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CF150T-5I(E-charm EFI) Maintenance Manual

1. Modify the airproof surface to the specific width by a es 45 milling cutter ee 8 15 CFMOTO Confirm again the contact of valve seat surface When the contact place is too high firstly grind it by 32 milling cutter then modify it to the specific width by 45 milling cutter When the contact place is too low firstly grind it by 60 milling cutter then modify it to the specific width by 45 milling cutter After modification apply grinding paste evenly to the valve seat and grind the valve configuration by valve gavel Notes Just beat gently while grinding the configuration do not press the gyration with strong force otherwise the valve seat will be damaged amp The valve shall be turned little by little for configuration grinding do not grinding the configuration always in the same place otherwise the grinding of valve seat surface will deflect amp Be cautious not let the grinding paste enter the gap between the valve stem and valve guide Clean the cylinder cover valve after the configuration grinding Confirm the contact of valve seat once again when the modification is entirely completed Assembly of cylinder cover gas outlet gate cylinder cover subassembly ri seal ring subassembly of valve stem gas inlet gate iij spark plug 8 cylinder air distribution system Cover the lower seat of spring and seal ring subassembly of new valve st
2. clutch branch unit gt 9 9 Remove 6 bolts Remove reduction box Take out positioning pin and sealing pad of reduction box Remove sealant adhered on the combination face Remove output shaft component Remove countershaft and countershaft gear p countershant Take out adjustment washer p adjustment washer 10 2 Disassemble of main shaft Remove the main shaft through knocking at its end face with a wooden harmer Check of reduction box Rotate each bearing cone in the reduction box and left box with finger to check for free and stable rotation without seizure In case of unstable rotation or shaking between outer race bearing and base hole of the bearing make replacement Check bearing holes in the reduction box and left box for scratch and damage Check the shaft portion and gear portion of the output shaft for wearing out or damage and in case of abnormality make replacement Check the shaft portion and gear portion of the main shaft for wearing out or damage and in case of abnormality make replacement 10 reduction box bearing counter shaft output shaft component 10 3 CFMOTO Check the countershaft for wearing out or damage and in case of abnormality make timely replacement Check the gear of the countershaft gear for wearing out or damage and in case of pr dr countershatt gear abnormality make timely replacement coun
3. Notes The reamer shall enter from the inlet side of firebox When the reamer is entering or going out it shall be always turning rightward while entering or going out If it turns leftward or the reamer does not turning while entering or going out the inner surface of valve guide will be damaged Special tools Reamer for valve guide 152MI 234 022300 34B Measure the interior diameter of valve guide Operation limit IN 5 04mm EX 5 04mm Calculate the gap between the valve stem and valve guide Operation limit IN 0 075mm EX 0 095mm It shall be renewed when the gap exceeds the operation limit Measure the interior diameter of valve guide calculate whether the gap is within the operation limit The valve shall also be renewed if the gap is not within the operation limit 8 12 8 cylinder air distribution system Renewal of valve guide Notes Because the valve works by taking the valve guide as axis when the valve guide is renewed sometimes the valve and valve seat cannot contact to airproof Therefore the valve seat shall also be modified when the valve is renewed Heat the whole cylinder cover evenly to 100 150 C Do not use gas jet for partial heating while heating the cylinder cover otherwise the cylinder cover may deform There is danger of burn do not operate with bare hands The valve guide comes out fro the side of firebox Do not damage the combination face of cylinder Make the new
4. Disassembly of stator Disassembly of wheel bearing Installation of wheel bearing D A of steering column locknut Disassembly of bearing adjusting nuts Disassembly of outer ring of steering column bearing Installation of upper bearing ring Installation of lower bearing ring Installation of plough inner ring Peak voltage mensuration 1 Maintenance information Lubricating grease Sealant Internal circumferential surface of cylinder liner Joint conical surface for installing the AC magneto rotor Bearing and side at the big end of the connecting rod Inner face of small end of the connecting rod Rotating surface of the main bearing for Crank Tooth surface of the timing chain wheel for Crank Tooth surface of the drive gear for oil pump Exclusively for 4 stroke External circumferential surface of piston pin motorcycle Piston ring groove SAE specification External circumferential surface of piston pin 10W 40 Full circumferential surface of piston ring API category engine oil Rotating surface of camshaft bearing with grade SE or SF Tooth surface of timing chain wheel Surface of valve rocker shaft Tooth surface of oil pump chain wheel Oil pump group Screw thread part and combination surface of drive wheel nuts Each lip of oil seal pressed into external circumferential surface Reduction gear tooth surface of gear shaft bearing part Cam profile surface or full circumferential surface of camshaft Inner hole surface o
5. Loosen the opening of fuel bolt the oil level shall reach volume device the opening 3 2 3 Test Adjustment Items for test and maintenance Maintenance period Determination standard mr CEN Transmission output shaft Loose Loose of connection connection can device sint ere ignition of spark plug Clearance of spark plug device sam 8 0 9 mm terminals dl GE connection on linkage sl 5 S abnormal sound Adjustment of timing fom fe a GO accelerating status ll ll sen speed mm 9 9 rd f ff ot air cleaner device Contamination and Gauge type the oil volume volume of engine oil En must be between the upper and lower limits nd 2 Status of connection mechanism of body of throttle valve kn DN mn 1 8 1 4r om pe JE KE device Pervasion Waste gas Damage on pipeline prevention reduction Clearing of ventilation opening device of device hazardous gas with black smoke and malodor CFMOTO Items for test and maintenance Maintenance period Determination standard Test _ Test item Daily 6 month Annual Test Test Test EE device and turning Function indicator EE GB RE RE Vent pipe and muffler Any loose or damage of installation Performance of muffler re Loose and damage 10 1 Others Lubricating grease status of each part of frame The parts whose failure can Determine whether be determined during there is failure on ope
6. Disassemble the hood of cylinder cover 8 6 Disassemble the left side cover 9 3 Turn the drive wheel of transmission make the two parallel reticle marks on chain wheel of camshaft parallel to the machining surface of cylinder cover and the groove opening of camshaft journal shall be upward Insert the feeler gauge between the valve rocker and valve test the valve gap Valve gap in cooling condition IN 0 05mm EX 0 15 0 20mm Steeler gauge Adjustment Loosen the locknut by spanner and loosen the adjusting screw for valve gap Insert the feeler gauge with selected thickness into between the valve rocker and valve Turn the valve gap adjusting bolt by socket spanner to contact the feeler gauge keep the position of socket spanner and tighten the locknut by spanner 8 4 8 cylinder air distribution system Turn the drive wheel of transmission for two revolutions and test again whether the valve gap meets the requirement Install the left side cover 9 20 Install the hood of cylinder cover 8 22 Disassembly of cylinder cover hood Disassemble the maintenance cover gt Chapter 2 Disassemble the bolts for cylinder cover hood and seal ring subassembly for cover hood bolts Disassemble the hood of cylinder cover Notes Be cautious not to damage the combination surface when disassembling the hood of cylinder cover Disassemble the locating pin seal ring for
7. Disassemble the three self tapping screws 3 located at the right of the soleboard Disassemble the soleboard Assembly Make assembling in the reverse 3 sequences of disassembling Ne self tapping self tapping solehoard screw 3 screw 3 2 7 CFMOTO Front fenderboard front Disassembly j fenderboard Disassemble the front wheel assembly 13 3 Disassemble the three bolts 1 Get the Front fenderboard off Assembly Make assembling in the reverse sequences of disassembling Front faceboard Disassembly Disassemble the four self tapping screws 2 and 3 which are connecting the front faceboard with the front trunk Disassemble the two self tapping screws 4 which are connecting the front faceboard with the front venting board Pull out the connector 2P for the left and right cornering lamp Get the front faceboard off Assembly Make assembling in the reverse sequences of disassembling Front air inlet opening and front air inlet grid Disassembly Disassemble the front faceboard 2 according to the above contents Disassemble the four self tapping screws 3 Get off the front air inlet opening I and the front air inlet grid 4 Assembly Make assembling in the reverse sequences of disassembling 2 8 2 Body and muffler Front venting board Disassembly f Disassemble the front faceboard 2 8 E screw l Disassemble the self tapping screws 2 and 3 Ta haggage
8. Driving depth of valve guide INEX 11 97 121mm J Automatic continuously variable transmission variator Moving disc subassembly for derailleur 24 007 24 028mm 24 2407mm External diameter of shaft sleeve for drive 23 959 23 98mm zen 92mm wheel disc Derailleur External diameter of centrifugal rotor 19 95 20 05mm 19 45mm subassembly Belt width 21 7 23 3mm 20 7mm 7mm Internal diameter of clutch outer rotary table 124 5 124 2mm Driven wheel of a Overhanging length of clutch spring 144 146mm clutc External diameter of driven rotary table 33 95 33 975mm 33 92mm Internal diameter of moving driven rotary table 34 000 34 025mm 34 06mm 1 10 1 Maintenance information Reducing mechanism engine oil Upon disassembly 0 151 Recommended reducer oil Grade SAE15W 40 SF Starting motor Crank piston and cylinder Unit mm w gt fom Piston The IN mark shall face the air inlet side Interior diameter of piston pin hole External diameter of piston pin Interior diameter of the small end of 15 016 15 034 15 05 connecting rod Gap between cylinder and piston Gap between piston and piston pin Gap between piston pin and connecting rod 0 016 0040 106 Gap of piston ring Piston ring I 0 15 0 30 opening Piston ring II 0 10 0 25 Installation direction of piston ring Mark upward a Cylinder Interior diameter 52 4 52 419 58 58 019 52 449 58 049 ring and piston
9. f FAE a iT i i ES t i i x F i TN nn Ma f 4 i z l L pt z P ll j y l Fi t i r f a d Cautions The liquor dilute sulfuric acid in Battery is strong corrosive it may burn the skin and blind the eyes when it contacts them In case of contact please wash it with a great deal of clear water immediately and receive medical treatment in hospital Besides please also wash it by a great deal of clear when it contacts the clothes for avoiding skin burn The Battery and Battery liquor 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 articles such as dustproof goggles dustproof respirator and gloves shall be worn for protection when necessary 1 Maintenance information Special tools OLEA SEN Nesen 1 17 Layout of cables pipes and guy cables 1 19 Expansion prevention device for poisonous gas etc 1 24 Cautions 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 Cautions The coolant is poisonous please do not drink it do not let it contact the skin eyes neither clothes In case it contacts the skin or clothes please suds it immediately When it contacts the eyes please wash it thoroughly with a great deal of clea
10. magnetogenerator temperature sensor Disassemble the insert element of water temperature sensor Disassemble the cap of spark plug Loosen the positive wire of starting motor the negative ire of starting motor and belt hi 8 can of snark plus negative wire of starting motor 7 2 7 Disassembly and assembly of engine oil injector high pressure oil pipe and hoop Loosen the locknut disassemble the gun guy cable disassemble the water inlet pipe and hoop disassemble the water outlet pipe and hoop disassemble the combination of exhaust muffler 2 15 Disassemble the bolt 3 bolt 4 and remove the combination of back brake calipers locknut UN gu water recycled eh outlet disassemble the bolt 1 bolt 2 and loosen the ices ate pipe er pipe and hoop combination of back brake pipes Disassemble the hoop of high pressure oil pipe from the oil injector then remove the high pressure oil pipe holt 1 nut 2 bolt 3 holt 4 7 3 CFMOTO Take down the engine from the frame according to the following sequence Disassemble the rear shock absorber 14 5 2 Remove the engine hanger ste i l installation holt of hanger assembling bush assembling bolts and the bush AE rear shock absorber hanger assembling bolis Fi A disassemble the engine ey hanger k _ installation holt of 3 Disassemble the hanger shaft gl ye gt d rear shock absorber nu
11. DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN BEGIN TO FLASHING TO CODING THE FIRST ERROR e THIS LOOP CONTINUE UNTIL THAT THE ENGINE ON IF POSSIBLE OR KEY OFF 4 KEY ON ENGINE OFF gt EXCEEDED MAINTENANCE TIME AND NOT ERRORS PRESENT e DIAGNOSTIC LED ON FOR 5 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN BEGIN TO FLASHING TO CODING THE EXCEEDED MAINTENANNCE TIME 15 SHORT FLASHING THAN THE DIAGNOSTIC LED TURN OFF AND STAY OFF e THIS SINGLE LOOP IS REPEATED EVERY TIME THAT THE KEY OFF AND THEN KEY ON TO RESET THE MAINTENANCE TIME FLASHING TO EXECUTE THIS PROCEDURE e TO HOLD THE TPS FULL OPEN AND THEN KEY ON e TPS ALWAYS FULL OPEN THE DIAGNOSTIC LED TURN OFF e TPS ALWAYS FULL OPEN AFTER 10 SECONDS THE DIAGNOSTIC LED ON FOR 5 SECONDS AND WITHIN THIS 5 SECONDS TO CLOSE THE TPS AND KEY OFF THIS IS THE PROCEDURE TO RESET THE DIAGNOSTIC LED WHEN EXCEEDED THE MAINTENANCE TIME THIS EVENT IS REPEATED WHEN THE MAINTENACHE TIME IS AGAIN PASSED THIS TIME MAINTENACHE TIME IS A PARAMETER OF THE ECU MAP 5 KEY ON ENGINE OFF gt EXCEEDED MAINTENANCE TIME AND ONE OR MORE ERRORS PRESENT DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN BEGIN TO FLASHING TO CODING THE ERRORS TO SEE THE ERRORS CODING TABLE e CODIFIED THE FIRST ERROR THE DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN FLASHING TO CODING THE SECOND ERROR THIS LOOP CONTINU
12. adjustment Test of engine oil in reduction box discharging plug screw Cover of engine oil filtering screen Oil discharging bolt Spark plug Lubricating device Mounting bolt of oil pump and body Screws for cover plate of oil pump Cooling device Draining bolt Water temperature sensor Impeller of water pump Hood for cylinder cover cylinder cover Bolts of cylinder cover hood Double head bolt for cylinder Short 2 Long 2 Bolts for timing chain wheel Bolts of tensioner spring seat Pin shaft with screw thread for tensioning plate Belt infinitely variable speeds mechanism Bolts for left cover Nuts of speed changer Nuts special for clutch Clutch nuts AC magneto Nuts for AC magneto Bolts for case flange Internal hexagonal bolt overrun clutch 1 14 22 2 2 20 2 0 25 2 5 12 1 2 10 1 0 2 0 2 8 0 8 12 1 2 10 1 0 10 1 0 30 3 0 30 3 0 9 0 9 10 1 0 13 1 3 10 1 0 59 6 0 59 6 0 53 5 3 59 6 12 1 2 15 1 5 Vehicle 1 Maintenance information Category Quantity Diameter of screwFastening torque Remark thread mm N m kgf m Disassembly and assembly of engine Mounting bolts for engine hanger Nuts for engine hanger shaft Front wheel front suspension steering gear Steering column locknut Nuts for assembling steering handle Nuts of front wheel shaft Upper Mounting bolts on shock absorber Rear wheel back suspension Nuts of rear wheel shaft Upper
13. cable pipe and hoop pipe and hoop The water pipes shall be installed properly the joints shall be with no helt negative wire of starting motor helt leakage Connect the guy cable adjust the gap of accelerator rotating handle 3 15 Lock the locknut tightly when the gap 1s adjusted Install the positive wire of starting motor and negative wire of starting motor properly and bind them properly 7 6 7 Disassembly and assembly of engine Install the cap of spark plug cap of spark plug Install the insert element of water temperature sensor insert element of temperature sensor Install the insert elements 2P 3P of magnetogenerator insert the insert elements 2P and 3P into the jacket and bind them properly positive wire of Install the combination of exhaust muffler 2 15 install the air cleaner 5 10 install the body of throttle valve and idle air control valve Chapter 5 inject the coolant eject the air 6 4 and install the plastic parts of vehicle Chapter 2 z helt Ae a B 3F insert elements of sa AC magnetogenerator 1 1 CFMOTO 7 8 8 cylinder air distribution system Maintenance information 8 1 Renewal of valve guide 8 13 Error diagnosis ceeeee eee 8 2 Test correction of valve retainer 8 14 Compression pressure of cylinder 8 3 Assembly of cylinder cover 8 16 Adjustment of
14. friction flake of the clutch Operation limit 2 75 mm Clutch spring Examine the elasticity of the clutch spring Measure the free length of the spring Operation limit 140 mm Spring of the clutch 9 12 9 Continuously variable Transmission System amp Left Cover Driven turntable set Examine the abrasion and destroying of the driven turntable set Test the outer diameter of axis sheath of the driven turntable err j a set bi a Operation limit 33 92 mm driven turntable set Remove the driven turntable set Examine the abrasion and destroying of the moving driven turntable set Test the inner diameter of axis sheath of the driven turntable set Operation limit 34 06 mm Assembly of the clutch Cautions While assembling degrease and cleanse the strap gliding face of the driven turntable outer clutch and the circle face of turntable set Assembly of the driven turntable set Move the driven turntable set Assembly of the driven turntable set Check rolling pin ball bearing bearing 1 driven turntable set 1 driven wheel oil seal airproof bush elastic collar for shaft direction dowel roller o shape seal rim Remove the driven turntable set 9 13 CFMOTO CF MOTO Degrease and cleanse the strap gliding face of the driven turntable set Smear lubricating oil on the lip of the driven wheel install the lip towards the internal side of the moving driven tu
15. hood of cylinder cover seal ring of hood 8 5 CFMOTO Disassembly of camshaft support subassembly Disassemble the left side cover 9 3 Disassemble the hood of cylinder cover 8 5 Turn the drive wheel of transmission anticlockwise confirm that the reticle mark on the chain wheel of camshaft is parallel to the machining surface of cylinder cover and the groove opening of camshaft journal shall be upward 8 4 Disassemble the bolts of tensioner spring seat washer and spring Disassemble the bolts of tensioner remove the tensioner and shim Disassemble the oil channel joint and spring of oil channel joint Notes Do not let the bolts of timing chain wheel drop into the box Loosen the bolts which fasten the timing chain wheel Disassemble the timing chain wheel Disassemble the acorn nuts and shim 8 6 holis of tensioner spring seat I a oil channel joint and Spring holt 8 cylinder air distribution system Disassemble the camshaft support subassembly camshaft support subassembly Disassemble the three hole purpose elastic collars in the hole of rocker shaft and hole of camshaft Disassemble the valve rocker Notes Pull the rocker shaft out by an M5 bolt bolt Disassembly of camshaft Disassemble the camshaft subassembly camshaft subassembly 8 CFMOTO Test Camshaft Turn the outer circle of bearing by fingers test whether
16. 4 and then disassemble the rear reflector5 Assembly Make assembling in the reverse sequences of disassembling 2 13 CFMOTO Fuel tank Disassembly Cautions No smoking or naked fire is allowed at the ee Oo operation site for the gasoline is combustible holil 1 holt 2 T Not only flames but electric sparks shall be avoided Besides the gasoline is explosive please operate it in the place with nice ventilation Disassemble the seat cushion 2 2 Disassemble the trunk 2 3 Disassemble the maintenance cover 2 2 Disassemble the rear shelf 2 4 Disassemble the rear joint board 2 4 Disassemble the left guard board 2 5 Disassemble the right guard board 2 5 Remove the four bolts 2 and then seat cushion top board combination Remove the four bolts 2 and then fuel senor 3P connector Loosen the fuel tube 9 and the hoop 12 4 8 connecting the fuel switch pull out he fuel tube 9 loosen the suction tube 11 and the hoop 13 connecting the fuel switch pull out the suction 11 Take down the fuel tank Assembly Make assembling in the reverse sequences of disassembling Note Please don t damage the tubes and the mail cable assembly when assembling The mail cable assembly guy cables should set the correct position in accordance with the wiring diagram requirement of cables tubes and guy cables When the fuel tube disassemble 9 is disassembled please avoid the leakage
17. 8 r column Remove front damper 13 9 Remove handlebar 13 13 Remove the locking nuts of steering column Special tools Locking nut wrench 519 922 050002 13 6 13 Front wheel braking Suspension and steering system Erection Make assembling in the reverse sequences of disassembling Notes 1 Tightening torque of locking nut of handlebar 50 60N m 2 Correctly thread the main cable assembly throttle control cable brake fluid tube cables and wires as per the diagram Chapter 1 3 Correctly insert each plug into anti dust cap lubricating pil into the wires this with ch corresponding socket without any loosing or So eee dropping off 4 At fixing the throttle control cable pull out its anti dust cap add several drops of lubricating oil into the wires forwards backwards pull the cable for several time to make the lubricating oil enter the cable and finally tighten locking nut I and locking nut 2 5 At fixing the rotating handle of throttle coat grease on its inside and its fitted slide face and the handlebar 6 At fixing the left and right rear view mirror please note that the left rear view tighten locking mut 1 tighten locking nut 2 Fa Pa mirror is right thread and the right rear view mirror is left thread 13 Front wheel braking suspension and steering system 13 7 CFMOTO Braking pump Disassembly Remove the left and right rear view mirror g
18. Remove drain screw and washer Remove oil filtering component Special fhavheel disassembling t L ools trigger hole purpos elast drain Screw and washer FR fi oil fittering component Screw and washer icretainer g er al foe nump omponen 11 3 CFMOTO CF Moto hole purpose elastic retainer bolt Pai j bolt bolt Fa bok Erection of water pump Erection sequences 1 Fix bearing 6901 P6 onto water pump shaft and then insert it into the water pump shaft hole on the right side cover 2 Fix bearing 6000 P6 onto water pump shaft and clamp it with the hole purpose elastic retainer 3 Coat cylindrical face purpose sealant round circumference of the oil seal of water pump and fix it on the right side cover 4 Fix and the water seal component into the right side cover and heavily press it 5 Insert the washer onto the water pump shaft and tighten the water pump impeller in the water pump shaft 11 4 11 Right side cover magneto and water pump Sub assemble of right side cover vent hose Y schnorkel joint right side cover sealing pad outlet conduit joint ts seal ring pa Upper View window cover KR and its seal ring Ae upper View Indow cover positioning pin ON ii machine level 8 0 model airproof ring Cover of oil i filtering screen GE washer OP on rie o type seal ring drain screw filtratrio
19. away from the cut of piston Erection of crank box Coat grease on the inner lip of the new oil seal coat sealant round its outer circumference and then fix it onto the left crank box Fix positioning pin and sealing pad of crank box Erection of crank Tighten the left and the right box body with bolts at the specified torque After tightening the crank shall be able to freely run without any seizure Required torque 12N m 1 2kgf m Notes The bolts on the flange face of crank box shall be diagonally tightened in 2 3 times bolt During erection take cares not to damage box body combination face Re place the tension plate and threaded a ee ee een pin shaft and tighten them at the E fs specified torque Required torque 13N m 1 3kgf m a Erection of timing chain E m Erect the engine at the sequences reversed to gt 12 1 12 8 13 Front wheel braking suspension and steering system Fix the retaining ring of upper bearing on the steering column and tighten it with specified torque Special tools Adjustment wrench of steering column bearing 519 922 050002 Torque I ON m 1 0k g f m Leftwards and rightwards rotate the front fork to the left and right stop limit position for several times to make the retaining ring and bearing fully run in Loose the retaining ring of upper bearing on the steering column Manually tighten the retaining ring of upper bearing on Fix locking nut the
20. axle or skew of tire Deformation of frame Wearing out of tire or sidewise wearing out of tire Shaking of wheel bearing Shaking of fixing portion of engine Chapter 7 Running out of front wheel Deformation of rim Poor wheel bearing Poor tire Improper wheel balance Poor fixing of surrounding of axle Non free rotation of wheel Poor wheel bearing Bent front axle Drag of braking Excessively soft front suspension Weakening of elastic force of front damper Too low tire pressure Excessively hard front suspension Bent front damper Excessively high tire pressure Abnormal sound from front damper Poor front damper Loosing of tightened locations of damper Poor braking effect Poor adjustment of the brake Stain or damage of surface of braking disk Wearing out of skid 13 19 CFMOTO Special tools Bearing disassembling tool shaft Bearing disassembling tool head 10mm Press in tool handle A Press in tool sleeve 28 x 30 Pilot tools 10mm Locking nut wrench Adjustment wrench of steering column bearing bearing disassembling tool modular Rotor puller Disassembling tool shaft Disassembling tool weight Erecting tools A for steering column bearing race 27x 47mm Erecting tools B for steering column bearing race 30x 47mm Assembling tool shaft 13 20 07746 0050100 07746 0050200 00749 00 10000 07946 1870100 07746 0040100 07916 KM 10000 O7SMA GBCO100 0
21. be approaching during charging The electrolyte dilute sulfuric acid is a strong corrosive solution it is hazardous to be contaminated it corrodes clothe hurt skin and eye even blindness Flush with water when contaminated When it hits eye flush with water immediately and be treated in hospital The contaminated clothes may transfer the liquor to the skin it have to be changed and cleaned thoroughly Notice The setting and unsetting of plug and connector on the electric element lively spark may be erupted the unit such as the rectifier may be damaged Hence it should be carried out under the ignition switch off amp The charging of the battery should be operated dismounted from the car but the lid of the battery should not be removed Notice The battery has to be renewed when its service life is ended The ignition switch has to be off when dismounted the electric parts Before to preserve the battery in the car the connecting wire of the negative pole has to be removed Quick charge is not a conventional means it could shorten the service life of the battery The battery will be deteriorated when it is under deep charging and discharging charging and discharging completely frequently or standby under discharging for a long time making its service life shortened and capacity decreased The capacity will be decreased after the battery used for 2 or 3 years even under normal conditions The battery with capacity decr
