Page 1 All manuals and user guides at all-guides.com CF150T-6A Service Manual CF125T-22A WWW.CFMOTO.COM...
Page 2 All manuals and user guides at all-guides.com WWW.CFMOTO.COM...
Page 3 All manuals and user guides at all-guides.com QGH[ 25(:25' 6HUYLFH QIRUPDWLRQ 9HKLFOH %RG\0XIIOHU QVSHFWLRQ $GMXVWPHQW /XEULFDWLQJ 6\VWHP &DUEXUHWRU $LU &OHDQHU &RROLQJ 6\VWHP 5HPRYDO DQG QVWDOODWLRQ RI (QJLQH &\OLQGHU &\OLQGHU +HDG &\OLQGHU +HDG &RYHU $LU 0L[ 'HYLFH &97 7KH PDQX IDFWXUHU UHVHU YHV WKH 7UDQVPLVVLRQ ULJKW WR PDNH LPSURYHPHQWV RU PRGLILFD WLRQV WR WKH S URGXFWV...
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Page 5: Operation Attention
All manuals and user guides at all-guides.com Speical Tools Crease & Sealant 1-17 1-19 1-24 1-14 Operation Attention Cautions When the engine just stops, the temperature of engine, muffler is still high; please do not touch them with bare Safety cautions hands, for avoiding burn.
Page 6 All manuals and user guides at all-guides.com &)0272 Cautions The Battery may produce combustible and Cautions The personnel shall make them be aware of each other from time to time when operating for explosive hydrogen when it is being charged. So it safety confirmation.
Page 7 All manuals and user guides at all-guides.com Disassembly&installation Must use CFMOTO genuine parts or recom- mended parts for components,lubrication or Please clean the dirt, dusts on the vehicle before grease. maintenance. The gasket, O-ring, piston pin retainer and split pin must be renewed after disassembly. The parts of each system shall be arranged and stored separately, so that the parts can be assembled to the The elastic retainer will deform if it is opened too...
Page 8 All manuals and user guides at all-guides.com &)0272 The rubber parts shall be checked whether they are The recommended lubricating grease must be ap- aged upon disassembly, renew them in advance when necessary. Besides, try not to make volatile plied or injected in the appointed positions. oil, grease etc attach on the rubber parts, for they are not resistant to corrosion of gasoline or kerosene.
Page 9 All manuals and user guides at all-guides.com The side of oil seal with manufacturer’s sign shall be installed facing outside (the direction without oil). The tube shall be inserted to the base of joint when Avoid the crimp of oil seal lip when assembling, do installing the tube parts.
Page 10 All manuals and user guides at all-guides.com &)0272 RFDWLRQ RI 1XPEHUV CF150T-6A CF125T-22A 9,1 1XPEHU LCETDKP6 LCETDJPM (JQLQH 1XPEHU 1P58MJ-A(2) 1P52MI-B(2)
Page 11 All manuals and user guides at all-guides.com 7DEOH RI 0DLQ 3DUDPHWHUV Item Parameter Name and model CF150T-6A / CF125T-22A Length 19 50mm Width 71 5mm Height 119 5mm Wheelbase 13 20mm Engine model 1P58MJ-A(2) /1P52MI-B(2) Total displacement 15 2.7ml /124 .6ml...
Page 12 All manuals and user guides at all-guides.com &)0272 Item Parameter Type of air cleaner Paper filter element Inlet Type BING 7226101 Throttle Valve Device Diameter 26mm Idle-Air-Control Valve Type Siemens ABV379-008 Type Dry, auto-centrifugal Clutch Starting mode auto-centrifugal Gear Type Bevel Initial Transmission Gear ratio...
Page 13: Lubricating Device
All manuals and user guides at all-guides.com Lubricating Device Item Standard Operation limit 0.8l Replace Capacity 1.0 l Full Capacity Recommended engine oil (see the original). SAE-10W-4020W-50 are be used exclusively for 4-stroke motorcycle Selection must be made within the following range if substitute is preferable.
Page 14 All manuals and user guides at all-guides.com &)0272 &RRO DQW Item Standar d Full volume 0 .77l Res ervior volume 0 .33l Coolant capac ity 5 0 ( rate when us ing original Standard density s olution) Openning pressure of water inlet cap Temp.
Page 15 All manuals and user guides at all-guides.com *HDU ER[ It em St an d a rd 0 .1 5 l Engine oil Replacement 0 .1 5 l Disassembly Viscosity R e co m m en d ed S A E 1 5 W 4 0 / S F 6WDUWLQJ 0RWRU I t e m S t a n d ar d...
