top ball into top bearing race.
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
Install upper joint plate, lock up with bolt,

tightening torque:60-90N.m
Install:
-dashboared
-front shock absorber,handlebar(LH&RH)
-front wheel
-big light cover
-front fender
7-11
CFMOTO
Front Brake
Fluid Reservoir Removal

Remove:
-rear vire mirror(RH)
-2 pcs fixing bolt
Seperate fluid reservoir from right handlebar, do not
remove fluid reservoir from right handlebar without
changing hydraulic brake.
Master Cylinder Removal
Remove 2 pcs fixing bolt, remove master cylinder from

front shock absorber(LH)
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
Replace brake Fluid,

drain out air
Support main stand on flat ground, correct handlebar.
remove2 pcs fixing screw, fluid cup cover
NOTE
Cover coating and plastic parts with cloth to avoid
brake fluid.
Connect a transparent hose with relief valve, master

cylinder, loosen relief valve.
Suck out brake oil with injection tu
Brake Fluid Injection

Connect a transparent hose and injection tube with
7
relief valve, master cylinder, loosen relief valve.
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)
Drain out Air

Connect a transparent hose with relief valve, pinch front
brake lever without loosening, openn relief valve to drain
air, repeat several times until no air.
NOTE
Oil level should keep at least half when draining air.
7-13
CFMOTO
Brake Disc/Front
Brake Disc
Replace
Remove brake disc
Pres bracket, brake disc until inner pads can be get
as illustrated.
Remove outer brake pads after getting inner brake

pads.
Remove spring 1 and 2.
Install new inner and outer brake pads by reversing
the procedure for removal.
NOTE
Brake disc must be adjustmented after installing
before usage.
Measure Brake Disc Thickness

Measure brake disc thickness with micrometer or
calliper. Replace with a new one if over serviec limit.
Service limit: 3mm
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
Mounting nut, REAR ARM 80-100N.m

Fixing bolt/nut, Front shock absorber 35-45 N.m
Nut, front wheel axle 80-100N.m
8-1
Troubleshooting
Heavy steering
1.Warped rim
2.Improper tightening of wheel axle

3.Faulty tire
4.Improper tightening nut of wheel axle
5.Improper tightening nut of rear arm
Rear suspension is too soft

1.Weakened shock absorber
2.Rear absorber oil leakage
3.Improper rear absorber adjustment
Rear absorber is too hard

1.Improper rear absorber adjustment
2. Air pressure of tires is too high.
Abnormal noise with rear absorber

1.Rear shock absorber is bended.
2.Loosening of tightening parts
of rear shock absorber
3.Damping lack of oil
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
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.
Service Limit: 0.2mm
8
Set rear wheel on the rotating stage,
check the rims vibration
Service Limit:
Horizontal:2.0mm
Vertical :2.0mm
Check rear axle clearance,

to change if too big clearance
Check rear chain wheel, to replace if worn
Check driving chain,to replace if necessary
8-3
Dissemble rear wheel
Remove SHAFT SLEEVE,REAR WHEEL (LH)

Remove dust boot
Remove chain comp.Remove RUBBER
CUSHION, check if there is any looseness or
worn to replace in time.
Remove rear brake comp.
Use special tool to disemble rear wheel axle

(LH&RH)
Assemble
Follow the opposite way of dissemble when As-
semble rear wheel
Use butter when assemble dust boot
Rear wheel axle nut:80-100N.m
Note;
Assemble the rear axle bearing first, then press
the rear axle to assemble
8-4
Rear Arm
Disassembly
Remove
Rear wheel-(8-3)
Loose 2 nuts, remove rear right absorber
Loose rear armer nut
Loosen the 2 bolts, remove chain protector

Loosen the 2 bolts, rear (LH) shock
absorber
Remove SHAFT, REAR ARM, disemble rear arm
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
To install brake shoes into hole of rear brake shoes

(spring to install properly)
Cover the brake drum(spring position inside)
Note
Installed rear wheel, check driving chain, rear
wheel position, brake drum and brake pedal clearance .
8-5
9 ELECTRIC SYSTEM
Electric Apparatuses
Charging system....................... 9-1