22. bolt 2 disassemble the small circulating water hoop 2 OA pipe eject the coolant waier ouilet pipe i ii unplug the wire of temperature switch of radiator ri ud and disassemble the radiator Assemble Make assembling in the reverse sequences of disassembling Water pump Maintenance Inspect whether there is coolant leakage at the draining hole at lower part of the water pump When there is coolant leaking from the draining hole it means that the water seal subassembly is damaged and the water Balicatdcainine teeta skin seal subassembly for water pump shall be renewed 7 11 4 6 8 6 Cooling system Diagram of cooling system water inlet pipe of radiator radiator combination water outlet pipe of radiator pipe of assistant water box _ steel pipe combination IV left TT steel pipe combination I right of cooling water i assistant water box water outlet pipe of engine 5i steel pipe combination I defi steel pipe combination rizh 4 of cooling water Ve Y Gl water inlet pipe of engine joining pipe 6 9 7 Disassembly and assembly of engine Maintenance information 7 1 Disassembly of engine 7 4 Installation of engine 7 2 Maintenance information Notes during operation When disassembling or assembling the engine the vehicle shall be supported firmly by jack etc Be cautious not to damage the fram
23. fix the said oil seal with its lip towards reduction box side Notes At fixing oil seal keep it flush with end face not stop the leaking port on middle output shaft s oil seal _ 10 5 CFMOTO Disassemble and assemble of bearing and oil seal in left box Remove the oil seal of main shaft Disassemble main shaft bearing countershaft bearing and output shaft in the bearing left box with the procedures of 10 5 Disassembling of main shaft bearing in reduction box Vertically press the new main shaft bearing into the left box body till stopping Erect the main shaft bearing countershaft bearing and output shaft bearing with the same method Erection of main shaft Pull the main shaft into the left box body with crank box combined bushing and crank box combined shaft tools Coat grease on lip of the oil seal of new main shaft Fix the oil seal with its lip towards reduction box side oil seal of 10 6 10 reduction box Assemble of reduction box Erect the adjustment washer Fix countershaft gear and countershaft to the reduction box and insert the adjustment washer onto the shaft Erect the output shaft countershaft Erect the positioning pin EEE Soak the sealing pad of the reduction box in kerosene and then fix the sealing pad onto the combination face of the left box Erect the reduction box Place and tighten the bolts Tightening torque 22 N m 2 2 kgf m Fi
24. it is installed in the groove properly circlip 1 Maintenance information M Fach fastening part must be inspected whether they are MM The brake fluid and coolant may damage the tightened and work well after assembly application surface plastic parts rubber parts etc Do not let the fluid attach to such parts In case of attachment wash it immediately with water Ga ou A lt lt M The side of oil seal with manufacturer s sign shall be st 3 i Siik Pa lt installed facing outside the direction without oil Avoid the crimp of oil seal lip when assembling do M The tube shall be inserted to the base of joint not let the burrs damage the oil seal lip when installing the tube parts If there is tube clip The oil seal lip shall be applied with grease before the tube clip shall be installed in the sunken slot of assembly tube The tube that is without tightness upon installation shall be renewed manufacturer s 1 sunken slot Dy a SG 7 3 tube clip E Avoid the entry of dusts dirt into the engine or the oil pressure system of brake joint Pa Pe er Aa ee ee ne gr ee ee E The gasket attached to the combination surface of each cabinet of engine shall be cleaned before assembly The impact mark on the contact surface must be removed by whetstone evenly E The stayed cables shall not be over contorted or bent Deformed or damaged stayed cables will cause malfunction or dilapidation E
25. micrometer Service limit 0 2mm Rim Check the rim for damage deformation and scratch and replace the rim in case of abnormality Slowly rotate the wheel and measure the run out of the rim with micrometer Service limit Axial 2 0mm Radial 2 0mm Wheel bearing Rotate the bearing cone with finger check it for free and steady rotation and check for loosing when it is erected onto the hub In case non free or unstable rotation abnormal sound or shaking replace new one Notes Replace the bearings in package left and right bearing 13 Front wheel braking suspension and steering system 13 17 CFMOTO Front wheel Disassembly Lift the frame with jack raise the front wheel unscrew the front axle nut withdraw front axle pull out the braking disk from the brake caliper and remove front wheel Take out counter 13 18 link of speedom e line front hydraulic pressure brake disk front axle convention 13 Front wheel braking Suspension and steering system Diagnosis of Error s Heavy handlebar Excessively tightening of threads of upper portion Damage or wearing out of steering bearing Damage wearing out or stepping of inner and outer bearing race Deformation of steering column Low tire pressure Wearing out of tire Loosing of handlebar Damage or poor tightening of steering bearing damage Unmatched left damper and right damper Deformation of front
26. mixture ratio according to the lowest temperature in the region where it is used froni venting Coolant leakage shall be inspected plate when the coolant volume decreases evidently When there is absolutely no coolant in the assistant water box there may be air mixed into the cooling system then the cooling system shall be exhausted Coolant leakage Inspect whether the pipeline water pump water pipe and the connection of radiator are leaking It shall be disassembled and repaired if there is leakage gt Chapter 6 Inspect whether the radiator pipeline is aged damaged or chapped The rubber pipe will age naturally due to heat and long time operation Along with the aging the heating of cooling system will break the pipeline Nip the pipe by fingers to inspect whether there are tiny cracks Renew the parts when abnormity is discovered during above overhaul Inspect the tightness of coolant pipeline hoop fasten it when it is loose See 6 8 for details of radiator disassembly and assembly Inspect whether there is dirt block or damage on the radiation fin of radiator Modify the bending of radiation fin remove the blocking dirt with water and compressed air The radiator shall be renewed if the damaged area of radiation fin of the radiator is over 20 of the entire area 6 8 Please refer to page 6 4 for renewal of coolant assistant water box lower limit 7 3 Test Adjustment wa
27. moving part if the action is not smooth 4 port axis Wain support axis m S Steel bowl of front fork Side su The broken line in the diagram indicates the invisible parts in the schematic diagram 3 20 4 Lubricating system Maintenance information 4 1 OL PUMP sagaene 4 2 Error diagnosis 00 4 Maintenance information Notes during operation amp The oil pump will be maintenanced after the right side cap has been disassembled Chapter 11 If each measured value of the oil pump exceeds the using limit the oil pump group needs to be renewed amp During assembling or disassembling the oil pump please pay attention to do not let the foreign inclusion into the interior of the engine After the oil pump has been assembled check whether there is the phenomenon of oil leakage Maintenance standard Commended engine oil SAE1OW 40 20W 50 special for 4 stroke motorcycle When using substitute please choose from the following range Er N 50 API SE or SF engine oil i SAE Choose from the left table according to the environment air am temperature rotor external rotor pump and the main body Fastening torque Construction bolts for the body of oil pump 1ON m 1 0kgf m Screws for the cover plate of oil pump 2N m 0 2kgf m Isolation board subassembly B for oil pump 1ON m C 1 0kgf m Isolation board A for oil pump I0N m 1 0kgf m Error diagno
28. new upper bearing 13 18 13 2 13 Front wheel braking suspension and steering system Fix the steel cup of new upper bearing on the steering column with following special tools Special tools steering column bearing race erecting tools A 519 922 050005 Assembling tool shaft 519 922 050006 Steering column bearing race erecting tools B 519 922 050007 Assembling tool shaft 519 922 050008 Maintain the assembling tool shaft and press the upper bearing steel cup into the steering column while locking the nut Replacement of lower retaining ring of upper bearing m upper bearing steel cup upper bearingn steel boy i r ae i i Maintain the assembling tool shaft Upper bearing steel rings 15 steering column bearing race erecting tools Remove lower retaining ring of upper bearing 13 and steering system Front wheel braking suspension lover bearing steel cup front fork combination 13 3 CFMOTO Fix the special tools onto the square tube of support and remove upper bearing steel cup Special tools Bearing disassembling tool modular 519 922 050000 Rotor puller 519 922 050010 Disassembling tool shaft 5 19 922 050003 Disassembling tool weight 519 922 050004 Erection Fix the new lower bearing steel cup and following special tools onto the steering column Special tools steering column bearing race erecting tools A 519 922 050005 Assembling tool shaft 519 922 0500
29. of disassembling holt Disassembly of oil injector branch vil injector cap a assembly ine of 5 ring 0 Push both sides of the snap spring of oil injector oil injector cap cap by the thumbs of both hands and remove the l PA oil injector snap spring of oil injector cap Separate the cap of oil injector and oil injector Assembly of oil injector branch assembly Install the cap of oil injector onto the oil idle speed air inletpipe idle speed air outlet pipe injector then aim the groove of snap spring of i oil injector cap at the dummy club on the cap of oil injector and press the snap spring of oil injector cap into it Disassembly of idle air control valve Disassemble the trunk 2 3 Disassemble the idle speed air inlet pipe and idle speed air outlet pipe Ae ea Loosen the belt disassemble the insert element insert element of idle air control valve and remove the idle air control valve Installation of idle air control valve Make assembling in the reverse sequences of disassembling 5 4 5 Oil supplying system air inlet system Disassembly of air cleaner insert element of air Disassemble the trunk 2 3 Disassemble the insert element of air temperature sensor Loosen the connecting hoop of air cleaner waste gas pipe hoop of crankcase and remove the crankcase venting hose bolt I holt 3 bolt 2 Disassemble the bolt 1 bolt 2 and bolt 3 Disassemble the air c
30. once when it drivings for 2 000 3 000km Coolant Renew it once every year The engine oil of Transmission Renew it once every year the engine oil Renew it first driving for 1 000km or one month Renew it once after driving for 3 000km afterwards 3 1 CFMOTO Mode of Test and overhaul Overhaul time Items for test and maintenance Maintenance period Determination standard Test part Test item Daily 6 month Annual Test Test Test i Steering Operation flexibility handlebar steering column rom of steering column Oo Brake device Braking Clearance handle Brake effect Connecting Loose and damaged bar and oil pipes Hydraulic Quantity of front and The level of brake fluid shall brake and rear brake fluid be above the LOWER limit brake disc Abrasion and damage of brake disc thickness is less than 3mm Wheel Tyre pressure Front wheel 200kPa 2 50kgf cm2 Rear wheel 225kPa 3 00kgf cm2 gt a AO a damage Tyre groove depth No abrasion indication and abnormal appeared on the tyre surface abrasion depth of remained groove shall not be less than 1 6mm MS and wheel axis i wheel bearing a O B G wheel bearing Vibration of connection and damage on vibration arm ter a TOP absorber damage Fumetion SO Transmission Gear box Oil leakage and oil The working discs of the front and rear brake discs shall be renewed in time when their Bumper Suspension device arm
31. pothook i assembly at the left and the right of the front trunk mi Disassemble the self tapping screws 4 at the left and the right of the soleboard Get off the front venting board inal D screw I seirinin ua Fo gt SCrews 2 Assembly sil el l front trunk el ke Make assembling in the reverse sequences ee self ing screws 3 of disassembling Let Mi tapping Self tapping Ss screws 4 sr i nl Baggage pothook assembly Disassembly Disassemble the two screws 1 on the baggage pothook assembly Disassemble the baggage pothook assembly Assembly Make assembling in the reverse sequences of disassembling Front trunk assembly Disassembly Disassemble the front faceboard 2 8 Disassemble the front venting board 2 9 Disassemble the baggage pothook assembly 2 9 front unk 4F cane clon of fuse box Disassemble the connector 4P for the fuse box Disassemble the front Trunk assembly Assembly Make assembling in the reverse sequences of disassembling 2 9 CFMOTO Pre a ge fio iss Gr A f y J if Pie EE W 1 ra 2 i ii fy MT NT MA wy MT YI HR J H a aa oe Fr i A tr i i F z in i SN i at l E ee K jr fir E 1 1 a Nr i N i Ween A N F 4 Let SA J i Ton Wani 1 k le hA a im ANY 7 p E g tr gt E P EN re L SA 1 pr 1 Left cover of front trunk Disa
32. range at mA level is selected the fuse of the multi meter will be burned out by large current Leaking current Less than ImA When a leaking current is bigger than the specified one there must be some abnormality existing in the circuit In order to locate the abnormality you should test the current value while detach the connecting point of the connector according to a proper sequence Rectifier regulator Rectifier regulator 3P tio Check System Rectifier requla or Cautions The said measure can be done without removing the AC magneto from the engine Remove the left protective board 2 5 Remove the right protective board 2 5 Remove the rectifier regulator 15 7 ctifier regulat Detach the linking of the two connectors of the or 4P connection rectifier regulator 15 6 15 Battery Charging System Rectifier regulator Measure the resistance between the individual terminals by a multi meter as shown in the table below In case one of the values falls out of the specified range replace it with a new one with the multi meter switched to the diode scale Cautions In case the probe is not connected while the multi meter shows a reading of less than 1 4V then replace the battery of the meter Si o TI Fett Vell Velle Green Yaw ee o o woso gt ww a ME 20 On Yelow o II 400500 s Man Red 400 500 400 500 400 500 750 850 _
33. ring 7 HOES Piston ring II 0 02 0 044 Deformation on the top Cylindricity 1 11 CFMOTO Front wheel Rear wheel arme msn gt Brake system Front brake Gap of brake handlebar 10 20mm mn Back brake Gap of brake handlebar 10 20mm EG 1 12 1 Maintenance information Battery charging device Model of rectifier 3 phrase loop rectification silicon control voltage stabilizing in parallel Voltage between terminals Full charge Ignition device Item Standard Ignition mode ECU control unit ignition mode Spark plug Selection o G Gap of spark plug 0 8 1 0mm Ignition period Max advance angle 43 BTDC Peak voltage Light instrument switch trigger coil O i moe eS 1 13 CFMOTO Fastening torque Torque Nom gf m Torque Nom gt m 5mm Bolt nut 5 0 5 5mm Screw 4 0 4 6mm Bolt nut 10 1 0 6mm Screw 9 0 9 8mm Bolt nut 22 2 2 6mmSH Bolt with flange 10 1 0 10mm Bolt nut 34 3 5 6mm Bolt with flange nut 12 1 2 12mm Bolt nut 54 5 5 8mm Bolt with flange nut 26 2 7 10mm Bolt with flange nut 39 4 0 The places which are not recorded in the following table shall be tightened according to standard torque Cautions 1 The screw thread combination surface shall be applied with engine oil 2 The self lock bolt shall be renewed upon disassembly Category Quantity Diameter of screw Torque Remark thread mm N m kgf m Spot test
34. rod Service limit 15 05mm 12 5 CFMOTO Rotate the crank bearing and check for abnormal sound and shaking In case of abnormal sound or shaking replace the t crank bearing B m Piston and cylinder Check outer circumference of piston for scratch Check piston ring slot for wearing out and oil port for blocking Measure the outside diameter of piston at 90 with vertical to to the piston pin hole at position 6mm below the lower end of piston Service limit 52 32 57 92 mm Calculate the gap between piston and cylinder cylinder bore 8 12 Service limit 0 08mm Measure the inside diameter of the piston pin hole in direction X and Y respectively and take the maximum value as the inside diameter of the piston pin hole Service limit 15 04mm Slide location of piston pin and slide locations at small end of connecting rod totally3 locations Measure the outside diameter of piston pin Service limit 14 98mm piston pin Calculate the gap between the piston pin and piston pin hole Service limit 0 04mm Calculate the gap between the piston pin and the small end of connecting rod Service limit 0 06mm Check the upper face and the lower face of the piston ring for scratch sidewise or wearing out 12 6 12 Box body crank and piston Fix the piston ring into the correct piston ring slot and press the piston ring till reaching basically same position of side faces of the piston Mea
35. s possible to damage the fuel pump 6 If the motorcycle isn t used for a long time you d better let the fuel oil out before using in order to avoid the fuel line plugging 7 When washing the motorcycle prevent the water from crushing into electrical components and cables 8 Only after switching off the power cutting off the join of wire and battery can ECU be pulled out avoid the damage of ECU Don t insert and pull out the ECU rashly 9 TPS sensor restrictor place sensor moves randomly it is hard to start engine probably 10 Avoid counter electrode when dismounting battery When the motorcycle heeling to the land for 7 seconds the heel sensor works the engine automatically flameouts powers off You can start it when processing the power again 11 Maintenance attention when ECU has worked for 100 hours the error light flashes continuously 15 times when switching on the power prompts that it s time to go to the service apron for maintaining 21 Electron diagnostic system and error diagnosis 20 2 20 Electric injection diagnostic system and error diagnosis III Error diagnosis I he error that relates to the ECU system comes from connection error so when checking the anomaly of the system please affirm the followings a power supply battery voltage fuse integrity initiating relay coil b frame bracket iron fuel supply fuel pump fuel filter screen d ignition system sparking plug ignition coil screened
36. steering column and then loose it backwards rotating cca a locking by 45 1 8 revolution kV Pa Align the pawl of retaining washer with the groove of i HUA front fork and fix locking washer Fix locking nut of steering column Special tools Wrench for locking nut 07916 KM10000 Torque 6 8 N m 7 0kgf m Leftwards and rightwards rotate the front fork to the left and right stop position for several times to confirm no upwards downwards shaking and free movement retaining ring of upper bearing Fix following parts handlebar 13 13 front damper 13 9 locking nut front mud guard 2 8 front wheel 13 3 header board 2 8 13 Front wheel braking suspension and JMFERER f r Geklig nut steering system 13 1 CFMOTO Press the new lower retaining ring of upper bearing into the front fork with special tools and hydraulic press Special tools Press in tool front fork guard 519 922 050009 retaining washer r Press in tool front fork fitting upper ball retainer Fix locking nut remove lower bearing steel cu p per bearing keep of retaining ring lower bearing keep of retaining ring Bp gt Tin upper bearing steel cup S k lower ball retainer dustproof ring front intubatton combination lower bearing keep of retaining ring front fork Erection After coating grease on new lower bearing fix the front fork Fix after coating grease on
37. subassembly for holder for valve stem valve stem shall not be used again Remove the accumulated carbon attached to the firebox and valve Notes The accumulated carbon can be removed easier when it is immersed with gas Notes Gas 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 vapored gas is explosive please operate it in the place with nice ventilation Notes Please be cautious not to damage the combination face with the cylinder and the valve retainer Test whether there is chapping around the hole of spark plug valve retainer Clean the combination face with cylinder 8 11 CFMOTO Valve spring Test whether the elasticity of valve spring is weakened or it is damaged Measure the overhanging length of valve outer spring Operation limit 33 5mm Measure the overhanging length of valve inner spring Operation limit 30 8mm Valve stem Test whether the valve is bent valve deflexion damaged burnt whether there is deflected abrasion at the end of valve stem Put the valve into the valve guide test the actions of valve Measure the external diameter of the valve stem which corresponds to the sliding part of valve guide Operation limit IN 4 965mm EX 4 945 mm The accumulated carbon on the valve guide shall be removed by reamer before measuring the interior diameter of the valve guide
38. temperature quickly Besides the thermometer must not contact to mul i meter container base Disassembly Remove seat mat gt 2 2 Remove trunk gt 2 3 Water temperature sensor Remove water temperature sensor connector Remove water temperature sensor Put water temperature sensor into the container with cooling water slowly make liquid warm measure the resistance value of temperature sensor 50 C 154 16 Q 88 C 52 4 Q 100 C 27 3 Q 120 C 16 2 Q Replace the water temperature sensor when it is over the specified value install water temperature sensor join the connector of water temperature alarm switch pour into cooling liquid discharge air Install the trunk and seat mat at the reverse order of removal 18 12 19 Circuit principal diagram wiring diagram circuit principle diagram H H AHH ASHE mm bn mn ft 14 1 i l a k ul gee p 1 j 1 T 3 1 B p fi Ai E 5 T e ib TE z Cir f PPETI TI 5 mr br if jot d ME E mra H 2 EEE TET 232 teH O O O O l m EEE SL fo a 255 fr a ia a st IG EE ll fl td ETT J E vr A 3 nam MENE 20 Electric injection diagnostic system and error diagnosis Introduction to the electric injection system 6 0 0 66 6 6 6 6 00 0 6 6 6 0 0 610 06 006 EE PR 20 1 NE EE EE NR T T 90 2 Error diagnosis TOErrErrerrrrerrrrrrerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrerrrrrrrrerrr
39. the self tapping screws 2 and 3 which are connecting the left heel of foot board with the soleboard Disassemble the screw 4 which is connecting the left heel of foot board with the motorcycle frame Disassemble the bolt 1 get the left heel of foot board off Assembly self tapping holt I Screw 2 1 left heel of foot hoard self tapping self tapping screw 5 screw 3 screw 4 i Make assembling in the reverse sequences of disassembling Right heel of foot board Disassembly Get the rubber of foot board off Disassemble the maintenance cover 2 2 Disassemble the self tapping screw 6 which is connecting the right heel of foot board with the right guard board Disassemble the self tapping screws 8 and 9 which are connecting the right heel of foot board with the soleboard Disassemble the screw 7 which is connecting the right heel of foot board with the motorcycle frame Disassemble the bolt 10 get the right heel of foot board off Make assembling in the reverse sequences of disassembling Assembly PT irae self tapping EN ii screw 9 holt 10 screw right heel of foot board Make assembling in the reverse sequences of disassembling 2 6 2 Body and muffler Soleboard Disassembly Disassemble the four self tapping screws 1 which are connecting the front part of foot board with the soleboard Disassemble the three self tapping screws 2 located at the left of the soleboard
40. to PIN2 INJECTOR Wire 2 connect PIN87 MAIN RELAY to PIN1 INJECTOR INJECTOR FAULTY INJECTOR NOT CONNECTED WIRING FAULTY Short Circuit between the wire that connect PIN7 ECU to PIN2 INJECTOR and GND gt ONLY ENGINE ON RPM gt ZERO INJECTOR FAULTY WIRING FAULTY Short Circuit between the two wires of the IDLE VALVE Wire I connect PIN8 ECU to PIN2 IDLE VALVE Wire 2 connect PIN87 MAIN RELAY to PINI IDLE VALVE IDLE VALVE FAULTY IDLE VALVE NOT CONNECTED WIRING FAULTY Short Circuit between the wire that connect PIN8 ECU to PIN2 ERROR_INJECTOR_S C 1 L F 1S F ERROR_INJECTOR_O C ERROR_IDLE VALVE_S C ERROR IDLE VALVE O C IDLE VALVE and GND IDLE VALVE FAULTY WIRING FAULTY Short Circuit between the wire that connect PIN4 ECU to PIN85 FAN RELAY and BATTERY ERROR FAN RELAY S C F FAN RELAY FAULTY To execute the ACTIVE DIAGNOSIS FAN TEST only if there is no problem on the TH gt O SENSOR FAN RELAY NOT CONNECTED WIRING FAULTY Short Circuit between the wire that connect PIN4 ECU to PIN85 FAN RELAY and GND gt THE FAN ALWAYS ON FAN RELAY FAULTY WIRING FAULTY Short Circuit between the wire that connect PIN3 ECU to PIN85 MAIN RELAY and BATTERY gt ERROR 17 CAUSE ERROR 32 ONLY WITH ENGINE ON MAIN RELAY FAULTY ERROR FAN RELAY O C ERROR MAIN RELAY S C MAIN RELAY NOT CONNECTED gt ERROR 18 CAUSE ERROR 12 AND ERROR 14 1 L F 8 S F WIRING FAULTY Short Circuit between the
41. tyres etc Specified air pressure tyre 200kPa 2 00kgf em2 225kPa 2 25kgf em2 100 80 14M C 120 80 14M C 3 7 CFMOTO Loose of wheel nuts and axes Inspect the loose of nuts on front wheel axis and rear wheel axis Fasten according to specific torque when it is loose Torque Nuts on front wheel axis 80N m 8 2kef m Nuts on rear wheel axis 140N m 14 3kgf m Vibration of wheel bearing Support the main bracket lift the front wheel and turn the steering handle to the limit position either leftward or rightward shake the wheels axially inspect whether there is vibration If there is vibration disassemble the front wheel and inspect the wheel bearing gt 13 4 Suspension system Action Front suspension Hold the front Braking handle tightly compress the front suspension up and down for several times for confirmation of the action If there is vibration or abnormal sound inspect the front shock absorber Steering column Inspect whether the front shock absorber is leaking whether there is damage loose on each fastening part Rear suspension Compress the rear suspension up and down for several times for confirmation of the action If there is vibration or abnormal sound inspect the rear shock absorber hanger pivot Inspect whether the rear shock absorber is leaking whether there is damage loose on each fastening part 3 8 3 Test Adjustment Vib
