Tomberlin CrossFire 150 Service Manual

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CrossFire 150

Service Manual

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Page 1 CrossFire 150 Service Manual...
Page 2: Table Of Contents
TABLE OF CONTENTS Model Identiﬁ cation..............................1 Starting the Engine..............................1 Break in Procedure..............................2 Checks and Services..............................3 Engine Oil................................4 Final Gear Oil................................5 Spark Plug................................5 Battery..................................6 Air Filter.................................10 Torque Chart................................11 Valve Clearence Inspection............................12 Valve Mechanism Inspection and Servicing......................13 Cylinder Head Removal/Installation........................13 Camshaft................................14 Cam Chain................................17 Rocker Arm and Rocker Shaft..........................18 Valve and Valve Spring............................18 Cylinder..................................23...
Page 3 Transmission................................33 CVT Mechanism..............................37 Drive Belt Pulley..............................38 Clutch..................................39 Driven Belt Pulley..............................40 Transmission Belt..............................42 Carburetor................................42 Chain and Axle...............................48 Rear Axle Removal..............................48 Rear Sprocket Removal............................49 Axle Bearing Removal............................49 Swingarm................................49 Charging System..............................50 Ignition System..............................54 Electrical Starting Mechanism..........................58 Armature Inspection...............................59 Carbon Brush Inspection............................59 Starter Motor Installation............................59 Starter Clutch.................................60 Reduction Gear Inspection.............................60 Engaging Mechanism.............................61...
Page 4 Brake Bleeding Fluid Change..........................66 Rear Brake Disk Removal............................66 Front End Adjustments............................67 Adjusting the Shocks.............................68 Wiring Diagram..............................69 Notes..................................70...
Page 5: Model Identiﬁ Cation
MODEL IDENTIFICATION VIN NUMBER The vehicle identiﬁ cation number is stamped on a plate welded to the frame behind the driver’s seat. ENGINE NUMBER The engine number is stamped in the block below the left hand engine cover (directly in front of the oil drain plug).
Page 6: Break In Procedure
BREAK-IN PROCEDURE • 0-10 hours of operation Do Not accelerate past half (1/2) throttle for long periods of time. Do Not operate the machine at one continuous throttle. Vary the throttle during operation. Allow the engine to cool for ten minutes after each hour of use. •...
Page 7: Checks And Services
PERIODICAL CHECK AND SERVICES The maintenance intervals in the following table are based upon average riding conditions. Riding in unusually dusty areas require more frequent servicing. Items Initial Daily Monthly Quarterly Yearly Service Tire Pressure Inspect Inspect Chassis Inspect Inspect Fasteners Inspect Inspect...
Page 8: Engine Oil
MAINTENANCE AND TUNE-UP PROCEDURE This section describes the servicing procedures for each item in the Periodic Maintenance requirements. ENGINE OIL API Classiﬁ cation SF – SG (SAE 15W – 40) It is important to inspect the engine oil before each period of operation. The engine oil should be changed every 50 hours.
Page 9: Final Gear Oil
• Shut off engine and check the oil level with dipstick, do NOT screw the dipstick in when taking this reading, doing so may cause a false reading. Add oil if necessary to reach safe amount; Do Not overﬁ ll. FINAL GEAR OIL Inspect ﬁ...
Page 10 FILLING THE BATTERY The following procedure should only be performed by an adult utilizing extreme caution. While attempting this procedure, individuals should wear rubber gloves, eye protection, and have water available in case the electrolyte solution comes into contact with skin or eyes. Children should not attempt to complete this procedure, and should NOT be allowed near the area when attempting to ﬁ...
Page 11 - The battery needs to sit for Thirty (30) minutes before charging. Letting the battery sit will allow the electrolyte to penetrate the plates and provide a longer battery life as well as better battery performance. Place the cap strip loosely over the holes in the top of the battery while allowing it to sit. - After sitting for thirty (30) minutes, the battery is ready for charging.
Page 12: Battery
WARNING: Do NOT open sealed caps to add water to the battery. - Batteries contain sulfuric acid. Eye protection should ALWAYS be used when working around battery acid. - While attaching the red and black cables for charging, be sure that the charger is not plugged into the outlet. - Charge the battery in a well ventilated area out of reach of children and animals.
Page 13 BATTERY CHARGING Note: Use a battery charger with 2 amps or less. Charging Rate: 0.7 A x 5 ~ 10 h (Charge for 5 – 10 hours @ 0.7 Amps) REMOVING THE BATTERY AND CHECKING VOLTAGE: • Remove the wide, black battery cover strap and the gray battery cover. •...