Electrical Starting system ..............9-4
Ignition system ........................ 9-6
9-1
Charging System
Charging Diagram
9-2
9 ELECTRIC SYSTEM
Regulator
Measure resistances among connecting line

When Engine gets started and battery is fully
ends by multimeter(See below Picture). If one
charged, if the voltage between red line and
value is out of specified range. Please replace a
green line is more than 15V or less than 12V,
new one.
please replace it with a new one.
(Engine at 5000rpm)
Turn Meltimeter on Diode
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
Caution when starting engine

7.Connect the lines according to circuit diagram.
8.Check whether parts are connected properly

before starting. 9
9.Check air circulation system.
10.Check fuel system.
If blocked, clean clogged parts and ensure smooth
fuel system.
If leakage, try to reconnect the leaked parts and en-
sure leakless fuel system.
11.Release throttle and turn off ignition swtich. Push
starting switch with 3-5 seconds.
12.After starting engine, warm up engine , check idle

speed after it’s stable.
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
4. Turn the gear at Neutral, and Turn the ignition switch

at ¡°ON¡±.Run the engine few seconds by pushing
startig buttin, and measure Peak value of Pick-up Coil.
5. Repeat few times to get the highest peak value.

Turn Mulitimeter to AC.
Ignition coil primary Peak value 12V
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.
Voltage of Pick-up Coil Peak value

3. Refer to User Guide when using Peak value
voltage adapter:
4. Connect Multimeter and Peak value voltage
adapter as shown in pictures on the righ
+ Probe:Green Downlead
- Probe: Blue Downlead
Notice:
Please check the User Guide when using
Mulitimeter and Peak value voltage adapter.
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
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
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
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
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
10-3
Brake light/Tail light bulb
Remove
Remove the seat.
Unscrew the tail light holder
Take out the bulb of Tail light.

Replace the bulb with a new one if it was
damaged.
Bulb specification:12V P21/5W
Installation
Ignition Switch
Remove
Remove the 2 pieces of screw.
Take off the ignition switch lock.
Inspection:
Check if the coupler terminals are connected.
Front brake light switch

Disassemble front brake switch wire, inspect the
connection of wire.
Apply the front brake: brake light works
Release the brake: brake light doesn’t work
10-4
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.
Left handlebar switch

Remove fuel tank-(2-4)
Disassemble the connection of left handlebar
switch harness-(1-12)
Check according to the following table if the coupler
terminals are connected.
Right handlebar switch

Remove fuel tank-(2-4)
Disassemble connecter ofright handlebar
switch harness-(1-12)
Check according to the following diagram if the
coupler
terminals are connected.
10
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
Connect Fuel sensor harness with main cable.

Turn on Ignition switch.
Swing the floater slowly, and check the needle on the oil
gauge.
If the needle can not reach F or E point, please replace
new oil gauge.
If the needle swings instability, please replace new fuel
sensor.
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
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
Starting Failure Difficult Starting, Unstable Idle Speed

1.Too much fuel in the engine 1.Air circulation is not right
—air filter blocked 2.Fuel system clogged
—air circulation is not right 3.Ignition system doesn’t work properly
2.No fuel in carburetor 4.Hole of fuel tank cap clogged

—fuel filter clogged
—fuel pipe clogged
Stall when accelerating

Ignition system doesn’t function properly
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
Ignition switch lock Fuse box
CDI
Flasher relay Fuel sensor
High beam indicator
Turning indicator(RH)
Turning indicator(LH)
Starting Motor
Instrumert indicator
Engine rotate speed indicator

Rear turning signal(RH)
Fuel indicator
Tail light/ brake light
12v 21/5w
Water temperature indicator
Rear turning signal(LH)

Neutral gear indicator
water Thermostat
Fan motor
Front turning light(RH)
Water Temperature alarm
Head light
Horn
Position light
Front turning light(LH)
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
Overriding switch Horn Clutch switch Regulator