Page 16 All manuals and user guides at all-guides.com &)0272 )URQW :KHHO Serv ice Item Sta ndard Lim it Bending, front wheel shaft 0.2mm Play of wheel Vertical 0.8mm 2.0mm Horizontal 0.8mm 2.0mm Fro nt wheel Groove 1.6mm 22 5kP a 2.25 kg f Tire pressure 5HDU :KHHO...
Page 17 All manuals and user guides at all-guides.com %DWWHU\ &KDUJLQJ 'HYLFH Item Stan dard P e rm a n e n t m a g n e t Typ e A C type Magnetor Output 3 - p h a s e A C Motor Charging Coil Resistance(20? 0.2-0.3 Ω...
Page 18 All manuals and user guides at all-guides.com &)0272 Tightening Torqure Torque Torque Item N·m(kgf·m) Item N·m(kg f·m) 4 0.4 5mm Screw 5mm Bolt Nut 50.5 6mm Screw 9 0.9 6mm Bolt Nut 101.0 6mmSH Bolt with flange, 8mm Bolt Nut 222.2 1 0 1.0 Nut...
Page 19 All manuals and user guides at all-guides.com ) U D P H T hr ead No. of Tightening torque Remar Type Bolt & diameter m kgf mm Engine disassembly Engine suspension mounting bolt 55 5. 6 Engine suspension shaft nut 55 5.
Page 20 All manuals and user guides at all-guides.com &)0272 Special Tool Tool name Tool No. Usage Fuel system Adjusting tool for mixed gas screw Adjusting mixed gas screw Cylinder cover comp, Valve Valve assembly jigs 1P 5 2 M I- A- 9 2 2 - 0 2 00 0 0 Disassemble valve system Repair/clean the Valve guide reamer 5 mm 15 2 M I- 2 3 4- 0 22 3 0 0- 3 4B...
Page 21 All manuals and user guides at all-guides.com Lubricant, Sealant Application Areas Notes Grease type Inner surface, cylinder cover Joint cone of installation, AC generator rotor Bearing/side, connection rod big end Inner side, connection rod small end Drive bearing surface, crankshaft Timing sprocket gear surface, crankshaft Driven gear teeth surface, oil pump Piston pin outside surrounding surface...
Page 22 All manuals and user guides at all-guides.com &)0272 Application areas No te s Types Bearing seat, motor head pipe Multi-purpose lubrication Lip , front wheel dust-proof seal Joint, throttle cable Throttle handlebar part Pivot, rear pedal(L) Pivot, rear pedal( R ) Pivot, side stand Oil seal lip, rear fork Gear surface and running part,...
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Page 30: Overhaul Info
All manuals and user guides at all-guides.com 2-10 2-11 2-12 2-13 2-14 2- 7 Overhaul Info Operation Cautions Warning: Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should be done in a well-ventilated place.
Page 31: Installation
All manuals and user guides at all-guides.com &)0272 Seat Seat Disassembly Open the seat with ignition key Remove Cotter Pin and Parallel Pin Remove seat Installation Reverse the removal procedure for installation Caution Make sure there is no deviation of the seat by shaking it after installation.
Page 32 All manuals and user guides at all-guides.com U X Q N 5HPRYDO Installation Reverse the removal procedure for installation 6HDW 6RFNHW 5HPRYH...
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Page 34 All manuals and user guides at all-guides.com 0LGGOH 3URWHFWRU 3ODWH 'LVDVVHPEO\ Installation Reverse the removal procedure for installation 8SSHU &RYHU DLO /LJKW 'LVDVVHPEO\ ,QVWDOODWLRQ /RZHU &RYHU DLO /LJKW 'LVDVVHPEO\ ,QVWDOODWLRQ...
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Page 41 All manuals and user guides at all-guides.com &)0272 Fuel Tank Disassembly Caution: Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should be done in a well-ventilated place.
Page 42 All manuals and user guides at all-guides.com 0XII OHU 'LVDVVHPEO\ &DXWLRQ 'LVDVVHPEOH WKH PXIIOHU DIWHU LW LV I XO O\ F R RO HG ,QVWDOODWLRQ 5HYHUVH WKH UHPRYDO SURFHGXUH RI LQVWDOODWLRQ TighteningTorque: Nuts, front elbow: 30N•m(3.0kgf•m) Bolts, muffler: 40N•m(40.5kgf•m) Notice: Replace the sealing gasket when install- ing the muffler.
Page 43 All manuals and user guides at all-guides.com &)0272 9LVLEOH 3DUWV...
Page 44: Inspection And Adjustment
All manuals and user guides at all-guides.com 3 Inspection & Adjustment Overhaul info Ignition device 3-10 Replacement of parts Lubricating device 3-11 Inspection Instruction Fuel device 3-12 Steering column Cooling device 3-16 Brake system Exhaust gas recycling device 3-18 Wheel Lighting device 3-19 Suspension system...