Page 14: Air Filter
AIR FILTER Clean at least every 3 months. More often if operating in dusty conditions. If the air ﬁ lter is clogged with dust or debris, the performance of the kart will be affected and if left un-serviced, engine damage can occur. Follow the procedure below to service the air box: •...
Page 15: Torque Chart
NUTS AND BOLTS Nuts and bolts should be checked to ensure that they are tight before every ride.. Because frequent operation can cause the kart’s nuts and bolts to loosen, they should be checked and tightened often. When tightening nuts/bolts, please reference the chart below. TIGHTENING TORQUE CHART Tables FASTENER...
Page 16: Valve Clearence Inspection
VALVE CLEARANCE INSPECTION Note: Inspection and adjustment of the valves must be done when the engine is cold. Suggested temperature is below 95° F / 35° C. • Remove the cylinder head cover. Take care not to damage the O-ring gasket. If damaged, the gasket must be replaced with a new gasket.
Page 17: Valve Mechanism Inspection And Servicing
VALVE MECHANISM INSPECTION AND SERVICING The diagram below depicts the common valve train of a four-stroke engine. It consists of an over-head valve train with the intake port, exhaust port, and cam shaft located in the cylinder head. The valves are located in the top of the combustion chamber.
Page 18: Camshaft
CYLINDER HEAD INSTALLATION • Install new gasket and dowel pins onto cylinder. • Install cam chain guide. • Install cylinder head. • Align the “T” mark on the ﬂ ywheel with the index mark on the engine case by turning the ﬂ ywheel. •...
Page 19 • Turn the ﬂ ywheel counter-clockwise to make the “T” mark on the ﬂ ywheel align with the mark on the crank- case. • When the hole on the cam chain sprocket is pointing upwards and cam lobes are pointing down, it is at top dead center position.
Page 20 After installing, adjust the valve clearance. • Torque the cylinder head nuts and bolts. Bolts: 95 in. / lbs. Nuts: 16 ft. / lbs. • Insert small straight screwdriver and turn the cam chain tensioner bolt counter-clockwise and release the lock. Do NOT tighten.
Page 21: Cam Chain
CAM CHAIN TENSIONER The cam chain tensioner prevents the cam chain from being vibrated off when the engine is running. It is a common feature found in most four-stroke engines. Note: the cam chain tensioner is a spring loaded device and should not need to be adjusted unless you are re- moving and installing camshaft.
Page 22: Rocker Arm And Rockershaft
ROCKER ARM AND ROCKERSHAFT ROCKER ARM AND ROCKERSHAFT REMOVAL • Remove the camshaft holder. • Pull rockershafts out by inserting a 5 mm bolt in the rockershaft. • Remove rockerarm ROCKER ARM AND ROCKERSHAFT INSPECTION Inspect for damage on the rocker arm and rockershaft and check if the oil hole is clogged. •...
Page 23 • Remove the upper spring retainer, valve spring, lower spring seat, and valve stem oil seal. Note: remove the parts and place them aside in order to aid reassembly. • Remove the valve from the other side. Keep the intake valve and exhaust valve parts separate. VALVE AND VALVE SPRING INSPECTION •...
Page 24 CLEANING THE VALVE GUIDE: • Remove the valve and valve springs • Use a valve guide reamer to clean up the carbon accumulation. Note: only turn right when using the reamer and do not push in or out directly with the reamer. MEASURING THE VALVE GUIDE INNER DIAMETER: Service limit 5.03 mm 0.198 in.
Page 25 WARNING When using the reamer, cutting oil must be used. Only turn right, do not push in or out directly. VALVE SEAT The relative position between the valve seat and the working surface of the valve is very important for attaining a proper valve seal.
Page 26 VALVE AND VALVE SEAT SEAL INSPECTION The seal between the valve seat and valve can be inspected by coating the seat and valve seating surface with layout ﬂ uid or a magic marker. • Put valve in seat; spin valve back and forth with very light pressure. •...
Page 27: Cylinder
ENGINE COMPONENTS INSPECTION AND SERVICING INSPECTION AND SERVICING: ENGINE COMPONENTS AND CRANK CONNECTING ROD MECHANISM CYLINDER CYLINDER REMOVAL: • Remove cylinder head (See Cylinder Head Removal under Valve Mechanism Inspection). • Remove cylinder • Clean gasket surface CYLINDER BORE INSPECTION: •...