Dimmer switch Turning switch
3-Phase shift sensor Magneto Lgnitioncoil and spark plug
Automatic switch
Thermostat
-49-
13 Troubleshooting
Troubleshooting
Engine ............................. ............. 13-2

Carburetor............................................ 13-5
Cooling system/Radiator.................... 13-6
Ignition system........................................ 13-6
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
Gear not in Nuetral position Shift to N postion
1.Improper valve clearance Replace

2.Unsuitalbe valve seat Replace or repair
3.Defective valve Replace
4.Rocker or rocker arm wear Replace
5.Dirty spark plug Replace
No idle speed or
6.Incorrect valve clearance Replace or adjust
unstable speed
7.Ignition coil failure Replace
8.CDI failure Replace
9. Flywheel failure Replace
10.Fuel level unsuitable of float chamber Adjust height of float
11.Injector blocked of carburetor Clean
12.Fuel switch failure Replace
13.Improper position of idle screw Adjust
13-2
13 Troubleshooting
Troubles Possible causes Solutions
1.Valve spring getting weak Replace

2.Camshaft wear Replace
3.Spark plug dirty Clean or Replace
4.Spark plug gap too narrow Adjust or Replace
High RPM unstable 5.Valve timing incorrect Adjust
6.Ignition coil failure Replace
7. Float too low Adjust height of float
8.Air filter too dirty Clean or Replace
9.Fuel blocked inside carburetor Clean
10.Fuel switch failure Replace
1.Engine oil too much Check oil level and drain

Blue or black exhaust 3.Valve wear Replace
gas 4.Cylinder wear or scraped Replace
5.Valve stem wear Replace
6.Oil seal of valve stem damaged Replace
1.Valve clearance improper Adjust

2.Valve spring getting weak Replace
3.Valve timing incorrect Adjust
4.Cylinder wear Replace
6.Improper valve seat Replace or repair
7.Spark plug dirty Clean or replace
Power not enough
8.Improper spark plug gap Clean or replace
9.Injector of Carb. blocked Clean or replace
10.Improper float level Adjust float level
11.Air filter too dirty Clean or replace
12.Rocker arm or Camshaft wear Replace
13.Air leakage of inlet pipe Tighten or replace
14.Engine oil too much Check oil level and change
1.Carbon deposit on piston head Clean

2.Engine oil too less or too much Check and add or drain 13
3.Fuel hose blocked Clean
4.Float level too low Adjust float level
Engine overheating
5.Air leakage of inlet pipe Tighten or replace
6.Unsuitable engine oil Change oil
7.Cooling system failure(See13-6)
13-3
Valve abnormal noise

1.Valve clearance too big Adjust
2.Valve spring worn or damaged Replace
3.Rocker arm or camshaft worn Replace
Piston abnormal noise

1.Piston worn Replace
2.Cylinder worn Replace
3.Carbon deposit inside combustion
chamber Clean
4.Piston pin or pin hole worn Replace
5.Piston ring or groove worn Replace
Timing chain abnormal noise

1.Chain stretched out Replace chain and sprocket
2.Chain sprocket worn Replace chain and sprocket
3.Tensioner failure Repair or replace
Engine abnormal
noise
Clutch abnormal noise
1.Clutch gear worn or damaged Replace clutch gear
2.Cushion rubber aging or damaged Replace clutch gear
Crankshaft abnormal noise

1.Bearing noise Replace
2.Crankshaft pin bearing worn Replace
3.Clearance too big Replace
Transmission abnormal noise

1.Gear worn or damaged Replace
2.Main shaft or countershaft worn Replace
3.Bearing worn Replace
4.Bush worn Replace
1.Clutch drive disc worn Replace

Clutch slippery 2.Clutch driven disc worn or damaged Replace
3.Clutch spring getting weak Replace
13-4
13 Troubleshooting
1.Gear damaged Replace

Gear shift not smooth 2.Shift fork bent Replace
or locked 3.Shift drum worn Replace
4.Improper shift lever Adjust
2.Carburetor
1.Injector blocked Clean