Page 45 All manuals and user guides at all-guides.com &)0272 Check & Maintenance Mode Interval Check & Maintenance Item Intervals Standard Part Item year Steering Operation Agility Handle Steer Damage Installation status Devi Front steering coulmn fork Sway of steering stud bearing Front wheel lever end 10-20mm Play Brake...
Page 46 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Check & Maintenance Item Intervals Every Standard lifa year Part Item Slack of joint parts Output shaft issi (Transmis Sway of spline sion syst shaft) Spark plug gap 0.8 Status of spark plug Ignition 0.9mm...
Page 47 All manuals and user guides at all-guides.com &)0272 Check & Maintenance Item Intervals Standard Halifa Every Part Item Daily year year Lighting device and turning Function indictors Alarm and lock device Function Instruments Function Slack or damage caused Exhaust pipe and muffler installation Function of muffler Frame...
Page 48: Steering Column
All manuals and user guides at all-guides.com 3 Inspection & Adjustment Steering Column Park the scooter with main stand, lift front tire, hold the lower part of shock-absorber and shake back and forth to see if there is any sway. In case of any sway, check if it is the problem of the steering column or other parts and then do the maintenance accordingly.
Page 49 All manuals and user guides at all-guides.com &)0272 Brake pump comp. <Fluid level> Check the brake fluid level When the brake fluid level is near to the lower limit, check brake pump, brake hoses and leakages at the joints.Remove the two mounting screws on oil cup cap, take down the cap, add DOT3 or DOT4 brake liquid till the...
Page 50 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Wheel & Tire Tire Pressure Check the tire pressure with a pressure gauge. Note Check tire pressure when tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause deflected wear of the tires.
Page 51 All manuals and user guides at all-guides.com &)0272 Looseness of Wheel Nuts and Wheel Axle Nuts Check front and rear wheel axle nuts for looseness. Tighten in case of any looseness according to the Specified torque: Tightening torque: Front wheel axle nut: 80N (8.2kgf m) m(14.3kgf m) Rear wheel axle nut: 140N...
Page 52 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Rocking of the joining part Park the scooter with main stand and rock engine up and down to check if there is damage or rocking with the cushion collar of rear suspension. Replace the cushion collar in case of any rocking.
Page 53 All manuals and user guides at all-guides.com &)0272 Ignition Devices Spark Plug Remove left side panel Remove the spark plug cap. When removing the spark plug, clean the joint face of spark plug with compressed air to prevent dust from entering the combustion chamber. Remove spark plug.
Page 54 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Install the spark plug. Note To avoid damage to the thread of spark plug hole, when installing the spark plug, revolve it into cylinder head with hand and then tighten it with a spanner.
Page 55 All manuals and user guides at all-guides.com &)0272 Install the cleaned drain bolt and new sealing gasket, and tighten it according to the recommended torque. Torque: 25N m(2.5kgf m) Add the recommended engine oil. 0.8L(for replacing) Engine oil capacity: 1.0L(for disassembling) Check the oil level with the dip rod while adding till the oil level reached the upper limit.
Page 56 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Replacement of air filter element Remove 2 bolt 1 as shown in pictures. Remove air box. Remove air filter element and replace. Reverse the removal order for installation. Idle speed inspection RPM of Idle speed inspection:1700 170rpm...
Page 57 All manuals and user guides at all-guides.com &)0272 Check Exhaust To ensure the required insert depth of the sensor (60cm),use a connector and connect it to the muffler. After strictly adjusting the idle speed, measure the density of CO (CO%) and HC (HC%). CO at Idle speed: below 3.8% HC at idle speed: below 800ppm RPM at idle speed: 1700¡À170rpm...
Page 58 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Checking the throttle handle Turn the throttle handle, and check if it can turn smoothly. In case the turning of the throttle handle is not smooth enough, Check if there is damage with the throttle cable, or rust with the steel wire or any stickness with the throttle handle.
Page 59: Cooling Device
All manuals and user guides at all-guides.com &)0272 Cooling device Caution Check of coolant level should be done on the reservoir tank instead of the radiator. If the radiator cover is opened while the engine is hot (over 100¡æ), the pressure of the cooling system will drop down and the coolant will get boiled rapidly.
Page 60 All manuals and user guides at all-guides.com 3 Inspection & Adjustment When the coolant level is below the lower limit, open right cover of front trunk and remove cap of reservoir tank. Add coolant till the upper limit (coolant or diluted original liquid). Recommended coolant: CFMOTO coolant Standard density: 50%( Freezing temperature of coolant varies according to the different...
Page 61 All manuals and user guides at all-guides.com &)0272 Exhaust recycling device Check if there’s any deposit in the discharge duct (at right bottom of air filter). If there’s deposit, remove the discharge plug; drain the deposit from the duct. Install the discharge plug and fix it with the clamp.