42. valve gap 8 3 Test of cylinder body 8 17 Disassembly of cylinder cover hood 8 5 Assembly of cylinder body 8 18 Disassembly of camshaft support Assembly of cylinder cover 8 19 SUDAS MOIY Lune 8 6 Assembly of camshaft support Disassembly of cylinder cover 8 9 Subassembly teeererereeeeeeeeeeeeeeeee 8 20 Disassembly of cylinder body 8 10 Assembly of cylinder cover hood 8 22 Disassembly of cylinder cover 8 11 Maintenance information Notes to operation amp The maintenance of cylinder cover hood camshaft subassembly camshaft support subassembly rocker cylinder cover subassembly and cylinder body group can also be carried out in the engine in car status Be cautious not to damage each combination surface when disassembling the cylinder cover hood cylinder cover subassembly and cylinder group The parts shall be marked respectively when disassembled for awareness of their disassembly positions and they must be installed back to the original places The parts shall be washed after disassembly and before test and determination and they shall be blown to dry with compressed air Before assembly in order to ensure the initial lubrication the shaft journal of camshaft subassembly cam surface rocker shaft and rocker inner hole shall be applied with lubricating oil The lubricating oil supplied to camshaft subassembly is supplied through the oil path in the cyl
43. valve guide enter it from the side of camshaft when the cylinder cover is not cooled yet When the cylinder cover is cooled the reamer enters from the side of firebox and reams the valve guide carefully Notes The reamer must enter from the side of firebox Be cautious not to make the reamer deflected if the reamer cuts in deflected status the valve guide hole is deflected which may cause leakage of the airproof of valve stem or there will be a big deflexion on contact with the valve seat so that the airproof surface of valve seat cannot be modified Clean the cylinder cover remove the scrap iron Test modify the contact surface of valve seat Special tools Valve line countersink drill 152MI 236 022301 27 Test modification of valve retainer Test Remove the deposit on the valve such as accumulated carbon The valve face is with chap deflected abrasion renewal Apply a thin layer of red lead to the valve seat of cylinder cover Do not let the valve rotate knock the valve gently with valve gavel test the airproof contact 8 13 CFMOTO Notes The valve cannot be modified When the valve face is with chap uneven abrasion or no contact with the valve seat the valve shall be renewed Remove the valve test the airproof surface of valve seat by checking the attachment of red lead on the valve face The valve seat shall be modified when there is scratch If the valve inclines test t
44. 0l 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 CONTENT Maintenance information Body and muffler Test adjustment Lubricating system Oil supplying system air inlet system Cooling system Disassembly and assembly of engine Hood of cylinder cover cylinder cover cylinder body air distribution system Continuously variable Transmission System amp Left Cover Reduction box Right side cover magneto and water pump Box body crank and piston Front wheel braking suspension and steering system Rear Wheel Braking Suspension Battery Charging System Ignition System Electrical starting system amp overrun clutch Light instrument switch Circuit principle diagram Electric injection diagnostic system and error diagnosis Function of buttons of diagnosis analyzer EEU Errors Coding Table Notes during operation 5 1 1 Cautions to disassembly assembly 1 3 Number marking position 068 1 6 Table of main parameters 606 1 7 Table of maintenance parameters 1 9 Fastening torque saadan 1 14 Notes during operation Safety cautions Cautions Exhaust contains toxic ingredients Do not run the engine in closed places or places with poor ventilation for a long time R _ i i iF Ja F E d r Padi 1 he yT ts 7 eT k pu 1 IN 4 r a fi oF f Y hi t r P ii F F CL i
45. 14 4 Error diagnosis Cor ccc ccc cccccccccccccccccccce 14 2 Rear bumper Cec cccccccccccccccccccce 14 5 Rear wheel Coe ccccccccccccccccccccecccccececoce 14 3 Maintenance Information Notes During Operation Notes e Only after the frame is surely supported on the ground may the rear wheel and suspension system be maintained e Must use high quality parts of installing bolt and nut of rear bumper e The wheel shall not be excessively applied with force avoiding the wheel damaged In order to protect tire bead tires shall be assembled on or disassembled from tire bead with special tire rod and tire bead protector Item Standard Operation limit Rear wheel Running out of Longitudinal P 20m tire bead Twa cc MAE o a a Rear brake Gap of braking handlebar 102 20mm Maintenance standard Tighten torque Rear wheel axis nut 140N m 14 3 kgf m Installing bolt above bumper 55N m 5 6kgf m Erect bolt under bumper 30N m 3 lkgf m Erect bolt on rear fork 55N m 5 6kgf m 14 1 CFMOTO Error diagnosis Running out of rear wheel Tire bead deformation Poor tire e Over low tire pressure Improper wheel balance e Poor fixing axle nut of wheel Excessively soft rear bumper e Weakening of elastic force of spring e Oil leaking from rear bumper Excessively hard rear bumper Bent rear bumper Excessively high tire pressure Poor braking effect e Poor adjustment of the brake Stain or dama
46. 15 7 CFMOTO Check whether the connector terminal is loose bent rusted or breaking off Proceed to check the main cable end of the two connectors of the rectifier Items Standard Battery voltage exists between the red terminal of the battery wire and the grounding wire of the car body wire of the car body The resistance value between one yellow terminal to another yellow yellow yellow shall be 0 1 0 462 at 20 C The black exit leads of the ignition switch shall be ignition switch black conductive to black terminal Disassembly Rectifier regulator car frame combination Remove the left protective plate 2 5 Remove the right protective plate 2 5 Remove the bolt I and 2 Dismantle the linking of the 2 rectifier connectors Remove rectifier readjusted Make assembly in the reverse sequences of the dismantling procedures _ Rectitier regulator Rectifier reguiator 4Pconnection spegnnectian Cautions All the guy cable cable and hose should be laid as per the relevant wiring schematic drawings Chapter 1 15 8 15 Battery Charging System AC magneto test Remove the left protective plate 2 5 Remove the right protective plate 2 5 Dismantle the AC magneto yellow yellow yellow triggering coil black white green and the link of the connector Resistance of the magneto coil m Measure the resistance between the 3 phase magneto stator coils M Ifthe resistance val
47. 4 1 5 1kgf m Fix front wheel 13 3 Fix brake caliper combination holt 3 Insert the brake caliper onto brake cable disk place bolt 2 and tighten the brake caliper combination at specified torque Torque 4 0 5 ON m 4 1 5 1kgf m bolt 1 Place bolt I and fix front brake tube combination nol Handlebar Handlebar front guard combination Disassembly Remove the left and right rear view mirror 13 12 Remove two self taping screws I left j front wheel front wheel bearing bearing mut and right for handlebar rear guard Remove two screws 2 left and right for handlebar rear guard Withdraw 4P connector of headlamp Remove handlebar front guard and headlamp Erection Make assembling in the reverse sequences of disassembling 13 Front wheel braking suspension and oN steering system SCrewS 2 selttaping screws 1 13 11 CFMOTO Front damper Disassembly Remove front wheel 13 3 Remove bolt land bolt 2 Remove 4 fixing bolts 3 sealing cap and sealing ring Remove damper Notes Not inverse the damper to avoid flowing out of its fluid Inspection Check damper oil leakage weathered oil seal and damage and make replacement if case of abnormalities Notes The sealing ring shall be free of damage 13 12 batt 3 damper a ooi front wheel bearing mut sealing rin sealing cap 13 Front wheel braking Suspension and steering system Coa
48. 6 steering column bearing race erecting tools B 519 922 050007 Assembling tool shaft 519 922 05008 Maintain the assembling tool shaft and press the lower bearing steel cup into the steering column while locking the nut 13 4 upper bearingn steel boy Maintain the assembling tool shaft upper bearing an steel cup i steering column bearing race erecting tools lower bearing steel cup front fork combination 13 Front wheel braking Suspension and steering system Take out retaining washer Remove the retaining ring of upper bearing on the steering column Special tools Steering column bearing adjustment wrench 519 922 050002 Remove upper ball retainer Remove the front fork Remove lower ball retainer Fix the special tools on the stem of frame and remove lower bearing steel cup Special tools Bearing disassembling tool modular 519 922 050000 Rotor puller 519 922 050010 Disassembling tool shaft 5 19 922 050003 Disassembling tool weight 519 922 050004 13 Front wheel braking suspension and steering system lower bearing steel m Cup front fork Disassembling tool steering column bearing adjustment wrench upper bearing retaining ring owe hall retainer i 13 5 CFMOTO Front fork Disassembly Remove header board 2 8 Locking nut wrench al Remove front wheel 1 3 3 locking nuts lt of steering Remove front mud guard 2
49. 7 1 inject time Map 2 inject time out 3 injection phase 4 ignition advance 5 RPM 6 TPS 7 Air temperature 8 Air temp cor 9 Engine Temp 10 Eng Temp cor 11 Air pressure 12 Air pres cor 13 Battery voltage 14 Battery inj off 15 Lambda offset 16 Lambda cor 17 Crank cor 18 General cor 19 Idel phase 20 Idel duty 21 ECU Temperature 22 Error code 23 Life time Injection time Injection correction Injection initial phase Ignition advance Engine speed TPS Throttle position scope TPS 0 Full closed throttle TPS 100 Full opened throttle air temperature air temperature injection correction engine temperature engine temperature injection correction air pressure air pressure injection correction battery voltage battery voltage injection correction lambda offset Lambda injection correction crank correction General correction of pulse spectrum Idle valve opening phase Idle valve duty ECU temperature Error code ECU life time 21 Function of buttons of diagnosis analyzer FIG 1 21 5 CFMOTO Diagnosis Main menu Move the selection bar with up or down button to diagnosis Press OK Button for acknowledgment FIG 18 Options will be shown at bottom of the diagnosis menu FIG19 Move the selection bar with up or down button to Error check FIGI9 and press OK Button for acknowledgn Options will be shown at bottom of the Error check menu FIG20 Current error Previous
50. 7JAC PH80000 07JAC PH80100 07JAC PH80200 07741 0010201 07YMF GEE0100 07Y MF GEE0200 O7VMF KZ30200 13 Front wheel braking Suspension and steering system Maintenance information 13 1 Front damper tei esrersseretdeer 13 9 Diagnosis of Error Geeeeesescecocoecooooo 13 2 Handlebar cocoocococoooococoocooooo 13 10 Front wheel cecoococococoocococoooocoocoooo 1 3 a3 Front fork cecoocococoooococoocooooo 1 3 l 5 13 Front wheel braking suspension and steering system Maintenance information Notes during operation Notes Only after the frame is surely supported on the ground may the front wheel and suspension system be maintained The lighting instrument and switches shall be maintained as per Chapter 18 The wheel shall not be excessively applied with force Cares shall be taken not to damage the wheel In order to protect the rim from damage the tire shall be assembled on or disassembled from the rim with special tire rod and rim protector Maintenance basis Item Standard service PEN Bendingoffrontaxle a front ae 0 2mm 2mm Residual groove tire pressure 200kPa 2 0kef cm2 Gap of braking handle 10 20mm Tightening torque Set nut of handlebar 55 N m 5 6kgf m Nut of front axle 80 N m 8 Ikgf m Set bolt of front damper 40 N m 4 1 kgf m 13 21 14 Rear Wheel Braking Suspension Maintenance information teteteeeee gt 14 1 Rear fork Cer cccccccccccccccccccccces
51. D2 asse mb EEE ENER 5 4 Inspection of fuel pump 66 5 3 Disassembly installation of Idle Air Control Disassembly installation of high pressure oil Ver 5 4 PUD NS 5 3 Disassembly installation of Air cleaner 5 5 Disassembly installation of body of throttle Disassembly of Air cleaner 5 6 VAINE J den DE Disassembly installation of oil injector branch er 1 0 EE EG 5 3 Maintenance information Notes during operation Notes 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 vapored gasoline is explosive please operate it in the place with nice ventilation The guy cable shall not be distorted bent excessively The deformed or damaged guy cable may cause improper actions Loose the high pressure oil pipe before disassembly discharge the gasoline in the high pressure oil pipe and put it in a container When the body of throttle valve is disassembled the air inlet shall be covered by dishcloth or tape for avoiding the entry of other objects into the engine from the air inlet side of the engine When the vehicle will be stored for more than one month the gasoline in the high pressure oil pipe and cap of the oil injector must be discharged Otherwise the gasoline will age and form colloidal elements which may block the nozzle of oil injector therefore the engine cann
52. E ON RPM gt ZERO gt IN THE STARTING PHASE THE ECU NOT SHOW THE ERROR 30 BUT THE RPM VALUE 0 THE DIAGNOSTIC INSTRUMENT gt MAIN MENU gt STATUS MONITOR gt REAL TIME VALUES 9 5 PRM gt RPM 0 ERROR PICK UP 3L F 18 F e PICK UP SENSOR FAUTLY e IGNITION COIL NOT CONNECTED e WIRING FAULTY Short Circuit between the wire that connect PIN3 ECU to PIN85 MAIN RELAY and BATTERY gt ONLY ENGINE ON RPM gt ZERO e IGNITION COIL FAULTY ERROR_IGNITION_CURRENT 3 LF 2 S F OSS DIAGNOSTIC LED 1 KEY ON ENGINE OFF gt NOT ERRORS PRESENT e DIAGNOSTIC LED ON FOR 5 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND STAY OFF 2 KEY ON ENGINI OFF gt ONLY ONE ERROR PRESENT e DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN BEGIN TO FLASHING TO CODING THE ERROR TO SEE THE ERRORS CODING TABLE e CODIFIED THE ERROR THE DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN REPEATS THE ERROR CODE e THIS LOOP CONTINUE UNTIL THAT THE ENGINE ON IF POSSIBLE OR KEY OFF 3 KEY ON ENGINE OFF gt MORE ERRORS PRESENT e DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN BEGIN TO FLASHING TO CODING THE ERRORS TO SEE THE ERRORS CODING TABLE e CODIFIED THE FIRST ERROR THE DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN FLASHING TO CODING THE SECOND ERROR THIS LOOP CONTINUE UNTIL THAT THE LAST ERROR IS CODIFIED THAN THE
53. E UNTIL THAT THE LAST ERROR IS CODIFIED THAN THE DIAGNOSTIC LED ON FOR 10 SECONDS THEN THE DIAGNOSTIC LED TURN OFF AND THAN BEGIN TO FLASHING TO CODING THE FIRST ERROR e THIS LOOP CONTINUE UNTIL THAT THE ENGINE ON IF POSSIBLE OR KEY OFF e THE CODIFIED OF THE EXCEEDED MAINTENANCE TIME NOT EXECUTED UNTIL THAT SOME ERRORS ARE PRESENT e RESTORED THE INJECTION SYSTEM AND KEY ON ENGINE OFF THE LOOP IS THAT ONE AT THE POINT 4 EXCEEDED MAINTENANCE TIME AND NOT ERRORS PRESENT
54. MOTO vent hose water pump outlet hose CF Moto Disassemble of right side cover Remove body plastic parts 7 2 Drain coolant gt 6 4 Drain lubricating oil from crank box 3 11 Notes water pu Miet haze The right side cover shall be disassembled under cold engine state Remove water inlet hose water outlet hose water DUMP COVET and vent hose Remove water pump cover positioning pin and water pump cover sealing pad Remove bolts of right side cover bolt and take out the right side cover Disassemble of flywheel combination Ku oil duct connector and spring of EEE er oil duct connector j Remove positioning pin and right side cover sealing pad dual gear shaft positioning pin Remove dual gear and dual gear shaft Remove nut and washer 11 2 11 Right side cover magneto and water pump Fix the flywheel combination with special tools and then remove the flywheel combination with special flywheel disassembling tools Special tools Special flywheel disassembling tools 152MI 922 030000 Disassemble of driven gear Remove bolts fixing plate and driven gear component Disassemble of stator combination Remove the stator combination and trigger Remove the hole purpose elastic retainer Clamp the water pump shaft at the back side clockwise remove the water pump component with open wrench Remove the machine level stick upper view window cover and seal ring of the upper view window cover
55. Mounting bolts on shock absorber Lower Mounting bolts on shock absorber Mounting bolts of back fork Braking device Mounting bolts of front brake disc Mounting screws of rear brake disc Mounting bolts of front brake clamp Mounting bolts of rear brake clamp Muffler Mounting nuts of muffler joint Mounting bolts of muffler shell Oxygen sensor Others Taillight Screw group for stoplight 55 5 6 55 5 6 68 7 0 55 5 6 80 8 1 40 4 1 140 14 3 55 5 6 30 3 1 55 5 6 12 1 2 26 2 7 30 3 1 30 3 1 26 2 7 55 5 6 60 6 1 8 0 18 1 15 CFMOTO Special tools Cylinder cover group and valve Assembling clamp for valve Valve pipe reamer 5mm Milling cutter for valve seat Valve line countersink Drill 27mm 45 IN Valve line countersink Drill 27mm 45 EX Belt infinitely variable speeds mechanism Universal stand Compression tools for clutch spring Reducing mechanism Pressure assembly of main shaft Rolling bearing 6202 Rolling bearing 6201 Disassembly tools group for disassembling bearings Rolling bearing22X50X14 Rolling bearing 6301 Rolling bearing 6004 Rolling bearing 6205 AC magneto starting motor Flywheel puller Front wheel front suspension steering gear Shaft of bearing disassembling tools Head of bearing disassembling tools 12mm Handlebar A of pressing tool Outer cover of pressing tool 28x32 Guide tools 12mm Spanner for locknut Adjusting spanner for steerin
56. To require air temperature 16 9 17 Electrical starting system amp overrun clutch Maintenance information seede eee 17 1 Starting the relay Peery Ree ee 17 2 Error diagnosis ereereseeeeeseeeeeecceo 17 1 Subassembly of starting motorssssss sssssess 72 Overrun clutch PE E A T NE RE wie 6 050 e e eles eee 17 5 Maintenance information Notes during operation Put all the wires with the same color in bundles Wires with different colors should be put on sleeves with the same color at the place the device is connected with the wire Before disassembling the wire be aware of the color of the wire The connector should be linked to that of the same color Maintenance standard Items standard values Usage limit Length of the brush 7mm Error diagnosis The starting motor does not run Battery low Main switch does not work well amp Starting switch is not in good condition Defective starting relay Ill connection in wire bundles connectors and connecting posts short circuit or wire breakage Defective starting motor Fuse burn Starting motor with insufficient torque Battery low Ill connection in wire bundles connectors or connecting posts Bits or chips are jammed in electric motor or starting gears 17 1 CFMOTO CF Moto Starting relay 4P insert connector of Starting relay Notes Before test make sure that the battery is in good condition In case of start failure check
57. When assemble the helmet type parts the helmet must be inserted into the groove if there is groove 1 5 CFMOTO Number marking position CF150T 51 CF125T 2 11 Vehicle frame number LCETDKP6 LCETDJPM Engine number IPS58MJ A 1 1P52MI B 1 marking position of vehicle frame number i na r Gr i I i i j Fy Lio kart af Hl at ye ta r ge ad F P FR Ep ts ie E dat red JER I ae z 3 aa ar ll te rd a a i up j io SE lt Pt l of ry h I ee fea r i n i ci mf Poe pa ee ci weel j p E i gt I f l g gr ag r r Fl j i r i 3 ee Ti i z I ag o Lee A n I I Pi i F i 1 iy j Fos m kV fe i Po m pal F a a 1 Maintenance information Table of main parameters wi Total capacity 152 7ml 124 6ml Rear wheel 110 80 16 Rotortype S Type of lubricating oil pump Rotor type Tyre specification Air distribution Phase Type of lubricating oil filter Full flow filtration screen Cooling mode Forcing water cooling l 7 CFMOTO Type of air cleaner Paper filter core E l BING 7226101 Air inlet device Body of throttle valve Idle air control valve Siemens ABV379 015 Dry automatic centrifugation type Clutch l l Automatic centrifugation type l Type of gear Bevel wheel l stage reduction l Transmission l o of gear Bevel wheel device 2 stage reduction Variable speed gear Automatic infinitely variable speeds Variabl
58. aces M The elastic retainer will deform if it is opened too wide upon disassembly then it will easily fall off when assembled again Please do not use the elastic retainer that is already loose and without elasticity M 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 M Inspect the necessary sites upon disassembly measure the relevant data so that the original status can be resumed after assembly E Insert and arrange the bolts one by one and make sure the insertion volume of each bolt is equal before inserting them when the bolt length is unidentified M 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 A Frey EIA 1 3 CFMOTO E The rubber parts shall be checked whether they are aged upon disassembly renew them in advance when necessary Besides try not to make volatile oil grease etc attach on the rubber parts for they are not resistant to corrosion of gasoline or kerosene M Proper special tools must be applied to the operations which require special tools M The inside or outside track of ball bearing shall be turned manually for confirming the flexibility and smoothness of turning T
59. ake off the AC magneto stator Assembling the trigger Assemble the trigger by the inverse order of disassembling Disassembling the ignition coil Disassembling Disassemble the maintenance cover 2 2 Take off the spark plug cap from the spark plug Disconnect the primary connector of the ignition coil Unfasten the mounting screw of the ignition coil and disassemble the ignition coil Assembling Assemble the ignition coil by the inverse order of disassembling Note Cables should pass through the correct position ignition coil balt according to wiring diagrams of cables pipes adapter and wires Chapter 1 16 6 16 Ignition System Ignition system Ignition coil Primary voltage of the ignition coil Pull the spark plug cap out of the cylinder head put a new spark plug into the spark plug cap connect the circuit correctly taking the cylinder head as ground Measure the primary voltage of the ignition coil with a multi meter by the following order Connect the multi meter and the peak voltage adapter by the following order probe white yellow lead or ground Probe black yellow lead Note Make sure that the battery voltage 12V and the ignition coil lead is not disconnected Refer to relevant manuals while using the multi meter and the peak voltage adapter Switch the shift to zero span and switch the ignition switch to ON Press the START button and let the cranks
60. all the brakes switches and relays refer to Chapter 16 Disconnect the starting relay 4P connector and remove the starter Input the power Turn ON the ignition switch 4P insert connector of headlamp redAwhite end Holding the front rear brake to check for sure that the battery voltage exists between the red white end of the wire and the body grounding wire When abnormality is found in the inspection check the ignition switch braking switch main fuse 15A and secondary fuse 10A Replace the starting relay when there is no abnormality Grounding circuit Disassemble the starting relay 4P connector and remove the starter Press down the start button and check whether the green end of the starting relay 4P connector is linked with the car body grounding wire If the linking is through that s OK otherwise check whether the main cable is broken or short circuited Starting motor ubasse Starting motor subassembly Disassembly Remove carburetor and arr filter Unscrew the starting motor anchor bolts and remove the motor subassembly Disassemble the starting motor subassembly Unscrew the starting motor case bolts and remove the motor case and seat 17 2 17 Electrical startin Test Measure the length of the brushes Usage limit brush with length less than 6 5mm should be replaced Check the variation in color of the commutator Replace the commutator with color cha
61. and supplement DOT 3 or DOT 4 brake fluid up to Bolt 2 w lie the upper limit TND L KER No dust or water can be mixed when supplementing the brake fluid Please apply the brake fluid with appointed brand for avoiding chemical reactions Please do not splash the brake fluid onto plastic and rubber parts for it may cause damage on the surfaces amp Turn the steering handle leftward and rightward slightly and then disassemble the oil cup cap when the brake pump combination 1s in horizontal status Brake disc brake pad Abrasion of brake pad Inspect the abrasion of brake pad at the marked place If the abrasion reaches the abrasion limit groove renew the brake pad Notes The brake pad shall be renewed in set Test and renewal of brake disc Inspect whether there is abrasion damage on the sliding surfaces of brake disc and the brake disc shall be renewed in time when its thickness is no more than 3mm The limit operation thickness of brake disc 3mm Thickness 3mm Oil renewal Renewal of brake fluid The brake fluid shall be renewed annually 3 6 3 Test Adjustment Wheels Tyre pressure Inspect the air pressure of tyre with barometer Notes The test of Tyre pressure shall be carried out when the tyres are cool If the vehicle is used when the Tyre pressure is improper the operation and riding will be less comfortable and may cause deflected abrasion on
62. ap piston ring 0 02 0 044mm 0 07mm ed ee gap I piston ring 0 10 0 25mm 0 07mm II Keep the mark of piston ring upwards erection direction Maintenance standard Tightening torque Bolts on flange face of box body 12N m 1 2kgf m Chain tension plate purpose threaded pin shaft 13N m 1 3kgf m Error diagnosis Too low compression pressure Wearing out or damage of piston ring Wearing out of cylinder or piston Poor seal of cylinder head or valve gt Chapter 8 Burning out breaking or seizure of piston ring Excessively high compression pressure carbon in piston head or combustion chamber Blue smoke in the exhausted gas Wearing out of cylinder piston ring or piston Wearing out of valve duct or damage of oil seal of valve Abnormal sound Wearing out of cylinder or piston Poor erection of piston ring Damage of surrounding of the piston and inner face of the cylinder Damage and wearing out of f crank bearing 12 2 12 Box body crank and piston Disassemble of the box body Remove the engine from the frame gt Chapter 7 Before disassembling the box body remove D a r related parts from the engine as per page 12 1 fs Remove threaded pin shaft and tension plate component Unscrew bolts from box body Keep the right box body downwards and remove left box body Remove crank crank box sealing pad and positioning pin Remove crank oil seal Notes Not pry the box bo