Hard to start 2.Injector chanel blocked Clean
3.Leakage of joint Tighten,adjust or replace oil seal
4.Choke opened fully Close or Tune choke
1.Air intake pipe blocked Clean

2.By-pass air pipe blocked Clean
3.Choke opened fully Close or Tune choke
Idle or low RPM 4.Unsuitable idle screw torque Adjust
unstable 5.Float level improper Adjust

2. Main jet blocked Clean
3.Needle valve blocked Clean
High RPM un-
4.Choke closed fully Clean
stable
5.Fuel filter blocked Clean or replace
6.Float level improper Adjust
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
1.Radiator or water hose blocked Clean

2.Air bubble inside cooling system Remove bubble and add coolant
3.Water pump failure Check and replace
Engine overheating 4.Bad quality coolant Replace
5.Thermostat failure Replace
6.Fan motor or thermo switch failure Check and replace
Coolant temp. too 1.Fan motor or thermo switch failure Replace

low 2.Thermostat failure Replace
4.Ignition system
1.CDI failure Check and replace

No spark or too 2.Spark plug failure Check and replace
weak spark 3.Flywheel failure Check and replace
4.Battery voltage insufficient Check and replace
5.Ignition coil failure Check and replace
6.Pick-up failure Check and replace
13-6
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April,2011

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CF150-A Service

All rights reserved

Zhejiang CFMOTO Power Co., Ltd.

Cautions The liquor (dilute sulfuric acid) in Battery is

Cautions Uniform (pilot uniform etc), cap, safety boots

Cautions The personnel shall make them be aware of

The gasket, O-ring, piston pin retainer and split

The parts shall be washed and the cleanser shall

Insert and arrange the bolts one by one and make

corrosion of gasoline or kerosene.

When disassembling the pressed ball bearing, the dis-

The inside or outside track of ball bearing shall

Install oil seal with the side of manufacturer’s mark

Do not mix mud or dust into engine or the hydraulic brake

When assembling the parts of protection caps, insert the

Fuel capacity 15L

Lights, Dashboard, Switchs

P le as e a pp l y s ta nd ar d to rq ue to t i g ht en if t or que va lue is no t d ec rib ed at belo w t ab l e

1.Throttle cable 2.Harness,handlbar switch(RH) 3.harness dashboard

General precaution information................................................... 1-16 1

with nice ventilation.

4. ·Do not use gasoline to wash or clean components or parts

necessary to inspect its marking line or any leakage.

screws, must clean it before assembly.

Introduction of fuel, engine oil and coolant

Eng ine oil：O il type (SAE10W －40)

Oil grade :API (SF or SG ) 1

as right picture show s acc ording t o temperature.

Caution： Do not mix other brand coolant to use.

Eng ine break-in

perform ance and reliability.

Rec omm ended break-in period is 1000Km.

Notes for break-in：

3、 Keep oil path sm ooth.

Av oid sudden acc elerat ion; Turn throttl e sl owly.

· After break-i n, do a complete m aintenanc e and dri ve normall y.

Left side view

Right side view

Engine technical specifications

3 Dis placem ent 144.9m l

4 Co mpres sion ratio 9.8：1

5 I dle spe ed 1500± 150r/min

6 Sta rting m ode Carburetor

Ty pe Pres sure s plash

Lu bricatio n O il pum p Rotor drive

O il grade SA E10W －40/ SF

Cooling Coo ling type Close-lo op recycle c ooling

Clutc h ty pe Wet a nd mu lti-disc ma nual clutch

Tra nsimission type Constant me sh

Num ber of g ears s hift 5 gea rs

Ty pe and order of gear shifting Mechanica l rec iprocatin g /1-0-2-3-4 -5-4-3-2-0-1

Transmis sion Prim ary ratio 3.471

Tra nsimission ratio 2 gear 1.857

ratio 3 gear 1.368

13 Dime nsion L×W × H（m m）：386× 311× 439

15 Drive m ode Chain drive

Item Standard data Service data Remarks

Clearance between valve guide bush IN. 0.01-0.037 —