Page 28: Piston
PISTON SET PISTON PIN INSPECTION AND SERVICING: • Insert the piston pin horizontally into the piston pin hole, and inspect the clearance between piston and piston pin. Service limit 0.02 mm 0.001 in. MEASURING THE EXTERNAL DIAMETER OF PISTON PIN: •...
Page 29 CONNECTING ROD END INSPECTION: • Measure the inner diameter of the connecting rod at the small end. Service limit 15.06mm 0.593 in. • If the connecting rod is damaged beyond the service limit, the crankshaft should be replaced. PISTON RING INSTALLATION GAP: •...
Page 30: Crankcase And Crankshaft Removal
CRANK CONNECTING ROD SET CRANKCASE AND CRANKSHAFT REMOVAL: In order to remove the crankcase and crankshaft, one must ﬁ rst: Remove the engine. Remove the covers for the cylinder head, clutch, and fan. Remove the cylinder shroud. Remove the cam holder Remove the cam chain tensioner bolt and cam chain tensioner.
Page 31: Crankshaft Inspection
CRANKSHAFT INSPECTION CONNECTING ROD SIDE CLEARANCE: • Measure connecting rod big end side clearance with a feeler gauge. • Compare to speciﬁ cations. • If the clearance is greater than service limit the crankshaft assembly must be replaced. Service limit 0.55 mm 0.022 in.
Page 32: Crankshaft And Crankcase Installation
CRANKSHAFT AND CRANKCASE INSTALLATION • Install the crankcase oil seal. • Place the cam chain into the left crankcase. • Put the crankshaft into the left crankcase. Do not allow the cam chain to damage the oil seal. • Mount the new dowel pins and gasket on the left crankcase -- joining the right crankcase and the left crank- case together.
Page 33: Lubrication System
LUBRICATION SYSTEM INSPECTION AND SERVICING Explanation of lubrication system process: After the lubrication oil crosses the ﬁ lter screen, it is pumped by the oil pump. Some of the oil goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod. Another amount of oil goes through some oil passages, such as the shaft neck of the camshaft, and splashes on the cam rockershaft and cam chain.
Page 34: Oil System
OIL SYSTEM INSPECTION AND REPLACEMENT OIL PUMP REMOVAL - Drain Oil • Remove the ﬂ y wheel from the magneto. • Remove the stator coil and trigger winding. • Remove the right crankcase cover bolts and remove the right crankcase cover. •...
Page 35 Note: when assembling, align the unﬁ lled corner of the oil pump shaft with the corner of the inner rotator, and then mount. • Mount the dowel pin. • Once the oil pump plate is aligned with the dowel pin -- mount it. •...
Page 37: Transmission
REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING The structure of the rear transmission mechanism is shown in the picture on the previous page. 1. Cover Transmission 2. Gasket Transmission Cover 3. Radial Ball Bearing 4. Radial Ball Bearing 5. Radial Ball Bearing 6.
Page 38 • To check level, remove level screw on the left rear engine case. If gear oil does not come out of hole, add until it does. • To drain gear oil, remove the drain plug at the rear bottom of the engine case. It is recommended to warm the engine for 10 minutes or more before draining ﬁ...
Page 39 • Remove the ﬁ nal gear shaft bearing. • Remove the sub shaft bearing. • Drive in the new ﬁ nal gear shaft and bearing. Note: When driving in the ﬁ nal gear shaft bearing, keep the bearing parallel. Do the same and keep the bearing parallel when installing the sub shaft bearing and the driven pulley shaft bearing.
Page 40 • Mount the drive pulley, the transmission belt, and the left crankcase cover. • Add 80W-90 gear oil in the transmission case until it gets to the proper level. Gear Oil Amount: 115 cc ml 4 oz.
Page 41: Cvt Mechanism
BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING The belt driven CVT mechanism consists of a notched driven belt and two belt pulleys (the drive belt pulley and the driven belt pulley) whose diameter can be adjusted. The driving belt pulley is mounted on the engine crankshaft, and the driven belt pulley connects with the rear driven mechanism.
Page 42: Drive Belt Pulley
The clutch shown in the picture below is the automatic dry centrifugal weight clutch. DRIVE BELT PULLEY DRIVE BELT PULLEY REMOVAL • Remove the left crankcase airpipe lock bolt. • Remove the kick starter and remove the left crankcase ﬁ xing bolt. •...
Page 43: Clutch
• Put the drive plate hub into the drive plate. • Install the movable drive plate on the crankshaft. • Enlarge the driven plate belt groove, and mount on the driven belt. Mount the other end of the driven belt on the drive plate hub.