63. assembling in the reverse sequences of disassembling holt 3 2 12 2 Body and muffler Taillight Disassembly Disassemble the rear shelf 2 4 Remove the seating mat 2 2 Disassemble the maintenance cover 2 2 Disassemble the rear connecting board 2 5 Disassemble the left guard board 2 5 Disassemble the right guard board 2 5 Remove the two bolts I and two bolts 2 Pull out the connector 6P of the rear taillight F connector Get off the taillight Assembly Make assembling in the reverse sequences of disassembling Rear fender assembly Disassembly Disassemble the rear shelf 2 4 Disassemble the seating mat a fal 2 Pg 2 2 1 ee Disassemble the maintenance cover A Po p AGS a ak Tr 2 2 a i s 7 Disassemble the rear connecting mer 3 l i h m board 2 5 rear fender assembly i Disassemble the left guard board 2 5 Disassemble the right guard board 2 5 Disassemble the taillight according to the above content Remove the four bolts 1 get off the rear fender assembly Assembly Make assembling in the reverse sequences of disassembling Disassembling of the Rear fender group Remove the two bolts 8 and then disassemble the rear license board 9 Remove the two bolts 8 and then disassemble the support of rear license board 7 Remove the two nuts 2 and then disassemble the left and right reflector 6 Remove the nuts
64. at 2 2 Disassemble the maintenance cover 2 2 Disassemble the trunk 2 3 Disassemble the guy cable of seating mat from the lock of seating mat 2 3 Disassemble the rear shelf 2 4 Disassemble the self tapping screw 2 which is connecting the left heel of foot board with the left guard board pull out the left guard board from the rubber ring on the rear taillight and then disassemble the left guard board Assembly i self tapping screw 2 Make assembling in the reverse sequences of left heel of foot board left euard hoard disassembling Right guard board Disassembly Disassemble the rear connecting board 2 5 Disassemble the seating mat 2 2 Disassemble the maintenance cover 2 2 Disassemble the trunk 2 3 Disassemble the left guard board 2 5 Disassemble the rear shelf 2 4 Disassemble the self tapping screw 3 which is connecting the right heel of foot board with the right guard board pull out the right guard board if self tapping screw 3 from the rubber ring on the rear taillight and right guard hoard right heel of foot board then disassemble the right guard board Assembly Make assembling in the reverse sequences of disassembling 2 5 CFMOTO Left heel of foot board Disassembly Get the rubber of foot board off Disassemble the maintenance cover 2 2 Disassemble the self tapping screw 5 which is connecting the left heel of foot board with the left guard board Disassemble
65. cap e air access air filter idle valve f others ignition angle idle spread atomization TPS reset 2 common errors a the engine fails to start abnormal diagnosis analyzer fuel pump ignition coil injector fuel supply oil quantity in the fuel tank fuel pump start fuel pressure fuel flow ignition sparking plug ignition coil screened cap data reliability coolant temperature firing angle injection phase inlet air temperature 20 3 CFMOTO b The cold hot engine starts in difficulty abnormal diagnosis analyzer fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure fuel supply oil quantity in the fuel tank fuel pump start fuel pressure fuel flow start speed start motor initiating relay battery ground wire ignition sparking plug ignition coil screened cap trigger signal ignition advance data reliability coolant temperature inlet air temperature TPS position idle valve air filter 20 4 20 Electric injection diagnostic system and error diagnosis c Flameout unstable too low speed of engine in idle speed abnormal diagnosis analyzer fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure fuel supply the low fuel pressure pressure adjustive valve fuel pump fuel filter screen fuel flow inlet gas system cleaning air filter idle valve gas handling system tightnes
66. ccs cceccs 3 19 Suspension system eee cee cee cee cee cee 3 8 Others eee cc cece cee ces cece ccc ccc ccc ccc ces 3 20 Transmission Cec ccc ccc ccc ccc ccs cccceccce 3 9 Maintenance information Notes during operation Notes amp Itis 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 CQ etc When 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 amp 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 Please be cautious that do not let the turning pieces such as driving system etc as well as movable pieces clip your hands or clothes Notes 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 Replacing parts regularly The renewal period is determined according to year or driving distance it shall be implemented when either condition is met Items need regular renewal Renewal period Remarks The filter core of air cleaner Clean or renew it
67. d pay attention not to be scalded The temperature is very high when the headlamp is ignited while replacing the bulb if you touch the glass surface of the bulb with bare hands or hands in dirty gloves then the oil will be attached to it which will form into hot spot inducing hot distortion of the glass and destroying the bulb Please pay attention to the followings while replacing the bulb Don t replace it while igniting the light must not run it until the ignition switch at and the bulb is cooling down Must wear clean gloves when replacing the bulb lest the oil be attached to the glass surface When the glass surface is attached with oil must wipe it up with clean cloth dipped with alcohol or banana water When using the battery firstly confirm if it is in order or not Check and test the transmittance of the switch under its bodywork Erection After exam and test of all parts the cable and guy cable must be correctly passed through strictly according to the concerned layout chart 1 20 The removal and Erection of taillight set and back turning indicator set refers to Chapter 2 18 1 CFMOTO auxiliary 2X 5A 2X 10A light bulb headlamp Hi Lo 12V 35 35W Maintenance standard Error diagnosis fail to ignite the headlamp e broken fuse e open main cable e open main cable e burnout bulb e broken night switch 18 2 18 Light instrument switch replace bulb bulb of the headlamp N
68. dy combination face with screw driver When the right box body is difficult to take out its projected portion shall be lightly knocked with a plastic harmer and then the left box body is Slowly and evenly lifted Check the tension plate for scratch damage and sidewise wearing out 12 3 CFMOTO crank box sealing pad positioning pin Piston Disassemble of piston Before disassembling the piston remove related parts from the engine as per page 12 1 Remove retainer of piston pin crank oil seal Pull out piston pin and take out piston Enlarge the opening of the piston ring and take out the piston ring from piston top Notes The piston ring is liable to break and thus the opening shall not be excessively large Prevent the piston from damage by the piston ring Clear off stains such as carbon from the piston Clear off carbon from the piston rig slot with old piston ring piston pin piston ring Notes Take cares not to damage piston ring slot The wire brush would damage piston ring slot and thus it shall not be used piston ring 12 4 12 Box body crank and piston Check Crank Measure the side gap of the big end of connecting rod Service limit 0 5mm Measure the radial gap of the big end of connecting rod Service limit 0 05mm Measure the crank run out Service limit 0 10mm Measure h2nm Measure Ri mm Measure the Inside diameter of hole at small end of connecting
69. e Ambient atmosphere pressure 4 When the engine is in cold position the idle valve controls the adjustment of system idle speed and the idle valve is controlled by ECU ensure the stabilization of idle speed 5 Composition of the fuel fuel pump fuel filter screen injector pressure adjusting valve fuel tank oil pipe tunnel and others Fuel pump fuel filter screen pressure adjusting valve are fixed in fuel tank by bracket 6 Composition of the ignition circuit Ignition coil high pressure down lead high pressure cap ECU sparking plug and so on ECU controls the ignition advance ensuring the ignition 20 1 CFMOTO CF Moto II Notes 1 This chapter states the main error diagnosis in electric rejection diagnostic system and the whole engine The errors excluding in the chapter please refer to other chapter Before debugging the electric injection system please check the error records When checking the error records don t cut off the join of wire and battery 2 The pressure supplied to the system by fuel oil is 2 45 Bar so smoking and fire is forbidden when removing the conduit coupling Take care of the fuel oil splashing into eyes 3 Cut off the join of wire and battery when repairing electrical components exclude special requirement 4 When examining operating function the battery voltage must be above 12V 5 When starting the engine ensure that the fuel oil in fuel tank is more than 2 litres or it
70. e the engine bolts and cables upon operation The frame etc shall be wrapped for protection when disassembling or assembling the engine The engine may not be disassembled from the vehicle upon the following operation Oil pump Chapter 4 Oil supplying system air inlet system Chapter 5 Cylinder cover hood cylinder cover cylinder body camshaft Chapter 8 Infinitely variable speed system left side cover 7 Chapter 9 Reduction box 7 Chapter 10 Right side cover AC magnetogenerator water pump gt Chapter 11 Piston piston ring piston pin Chapter 12 The engine shall be disassembled from the vehicle upon the following operation E Crank shaft gt Chapter 12 Fastening Torque Bolts for assembling the engine hanger 55 N m 5 6 kgf m Nuts for hanger shaft of engine 55 N m 5 6 kgf m Construction bolts for rear shock absorber upper 55 N m 5 6 kgf m Construction bolts for rear shock absorber lower 30 N m 3 1 kgf m Construction bolts for rear fork 55 N m 5 6 kgf m 7 1 CFMOTO positive wire of Disassembly of engine Disassemble the plastic parts of the vehicle Chapter 2 Disassemble the body of throttle valve and idle air control valve 5 3 Disassemble the air cleaner gt 5 10 Eject the coolant 6 4 2P insert elements of 3P insert elemenis of AC magnetogenerator AC magnetogenerator Disassemble the 3P 2P insert elements of AC insert elements of water
71. e speed ratio 25 08 Turning device Turning angle Type of braking device Buffer unit Suspension mode 1 8 1 Maintenance information Table of maintenance parameter Lubricating device Capacity of engine oil When the engine renews oil Recommended engine oil see the original E SAE 10W 40 20W 50 are be used exclusively for 4 stroke relationship of air motorcycle temperature and viscosity Selection must be made within the following range if substitute is preferable E API classification SE or SF grade engine oil E SAE specification select from the table at right according to the outdoor temperature pump The body Gap 0 15 0 23mm rotor Gap of end face 0 05 0 10mm Fuel device Capacity of fuel tank Full capacity 7 81 E DC13 5V Pressure 0 25 0 Pressure 0 25 0 007Mpa Oil supply device Fuel pump Flowrate gt 35Lh sd rate Flowrate gt 35Lh sd 35L h EE EE Current lt 220A 2 20A Safe pressure 0 5 0 Safe pressure 0 5 0 6Mpa sd Idle rotate speed 1700 100r min 1 9 CFMOTO Cooling device Cylinder cover valve Mem Standard o Standard Operation limit Operation limit Compression pressure of Eg 700kPa 7 0kgf cm 260r min Valve gap IN 005mm gt EX 020mm Je gt Skewness of cylinder cover oo e fot fa sm E EX 3033 3045mm 3028mm Valve rocker Valve Sleeve for le Gap of valve stem and valve guide 0 01 0 037mm 0 03 0 057mm
72. e where it is used The coolant is made by diluting the original fluid of coolant with soft water Standard concentration of coolant 50 Recommend Chunfeng Coolant ready for application need no dilution 6 4 6 Cooling system Coolant discharging Discharge the water entry cap Notes The water entry cap can be opened only when the coolant is confirmed cooled To disassemble the front decorative sheet gt 2 8 and open the water entry cap Disassemble the draining bolts Disassemble the draining bolts sealing shim and discharge the coolant When the coolant is discharged assemble new sealing shim draining bolts and tighten them Bolts of draining sealing shim Auxiliary water box af Disassembly ri Disassemble the front faceplate 2 8 Disassemble the front venting plate 2 9 ct Disassemble the two bolt 2 on the assistant water box loosen the hoop 5 of assistant water box Disassemble the connection ff between water pipe 6 of Auxiliary water box and the assistant water box remove the J assistant water box open the cover 3 of Fo assistant water box discharge the coolant in i the assistant water box and wash the F Je E gx J rm i Auxiliary water box with water i 3 ir Et Assemble EO L fy he EN Make assembling in the reverse sequences of disassembling CFMOTO Injection of coolant Open the water entry cap inject the coolant int
73. eased has raised its voltage after recharging but its load capacity is poor it should be renewed Charging the battery conventionally to 12 4V when the open voltage voltage between terminals is less than 12 4V The check of the charging system should be carried out according to the sequence of the trouble examination 15 3 The service parts used in the charging system refers to figure page 15 9 The assembly and disassembly of the AC magneto refers to Chapter 11 The check of the battery is carried out according to the instructions of the battery tester 15 2 15 Battery Charging System Reference for inspection Pattern of rectifier 3 phase ring type rectifying controllable integrated with stabilizing voltage rm 3 0A X 1 0 hour Error Diagnosis Battery flooding Check battery with recommended battery tester Recommend battery tester BM310 Abnormal by YUASA or other corresponding Abnormal battery Normal Remove the connection between rectifier and linker and re test the creepage current Current Below ImA Measure creepage current of battery Abnormal 15 5 Abnormal current Below Normal normal Abnormal Check AC magneto charge coil Abnormal Resistance 0 1 0 4 Q Poor rectifier Main cable short AC magneto short or cut Poor ignition switch Normal Check the voltage of unit of battery and record the test dada 15 4 Start engine and put headlam
74. easure peak voltage of the trigger o coil by the order described below Connect the multi meter and the peak voltage adapter according to the right figure Probe black lead Probe dark blue lead Note Refer to relevant manuals while using the multi meter and the peak voltage adapter magneto Switch the shift to zero span and switch the ignition switch to ON Press the START button and let the engine rotate for several seconds then measure the peak voltage of the trigger coil Repeat the measurement for several times to get the highest peak voltage of the trigger coil Switch the multi meter to V span AC Peak voltage of the trigger coil gt 4V If the peak voltage of the trigger coil is not within the designated area replace the coil with a new one 16 5 CFMOTO Disassembling the trigger edge connectors ee eh Disassemble the connector of AC magneto Disassemble the inlet pipe and the outlet pipe of the pump to drain the cooling water Chapter 6 Disassemble the ventilation hose of the crankcase Chapter 11 Disassemble the exhaust muffler Chapter 2 Disassemble the right side cover 7 Chapter 11 Note Since the stator is mounted on the side cover it is attracted by the magnetic force of the rotor While disassembling be careful not to let the right side cover clip and hurt you fingers Unfasten the bolt to take off the trigger Unfasten the bolt and the washer to t
75. ection Press upper bearing with special tool Click upper clip ring 5 Install oil seal I and oil seal 6 Assemble rear fork assembly in the reverse sequences of disassembling and tightly screw all of bolts and nuts to specified torque Rear fork Disassemble Remove muffler gt 2 15 Remove right rear shock absorber bolt 4 Remove rear wheel axis nut 1 Remove two bolts 2 Remove two bolts 3 Take off rear fork assembly 14 4 14 Rear Wheel Braking Suspension Rear Wheel Braking Suspension Rear Bumper Left Rear Bumper Disassemble Firmly support car body with main bracket Remove mending cover gt 2 2 Remove seat mat gt 2 2 Remove trunk combination gt 2 3 Remove rear goods shelf gt 2 4 Remove rear joining board 2 5 Remove left defender gt 2 5 Remove fixed bolt 1 above left rear bumper Remove fixed bolt 2 below left rear bumper Remove left rear bumper Right Rear Bumper Disassemble Firmly support body with main bracket Remove mending cover gt 2 2 Remove seat mat gt 2 2 Remove trunk combination gt 2 a Fa Remove rear goods shelf gt 2 4 Remove rear joining board gt 2 S As Remove left guarder gt 2 5 Remove right guarder gt 2 5 Remove muffler gt 2 15 Remove fixed bolt 3 above right rear bumper Remove fixed bolt 4 below right rear bumper Remove right rear bumper 14 5 CFMOTO Te
76. em in the valve guide Apply Mo based solution or lubricating oil valve locker to the internal circumferential surfaces of valve stem valve guide valve spring seat Turn the valve slowly put it into the valve guide be cautious not to damage the seal n Pr seal ring subassembly ring subassembly of valve stem alve spring holder for valve stem The end with smaller pitch of valve inner outer spring shall be installed towards the firebox Install the upper seat of valve spring N Compress the valve spring by the compressing bite of firebox tools for valve spring install the valve locker Notes In order to prevent the weakening of elasticity of valve spring do not compress the valve spring excessively into the required length Test of cylinder body Test the abrasion damage situation of inner surface of cylinder Measure the interior diameter of cylinder at the upper middle and lower positions 6 places in the directions of piston pin and vertical to it X Y directions and make record Take the max value as the interior diameter of cylinder Operation limit 52 449 58 049mm 8 17 CFMOTO Installation of cylinder body Test whether the chain guide is with scratch damage or deflected abrasion 4 water inlet hose a Remove the paper pad dirt on the combination face test whether there are other objects in the cooling water way oil path and bolt holes Install the sealing gask
77. en intake manifold inlet and cylinder caliber air tightness between intake manifold inlet and restrictor valve block inlet hose air filter exhaust system air tightness air tightness between the exhaust pipe and cylinder caliber air tightness between the exhaust pipe and muffler muffler welding other plugs of the exhaust pipe 20 7 CFMOTO f When the restrictor opens lightly the engine works irregularly abnormal diagnosis analyzer fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure gas handling system cleaning air filter strainer element restrictor valve block idle valve data reliability coolant temperature signal air temperature signal TPS position signal ignition advance gas handling system tightness inlet hose air filter 20 8 20 Electric injection diagnostic system and error diagnosis g When the engine speed is in maximum power of the engine goes down the engine works irregularly when accelerated abnormal diagnosis analyzer fuel supply data reliability gas handling system tightness ignition system fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure oil level fuel pressure fuel filter screen injection capacity coolant temperature signal air temperature signal TPS position signal ignition advance inlet hose sealing air filter sealing air filter st
78. enon of air leakage Fastening torque Screws for taillight stoplight 1 8N m 0 18kgf m 1 8N m 0 18kgf m 1 8N m 0 18kgf m Screws for rear turning indicator housing Screws for rear taillight housing Error diagnosis The noise from exhaust is big e The muffler has been broken and damaged Air leakage Lack of air The muffler is deformed Air leakage The muffler is choked 2 1 CFMOTO Seating mat Disassembly Open the lock of seating mat by the key of ignition switch and then remove two nuts I shown in the drawing Get the seating mat off Assembly Make assembling in the reverse sequences of disassembling Cautions After the seating mat has been assembled shake up and down rear and forth to confirm whether there is deviation self tapping screws 2 Ki ER Maintenance cover Disassembly Get the rubber of foot board off and remove the three self tapping screws 2 shown in the drawing then disassemble the maintenance cover Assembly Make assembling in the reverse sequences of disassembling 2 Body and muffler Trunk holi 1 hotl unk Disassembly Disassemble the seating mat gt 2 2 Remove the bolts I shown in the drawing Remove the screw 2 shown in the drawing Disassemble the trunk Assembly Make assembling in the reverse sequences of disassembling screw 2 bolt thefiproof support for seating mat lock Lock seat of seating mat Di
79. er assembling bolis ey hanger i 7 a installation holt of rear shock absorber i rear shock absorber 4 y nut of hanger shafi hanger ee e bolis ae FA 1 f a tt Mi I a PAN det hanger shaft SS i engine h F 6 Tighten the following nuts bolt according to specific torques Hanger assembling bolts Torque 55 Nem 5 6kgf m Back shock absorber construction bolts upper Torque 55 Nem 5 6kgf m Back shock absorber construction bolts lower Torque 30 Nem 3 1 kgf m Hanger shaft nuts Torque 55 Nem 5 6kgf m Rear fork construction bolts Torque 55 Nem 5 6kgf m Rear wheel shaft nuts Torque 140 Nm 14 3kgf m 7 5 CFMOTO Install the combination of back brake calipers tighten the bolt 3 and bolt 4 according to specific torques The tightening torque of bolt 3 and bolt 4 is Torque 30N m 3 1kgf m Install the vehicle parking guy cable adjust the vehicle parking 14 6 Install the combination of back brake pipes tighten the bolt 1 and bolt 2 bolt 1 nut 2 holit bolt4 Notes The combination of back brake pipes shall pass through the proper position it shall not interfere the rear wheel back brake disc or other parts Install the water outlet pipe water inlet pipe and small circulating water pipe and tighten with corresponding ring hoops Notes The water pipes shall not be with cracks or other damages locknut ZUNgUy Wa T i eee
80. errors Deleting previous errors Move the selection bar selection to Current error and press OK button for acknowledgment The screen shows the current error code and related information Press ESCB Button for exiting and return to Error check FIG20 Move the selection bar with up or down button to Previous errors and press OK Button for acknowledgment The screen shows the previous errors code and related information Press ESCB Button for exiting and return to Error check Move the selection bar with up or down button to Deleting previous errors and press OK Button for acknowle The screen will prompt Deleting previous errors Press OK Button for acknowledgment to delete the previous errors from the memory Press ESCB Button for exiting and return to diagnosis 21 6 21 Function of buttons of diagnosis analyzer FIG 1 Diagnosis activation Main menu Move the selection bar with up or down button to Diagnosis activation and press OK button for acknowledgment FIG21 Options will be shown at bottom of the menu FIG22 Test of fuel pump relay Test of fan relay Test of idle valve Check of ignition coil Check of injector Move the selection bar with up or down button to Test of fuel pump relay and press OK Button for acknowledgment Press OK Button again to implement the test of target sample or Press ESC Button to cancel the test After activation the screen will show definite results and information confirmation Move the selec
81. ers eee Clutch subassembly Assembly of clutch Spring of the clutch Remove hardware below from clutch spring compress tool Clutch combination Mobile driven wheel disc groupware Clutch spring sleeve Shock absorb washer sleeve Remove the driven turntable set Plastic washer TOR retaining ring Disassemble clutch combination and mobile driven wheel disc groupware Disassemble Clutch Combination Remove retaining ring centrifugal block groupware Clutch Disassembly back spring and centrifugal block groupware from driven wheel disc groupware F i ee ta gt driven disc Clutch Disassembly back spring groupware 9 9 CFMOTO CF Moto Remove shock absorber glue block groupware from driven wheel Disassemble driven wheel Remove airproof bush Remove direction dowel roller and mobile driven wheel disc groupware Check direction dowel and roller for damage or wearing Remove driven wheel oil seal and o shape seal rim Replace a new one when reinstalling Check rolling pin bearing and ball bearing inside the mobile sub traction wheel for non free rotation sticking and shaking Replace in case of any 9 10 driven turntable soleplate shock absorber glue block groupware a 1 m airproof bush mobile driven wheel disc groupware driven wheel oil seal o shape seal rim 9 Continuously variable Tra
82. et for cylinder body cylinder body water inlet hose and locating pin in such sequence Slip the shim on the bolts for cylinder body rotate into the bolt hole but do not tighten it 8 18 Install the chain guide Turn the crank shaft variable speed drive wheel to raise the piston to the upper dead point namely make the piston top face equal to the cylinder combination face Notes Do not make the crank shaft turn again during the following operation Install the shim locating pin for new cylinder cover Cylinder cover installation Install the cylinder cover subassembly Install the bolts and washers for cylinder cover revolve them but do not tighten Install the locating pin 8 cylinder air distribution system locating pin a a a Pe nL holis and washers cylinder cover subassembly 8 19 CFMOTO Installation of camshaft support subassembly Installation of camshaft subassembly Install the camshaft into the camshaft hole of camshaft support camshaft subassembly Apply the head of rocker shaft with some lubricating oil and make it enter the hole of rocker shaft meanwhile enter the rocker bolt Install the elastic collar for hole into the collar Es collar for hole groove of rocker shaft hole and camshaft hole Apply lubricating oil to the cam surface of camshaft Install the cam top of camshaft towards the side of crankcase Press it
83. f valve rocker shaft Valve stem guide running surface Screw thread part of water temperature sensor Screw thread fastening Screw thread part of Mounting screw for timing chain wheel emulsion Ball bearing of driven wheel 6901UU 5 0 5 5g shall not Multi purpose Needle bearing of driven wheel be attached on the lubricating grease Running surface of movable driven grooved wheel running surface of drive belt Sealing surfaces of all O rings Shall not be applied Fastening bolts for cylinder body to the pointed places 1 17 CFMOTO Ball race of head tube Lip of front wheel dustproof oil seal Joints of both ends of instrument soft shaft Joints of accelerator guy cable Handlebar of accelerator Multi purpose Rotating part of left and back footstep lubricating grease Rotating part of right and back footstep Rotating part of side support Lip of rear fork oil seal Counter gear tooth face of pinion Moving part Shaft part of main support Lip of dustproof seal under front shock absorber 5 oil for shock absorber Internal circumferential surface of steering handlebar P Engine 1 18 1 Maintenance information Wiring diagram of cables pipes and guy cables speedometer and odometer clock set insert element of ee an speedometer and odometer es il P a 1 oil pipe of vil pipe of nr hack brake ni brake KATE oe FR i el guy cables of soft axis set accelerator te he a I 1 4F insert element
84. g column bearing Tool group for bearing disassembly Rotor puller Shaft of disassembling tools Heavy hammer of disassembling tools Installation tool A for the bearing race of steering column 27x 40mm Shaft of assembling tools Installation tools B for the bearing race of steering column 30x 50mm Shaft of assembling tools Cover for front fork of pressing tools Charging and ignition device Peak voltage stabilizer D A indicates Disassembly and assembly 1 16 1P52MI A 922 020000 152MI 234 022300 34B 152M1 236 022301 27 152M1 236 022301 27 1P52MI A 922 040000 152M1 922 070000 152M1 921 070000 1P39MB 921 110001 1P39MB 921 080001 1P52MI A 922 050000 1P52MI A 922 060000 1P52MI A 922 080000 172MM 921 030000 1P52MI A 92 1 020000 1P52MI A 921 010000 1P52MI A 92 1 030000 152M1 922 030000 519 922 070001 519 922 070002 519 922 070003 519 922 070004 519 922 070005 519 922 05000 1 519 922 050002 519 922 050000 519 922 050010 519 922 050003 519 922 050004 519 922 050005 519 922 050006 519 922 050007 519 922 050008 519 922 050009 519 922 150000 Disassembly of gas distribution system Repair cleaning of valve guide Modification of valve seat D A of nuts for drive grooved wheel D A of nuts for clutch cover D A of nuts for driven grooved wheel Main shaft pressed into Counter shaft bearing pressed into Disassembly of bearing Installation of main bearing Installation of output shaft bearing
85. ge of surface of braking disc or brake shoe block e Wearing out of brake shoe block 14 2 14 Rear Wheel Braking Suspension Rear wheel ler rear brake caliper TEM 1880 BUMPET rear wheelmud guard Disassemble N y 5 Fa Firmly support car body with main bracket Remove rear wheel mud guard 2 12 Remove muffler 2 15 Remove right rear bumper gt 14 5 Remove rear brake caliper gt 14 6 Remove rear fork gt 14 4 Remove rear fork inner axle cover Remove rear wheel Test Muts of rear wheel shaft back fork Tire bead Check the tire bead for damage deformation and scratch Slowly rotate the wheel and measure the run out of the tire bead with micrometer referring to page Replace in case of abnormality Operation limit Longitudinal 2 0mm Lateral 2 0mm Erection Make assembling in the reverse sequences of disassembling Besmear whorl glue at thread and combining surface of rear wheel axis nut and tighten it with specified torque Torque 140N m 14 3kgf m rearforkinner axle cover rear wheel 14 3 CFMOTO Disassemble rear fork Remove front oil seal 1 Remove rear oil seal 6 Open clip ring 5 Open bearing 4 with special tool Test Test the bearing rotation is free and whether ball bearing is damaged 3 m a t Haa HEE EE E SSeS Se SESE FERS VRS N T YE S E er Replace if damaged J e i rearwheel axis nut Pa4kfork bolts Er
86. ght cover of front trunk Disassemble the two screws 10 and then get off the striking board of right lock for front trunk 11 Disassemble the two screws 9 and then get off the s right lock seat for front trunk 8 Assembly Make assembling in the reverse sequences of disassembling Left air outlet grid Disassembly Disassemble the front Trunk assembly 2 9 Disassemble the three screws 4 Get off the left air outlet grid 3 Assembly Make assembling in the reverse sequences of disassembling Right air outlet grid Disassembly Disassemble the front Trunk assembly 2 9 Disassemble the three screws 4 Get off the right air outlet grid 2 Assembly Make assembling in the reverse sequences of disassembling 2 11 CFMOTO Front part of footboard Disassembly Disassemble the maintenance cover 2 2 Disassemble the accumulator 15 4 Disassemble the front faceboard 2 8 Disassemble the front venting board gt 2 9 Disassemble the soleboard 2 7 Disassemble the left heel of the footboard 2 6 Disassemble the right heel of the footboard 2 6 Disassemble the front Trunk assembly 2 9 Disassemble the two bolts I at the front of the footboard and then disassemble the footboard Assembly holt 2 Make assembling in the reverse sequences of disassembling Fender of Rear wheel Disassembly Remove the two bolts 2 Remove the bolts 3 Disassemble the fender of rear wheel Assembly Make
87. gnosis table e Refer to the legends for the configuration of the parts of ignition system gt 16 7 e ECU controls the ignition device of the unit therefore the ignition system automatically adjusts the ignition period e You should pay great attention to ECU It may fail when it falls onto the ground or is under strong impact In addition if you disassemble or assemble the connector or joints during the time when the current is flowing through overvoltage will be generated on ECU and thus cause the damage of internal circuit of the ECU therefore you must conduct operations after turning off the ignition switch e Failures of ignition system are mostly caused by poor contact of connectors and joints therefore you should check up whether the connectors and joints are contacted or not before maintenance e Spark plug with appropriate calorific value must be used Using inappropriate spark plug may cause poor operation or damage of the engine e Refer to Chapter 18 for switch examination 16 1 CFMOTO Maintenance standard choosing SCS Special tools Peak voltage pickup O7HGJ 0020100 Used together with digital multi meter sold on the market whose input resistance is larger than 10OMQ DCV 16 2 16 Ignition System Ignition system Error diagnosis e Cannot start engine First use diagnostic meter to look for the error code Chapter 20 then check up whether the oil circuit and the gas circuit are in n
88. h pressure oil pipe with container when loosening the clamping band which is exclusively for oil pipe Installation of high pressure oil pipe Make assembling in the reverse sequences of disassembling Please use the OETIKER air inlet l l l l accelerator guy cable connecting hoop pinchers for clamping band when installing the 30 T clamping band which is exclusively for oil pipe Disassembly of body of throttle valve Disassemble the trunk 2 3 loosen the belt and disassemble the insert element of the throttle valve body Loosen the locknut remove the adjusting nut and remove the accelerator guy cable from the accelerator rotating drum Disassemble the idle speed air outlet pipe on the body of throttle valve Loosen the air inlet connecting hoop the connecting hoop of air cleaner and disassemble the body of throttle valve Notes Do not adjust the bolts of throttle valve Do not remove the cap on the body of throttle valve Installation of body of throttle valve Make assembling in the reverse sequences of disassembling Disassembly of oil injector branch assembly Disassemble the trunk 2 3 Disassemble the high pressure oil pipe 5 3 Disassemble the belt disassemble the insert element of oil injector Disassemble the bolts remove the cap of oil injector and oil injector Installation of oil injector branch i assembly insert element 5 3 CFMOTO Make assembling in the reverse sequences
89. haft rotate for several seconds then measure the primary peak voltage of the ignition coil Repeat the measurement for several times to get the highest primary peak voltage of the ignition coil Switch the multi meter to V span AC 16 7 CFMOTO Primary peak voltage of the ignition coil 1200 V Warning While testing do not touch the probe or the spark plug to avoid electric shock If the peak voltage is lower than the specified value check the resistance of the ignition coil and the resistance of the trigger coil Disconnect ignition coil lead and spark plug cap to take off ignition coil Measure the resistance of the primary rolling thread and the secondary rolling thread of the ignition coil with a multi meter If the resistance of the primary rolling thread and the secondary rolling thread is within the given range the ignition coil is in good condition Switch the multi meter to Q span Ignition coil resistance primary rolling thread resistance 0 3 0 6 Q terminal ground secondary rolling thread resistance 5 12KQ terminal spark plug cap 16 8 16 Ignition System Ignition System ignition switch Trigger coil linker f j i i spark plug lgnition coil Circuit diagram of the ignition system fuse Lr far uer T Ignition coil spark plug current control 4 treatment output opening deyree ater temperature sensor l semaphore treatment of throttle valve
90. he picture orientation Set bevel board Install axle cover of driver transmission mobile dise wheel into the bush cave of transmission mobile disc Erection Notes Don t attach grease to tooth shape strap and the surface of strap sheave Hold two sides of transmission mobile disc and assemble it with axle cover of driver wheel Transmission axle cover of main traction wheel disc 9 7 CFMOTO CF Moto Install tooth shape strap Install driver wheel washer driver wheel dise and nut Besmear thread tighten glue on the thread on driver wheel and set and tighten it Tighten nuts on the driver wheel with air powered wrench pressing specified torque Torque 59N m C 6 Okgf m B Clutch Remove Left Cover Disassembly gt 9 3 Remove driver wheel gt 95 Fix groupware of external wheel disc with special clamp and remove fixed nuts Clutch Disassembly Disassemble Clap the groupware cave of driven wheel disc with the bulge of spring compress tool used in clutch Notes Clutch subassemblg Tighten clutch spring compress tool below the required torque Special tool Clutch spring compress tool 152MI 922 070000 9 8 9 Continuously variable Transmission System amp Left Cover Use table vice and other fixed EE clutch spring compress tool 1 Remove special nuts with sleeve wrench from clutch combination Notes Be cautious of clutch spring and avoid hurting oth
91. he gap between the valve guide scratch of seat surface inclined valve and valve stem and the valve guide shall be renewed if the gap 1s improper Modify the valve seat with milling cutter for valve seat if the contact surface is either too high or too low Measure the airproof width of valve face Standard value 0 9 1 1mm Operation limit 1 8mm Modify the valve seat with milling cutter for valve seat if the airproof width is uneven too wide or too narrow Modification Modification shall be carried out with milling cutter for valve retainer Refer to the operation instructions of milling cutter for valve retainer for details Under a pressure of 4 5kg along with a certain direction grind it while turning it by hands for modification Notes The milling cutter shall be applied with lubricating oil and remove the ground powder while grinding 8 14 8 cylinder air distribution system If there is chap scratch on the surface of valve seat grind and remove the chap scratch on the seat surface firstly by 45 milling cutter Notes The surface of valve seat shall also be ground when renewing the valve guide Be cautious not to grind excessively ak k x i a 1 aL r F surface chap Modify the outer side gradually by 32 milling cutter Modify the side gradually by 60 milling cutter EG Er N old width of surface
92. he oil filter screen spring fasten the filter screen engine oil filter screen cover with specific N filter screen cover torque Torque 20N m 2 0kgf m Fuel device Status of fuel system Inspect whether the high pressure oil pipe is aged or damaged The high pressure oil pipe shall be renewed when it is aged or damaged high pressure oil pipe 3 12 3 Test Adjustment Renewal of filter core of air cleaner Disassemble the 5 self tapping screws 1 according to the diagram Remove the right cover of air cleaner Remove the filter core of air cleaner and renew it Assemble the removed parts in reversed sequence self tapping screws 1 Idle speed Test Idle speed revolutions 1700 100rpm 3 13 CFMOTO Discharge Test For ensuring the regulated insertion depth ch 60cm of probe the connector as showed in 2 g r 2 C the right figure shall be prepared and a i Ke connected to the muffler LL s Mia Sr p kr hu v ah P A ae We as ii Ik a Measure the concentration of carbon monoxide CO and hydrocarbon HC when the idle speed is adjusted strictly CO concentration upon idle speed below 3 8 HC concentration upon idle speed below 800ppm Idle speed revolutions 1700 100r min 3 14 3 Test Adjustment Test of accelerator handle Turn the accelerator handle check whether it the clearance can operate smoothly and flexibly If it does not operate smo
93. he parts that are loose axially or radially shall be renewed The parts that are unsmooth shall be washed with 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 M Do not let the bearing race turn back when blowing the ball bearing by compressed air after washing If the bearing race turns back its high back turning speed will be beyond the limit that may result in damage of bearing The bearing shall be lubricated with engine oil or grease before assembly 1 4 E The recommended lubricating grease must be applied or injected in the appointed positions E When disassembling the pressed ball bearing the disassembled bearing must not be used again if the balls are forced for disassembly M The installation direction of single sided dustproof bearing shall be paid attention to upon disassembly The surface of open type or dual side dustproof bearing that is with the sign of manufacturer dimensions shall face outside upon installation single sided dual side dusiproof dusiproof hearing hearing open type hearing M The side with chamfer shall face the impact direction when installing the circlip The circlip that is loose already or without elasticity shall not be used again Rotate the circlip after assembly for confirming that
94. hell 2 of thermostat and take out the thermostat 11 Make assembling in the reverse sequences of disassembling Erect the foot plate 2 8 Inject the coolant eject the air 6 4 Assemble the carburetor 5 13 Maintenance Notes amp Atnormal temperature the thermostat shall be renewed even it is opened a little only amp The thermostat will be lagged in terms of time for its temperature detecting area is small So that the lift range of opening valve shall be inspected when keeping the full opening temperature for 5 minutes before and after amp The thermostat and thermometer shall not contact the bottom of the test container Put the thermostat into the water of container make the water temperature rise slowly and inspect the opening temperature of the valves of thermostat Operating temperature of opening valve 72 2 C Full opening lift range temperature 3 5 4 5mm 88 C Assemble the thermostat Refers to the above content 6 CFMOTO Radiator Notes Do not damage the radiation fin of radiator Disassemble the front faceplate 2 8 disassemble the bolt 1 bolt 2 disassemble 2P insert element of fan motor hi Ti if remove the fan motor combination Yo y H Lod ty FE dra Loosen the hoop 1 and hoop 2 Ein ii if fmm i Mn AN disassemble the water inlet pipe of ff Raion gt si radiator water outlet pipe of radiator j j er
95. iately and receive treatment in specific hospital after gargling amp The coolant shall be stored strictly in a safe place where children cannot touch Coolant volume Due to natural evaporation etc the assistant coolant will decrease so the volume water box shall be inspected regularly upper limit lower limit Notes front venting plate amp The coolant is with the functions of antirust freeze resistance It will rust in the engine and freeze in winter which may cause break of engine if tap water is adopted Therefore coolant must be used The motorcycle shall be raised vertically when inspecting the coolant The coolant volume cannot be checked correctly if the vehicle is inclining The test of coolant shall be carried out when the engine is warmed up Start the engine for warm up Stop the engine raise the motorcycle vertically on flat ground Check whether the coolant level of assistant water box is between the upper and lower limits When the coolant level is below the LOWER lower limit open the right cover of front storage box remove the cover of assistant water box and supplement the coolant up to the upper limit supplement coolant or dilute the original coolant for supplement 3 16 Recommended coolant Chunfeng coolant Standard concentration 50 the freezing temperatures of coolant upper limit are different according to different mixture ratio Please adjust the
96. il injector seat Disassemble the insert element of water temperature Sensor Disassemble the bolts disassemble the thermostat group 8 9 CFMOTO Disassemble the bolts and washers of cylinder cover Disassemble the cylinder cover subassembly Notes Stand the main support and press the rear part of the whole vehicle downward forcibly by hands then the cylinder cover can be removed Disassemble the shim locating pin of cylinder Cover Disassembly of cylinder body Disassemble the chain guide Disassemble the bolts washers Disassemble the air inlet hose cylinder body group 8 10 holts and washers of cylinder cove 8 cylinder air distribution system Disassembly of cylinder cover Valve assembly X Notes inols 4 The parts shall be stored separately when they are disassembled and they must be installed to the original positions upon installation Take out the valve locker by the compressing tools for valve spring Notes In order to prevent the weakening of the elasticity of valve spring just compress the valve spring to the length required for valve locker disassembly Special tools Valve assembly tools 1P52MI A 922 020000 Disassemble the compressing tools for valve pre spring take out the valve spring seat valve spring valve seal ring subassembly for valve V stem and valve spring holder spring seal ring subassembly The disassembled seal ring
97. in menu FIGIO Move the selection bar with up or down button to configuration FIG10 Press OK Button for acknowledgment The screen of diagnosis analyzer will show the options FIGI 1 Move the selection bar with up or down button to background light Press OK Button for acknowledgment FIGI1 Options will be shown at bottom of the background light menu FIG12 Constant lighting on Economical Move the selection bar with up or down button to Constant lighting on ar The screen background brightness is set at Constant lighting on FIG 12 Move the selection bar with up or down button to Economical and press C The default of screen background brightness is Constant lighting on Press ESC to return to configuration Move the selection bar with up or down button to Language and press OK Options will be shown at bottom of the Language menu FIGI3 English Italy French Germany Spanish Move the selection bar with up or down button to the desired language and Press ESC to return to configuration Move the selection bar with up or down button to LCD contrast and press OK With up or down button adjust LCD to proper contrast Press OK Button for acknowledgment or ESCB Button for exiting FIG 14 21 4 Real time data Main menu Move the selection bar with up or down button to real time data Press OK Button for acknowledgment Show the list of real time data FIG 15 FIG 16 FIG 1
98. inder body group cylinder cover subassembly and hood of cylinder cover amp The lubricating oil paths of the cylinder cover hood cylinder cover subassembly and cylinder body group must be cleaned before assembly Maintenance standard CF125 CF150T limit Compression pressure of cylinder 700kPa kgf cm 260r min Flatness of cylinder cover Camshaft Height of cam top 30 74 30 86mm 30 69mm 30 33 30 45mm 30 28mm 9 978 9 987mm 9 91mm External diameter of valve stem Valve rocker Valve Valve guide Interior diameter of valve guide sleeve 8 1 CFMOTO Driving depth of valve guide IN EX 11 9 12 1mm Contact width of valve retainer IN EX 0 9 1 1mm Clearance of valve stem and valve guide 0 010 0 037mm 0 075mm 0 030 0 057mm 0 095mm Valve spring Overhanging length outer inner spring Cylinder Interior diameter Roundness IN EX 35 0 32 3mm 33 5 30 8mm 52 4 52 419mm 50 Flatness of cylinder combination surface Cylindricity Fastening torque Bolts for hood of cylinder cover Acorn nuts for cylinder cover Bolts for timing chain wheel Bolts for tensioner spring seat Bolts for cylinder cover Bolts for tensioner Bolts for hood of cylinder body Error diagnosis 10N m 1 0kgf m 3SN m 3 5kgf m 9N m C 0 9kgf m 10N m 1 0kgf m 10N m 1 0kgf m 10N m 1 0kgf m 10N m 1 0kgf m amp Generally the poor airproof of perimeter of cylinder cove
99. ing system 13 6 Remove 5 bolts on braking disk and take out the braking disk Inspection Braking disk thickness Replace disk in case of thickness below 3mm Remove bolt and bolt 2 and then take out brake caliper combination Inspection brake caliper Check the brake caliper for crack and oil leakage from tightened locations and make replacement if any 13 Front wheel braking suspension and steering system combination 13 15 CFMOTO Disassembly w w J counter ra s front wheel steel ral front wheel bottom axleff cover valve mouth Pal wa oi Pa braking disk seal ring s front wheel left axle front axle Take out oil seal Fix the disassembling tool head onto the rim From back side fix the disassembling tool shaft to the disassembling tool head and then insert it into and remove the lower bearing Bearing disassembling tool head take out intermediate spacer ring fr Special tools Bearing disassembling tool shaft 519 922 070001 Bearing disassembling tool head 12mm 519 922 070002 Notes Replace the bearings in package Not use the removed bearing Bearing disassembling tool shaft 13 16 13 Front wheel braking Suspension and steering system Take out left axle cover offront wheel from left side of front wheel left side of bl wheel axle cover Inspection me Axle E 4 y Place the axle on the V shaped pad and measure EA i e its run out with
100. ises improperly The thermostat does not work well the thermostat has not been turned off Water leakage The water seal for water pump does not work well The O ring is aged damaged or with poor airproof The shim is aged damaged or with poor airproof The pipeline was not properly installed The pipeline is aged damaged or with poor airproof 6 2 6 Cooling system Performance maintenance Inspection of specific gravity of Water the coolant entry Notes cap The water entry cap can be opened and the front faceplate 2 8 and the water entry cap shall be disassembled when it is confirmed that the coolant is cooled already Check with densimeter whether the concentration of coolant is suitable for the air temperature in the place where it 1s used Inspect whether the coolant is contaminated Maintenance of water entry cap Notes The water entry cap must be opened when it is confirmed that the coolant is cooled Disassemble the front faceplate 2 8 remove the water entry cap refers to the water entry cap previous article Notes Water shall be applied to the sealed face of water entry cap when installing the measuring instrument for water entry cap onto the water entry cap Determine with the measuring instrument for water entry cap whether the water entry cap works well the water entry cap is OK if it can keep the opening pressure for 6 seconds Opening pressure of water ent
101. it can turn around flexibly and smoothly The camshaft shall be renewed f there is vibration or the turning is inflexible Test whether the surface of each cam is with scratch or stripping Measure the height of each cam top by micrometer Operation limit IN 30 69mm EX 30 28mm e Notes The valve rocker shall be tested when the surface of cam is worn or damaged Valve rocker valve rocker shaft Test whether the sliding part of valve rocker the surface contacting with the terminal of valve stem are scratched or worn Test the cam top of camshaft when the sliding contact surface of valve rocker is scratched or worn contacting surface sliding contact surface Measure the interior diameter of each valve rocker hole Operation limit 10 10mm Measure the external diameter of each valve rocker shaft Operation limit 9 91mm 8 8 8 cylinder air distribution system Disassembly of cylinder cover Notes edle pin TES Ge ig i The chain shall be suspended by steel wire so as not to fall into the vehicle Hold the vehicle firmly by the main support Disassemble the muffler 2 15 Discharge the coolant 6 4 Disassemble the body of throttle valve 5 3 Disassemble the hood of cylinder cover 8 5 Disassemble the camshaft support subassembly gt 8 6 Disassemble the locating pin Loosen the bolts disassemble the oil injector seat subassembly Disassemble the shim for o
102. leaner assembly Assemble Make assembling in the reverse sequences of disassembling 5 5 CFMOTO Disassembly of Air cleaner Disassemble the five bolt 14 disassemble the front shell 23 of air cleaner take out the seal ring 13 cleaner core and support 24 of cleaner core disassemble the bolt 7 take out the air temperature sensor 6 loosen the hoop 10 and disassemble the oil storage pipe 12 5 6 6 Cooling system Maintenance information 6 1 TENCTIMOS AL vassere 6 7 Error diagnosis 066 6 2 Radiator sareno oraes 6 8 Performance maintenance 6 3 Water PP sarte 6 8 Auxiliary water box 6 5 Cooling system diagram 6 9 Maintenance information Notes during operation Notes When the temperature of coolant is above 100 C if open the cover of radiator the pressure of cooling system will decrease the coolant will suddenly boil and vapor will be ejected which may cause hazard Therefore the cover must be wrapped with rag etc and opened gently when the temperature of coolant has dropped The Maintenance of coolant must be carried out when it is cooled completely amp The coolant is poisonous so it is not drinkable Do not let it contact the skin eyes or clothes either M Incase it contacts the skin or clothes wash it immediately with soap E Incase it enters the eyes wash it thoroughly with water immediately and receive treatment in specific hospital M Incase
103. n core pe groupware i HER spring ar Erect the water pump component as per the diagram Erect the upper view window cover machine level stick and its seal ring Supper view window Fix machine level stick 1 a cover and its seal ring Erect the oil screen component r Erect the drain screw and washer Cover of engin screen i l group drain screw mwashe 11 5 CFMOTO CF Moto Erection of stator combination trigger Serew and washer Fix stator combination and trigger and hole purposejelasticretainer A a tighten them with bolts and washer The chamfered face of the inner hole of the washer is faced towards the bolt Notes Clamp the wires of stator combination and trigger with compression plate and coat tread tightening glue on locking bolts Insert the sealing fixture block of wires into the slot Notes Apply sealant Erection of driven gear component Fix the driven gear component onto crank insert the fixing plate onto the driven gear tighten the fixing plate with bolts and adjust the fixing plate till not contact or colliding with the toothed disk end face of driven gear component Fix the flywheel combination insert the pin into the hole on the crank and lock the nuts with specified torque oe Ties out and washer Check the pin for being inserted ee At erecting of flywheel combination align the semi circular key on the crank Torque 59 N m 6 0Kgf m 11 6 11 Right side c
104. nged happening to 2 or more commutator to avoid short circuit Confirm that all the commutators are mutually conductive rotor commutator 17 3 CFMOTO CF Moto Confirm that no conduction existing between the rotor shaft and the individual commutator Assemble Put the O sealing ring in the groove on the 0 sealing ring CON O sealing ring motor cover A starting motor seat Apply a litter grease on the O sealing ring Align the boss 17 4 17 Electrical starting system amp overrun clutch Apply grease on both ends of the rotor shaft and mount the rotor on the starting motor case While pressing the brush into the brush seat mount the brush seat on the commutator Align the boss of the starting motor case to the groove on the motor case and mount the motor seat on the case Tighten the bolts Place the O sealing ring on the groove in the motor positioning boss Assemble Notes Mount the starting motor in front of the engine make the wiring and confirm the direction of rotation in operation Proceed to install in the sequence oppose to the dismantling Overrun clutch Disassemble Take down the right cover 11 2 Take down the dual gear and gear shaft 11 2 Remove the flywheel subassembly gt 11 3 Remove the hexagonhead screw fixing the overrun clutch Align the Starting motor Ubasse I 17 5 CFMOTO CF Moto U