Page 44: Driven Belt Pulley
• Remove the clutch shoes and the spring. CLUTCH INSTALLATION • Mount the clutch damper rubber on the drive plate pin. • Mount the new clutch shoes set and spring on the drive plate. • Install the connecting piece, the circlip, and the bottom plate. •...
Page 45 DRIVEN PLATE BEARING REPLACEMENT Note: If the driven plate needle bearing and the ball bearing are loose, damaged, or have some unusual sound, they should be replaced. • Remove the needle bearing from the driven plate. Note: The removed bearing cannot be reused. •...
Page 46: Transmission Belt
TRANSMISSION BELT TRANSMISSION BELT INSPECTION • Remove the left crankcase cover. • Inspect if the transmission belt is worn. • Measure the width of the belt. • Replace the belt if its width is less than the service limit below: Service limit 19.0 mm 0.748 in.
Page 47 • Remove the two screws holding choke to body of carburetor and inspect seal. • Remove the two screws holding vacuum pod to body. • Remove spring and pod; inspect pod for tares or holes. • Remove air adjusting screw, spring, washer and o-ring. •...
Page 48 CARBURETOR CLEANING WARNING Always wear eye protection when working with cleaning agents. • Clean the carburetor body, jets, and all the air passages in body with carburetor cleaner. Note: It may be necessary to soak parts in a high caustic carburetor cleaner. Do not soak rubber parts.
Page 49 • Install slide assembly making sure that jet needle slides into needle jet. Also ensure that tab on diaphragm is inserted correctly on body of carburetor. • Install diaphragm spring, top, and two screws. • Lubricate O-ring on air mixture screw with grease and install in carburetor. •...
Page 50 • When plunger is covering hole completely the fuel ﬂ ow is shut off. ENRICHMENT TESTING • Remove the two screws and clamp that secure the solenoid to mount. • Pull solenoid out of mount. • Measure the distance from the base of solenoid to sealing edge of plunger. •...
Page 51 CARBURETOR TROUBLESHOOTING RICH MIXTURE Symptoms: Fouls spark plug, black exhaust smoke, rough idle, skipping, poor performance, bog, backﬁ re. Possible causes: • Air ﬁ lter dirty or plugged • Air intake restricted • Choke plunger stuck • Float level to high •...
Page 52: Chain And Axle
CHAIN AND AXLE The belt driven CVT mechanism consists of a notched driven belt and two belt pulleys (the drive belt pulley and the driven belt pulley) whose diameter can be adjusted. The driving belt pulley is mounted on the engine crank- shaft, and the driven belt pulley connects with the rear driven mechanism.
Page 53: Rear Sprocket Removal
• Remove axle and bearing carriers as a unit. REAR SPROCKET REMOVAL • Remove the rear axle. • Remove four bolts holding sprocket to axle • Install new sprocket and reattach four bolts • Torque to 20 ft. / lbs. AXLE BEARING REMOVAL AND INSPECTION •...
Page 54: Charging System
CHARGING SYSTEM BATTERY The battery is an important component of the electrical system. This battery used on the vehicle is a mainte- nance-free battery. For long period of storage, the battery will discharge by itself, so it should be charged every 3 months.
Page 55 BATTERY INSTALLATION Apply grease on battery terminals to prevent corrosion. Connect the positive cable ﬁ rst, then connect the negative cable. BATTERY VOLTAGE INSPECTION Disconnect the cable from the battery terminals. First the negative pole, then the positive. Measure the voltage between the two poles of the battery: Battery Service Limit: Fully charged 12.8 V...
Page 56 GENERATOR ASSEMBLY COMPONENTS 1. Cooling fan 2. Generator assembly 3. Flywheel comp. 4. Stator comp. 5. Washer 6. Bolt 7. Nut 8. Bolt 9. Bolt STATOR INSPECTION Note: Inspection work can be done on the engine without removing the generator. •...
Page 57 GENERATOR REMOVAL AND INSPECTION GENERATOR REMOVAL •Remove the cooling fan cover bolt and screw. • Remove the cooling fan cover. • Remove the cooling fan bolt and remove the cooling fan. • Hold the ﬂ ywheel and remove the ﬂ ywheel nut. •...
Page 58: Ignition System
IGNITION SYSTEM INSPECTION AND SERVICING The circuit working principle is shown in the picture below. IGNITION TIME INSPECTION Note: The CDI ignition system has already been adjusted in the factory, so there is no need to readjust it. If inspecting ignition function is necessary, take followed steps to inspect ignition timing. •...