105. nscrew the bolts and remove the fixing plate driven wheel ha serm br and the driven wheel subassembly Assemble Make assembling in the reverse sequences of disassembling Apply a little lubricating grease to the dual gear shaft in the right box Tighten the three inner hexagon binding bolt in the overrun clutch with the designated torque at 12 14N m screw thread glue applied 17 6 18 Light instrument switch Maintenance information s se e 18 1 l l l Switch of braking Lightessssscsssesseees 18 8 Error diagnosis 000000000000000000000000000000000 18 2 Flectric horn Coc cccccc ccc ccc cce cee cee cee ooo ooo 18 8 Bulb replacement Coc ccccccccccccccc ccc cce ccc ccecee 18 3 Speedometer Coc ccc ccc ccccccccccececcecceeceeceeocee 18 9 Headlamp 000000000000000000000000000000000000000000000 18 5 Sg Fuel SENSON Pe seecessssssesccccsccsccsccccccces 18 10 Ignition switch lock ecococococooooooooooo ooo ooo 18 6 Water temperature SenSorsssssssrssseteress 18 12 Handlebar switch ecoccoocococoocooooooooooooooo ooo ooo 18 7 Maintenance information Notes during operation Notes The headlamp bulb has large power with high temperature while ignited touching it immediately with bare hands after closing light you will be scalded so you must not operate until the bulb is cooling down The check of temperature Notes switch concerns fire source and high temperature liquid so don t put combustible articles nearby an
106. nsmission System amp Left Cover Replace groupware bearing of driven Check rolling pin bearing uF f wheel Disassembly tools for disassembling bearings Remove rolling pin bearing with _ elastic collar for shaft wheel bearing special tool inside driven a at tw fe a r 3 y Js i Remove elastic collar for shaft and take off ball bearing Coat lubricating oil on new ball bearing Put the ball bearing with upper countermark into the turntable of driven wheel Replace groupware bearing of ball bearing dk driven wheel elastic collar for shaft Set elastic collar for shaft 9 11 CFMOTO Coat lubricating oil on the dre eee internal circle face of the moving tool Breanna tel Guide turntable of driven wheel f Smear lubricating oil on the new ve i if rolling needle bearing Bg Put the ball bearing with upper m VI countermark into the turntable of j C driven wheel Al ve Remove the driven sg Check rolling pin turntable set l bearing Check Outer turntable set of the clutch Examine whether there s any abrasion and damage in the outer turntable set of the clutch Measure the internal diameter of outer turntable set of the clutch Outer turntable set of the clutch Operation limit 125 mm Hoof friction flake of the clutch Examine whether there s any abrasion and damage in the outer turntable set of the clutch Measure the thickness of the
107. nt If it not in consistent to check if the main cable is broken or in short circuit otherwise check the fuel sensor and the fuel meter itself ere 18 10 18 Light instrument switch Remove 3P insert connector of fuel sensor Connect the multimeter between the terminals of 3P insert connector of fuel sensor Shake the fuel sensor bobber with hands measure the resistance value l 3P ingsert connector of fuel set Fuel sensor of bobber in various positions sensor connecting terminals yellow white green bobber position up 33 2 Q 20 down 566 4 Q 20 If the exam above is in abnormal then replace the fuel sensor ee AN Erection Make assembling in the reverse sequences of disassembling Notes Install the fuel sensor into the hole of the oil box to a right position SNE Ge EEE Connect the 3P insert connector of Sensor fuel sensor Check the fuel meter Put through the power supply check if the fuel meter can run normally Confirm the fuel meter to run normally install body plastic and seat mat at the reverse order of removal 18 11 CFMOTO Water temperature sensor Notes Pay attention not to be burn nor put combustible articles nearby Notes e The cooling liquid must immerse the whorl of switch the distance shall be over 40mm between ee fee A container base and switch head e Before measurement keep liquid temperature for 3min or so don t raise the
108. o the water entry Start the engine eliminate the air in the cooling system and install the water entry cap when it is confirmed through the water adding opening that the air in the cooling system is completely ejected Open the right cover of front storage box remove the cover of assistant water box supplement the coolant up to the upper limit of the assistant water box Notes Inspection of coolant volume shall be carried out when the motorcycle is vertical Exhaustion 1 Exhaustion shall be carried out according to the following sequence 2 Start the engine run it for several minutes at idle speed Spin the accelerator fast but gently for 3 4 Assembly of front storage hox cover of i Auxili water hox right cover of T front storage hox assistant water box upper limit lower limit froni venting plate times eject the air in the cooling system 3 Install the water entry cap properly when coolant is added again up to the entry opening Inspect the coolant level in the assistant water box and supplement the coolant up to the upper limit when it is insufficient install the cover of assistant water box 6 6 6 Cooling system Thermostat Disassembly and assembly Notes The radiator cover can be opened only when the coolant is confirmed cooled Disassemble the foot plate 2 12 eject the coolant 6 4 Disassemble the bolt 1 remove the upper shell 7 lower s
109. od or measurement method As for replacement method use multi meter to check 1 Measure the resistance of primary rolling thread it is generally around 10 the resistance of secondary rolling thread its normal value is around 4 2K G damping resistance its normal value is around 5K 2 Check ECU replacement method is generally used Check up whether ECU fails or not 3 Check ignition power The voltage between blue black wire and ground green wire should be 12 V If not you can check from the positive electrode of the battery to the blue black end in turn 4 Cable test You mainly check up whether the connections from the trigger signal input connected to the output of the trigger of magneto to the output connected to ECU terminal and to the ignition output 1 e black yellow wire are good or not 5 Check flameout switch when it is switched to the IGNITION position the black white wire and the green wire should be disconnected In the case of weak spark you can check the following 1 Check ECU by using replacement method 2 Check up whether partial short circuit error happens in the secondary rolling thread of the ignition coil or not or whether deterioration happens in the damping resistor 16 3 CFMOTO Ignition system examination Note digital multimeter e If the spark plug does not ignite first TOM U DUVEL_E you should make sure that no abnormal PN z conditions such as falling off l
110. of the fuel 2 14 2 Body and muffler Muffler Disassembly Notes When the muffler is in the cooling condition it can be disassembled Remove the 2 nuts 5 tie in at angle pipe in front muffler Take off bolt 14 15 Disassemble the oxygen sensor 16 Remove muffler i Assembly Make assembling in the reverse sequences of disassembling Torque The front angle tube nut 30N m 3 0kgf m Muffler bolt 40N m 40 5kgf m Notes When assembling the vent seal washer should be renewed 2 15 CFMOTO Name of outer parts front cover of hack cover of handlebar handlebar mn holding har Fa fender of rear wheel seating mat irunk shield hoard taillight rear fender f y i F cover front part of as a ri foot hoard i EP i m pa all f tes i Fa Da I BE od AN eS N ag le im P va s The broken lne means the unsighted parts in the drawing 3 Test Adjustment Maintenance information 9 1 snition device re 39 Replacing parts regularly 5 Lubricating device s 99es o LI Mode of Test and overhaul 3 2 Buel devpe sr 3 12 Steering column ee cee ccc ces cee ccc ces 3 5 Cooling device ee ccc ccc ccs cee ccc ces 3 16 Brake system Cec ccc ccc cccccc ccc cccccccce 3 5 Waste gas recycle device ccc ccc cccccs 3 18 Wheels Coe cre cer cee cee ccc ces cee cee cee ooo 3 7 Lighting device Cec ccc ccc ccc
111. oil shall be selected according to the table at right and the engine oil viscosity shall be suitable to the climate in the place where it is used Install the oil level gauge and tighten it Renew the engine oil Raise the motorcycle by main bracket Run the engine for warm up Turn off the engine disassemble the oil level gauge Disassemble the drain bolt and sealing gasket discharge the engine oil Make the motorcycle incline to left side press the startup button for 2 3 times 3 11 CFMOTO Install the washed drain bolt and new sealing gasket fasten it according to specific torque Torque 25N m 2 5kgf m Inject the recommended engine oil into the engine oil injection opening Oil capacity of the engine 0 8 upon renewing the engine oil 1 0 upon disassembly The engine oil must be determined by the engine oil level gauge while it is injected into the engine until the oil level reaches the drain bolt upper limit of engine oil level gauge sealing gasket Install the engine oil level gauge start the engine inspect whether there is oil leakage on the ir s engine Stop the engine and check the oil volume again Washing of engine oil filter screen Discharge the engine oil Remove the filter screen cover of engine oil Remove the spring filter screen and wash the spring filter screen F Inspect the O ring of oil filter screen cover Ne a renew it when necessary A S N as Install t
112. oltage meter in between the terminals of the battery Cautions When testing protect the circuit from short circuit Over voltage may be resulted when current flows through the terminals that are being connected or detached thus causing the damage of the multi meter and other electric parts Be sure to start operation only after the ignition switch is closed Test should be made to battery with full voltage Start the engine with high beam headlamp on Raise the engine rev gradually until a specified speed 5 000 rpm the value shall be normally in between 13 5 15V Measure the voltage between the terminals of the battery Standard The voltage of single unit of battery lt charging voltage lt 15V at5 000rpm Leaking test Remove the maintenance cover gt 2 2 Set the ignition switch to be position and then remove the negative lead from the battery 15 5 CFMOTO Remove the fuse right front box Link the current meter in between the negative terminal and the negative lead of the battery Measure the leak current with the ignition switch being under the State Cautions The fuse of the multi meter will be burned if the current to be measured is out of the measuring range Therefore the current should be measured from a large measuring range and to a smaller one step by step amp The current should be measured with ignition switch closed Note that when a smaller current
113. oosening Qu k x and poor contact happen among all parts kj SN N of the circuit then measure each peak Aa ID AN W voltage Ly Be i e Different kinds of multi meters have Peak voltage ue hj F different input resistances therefore the PE values they indicate are also different We cannot measure the correct value You must measure the voltage with a digital multi meter whose input resistance should be larger than IOMQ DCV Connect the peak voltage pickup to the digital multi meter Special tools Peak voltage pickup 519 922 150000 Used together with digital multi meter sold on the market whose input resistance is larger than 1OMQ DCV 16 4 16 Ignition System Ignition system Trigger coil Note e Measure the coil after connecting all circuits correctly If falling off happens in circuit connection you cannot measure the coil correctly e You must check the coil under the condition that there is compression pressure in the cylinder and the spark plug and its cap are installed normally If you measure the coil with the spark plug disassembled the peak voltage will Trigger coil rise Disassemble left guard plate C 2 5 Disassemble right guard plate gt 2 5 Disconnect ECU unit connectors magneto Connect the probe of peak voltage pickup to the following terminals of the main cable Special tools Peak voltage of the trigger coil Instrument for Measuring M
114. ormal condition or not If they are both normal then you should check the ignition system Ignition system error diagnosis Conditions of ignition system are as follows 1 Spark examination The procedures are Remove the spark plug disassemble the spark cap put the high voltage soft cable head to ground to check spark flashover If the spark flashover is over Smm it is in normal condition If it is less than 5mm the spark is weak If the spark is normal you should check the spark plug You can use replacement method to check it Abnormal conditions of spark plugs are as follows 1 The spark plug is wet This belongs to drowned spark plug phenomenon The reason is that the concentration of the mixed gas is too high You can turn off the oil circuit first and ignite several times 2 The spark plug is black and is seriously coked The reason is that the concentration of the mixed gas is too high or the engine oil leaks into combustion chamber You can clean and grind the spark plug to make it back to normal 3 Insulator of the spark plug cracks and gas leaking occurs 4 Short circuit happens between the two electrodes of the spark plug or the negative electrode and the thread the positive electrode and the input end are not connected 2 Abnormal conditions of the spark plug are of two cases no spark or weak spark In the case of no spark you can check the following 1 Check the ignition coil You can use replacement meth
115. ot start or the rotate speed is unstable Maintenance standard tem Standard Oil injector Idle rotate speed 1700 100rpm Air control valve of idle Siemens ABV379 008 Body of throttle valve BING 7226101 5 1 CFMOTO Error diagnosis Engine fails to start Too much fuel in the engine M The air cleaner is jammed M The ventilation of idle air pipe is not free There is air leakage between the oil injector and seat of oil injector There is no fuel in the oil injector m The fuel filter is jammed M The high pressure oil pipe is jammed M The oil injector is jammed Difficult to start or it extinguishes right after startup unstable idle speed The ventilation of idle air pipe is not free The fuel system is jammed The ignition system does not work well There is air leakage between the oil injector and seat of oil injector The holes on the cover of oil box are jammed It extinguishes when accelerating The ignition system does not work well the clearance of spark plug is improper 5 2 5 Oil supplying system air inlet system Disassembly of high pressure oil pipe Disassemble the trunk 2 3 loosen the belt hizh pressure oil pipe MYE Loosen the clamping band on the cap of oil injector which is exclusively for oil pipe loosen the clamping band on the gasoline tank which is exclusively for oil pipe remove the high pressure oil pipe Notes Hold the remained gasoline from the hig
116. otes The headlamp bulb has large power with high temperature while ignited touching it immediately with bare hands after closing light you will be scalded so you must not operate until the bulb bulb of the headlamp is cooling down Remove front cover of handlebar 13 10 Remove the 4P insert connector of headlamp Remove dustproof hatl0 and loosen clip reed 3 remove the lamp seat and bulb set of headlamp Remove front bulb and replace it i JP insert connector of headlamp Notes Must wear clean gloves when replacing the bulb When the glass surface is attached with oil the bulb will be broken must wipe it up with clean cloth dipped with alcohol or banana water When replacing the headlamp bulb you shall be sure that the 3 orientation flakes of bulb must point to 3 orientation holes of the lamp seat bulb specification 12V 35 35W Install according to the reverse order of removal After replacing the bulb adjust the light axis of the headlamp gt 3 19 Check to the headlamp T 66 p5 22 The ignition switchisat t move the lighting switch to the check the headlamp being on or not 18 3 CFMOTO On normal off broken main cable or short circuit brake bulb of taillight Remove self attack bolt 9 Remove taillight cover 1 Rotate the brake at counter clockwise remove taillight bulb 5 Replace brake taillight bulb bulb specification 12V 21 5W Make assembling in the reverse
117. othly determine respectively that whether the accelerator guy cable is damaged wire rope is rusted accelerator handle is stuck Inspect the clearance of the outer edge of accelerator handle Gap 1 8 1 4 of a revolution Adjust the clearance if it is not within the regulated range Remove the sheath of accelerator guy cable Loose the locknut of the accelerator guy cable turn the adjustor and adjust the clearance of accelerator handle After the adjustment fasten the locknut and install the sheath of accelerator guy cable The accelerator guy cable shall be renewed if the regulated clearance still cannot be achieved by adjusting the adjuster or the action is still not flexible 3 15 CFMOTO Cooling device Notes The liquid volume test shall be carried out in the side of assistant water box instead of the side of radiator If open the radiator cover when the engine is hot generally above 100 C the pressure of cooling system will reduce the coolant will suddenly boil Therefore the cover must not be opened until the temperature of coolant drops amp The coolant is poisonous so it is not drinkable Do not let it contact the skin eyes or clothes v In case it contacts the skin or clothes wash it immediately with soap v In case it enters the eyes wash it thoroughly with water immediately and receive treatment in specific hospital v Incase the coolant is drunk by accident try to vomit it immed
118. over magneto and water pump Sequentially re fix the dual gear dual dual gear shaft gear shaft oil duct connector and right side cover ra positioning spring of oil duct connector sealing pad a7 i pin Fix the positioning pin and sealing pad k mm 4 of right side cover Erection of right side cover Place the right side cover and diagonally tighten the bolts in 2 3 times Torque 12 N m 1 2kgf m spring of oil duct connector right side cover bolt Notes Fj The opening of the water pump shaft shall be aligned with the machine oil pump shaft otherwise erection would be impossible Sequentially fix the positioning pin water pump cover and its sealing pad and then tighten them with bolts Notes Diagonally tighten them in 2 3 times Re place water inlet hose water outlet hose and vent hose Fill coolant gt 6 6 Fill lubricating oil into the crank box gt 3 11 Erect body plastic parts Chapter 2 m water pump water inlet hose 11 7 12 Box body crank and piston Maintenance information PES PTE cee ees D 1 Crank piston eee ee Se ee ee 1 Di 4 Error diagnosis Coc c cc ccc ccc ccc ccc ccc cccccccccces 12 2 Assemble of box body ccccee 12 1 1 Disassemble of box body teseeeeeeeeeeeeeeees 12 3 Maintenance information Notes during operation The crank and crank box shall be maintained after disassemble of the box body and for their maintenance the engine shall be removed f
119. p on high beam When the engine rev is at 5 000r min the battery is normal so is the normal charge system Voltage between terminals charge voltage 15 5 Standard single unit voltage of battery lt charge voltage lt 15V Normal Abnormal Short circuit or broken line of Test rectifier system 15 6 the main cable Poor contact of linker Normal 15 3 CFMOTO Battery Disassembly Notes Before operation must make ignition switch at position Take down footstep rubber Take down the maintenance cover 2 2 Take down bolt 1 and bolt 2 as well as the battery press board set Loosen the bolt of cathode connection pole take apart the cathode lead connection of the battery Take down connection pole rubber cap and the bolt of anode connection pole Take apart the anode lead connection of the battery s i i i il battery hold down plate bolt 1 combination bolt 2 Assembly Make assembling in reverse sequences of disassembling Notes After assembling smear clean lubrication oil on the connection pole After assembling tightly install the cover on the anode connection pole Check Measure the voltage between battery terminals examine the measured state Full measurement 12 8V Shortage Below 11 8V Charge up when there s undercharge J ri Br y connection pole rubber cap l node connection pole cathode connection pote Cautions When
120. r Notes Determination shall be made when the engine is spark plug warmed up Disassemble the maintenance cover gt Chapter 2 Disassemble the left guard plate Chapter 2 Disassemble the spark plug cap spark plug Select proper compression pressure gauge install it into the spark plug hole of cylinder cover The accelerator is fully open Measure the compression pressure of cylinder by electric starting Notes The compression pressure gauge and its accessories shall be installed strictly the connection must be with no pressure leakage The accumulator will overflow because it 1s electric starting so the starting motor must not operate continuously for 5 seconds or above Compression pressure 700kPa 7kgf cm 260r min When the compression pressure is too high test the carbon accumulation at the piston head and the firebox in the cylinder cover When the compression pressure is too low pour some engine oil into the hole of spark plug and measure again Compare the measured value with the previously measured value if the pressure rises measure the cylinder piston and piston ring gt Chapter XII If the pressure remains the same maintain the cylinder cover valve The valve leaks Improper adjustment on valve gap 8 3 CFMOTO Adjustment on valve gap Test hood of cylinder cover Notes i The test Adjustment of valve gap shall be carried out in cooling condition
121. r can be determined by measuring the compression pressure of cylinder or according to the sound from the upper cylinder cover seal of engine amp Test whether the ventilating pipe of crankcase smokes when it cannot start properly or run improperly at low speed If the ventilating pipe of crankcase smokes it means the piston ring is worn broken or blocked Unstable idle speed Ventilation of idle air pipe is not free The seat of oil injector is leaking Low compression pressure Fuel supply system does not work well Compression pressure is too low Improper adjustment on valve gap The valve is burnt or worn Incorrect adjustment on timing of air distribution Elasticity of valve spring is insufficient Poor airproof of valve seat The sealing gasket of cylinder cover is leaking The cylinder cover is deformed or chapped Incorrect installation of spark plug Compression pressure is too high Carbon is accumulated at piston firebox 8 2 Abnormal sound Cam surface of cam shaft subassembly is worn or damaged Improper adjustment on valve gap The valve is burnt or the valve spring 1s damaged The rocker rocker shaft are damaged The chain is stretched The chain tensioner does not function well The muffler emits blue smoke The valve guide or valve stem 1s worn The seal ring of valve stem is worn damaged The piston ring or cylinder is severely worn 8 cylinder air distribution system Compression pressure of cylinde
122. r water immediately and receive medical treatment in hospital In case the coolant is drunk by mistake please try to vomit it out and receive medical treatment immediately after gargling The coolant must be stored strictly away from where children can touch Cautions 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 1 1 CFMOTO Cautions The Battery may produce combustible and explosive hydrogen when it is being charged So it may explode if there is flame or electric spark So please charge it in the place with nice ventilation Cautions do not let the turning or movable pieces such as rear wheel clutch etc clip your hands or clothes when maintaining 1 2 Cautions The personnel shall make them be aware of each other from time to time when operating for safety confirmation 1 Maintenance information Cautions to disassembly assembly M The parts lubricant and grease must adopt the pure M Please clean the dirt dusts on the vehicle before parts of Chunfeng Brand or recommendation maintenance ae S M The parts of each system shall be arranged and stored The gasket O ring piston pin retainer and split pin separately so that the parts can be assembled to the must be renewed after disassembly original pl
123. rainer element sparking plug screened cap high voltage leg wire ignition coil 20 9 CFMOTO g Detonation abnormal diagnosis analyzer fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure fuel supply fuel pressure fuel filter screen injection capacity fuel quality data reliability coolant temperature signal air temperature signal TPS position signal Ignition advance gas handling system tightness inlet hose air filter 20 10 21 Function of buttons of diagnosis analyzer FIG 1 CFMOTO LOGO Function of buttons of diagnosis analyzer FIG 1 Selection bar Highlighting of selection bar Button 1 downwards The selection bar moves downwards SELECTION BAR DISPLAY Button 2 upwards The selection bar moves upwards Button 3 rightwards Review the parameters corresponding to the selected function Activate LCD background light When background light setting is selected Button 4 OK Selection of acknowledgement Button 5 Exit Cancel the executed selection Return to the upper level menu Return to the main menu Main menu FIG 1 21 1 CFMOTO Connecting diagnosis analyzer Note Before connecting diagnosis analyzer check for correct voltage of battery connection wires and fuses The plug of diagnosis wire 2P is in the right trunk Open the right front trunk cover A Connect the plug B of diagnosi
124. ration of connection Support the main bracket shake the engine leftward and rightward inspect whether there is damage vibration etc on the hanger cushion cover renew it when there is vibration Transmission Spot Test of lubricating oil in the transmission Inspect whether the transmission leaking Support the vehicle with main bracket put the vehicle horizontal Turn off the engine disassemble the engine oil Test bolt Inspect whether the oil level reaches the bolt opening Supplement the engine oil up to the lower edge of bolt opening when the oil is insufficient Recommended engine oil hyperbola gear oil 90 Inspect the status of sealing gasket install the engine oil Test bolt and fasten it Torque 22N m 2 2kgf m Ignition device Spark plug Disassemble the maintenance cover 2 2 3 9 CFMOTO Disassemble the cap of spark plug the cap of spark plug Clean the combination surface of spark plug with compressed air when disassemble the spark plug for avoiding the entry of dusts etc into the combustion chamber Disassemble the spark plug Inspect the consumption corrosion burn of the core l core electrode and side electrode of the spark plug as well as the damage of insulation electromagnet it shall be renewed if it is burnt side electrode Appointed spark plug 0 8 0 Sem Standard DPR7EA 9 Clearance of spark plug 0 8 0 9mm 3 10 3 Test Adj