Page 59 CDI COMPONENT The CDI component inspection is divided into two steps: 1. Inspect every wiring, winding or coil connected with CDI 2. Inspect the CDI component. • Remove the CDI component. • Inspect the connector. • Inspect the conduction condition and the resistance value of the main switch, the ignition charging coil, the trigger winding, and the ignition coil.
Page 60 IGNITION COIL INSTALLATION •Reverse the removal procedure for installation. Note: When installing, connect the blue wire from the CDI to the green terminal of the ignition coil, and con- nect the black wire to the second terminal. PRIMARY IGNITION COIL INSPECTION Standard Value 0.1 ~ 1.0 Ω...
Page 61 REGULATOR RECTIFIER MAIN WIRING – SUB ELECTRIC CIRCUIT CONDITION INSPECTION • Remove the 4-pin connector of the regulate rectiﬁ er. • Measure the conducting status between the main wiring terminals according to the previous wiring diagram. To check the wiring harness: Positive lead on battery + (red wire) –...
Page 62: Electrical Starting Mechanism
ELECTRICAL STARTING MECHANISM CONTROLING MECHANISM STARTER RELAY INSPECTION Turn the main switch to the “ON” position, and press the starting motor button, and listen for a “click” sound. If there is, it is normal; if there isn’t, follow the procedures below: Inspect if the brake switch is conductive.
Page 63: Armature Inspection
• Roll up the rubber, water-resistant, cover and remove the starter motor joint. • Remove the motor case bolt, the carbon brush seat, and the motor case. ARMATURE INSPECTION Inspect the armature surface for uneven wear, damage, or a change in color caused by high temperatures. Note: Do not use sandpaper to grind.
Page 64: Starter Clutch
• Put the carbon brush into the bracket, and then install the carbon brush base. Note: Do not damage the contact area of the carbon brush and the armature. While installing, do not damage the lip of the dust seal. •...
Page 65: Engaging Mechanism
ENGAGING MECHANISM STARTING CLUTCH REMOVAL • Remove fan. • Remove ﬂ ywheel. • Remove stator plate assembly. • Remove the right crankcase cover. • Remove the left crankcase cover. • Remove the starting clutch nut. Note: The nut is a left-handed thread. •...
Page 66: Brakes
• Measure the inner diameter of the ﬂ ange clutch. It should be replaced when the diameter is more than the service limit. Service limit 27.94mm 1.100 in. STARTING CLUTCH INSTALLATION • Install the spring, the roller, and the top pin on the body of the clutch. •...
Page 67: Rear Brake Inspection
REAR BRAKE INSPECTION • Remove 2 bolts holding caliper to frame. • Remove both outer plugs. • Remove brake pad pins and remove brake pads. • Check thickness of pads and replace if out of service limit. Service Limit Measuring thickness without backing plate 2.0 mm 0.080 in.
Page 68 • Remove caliper from mounting plate and inspect pins for bending, rust, or corrosion. • Lubricate brake mounting pins with grease and reinstall caliper on mounting plate. Check for proper move- ment of caliper on pins. • Make sure to not get grease or oil on brake pads or rotor. •...
Page 69: Front Brake Inspection
• Check master cylinder, break lines, and calipers for signs of leaking. • Check condition of brake rotor and thickness. Service Limit 3.0 mm 0.120 in. FRONT BRAKE INSPECTION The process for inspecting the front brakes is the same as the process for inspecting the rear brake. NOTE: If inspecting the front brakes, be sure to inspect the brakes on each side of the kart.
Page 70: Brake Bleeding Fluid Change
BRAKE BLEEDING FLUID CHANGE This procedure should be used to change the ﬂ uid or bleed the brakes. • Remove reservoir cap and diaphragm. Clean and inspect. • Drain old ﬂ uid from reservoir. Add brake ﬂ uid to upper mark on reservoir. •...
Page 71: Front End Adjustments
FRONT END ADJUSTMENTS CASTER - (-1 Inch) CAMBER - (-1 Inch) - The cart should have (1 Inch) of tow after the front tires have been centered.
Page 72: Adjusting The Shocks
ADJUSTING THE SHOCKS - The front and rear shocks each have ﬁ ve adjustable positions. - The default position has been set by the manufacturer and is located in the middle. - The tension of the shock will change depending on the way that it is rotated. - To increase the tension, rotate to the right, to decrease the tension, rotate to the left.
Page 73: Wiring Diagram
WIRING DIAGRAM...
Page 74: Notes
Notes...
Page 75 Notes...
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