125. ration relevant parts 3 4 3 Test Adjustment Steering column Raise the main bracket lift the front wheel hold the lower end of shock absorber and shake it forward and backward inspect whether there is vibration If vibration is felt it shall be determined that whether the Steering column vibrates or other part vibrates and corresponding overhaul shall be carried out If the Steering column vibrates enhance the locking force of locknut of steering column or disassemble the Steering column for overhaul Raise the front wheel from ground turn the steering handle leftward and rightward slowly and determine whether it turns smoothly and flexibly If block is felt inspect whether there is interference on the main guy cable assembly and stayed cable if no disassemble the Steering column inspect whether there is damage on the bearing race of steering column Brake system Gap of braking handle Operate the front and rear brake handles inspect the brake effect and action status of handles Inspect the handle clearance at the ends of the handles Gap 10 20mm 3 5 CFMOTO Brake combination Fluid volume Bolt 1 Inspect the brake fluid volume When the brake fluid volume reduces to around LOWER the lower limit the leakage of brake pump brake pipe and connections shall be inspected Disassemble the installation bolt 1 2 of the oil cup cap remove the oil cup cap
126. rntable set Smear lubricating oil on the new 0 seal ring install it on the moving driven turntable set Smear the lubricating oil on the lip of driven turntable oil install the lip towards the moving driven turntable set Fill proper lithium lubricating oil in the 34 hole of the moving driven turntable set the guiding groove the rolling needle bearing and the ball bearing Install the moving driven turntable set to the driven turntable set Smear the lubricating oil on the guiding pin and rolling poll then install them on the driven turntable set Install the airproof bush 9 14 driven wheel oil seal Remove the driven turntable set driven wheel oil seal o shape seal rim direction dowel roller a I Na Driven turntable set Remove the driven turntable set airproof bush at 9 Continuously variable Transmission System amp Left Cover Assembly of clutch set Assembly of clutch set collar driven wheel groupware return spring of the clutch centrifugal damping glue piece set Install the damping glue piece set on damping glue piece set the driven turntable soleplate of the clutch Pay attention to the installment direction of return spring of the clutch install the centrifugal set and the return spring of the clutch return spring of the clutch 9 15 CFMOTO CF MOTO collar Install the collar Assembly A
127. rom the frame Chapter 7 The disassemble box body shall be made in the following sequences Disassemble of engine gt Chapter 7 cylinder head cover cylinder head and cylinder body gt Chapter 8 left side cover and infinite transmission system gt Chapter 9 right side cover gt Chapter 11 electric start system gt IChapter 17 lubrication system gt Chapter 4 The piston and piston ring may be maintained on the entire motorcycle and for this purpose merely the cylinder head cover cylinder head and cylinder body are disassembled Chapter 8 During maintenance cares shall be taken not to damage the box body s combination face Take cares not to inner face of damage cylinder and piston Item Standard Service limit CT oa om Piston The erection direction mark In is towards the air inlet aa side Outside diameter of piston 52 37 52 39 57 97 57 99mm 52 32 57 92mm Inside diameter of piston pin 5 002 15 008mm 15 04mm Outside diameter of piston pin 14 994 15mm 14 98mm Inside diameter of hole at small 15 016 15 034mm 15 05mm end of connecting rod Gap between the cylinder and 0 02 0 04mm 0 08mm the piston In group assembled Gap between the piston and the 0 002 0 014mm 0 04mm ee ee e Gap between the piston ring 0 016 0 040mm 0 06mm ogee een fm 12 1 CFMOTO Inter piston ring piston ring 0 02 0 044mm 0 07mm gap and rv bm kl Inter slot g
128. rom transmission mobile disc axle cover of driver whee 9 Continuously variable Transmission System amp Left Cover Remove bevel board Remove centrifugal roller groupware Test Tooth shape strap Check strap for chap cog fall off cloth flake and abnormal wearing Measure strap width Service Limit 20 7 mm Centrifugal Roller Groupware Check for wearing and damage Measure external diameter of roll wheel Service Limit 19 45 mm bevel board J Tooth shape strap D a groupware of centrifugal roller a fi N uf aK 9 5 CFMOTO CF Moto mobile main traction wheel disc Move driver wheel Measure bush internal diameter of mobile driver wheel Operation limit 24 07 mm axle cover of driver wheel Check axle cover of driver wheel disc for wearing and damage Measure axle external of driver wheel disc Service Limit 23 92 mm Erection Erection bevel board _ Slippery piece Sram external of centrifugal roller R mobile main 5 elastic traction wheel Slippery bush cellar for disc piece Slippery piece Q shaft mobile main traction wheel disc 9 6 9 Continuously variable Transmission System amp Left Cover i AA Rolling the son Assemble groupware of centrifugal ra carries noodles roller into the slide groove of a seven together side re of centrifugal driver disc Set the same length ends of centrifugal roller according t
129. roup Install the insert element for water temperature sensor Installation of cylinder cover hood Install the seal ring for cylinder cover hood locating pin locating pin onto the hood of cylinder cover seal ring for cylinder cover hood 8 22 8 cylinder air distribution system Slip the joint of oil path spring to the joint of oil path insert to the pin in the camshaft hole Install the assembled hood of cylinder cover Install the seal ring subassembly for hood cover bolts and bolts for hood of cylinder cover hood of cylinder cover Inject the coolant eject the air 6 5 Install the muffler 2 8 Install the body of throttle valve 5 3 Install the left side cover 9 18 8 23 9 Continuously variable Transmission System amp Left Cover Maintenance Informationssssssssssesees 9 1 Clutch Disassemblyeeressssseeeees 9 8 Error Diagnosiserrsrrsrersetsesseeeeeeees ED Nese ee 9 8 Left Cover Disassemblyr stee ee Se 9 13 Transmission Disassemblycersssssssssess 9 4 Clutch Erectionsssssssssesseseess 9 17 Disassemble Speed Variator 9 4 Maintenance Information Notes During Operation Notes Please note if there are grease things on the tooth shape strap and the surface of the strap sheave Degrease it if there are or it may cause slip between tooth shape strap and strap sheave decreasing the transmission efficiency Any lubricate grease shall not be attached on main trac
130. rrrrrrrrr rrr rrr rr rr rie 2 eee 20 3 Engine fail LO startr eeeeececeeccecececceccecoececoecoccocoecoccoccecoococoococecocececoecoccoccecoecoecee 20 3 The cold hot engine starts in difficulty ETTE 6 6 6 S 66 6 05 6 6 0 0 0 600 0 0 EP 20 4 Flameout unstable too low speed of engine in idle speedsrrrrsrrrsrcceesesceeceseecesees 20 5 The engine can t return to idle speed the idle speed is too highrs sssssesreerees 20 6 When slowing down the engine made puffing sounds seeseeeeeeeeeeeeeeeeeceececeeceeceeee 20 7 When the restrictor is open the engine works irregularly s0snennanennnene 20 8 When the engine speed is in maximum engine power descends the engine works irregularly when accelerated 000000 000000 000000000000 00000000000 o 000000000 000000 000000000008 008 eee ooo 20 9 Detonation 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000000000 000000000000 008 C08 20 10 I Introduction to the electric injection system 1 The electric injection system is an integral system that composed of fuel injection and ignition 2 Fuel is spurted directly into the suction manifold by electric injector The time of injection and ignition is controlled by trigger signal and different sensor signals 3 The control of fuel atomization and ignition depends on the engine s rotate speed and restrictor opening scale Further adjustment depends on the following parameters Coolant temperature Inlet air temperatur
131. ry cap 108kPa 1 1 kg f cm2 water entry cap 6 3 CFMOTO Pressurized test of radiator Apply the specific pressure opening pressure f wate of water entry cap to the cooling system by EAUEr ai joan aP measuring instrument for water entry cap determine that whether it can keep for 6 seconds within the specific pressure range Notes amp Donot apply pressure which is above the opening pressure of water entry cap 108kPa 1 1 kg f cm2 otherwise the cooling system might be broken When there is pressure leakage inspect whether there is water leakage at the pipeline each connection the combination part of water pump and the drainage hole of water pump gt 6 8 Renewal exhaustion of coolant Fabrication of coolant Notes amp The coolant is poisonous so it is not drinkable Do not let it contact the skin eyes or clothes either eo ee E amp Incase it contacts the skin or clothes wash it immediately with soap Incase it enters the eyes wash it thoroughly with water immediately and receive treatment in specific hospital Incase the coolant is drunk by accident try to vomit it immediately and receive treatment in specific hospital after gargling The coolant shall be stored strictly in a safe place where children cannot touch Notes The coolant original fluid shall be mixed with soft water at the temperature which is about 5 C lower than the lowest air temperature of the plac
132. s air tightness between intake manifold inlet and cylinder caliber air tightness between intake manifold inlet and restrictor valve intake hose air filter ignition sparking plug ignition advance data reliability coolant temperature sensor air temperature sensor TPS position idle valve 20 5 CFMOTO d The engine can t return to idle speed the idle speed is too high abnormal diagnosis analyzer fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure fuel supply the low fuel pressure pressure adjustment valve fuel pump fuel filter screen fuel flow data reliability coolant temperature sensor air temperature sensor TPS position idle valve gas handling system tightness air tightness between intake manifold inlet and cylinder caliber air tightness between intake manifold inlet and restrictor valve block air filter inlet hose 20 6 20 Electric injection diagnostic system and error diagnosis e When slowing down the engine makes puffing sounds abnormal diagnosis analyzer fuel pump relay ignition coil injector trigger signal air temperature coolant temperature atmosphere pressure fuel supply the low fuel pressure adjustment valve pressure fuel pump fuel filter screen fuel flow data reliability coolant temperature sensor inlet air temperature sensor TPS position sensor idle valve gas handling system tightness air tightness betwe
133. s wire 2P with diagnosis analyzer C Note After connection of plug of diagnosis analyzer the screen will prompt checking connection Rotating the power key to ON The diagnosis analyzer will prompt Connected and after 5 seconds shows the main menu 21 2 21 Function of buttons of diagnosis analyzer FIG 1 Calibration of TPS Note At implementing the TPS calibration program check the throttle cable and ECU for correct state Set the selection bar with up or down button at calibration FIGS Press OK Button for acknowledgment Options will be shown at bottom of the calibration menu FIG6 Zeroing of LAMBDA pulse spectrum TPS calibration Set the selection bar with up or down button at TPS calibration FIG6 Press OK Button for acknowledgment FIG6 The screen prompts Press OK Button for acknowledgment or ESCB Button for exiting FIG7 aan Press OK Button to start calibration program Rotate the throttle handle to the maximum location and then fully return FIG8 Press OK Button for acknowledgment Information confirmed on the screen calibration completed FIG9 Press ESC Button to Return to the main menu Rotating the power key to OFF and remove the diagnosis analyzer FIG 9 21 3 CFMOTO Configuration of diagnosis analyzer Connect diagnosis analyzer and rotate the power key to ON The diagnosis analyzer will prompt Connected and after 5 seconds shows the ma
134. sassembly Disassemble the rear shelf 2 4 Disassemble the rear connecting board 2 5 Disassemble the left guard board 2 5 Disassemble the right guard board 2 5 Disassemble the theftproof support for seating mat lock Disassemble two bolts 3 by the open spanner Disassemble the guy cable of seating mat from the support for seating mat lock Get the lock seat of seating mat off 2 3 CFMOTO Remove the guy cable of seating mat lock clamp the place to prevent the ene form the lock seat of seating mat guy calbe coming off after the guy cable is clamped J Assembly guy cable of ju Nag i i TAN Make assembling in the reverse sequences o of disassembling amp del N F spa Cautions The guy cable of seating mat should be assembled according to the drawing H i F x push steel wire of guy cable into here push the guy cable of seating mat into the lock seat Rear shelf Disassembly Open the seating mat by the key of ignition switch and disassemble three bolts 1 then disassemble the Rear shelf Assembly Make assembling in the reverse sequences of disassembling 2 Body and muffler Rear connecting board Disassembly Disassemble the two self tapping screws I shown in the drawing and then get the Rear connecting board off Left guard board Disassembly Disassemble the rear connecting board 2 5 rear connecting hoard self tapping screw I Disassemble the seating m
135. se sequences of disassembling Speedometer Notes Before check confirm if the soft axis of the speedometer falls off the nut 2 is loose or the soft axes are broken or not Fill up stably the front tire with check frame Confirm the speedometer finger is turning round when the front tire is turning round lightly and quickly When the exam above is of abnormality you must replace the speedometer Removal and Erection Remove the front cover set of handlebar 13 10 Loosen nut 2 also the bolt on the counter remove soft axes Make assembling in the reverse sequences of disassembling The main cable and guy cablemust be correctly passed through according to the concerned layout chart 18 9 CFMOTO Fuel sensor disassembly Remove the back goods frame nl 3P inzert Remove the maintenance cover F connector of gt 2 2 E ved fuel sensor sensor pressboard Remove the back connecting board 2 5 Remove the left protective board gt 2 5 Remove the right protective board gt 2 5 Remove the of 3P insert connector of fuel sensor Rotate out oil box sensor pressboard by counter clockwise with screwdriver take out the fuel sensor check Remove fuel sensor referring to the contents above connect 3P insert connector of fuel sensor make the ignition switch at ar oy Stirring the fuel sensor bobber with hands confirm the scale of fuel meter being consiste
136. seceaeaneswedvecisaccues 2 1 Left and right cover of front trunk 2 10 Seating mat maintenance COVET 2 2 Left and right air outlet grid 2 11 Trunk lock seat of seating mat 2 3 Front part of foot board 2 12 Real Shell vasre 2 4 Fender of rear wheel 2 12 Rear connecting board left and right guard Rear taillight Rear fender 2 13 Oat vasse GN 25 FE sur 2 14 Left right Heel of foot board 20 Milet uer 2 15 Od GLOTT e 2 7 Name of outer parts rrrrrnrrrrrrrrnnnnnr 2 16 Front fenderboard front faceboard 2 8 Maintenance information Notes during operation Cautions No smoking or naked fire is allowed at the operation site for the gasoline is combustible Not only flames but also electric sparks shall be avoided Besides the vapored gasoline is explosive please operate it in the place with nice ventilation The muffler should be assembled or disassembled after cooling In this chapter the assembly and disassembly operation for the outer parts the vent pipe and the muffler will be explained amp The pipelines the guy cables etc should pass through the correct place according to the wiring diagram of cables pipelines guy cables etc amp During assembling and disassembling the muffler the shim should be changed new amp After the muffler has been assembled check whether there is the phenom
137. sembly Disassemble the screws and then remove the cover plate of the oil pump Disassemble the internal rotor and external rotor of the oil pump Notes of Maintenance Please measure a lot of places and then take of the max measured value If each measured value of the oil pump exceeds the using limit the oil pump group should be renewed Main body Gap Measure the external diameter of the oil pump outside rotor and the internal hole diameter of the oil pump body with the vernier caliper separately and then calculate the different value Gap value between them Using limit 0 25mm 4 Lubricating system 4 3 CFMOTO Gap between external rotor and internal rotor of the oil pump Assemble the external rotor and the internal rotor of the oil pump with the pump body and then measure the Gap with the Gap gauge the Gap between the external rotor and the internal rotor Using limit 0 20mm Assemble the external rotor and the internal rotor of the oil pump with the pump body and then measure the Gap with the Gap gauge the Gap between the rotor and pump body Using limit 0 12mm Oil pump assembly 4 4 4 Lubricating system Notes Before assembly wash every parts and components clean with the clean coal oil Assemble the external rotor and the internal rotor of the oil pump with the pump body Assemble the cover plate of the oil pump and then screw the screws down by the sta
138. sepower not enough e Tooth shape strap worn and torn e Weakening of elastic force of Clutch spring e Centrifugal roller worn and torn e Stain or damage of slide surface of mobile main traction wheel disc 9 2 9 Continuously variable Transmission System amp Left Cover Left Cover Disassemble Notes Cares shall be taken not to damage combining surface Disassemble the left and right parts of footplate gt 2 6 Disassemble three inside six angle bolts and remove air intake cover combination Remove air intake filter core Remove air filter combination gt 5 10 Remove five fixed bolts on the left cover Left Cover Disassembly Remove the seal on the left cover Remove location pin filter element air y intake covey a combinatio Erection Make assembling in the reverse sequences of disassembling five fixed bolts on the left location pin cover 9 3 CFMOTO CF Moto Disassemble Branch Assembly of Transmission Left Cover Disassembly Fix transmission and clutch with special clamp and loosen fixed transmission nut and washer with sleeve wrench Special tool 1P52MI A 922 040000 Special clamp tooth shape strap Remove driver wheel disc and tooth shape strap Hold the inside of transmission mobile disc and remove it and the axle cover of driver wheel Transmission axle cover of main traction wheel disc transmission mobile dist Disassemble Remove axle cover of driver wheel f
139. sequences of disassembling Back turning indicator bulb Remove bolt 9 Remove taillight cover 1 Remove right back turning indicator shell 7 Replace right back turning indicator bulb 4 Bulb specification 12V 10W Replace left back turning indicator bulb 4 with the same method bulb specification 12V 10W Make assembling in the reverse sequences of disassembling 18 4 18 Light instrument switch Instrument lighting lamp Remove front cover set of handlebar gt 13 10 Remove back cover set of handlebar gt 13 11 Remove 4 self attack bolt I Remove the instrument Take out the lamp seat and replace bulb from the instrument Bulb specification 12V 1 7W lighting bulb 3 12V 3 4W Cindicating bulb 4 Notes The main cable and guy cablemust be correctly passed through according to the concerned layout chart gt 1 20 Make assembling in the reverse sequences of disassembling Headlamp headlamp set Remove the front cover set of handlebar C gt Le LNG Remove the 4P insert connector of headlamp Remove 3 bolts 1 remove the headlamp 4 connector of headlamp 18 5 CFMOTO Make assembling in the reverse sequences of disassembling Notes Pay attention not to destroy the main cable when installing After operation adjust the light axis of headlamp 3 19 Notes The main cable and guy cablemust be correctly passed through according to the concerned layout chart gt 1 20 Ignition s
140. sereeeserereserereeeeeeeeeeserecesereresesereseseseeees 10 1 Nes RS 10 2 EE ET RE EN 10 3 Arrangement diagram of bearingtssesseseeeeeeeeeeeeeereeesereeesesereeesereseseeeeees 10 4 Disassemble and assemble of bearings and oil seals of reduction box 10 4 Disassemble and assemble of bearings and oil seals of left box 10 6 ENE CUS OAs Gane SAS ER 10 7 Maintenance information Notes during operation The reduction box may be maintained under the engine carried state The main shaft shall be erected with special tools and the bearing cone is fixed and then inserted onto the main shaft Maintenance basis aia 0 137 At disassemble 0 151 Recommended machine oil for reduction box Grade SAE 15 W 40 SF Tightening torque reduction box machine oil check drain screw 22 N m 2 2 kgf m Bolts of reduction box 22 N m 2 2 kgf m Error diagnosis The engine is able to start but unable to run Damage of reduction system Ablation of reduction system No connection of belt type infinite transmission system Chapter 9 Abnormal sound during running Wearing out of gear ablation damage of tooth face Wearing out or loosing of bearing Oil leakage Excessive filled machine oil Wearing out or damage of oil seal Damage of sealing pad of reduction box 10 1 CFMOTO Disassemble of reduction box Drain lubricating oil from the reduction box gt 3 10 Remove following parts rear wheel gt 14 3
141. sis Lack of engine oil Consume the engine oil naturally Leak out of the engine The piston ring has been worn out or can not be assembled well The valve guide or the valve stem has been worn out The oil seal for the valve stem has been broken and damaged The cylinder the piston or the piston ring has been worn out 4 1 CFMOTO Engine oil smudge The engine oil has not been renewed in time The piston ring has been worn out Mixed with coolant white turbidness The water seal subassembly for the water pump has not been sealed well The shims for the cylinder have not been sealed well Oil pump Notes During assembling or disassembling the oil pump please pay attention to do not let the foreign inclusion into the interior of the engine Disassembly Disassemble the right side cap gt 11 2 Disassemble the rotor subassembly and the driven gear subassembly 11 3 Disassemble the isolation board subassembly B for oil pump elastic collar for shaft oil pump chain Disassemble the elastic collar for shaft Disassemble the chain wheel and the chain of the oil pump Check whether the chain wheel of the oil pump has been damaged or worn out Disassemble the isolation board A for oil pump Ses baad A 4 2 Disassemble the oil pump group and then remove the shaft of the oil pump Check whether the oil pump group has been damaged or worn out Disas
142. ssembly Plastic washer Clutch spring Clutch combination Mobile driven wheel disc groupware sleeve BEN m Skgf m Assemble the following parts Clutch assembly Sleeve Spring of the clutch Damping washer Plastic washer Move the driven turntable set 9 16 9 Continuously variable Transmission System amp Left Cover Assemble rightly between the hole clutch spring compress tool of driven turntable set and the protruding part of spring compress tool of the clutch Cautions Don t fix the spring compress tool of the clutch over the needed Clutch subassembig wring square Fix the spring compress tool of a T EEVUE Wrenin the clutch with table vice etc ut Install driven nut Tightly fix the special nut of the clutch with sleeve spanner at the specified wring square Torque 88N mC 9 Okgf m F Clutch subassembly Take down the sub assembly of the clutch with the spring l i L KE iw compress tool of the clutch Assembly of the clutch ly j i L r Install the clutch and tighten the nut at appointed wring square Torque 53N mC 5 3kgf m Install the driver turntable r 912 Install the left cover 9 3 9 17 10 reduction box Maintenance information PrrrTrrrrrrrrrerrrrrrrrerrrrrrrrrrr rrr rrr rr rrr rr rrr rr er rir rr re 10 1 Error diagnosistteseeeeeseeeeee
143. ssembly Disassemble the front trunk assembly 2 9 Open the left cover of front Trunk 16 by the key of ignition switch Disassemble the two split pins 14 and then disassemble the two rotor shafts of front trunk 13 Get off the left cover of front trunk 16 Assembly Make assembling in the reverse sequences of disassembling Right cover of front trunk Disassembly Disassemble the front trunk assembly 2 9 Open the right cover of front trunk 15 Disassemble the two split pins 14 and then disassemble the two rotor shafts of front trunk 13 Get off the right cover of front trunk 15 Assembly Make assembling in the reverse sequences of disassembling Left lock of front trunk Disassembly Open the left cover of front trunk by the key of ignition switch Screw off the nut 17 and then disassemble the right lock of front trunk 19 Assembly Make assembling in the reverse sequences of disassembling 2 10 2 Body and muffler GER 2 fT BE pa j ji a 3 ay a LP R Fi nny I i Ji iF Th l igr f Fi r am i ed p han f j fij h Mr ee 3 f NN Lear W A R TIR i mi ii i f rt en FX EN pe Je pe K Hika A oe MND el a F E w dl ut p A aa MR MV AG al S den ra 4 va x l E T Pee L g L pl i H Be j Vi zI it Emm iE ger Right lock of front trunk Disassembly Open the ri
144. st Check bumper for oil leakage aging bush rubber and other scathes Replace it if abnormality Erection Make assembling in the reverse sequences of disassembling and tighten bumper installing bolt with specified moment Erect fixed bolt above bumper Torque 55N m 5 6kef m Erect fixed bolt below bumper Torque 30N m 3 1kef m Rear Brake Rear Brake Caliper Disassemble Remove bolt 3 and bolt 4 Remove rear brake caliper combination bolt 1 nut 2 Test Check the brake caliper for crack and oil leakage from tightened locations and make replacement if bolt 3 holt 4 any Test brake piece wearing situation 3 6 Rear Braking Disc Test Check the slide surface of braking disc for worn and impaired place Replace braking disc in time when the thickness is less 3mm screws of brake disc ja 14 6 15 Battery Charging System Setup of charging system 15 1 Test of charging system 15 5 Maintenance information 15 2 Rectifier readjusted 0000 15 6 Error diagnosis ccccee ence cece ees 15 3 AC magneto inspection 05 15 8 PIN oaeun buns este E E TE 15 4 magneto commutate booster 15 1 CFMOTO Maintenance information Notes during operation Notice Generally no hydrogen is generated during charging But some gases could be produced on overcharging hence no fire should
145. subassembly of _ a ll ri o s uel Ko water entry cap da i an motor set radiator it subassembly __eleciric g trumpet 1 19 CFMOTO AP connector of flashlig hi cooling water pipe 4P connector of ignition switch lock fuse box connector of diagnosis line 1 20 soft axis set 1 Maintenance information side incline sensor ECU le oil pipe of hack brake ignition coil subassembly connector of fuel pump 1 21 CFMOTO AF connector of fuel oil sensor Fi li starting relay voltage rectifier 1 22 1 Maintenance information high pressure oil pipe throtile hody oil sprayer conirol valve thermostat crankcase venting hose air inlet pipe for idle speed suilet pipe water pipe for for idle speed for idle speed small circle 1 23 CFMOTO Pervasion prevention device for poisonous gas etc Waste gas reduction device This device makes the hazardous waste gas from the crankcase to be filtered by air cleaner and enter in the firebox through carburetor for burning thus prevents the air pollution caused by direct discharge of poisonous gas from the engine air cleaner shell air cleaner core vee fresh air cylinder cover exhaust gas 1 24 1 Maintenance information 1 25 2 Body and muffler Maintenance information 5 2a Front venting board front trunk 2 9 Error diagnosis vevedas
146. supplementary charging is to be performed after the charging the voltage between the terminals should not be measured in less than 30 minutes after the charging is completed If you test the voltage soon after the charging the voltage between the terminals will change quite much so that correct measurement cannot be obtained Charging of the battery Cautions Generally no hydrogen is generated during charging But some gases could be produced on overcharging hence no fire should be approaching during charging Remove the battery refer to the aforesaid contents 15 4 15 Battery Charging System Connect the positive lead of the charger to the positive terminal of the battery H lead Connect the negative lead of the charger to the Y mi P negative terminal of the battery B N 198 Charging current x time Standard 0 7A X 5 10 hours le 9 Fast charging 3 0A x 1 0 hour bi A Cautions EN 9 Prevent the battery liquid temperature from being ge higher than 45 C When the temperature is too high accumulator reduce the current lead Charging with fast speed may cut down the life span of the battery or even destroy it Generally not use fast charging except for urgency Inspection of the charging system Inspection of the charging status Remove the battery 15 4 and install a battery with full voltage Set the ignition switch to the he position After the engine is warmed up connect the v
147. sure the gap between the piston ring and piston ring slot with a feel gauge Service limit First run of ring 0 07mm i Second run of ring piston ring 0 07mm Levelly fix the piston ring into the lower portion of the cylinder with piston head Measure the piston ring end gap with a feel gauge Service limit First run of ring 0 45mm Second run of ring 0 45mm Oil ring flat ring 0 9mm Erection of piston Notes During erection of piston cares shall be taken not to damage the piston ring or the piston Keep the marked face upwards and fix the piston ring onto the piston Notes The first run of ring and second run of ring are for respective application During erection of piston ring keep the marked face upwards The openings of the piston ring shall be staggered at 120 interval After erection check the piston ring for piston pin piston free rotation in the piston ring slot 2 rd Coat engine oil on the small end of connecting rod piston pin and piston pin hole At erection of piston after the crank is fixed onto the engine piston the mark In shall be towards the air inlet side Erection of new retainer of piston pin First run of ring Second run of ring vi a retainer of piston pin 12 7 CFMOTO Notes The retainer of piston pin shall be Sealing pad of crank box P sitioning pin surely inserted into the slot The opening of retainer of piston pin shall be kept
148. t 13 12 Remove handlebar front guard combination gt 13 10 Remove handlebar rear guard combination gt 13 11 Remove bolt I and braking wire connector Remove left braking pump Remove the right braking pump with the same way Notes 1 Not suspend the braking pump on the brake hose 2 In order to prevent air from entering hydraulic system due to up side down the braking pump shall be kept at the mounting position and fixed on the handlebar Erection Make assembling in the reverse sequences of disassembling Notes Fix the braking pump with the UP on the mounting base mark on the mounting base upwards Align the limiting column of mounting base with the positioning hole of the handlebar and fix the bolt Handlebar Disassembly Remove the left and right rear view mirror 1 3 1 2 Remove handlebar front guard combination 13 10 Remove handlebar rear guard combination gt 1 3 1 1 Remove the left and right braking pump gt 13 13 Remove screw 3 and take out throttle base throttle cable and rotating handle of throttle left braking pump batt 1 right braking Pump ha Me Br ope 15 i is ene Cee _ pr 1 rir Fags m up mark orientation hole _ SCrew 3 Er ae os The acceleragraph seat T B um ag rn ag accelerograph line Remove nut 5 bolt 4 and take out handlebar 13 8 13 Front wheel braking Suspension and steering sys
149. t grease on the projected portion of counter gear retainer Coat grease on the meshed portion and slide portion of the counter gear Align the groove of the counter gear with the projected portion of the retainer and fix them Erection Erect the front wheel while aligning the braking disk with the brake base Notes Confirm the alignment of counter component and the stop of front fork Tighten the nut through the front axle front braking Torque 80 90N m 8 0 9 0kg l ij y go a ar link of S N Fix the link of speedometer onto the speedom er line counter component and tighten the small screw counter Torque 3 5 5N m 0 35 0 5kgf m component 13 Front wheel braking suspension and steering system ar thane 13 13 CFMOTO Assembling _ _ front tyre nut counter front wheel steel front wheel bottom axle cover valve mouth ae gt ai xa front braking disk seal ring i front wheel left axle at front axle Assemble front wheel bottom axle COVET press bearing tool Coat grease on the rotating portion of the new bearing and at first inert the left bearing Fix the front wheel bottom axle cover Insert the right bearing Special tools Press in tool handle A 519 922 070003 Press in tool sleeve 28x 30 519 922 070004 Pilot tools 12mm 519 922 070005 Notes Parallel insert the bearing 13 14 13 Front wheel braking Suspension and steer
150. t is through P_eturning signal lamp switch between orange color grev light blue T black broven light green a r T a v EE H ld kp i M Shorn witch CFMOTO set switch Check if the switch connector terminals are transmitted to each other e e It is normal when it is through between turning signal lamp switch Check if the switch connector terminals are transmitted to each other It is normal MEN it is through between switch for brake light switch connector terminals Remove the front cover set of handlebar T3710 Remove the connector of brake light switch check if the switch connector terminals are transmitted to each other Grasping the brake handlebar it is transmitted while undoing it it is not transmitted and then it is normal When the exam above is of abnormality you must replace the brake light switch Electric horn ere ner Electric hom bolt 1 check hy pi Remove the front panel gt 2 8 7 vid Remove the connector of electric horn fag gt When connecting the full charged 12V battery confirm the electric horn resounding When the exam above is of abnormality you must replace the electric horn 18 8 18 Light instrument switch Removal and Erection Pull out the connector of electric horn Remove the electric horn install the bolt 1 take out the electric horn Make assembling in the rever
151. ted torque and the torque is 2N m 0 2kgf m After assembly pretighten the cover plate of the oil pump put the shaft of the oil pump into the body and finally check whether the shaft of the oil pump can rotate freely Assembly After aligning the two mounting holes on the oil pump group with the two mounting holes on the right box all of them can be assembled or the construction bolts can not be screwed down Assemble and tighten the two bolts of the oil pump group and the isolation board A for the oil pump and then screw them down by the stated torque and the torque is 10N m 1 0kgf m isolation board 4 5 CFMOTO Assemble the chain wheel and the chain of the oil pump Notes They should be assembled to their positions Assemble the new elastic collar for shaft into the groove for the elastic collar of the oil pump shaft Check whether the baffle ring has been assembled to its place elastic collar for shaft After jointing the isolation board subassembly B for oil pump with the isolation board A for oil pump screw them down with the bolts Assemble the rotor subassembly and the driven gear subassembly 11 6 Assemble the right side cap 11 7 isolation hoard subassembly B 4 6 5 Oil supplying system air inlet system Maintenance information 5 1 Disassembly assembly of oil injector branch Error diagnosis snnnnnnnnnnnnnnnnnnneer
152. tem Rear view mirror Disassembly right rear wiew Pull out rear view mirror sleeve mirror counterclockwise loose the nut and take out the left rear view mirror through counterclockwise rotation rear view mirror sleeve adjust nut Pull out rear view mirror sleeve clockwise loose nut and take out the right rear view mirror through clockwise il rotation left rear wiew mirror Erection Make assembling in the reverse rear View mirror sleeve adjust nut a om sequences of disassembling 13 Front wheel braking suspension and steering system 13 9 CFMOTO Handlebar rear guard combination Disassembly selt taping screw 1 Remove handlebar front guard i combination 13 10 eae Screw 2 Remove self taping screw I and self taping screw 2 Remove screw 3 9P Remove connector and socket of speedometer ink combination Remove link combination and the connection of speedometer SP connector and socket of speedo Remove instrument and handlebar rear guard l a Remove 5 switch connector Erection Make assembling in the reverse sequences of disassembling SCreyy 3 13 10 13 Front wheel braking Suspension and steering system Erection Fix damper Fix sealing cap and sealing ring of the damper Tighten it with specified torque Torque 50N m 5 1kgf m Fix locking bolt 3 of damper and tighten it with specified torque Torque 40 50N m
153. ter entry cap ri ok ry i al BJ water cooling system g outfall of TG iT engine ii I infall of a y 3 engine radiator En VG on pr i a i ai fer j T vr PP AT pA AE Tr ja el EET gt SATTE ETT TIR JE abe rote HAs ET ps F ATT ret ef rey eae mer nape erry mjr prn t vi i ki PE fj pidii Vel T TA T n 11 EET pe ii er i ser TV F vod E E pa en rad dd ET ke FP FTTYPT 189 HATT i ii nM Ik p F m ee TE kg LE rn a 3 17 CFMOTO Waste gas recycle device Inspect whether there is deposit in the discharge pipe at the right bottom of air cleaner of waste gas oil spray separation If there is deposit disassemble the discharge plug and discharge the deposit in the pipe Install the discharge plug after discharge and fasten it with hoop 3 18 the crankcase venting hose Lighting device Adjustment of headlamp optic axis Tweak the optic axis adjustment bolt with cross screwdriver for adjusting the far and short reaching of light Therefore the operation requirements can be met 3 Test Adjustment headlamp assembly optic axis adjustment bolt 3 19 CFMOTO Others Lubricating grease status of each part of the vehicle frame Make each movable part of the vehicle act determine the status of lubricating grease Add the recommended lubricating grease or lubricating oil to the
154. tershatt Arrangement diagram of bearing Arrangement diagram of bearing output shaft ae fn wa output shaft A205 I I counter shaft bearing bearing 201 main shaft counter shaft bearing 0301 oil seal output w shaft bearing or Ps i VE KVASS EN EE ak r FN VA BE iz HV e Bains HA E Ax BY hr A THA _ At S o rz r EW Loy a amk countershaft bearing 0202 22x50x14 output shaft 6004 main shaft bearing bearing oil seal of main shaft Disassemble and assemble of bearings and oil seals of reduction box Remove output shaft s oil seal from reduction box oil seal output shaft 10 4 10 reduction box Remove output shaft bearing with special tools Make assemble with special tools in reversed sequences of disassemble Remove the main shaft bearing and countershaft bearing at reduction box side with same special bearing disassembling tools Special tools Bearing disassembling tools 1P52MI A 922 050000 060000 080000 With special tools vertically press the new main shaft bearing into the reduction box body till stopping by the step on bearing bottom hole with its mark faced upwards Erect the countershaft bearing at reduction box side with special tools and same method Coat grease on lip of the oil seal of new output shaft and
155. the coolant is drunk by accident try to vomit it immediately and receive treatment in specific hospital after gargling E The coolant shall be stored strictly in a safe place where children cannot touch The Maintenance of water pump can be carried out in the engine in car status The supplement of coolant shall be carried out through the assistant water box Generally the water entry cap shall not be opened unless the coolant is being supplemented or discharged when the cooling system is being disassembled amp The coolant shall not touch the coating surface or it will damage the coating surface In case it touches such surface it shall be washed by water immediately The measuring instrument for water entry cap commonly sold in markets shall be used for coolant leakage determination at each connection when the cooling system is disassembled Maintenance standard Capacity of coolant Thermostat Fastening torque Bolts of draining for water pump 8 N m 0 8 k g f m Impeller of water pump 10 N m 1 0 k g f m Left screw thread 6 1 CFMOTO Error diagnosis The water temperature rises too fast The water entry cap does not work well The pipeline of cooling system is mixed with air The water pump does not work well The thermostat does not work well the thermostat has not been turned on The pipeline of radiator or cooling water pipe is jammed Lack of coolant The water temperature does not rise or r
156. tion bar with up or down button to Test of fan relay and press OK Button for acknowledgment Press OK Button again to implement the test of target sample or Press ESC Button to cancel the test After activation the screen will show definite results and information confirmation Move the selection bar with up or down button to Test of idle valve and press OK Button for acknowledgment Press OK Button again to implement the test of target sample or Press ESC Button to cancel the test After activation the screen will show definite results and information confirmation Move the selection bar with up or down button to Check of ignition coil and press OK Button for acknowledgment Press OK Button again to implement the test of target sample or Press ESC Button to cancel the test After activation the screen will show definite results and information confirmation Move the selection bar with up or down button to Check of injector and press OK Button for acknowledgment Press OK Button again to implement the test of target sample or Press ESC Button to cancel the test After activation the screen will show definite results and information confirmation Press ESCB Button for exiting and return to diagnosis Move the selection bar with up or down button to engine working time and press OK Button for acknowledgment After pressing OK Button again the screen will show total working time of ECU and the last maintenance time Press ESCB Button for exiting and return
157. tion wheel disc and centrifugal roller e The maintenance of continuously variable transmission system could be operated during engine is working e Avoid damage any combining surface when assembling on and disassembling e Avoid odds and ends clay sands and other things entering into and remain in the inner of engine Maintenance standard Transmission Groupware internal diameter 24 007 24 028 24 07 mm Main traction of speed variator mobile disc mm wheel External diameter of axle 23 959 23 98 mm 23 92 mm cover of main traction wheel disc Groupware external diameter 19 95 20 05 mm 19 45 mm of centrifugal roller Width of tooth shape strap 2i f 2 mi Driven wheel Internal diameter of clutch 124 5 124 2 mm 125 mm felly disc Free length of clutch spring 144 146 mm External diameter of driven 33 95 33 975 mm 33 92 mm a nn Internal diameter of mobile 34 34 025 mm 34 06 mm Fr a S Tighten Torque Left cover bolt 10 Ne m C 1 0kgf m Speed variator nut 59N m C 6 0kgf m Clutch nut 53 Ne mC 5 3kgf m Special nut 88 Ne m C 9 0kgf m 9 1 CFMOTO Error Diagnosis Though engine can start it cannot run and work e Tooth shape strap worn and torn e Bevel board damaged e Clutch rubber worn and damaged e Clutch spring broken off Engine flameouts when starting and rear wheel rotates in idle speed e Clutch back spring broken off Cannot reach the highest speed and hor
158. to diagnosis Press ESCB Button for exiting and return to main menu 21 7 ECU ERRORS CODING TABLE ERROR FLASHING ERRORS TYPE NUMBER NUMBER DIAGNOSIS ERROR TPS LOW I S F TPS NOT CONNECTED WRONG TPS CALIBRATION ERROR TPS HIGH 2 WIRING FAULTY Wire that connected PIN20 ECU to PIN2 TPS SENSOR is at WIRING FAULTY Short Circuit between the two wires of the TH2O SENSOR Wire connect PINI9 ECU to PIN1 TH2O SENSOR Wire 2 connect PIN17 ECU ERROR _TEMP H O LOW 3 3 S F to PIN2 THO SENSOR TH gt 0O SENSOR FAULTY voltage gt 5V TPS FAULTY TH gt O SENSOR NOT CONNECTED gt Before to execute the ACTIVE DIAGNOSIS FAN TEST to solve the problem at the TH2O SENSOR error 4 4 4 S F WIRING FAULTY Wire that connected PIN 19 ECU to PIN TH2O SENSOR is at voltage gt 5V TH gt O SENSOR FAULTY WIRING FAULTY Short Circuit between the two wires of the TAIR SENSOR Wire I connect PINI8 ECU to PINI TAIR SENSOR Wire 2 connect PINI7 ECU to PIN2 TAIR SENSOR TAIR SENSOR FAULTY TAIR SENSOR NOT CONNECTED ERROR TEMP AIR HIGH 6SF WIRING FAULTY Wire that connected PIN18 ECU to PIN TAIR SENSOR is at ERROR TEMP H gt O HIGH ERROR TEMP AIR LOW voltage gt 5V TAIR SENSOR FAULTY ERROR PRES AIR LOW 7 ERROR PRES Am MOH s ssk Je BUmUn ERRORVB HIGH 10 TLRs VOLTAGE REGULATOR EAvLTY O OOOO O e VOLTAGE REGULATOR FAULTY WIRING FAULTY Short Circuit between the two wires of the INJECTOR Wire I connect PIN7 ECU
159. to tight with 4 acorn nuts and shims acorn nuts and shims Screw the acorn nuts to tight for 2 3 times T according to the specific torque Torque 30N m 3 0kgf m Screw the bolts for cylinder body to tight according to the specific torque Torque 10N m 1 0kgf m Screw the bolts for cylinder cover to tight according to the specific torque Torque 10N m 1 0kgf m 8 20 8 cylinder air distribution system Install the timing chain onto the timing chain wheel Install the chain wheel onto the camshaft the upper reticle of chain wheel shall be equal to the upper plan of the cylinder cover Install the bolts for fastening chain wheel Torque 9N m 0 9kgf m Notes Confirm that the upper reticle of chain wheel is equal to the upper plan of cylinder cover before adjusting the valve gap and the groove opening on the camshaft journal is upward Press down the block on the tensioner by hands and retreat the tensioning rack of tensioner into the tensioner body Install the bolts for tensioner and tighten them Torque 10N m 1 0kgf m holis for tensioner spring seat Pi F Put in the tensioner spring washer and screw the bolts for tensioner spring seat to tight Torque 10N m 1 0kgf m holts for tensioner ubassembly of oil injector seat Install the shim of oil injector seat subassembly of oil injector seat and fasten with bolts 8 21 CFMOTO Install the thermostat g
160. ts of the engine draw the hanger shaft and remove the rear shock absorber hanger 4 Disassemble the rear fork 14 4 5 Disassemble the rear wheel 14 3 6 Disassemble the spring of bolis main support disassemble the main support construction bolts and the bush then dr remove the main support Installation of engine Notes The guy cables cables shall pass through the proper positions according to the wiring diagram of cables pipes and guy cables Chapter if 01 Mainbracket springsof boli hush main bracket Erect the main support onto the engine install the bush bolts and tighten to the specific torque Torque 26 Nem 2 7kgf m Hang the spring of main support Notes The outer surfaces of left and right bushes of main support shall be applied with lubricating grease 7 4 7 Disassembly and assembly of engine Install the engine to the frame according to the following sequence 1 Install the rear wheel to the engine 2 Install the rear fork to the engine install the nuts of back shaft and rear fork construction bolts and tighten them to the specific torque 3 Install the engine hanger to the engine and screw the hanger shaft nut 4 Install the engine hanger construction bolts and engine hanger assembling bush hoist the engine to the frame 5 Install the back shock absorber S installation bolt of hanger assembling bush r rear shock ahsorber v hang
161. ue is out of the specified range replace with a new stator coil m Check whether the insulation is good between the stator coil and the stator center Ifthe resistance is under 1M Q replace with a new stator coil With multi meter switched to 1X10 Q Resistance of the magneto coil 0 2 0 5 Q yellow yellow With multi meter switched to 1X100K Q Insulating resistance oo 2 yellow ground Performance of the magneto under no load condition Start the engine and keep at a running speed of 5000r min Use a multi meter to measure the voltage between the three output wires of the magneto stator Ifthe measured voltage is under the specified value use a new magneto With multi meter switched to AC scale Voltage value of the magneto under no load condition gt 140V AC at 5000r min 15 9 CFMOTO taillight Rectifier requiator ECT retrofire lock a jump start relay tusze box LE cable 15 10 16 Ignition System Maintenance Informationl Coc ccc ccc ccc TESTE 6 1 Trigger coill Cec ccc ccc ccc TE 6 6 Error diagnosis PETE 16 3 Ignition coill PET 6 6 Ignition system examination sseeeeeeeeeeeeeeee 16 4 Ignition System configurationl 6 7 Maintenance Information Notes during operation Notes Exhaust contains toxic ingredients Do not run the engine in closed places or places with poor ventilation for a long time e Check ignition system by order according to the contents in the error dia
162. ustment Install the spark plug back to the spark plug hole on the cylinder cover Notes In order to prevent damage on thread of the spark lr plug hole when install the spark plug firstly a Hi ay revolve it into the cylinder cover manually and then fasten it by spark plug spanner If the spark plug is new fasten it further by 1 4 ASS revolution when the sealing gasket contacts the combination surface Old spark plug shall be fastened according to specific torque Torque 12N m 1 2kgf m Install the spark plug cap Hr p I i ry i pm mid a ae m E mp nid Lubricating device Test of engine oil Run the engine for warm up Turn off the engine disassemble the oil level gauge clean the engine oil attached on the oil level gauge Put the motorcycle on flat ground make it vertical When the engine has been turned off for 2 3 minutes insert the oil level gauge but do not revolve it inspect the engine oil volume If the oil level is between the upper and lower limits it means the oil is sufficient When the oil reduces to close to the lower limit the engine oil shall be supplemented to the upper limit Recommended engine oil SAE 10W 40 20W 50 are exclusively for the four stroke motorcycle Selection shall drain bolt be made within the following range if substitute is preferable amp API classification SE or SF grade engine oil Notes The viscosity of engine
163. wire that connect PIN3 ECU to PIN85 MAIN RELAY and GND MAIN REALY FAULTY WIRING FAULTY Short Circuit between the wire that connect PIN10 ECU to 1 L F 9S F PIN85 START RELAY and BATTERY START RELAY FAULTY 8 ERROR MAIN RELAY O C ERROR ENABLE START S C 9 LAMBDA SENSOR NOT CONNECTED WIRING FAULTY Short Circuit between the two wires of the LAMBDA SENSOR Wire 1 connect PIN12 ECU to PINT LAMBDA SENSOR Wire 2 connect PIN11 ECU to PIN2 LAMBDA SENSOR ERROR_LAMBDA 2 ugk SFE LAMBDA SENSOR FAULTY DIAGNOSIS ONLY WITH ENGINE ON RPM gt ZERO 9 IF VEHICLE IS IN IDLE CONDITION TH20 gt 35 C MANAGEMENT LAMBDA ON gt ERROR 23 IS DETECTED FROM THE ECU AFTER ABOUT 3 MINUTS ROLL OVER SENSOR NOT CONNECTED WIRING FAULTY wire that connected PINI3 ECU to PINT ROLL OVER SENSOR is at voltage gt 5V ROLL OVER SENSOR FAULTY ROLL OVER SENSOR IN ON CONDITION gt ERROR 25 CAUSE ERROR 32 ONLY WITH ENGINE ON 2 L F 5 S F WIRING FAULTY Short Circuit between the wire that connect PIN13 ECU to PIN ROLL OVER SENSOR and GND ROLL OVER SENSOR FAULTY 2 L F 8 S F 2 L F 9 S F PL ERROR SAFETY SWITCH 0 4 2L F 45S F 25 ERROR SAFETY SWITCH 1 28 29 ERROR TEMP ECU HIGH ERROR TEMP ECU LOW PICK UP SENSOR NOT CONNECTED WIRING FAULTY Short Circuit between the wire that connect PINI5 ECU to PIN1 PICK UP SENSOR and BATTERY PICK UP SENOR FAULTY ERROR_PICK UP_O C DIAGNOSIS ONLY WITH ENGIN
164. witch lock Removal and Erection Remove the front panel set gt 2 9 remove the 2 boltsl remove the connector of 4P insert of ignition switch lock Take out the ignition switch lock Make assembling in the reverse sequences of disassembling Check Check if the switch connector i f 4P insert terminals are transmitted to each connectar ot gt other headlamp e e It is normal when it is through between Black Black green white Commies mL Ea 18 6 18 Light instrument switch 5 switches removal Remove the front cover set of handlebar gt 13 10 Remove the back cover set of handlebar messer LL switch set switch Remove all switches de awite Erection Install it at the reverse order of removal Pay attention to the switch corresponding with connector Starting switch Check if the switch connector terminals are transmitted to each other e e It is normal when it is through between Yellow red Green yellow set swich i light changing switch whitefalue brownublue MR e Check if the switch connector brown brow rule a terminals are transmitted to each other It is normal when it is through greenene re between White blue Black brown Starting switch PASS ING D ee horn switch Check if the switch connector terminals are transmitted to each other It is normal when i
165. x the following parts clutch branch unit gt 9 19 rear wheel gt 14 3 Fill lubricating oil of reduction box 3 10 CFMOTO Assemble diagram of reduction box bearing 6205 LLU Sera countersha 23 mf bearing 6301 N sealing pad of reduction box 10 8 11 Right side cover magneto and water pump Maintenance information 11 1 Erection of waterpump ttettereeree 11 4 Disassemble of right side cover 11 2 Erection of right side cover s s s 11 5 Disassemble of flywheel combination 11 2 Erection of stator combination 11 6 Disassemble of driven gear component 11 3 Erection of driven gear component 11 6 Stator combination er eesi erin riesis 11 3 Erection of right side cover sseeeeeeeeeeeeeee 11 7 Maintenance information Notes during operation Notes The right side cover stator combination and flywheel combination shall be assembled and disassembled under cold engine state The right side cover may be maintained under the engine carried state The AC magneto may be maintained under the engine carried state AC magneto shall be checked as per Chapter 15 Tightening torque Locking nut of flywheel combination 59 N m 6 0kgf m Bolt of right side cover 12 N m 1 2kgf m Bolt of water pump cover 12 N m 1 2kgf m Error diagnosis Error diagnosis of magneto gt Chapter 15 11 1 CF

CF150T-5I(E-charm EFI) Maintenance Manual

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