Page 62 All manuals and user guides at all-guides.com 3 Inspection & Adjustment Lighting Device Optic Axis adjustment of Front head light Adjust Optic Axis adjustment bolt with cross banner to adjust lenght of lighting.
Page 63 All manuals and user guides at all-guides.com &)0272 Others Lubrication of frame parts Turn the movable parts of vehicle body, and check the lubrication condition. In case of any stickness, apply recommended lubri- cation oil or grease to the parts. The dotted line means the parts which can not bee seen...
Page 64 All manuals and user guides at all-guides.com Overhaul info Troubleshooting Oil pump Overhaul info Caution he maintenance of the oil pump should be done after disassembling the right side cover. ( 11) When the measured values exceed the service limit, replace the oil pump. Do not mix impurities into the engine when disassembling the oil pump.
Page 65 All manuals and user guides at all-guides.com &)0272 Oil pump Caution Do not mix impurities into the engine when disassembling and installing the oil pump. Dismountling Remove: —right side cover( 11-2) —rotor comp, driven gear comp. ( 11-3) —Isolation plate B, oil pump comp. Removeshaft circlip.
Page 66 All manuals and user guides at all-guides.com Remove oil pump comp., and oil pump shaft. Check oil pump comp. for any damage or wear. Disassembling Remove screw and oil pump cover plate. Remove inner rotor and outer rotor. Note Multi spots should be measured and choose the max.
Page 67: Installation Of Oil Pump
All manuals and user guides at all-guides.com &)0272 Clearance between inner and outer rotors of oil pump Install inner rotor and outer rotor onto the oil pump body, measure the clearancebetweeninnerrotor and outer rotor with a plug gauge. . Service limit: 0.20mm Installation of Oil Pump End face clearance Install inner rotor and outer rotor to the oil pump...
Page 68 All manuals and user guides at all-guides.com Caution Wash clean all the parts with clean kerosene before assembly. Install inner rotor and outer rotor to oil pump body. Install oil pump cover plate, tighten the screw according to the specified torque. Torque: 2N m(0.2kgf m) Pre-tighten cover plate after assembly, install oil pump shaft, and make sure the shaft can turn freely.
Page 69 All manuals and user guides at all-guides.com &)0272 Install oil pump sprocket and chain. Note: Sprocket and chain should be properly installed Install shaft circlip into the shaft groove. Check if the circlip is properly installed Join isolation plate B with isolation plate A, and tighten with bolt.
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Page 76 All manuals and user guides at all-guides.com Overhauling info Thermostat Trouble shooting Radiator Performance overhauling Water pump Reservoir tank Cooling system drawing 2 YH U KD X O , Q IR U PD W LR Q & D X W L R Q , QV S HF W LR Q V W DQ G DU G 7 LJ KW H QL Q J WR U TX H...
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Page 132 All manuals and user guides at all-guides.com *HDUER[ Removal & Installation of gearbox bearing£¬oil seal 10-4 Removal & Installation of left crankcase bearing, oil seal 10-6 2YHUKDXO ,QIRUPDWLRQ 2 SH U D WL R Q & D X WL R Q 2 YH UK D XO 6W DQ G DU G 7 LJ KW H QL Q J 7R U TX H 7URXEOHVKRRWLQJ...
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Page 155 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Overhaul information Front shock absorber 13-1 13-9 Troubleshooting Steering bar 13-2 13-10 Front wheel Front fork 13-3 13-15 Overhaul information Operating notes Notes •Securely support the scooter when overhauling the front wheel and suspension systems. •Refer to chapter 18 for overhaul and inspection of lights, instruments and switches.
Page 156 All manuals and user guides at all-guides.com &)0272 Special tools 07746-0050100 Shaft, bearing remover 07746-0050200 Remover head 10mm, bearing remover 00749-0010000 Handle A , press tool 07946-1870100 Press tool outer sleeve 07746-0040100 Guide tool 10mm 07916-KM10000 Locknut spanner 07SMA-GBC0100 Bearing adjusting spanner, steering column 07JAC-PH80000 Bearing remover set, 07JAC-PH80100...
Page 157 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Front wheel Removal Support the frame with jack, raise the front wheel, remove front wheel axle nut. Remove front wheel axle, remove brake disk from brake calipers, remove front wheel.
Page 158: Wheel Bearing
All manuals and user guides at all-guides.com &)0272 Remove axle collar from front left side of wheel. Inspection Wheel axle Set axle on a V block, measure axle wobble with centesimalgauge. ServiceLimit:0.2mm Check the rim for damage, warpage or scrapes. Replace with a new one, if any.
Page 159 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Diassembly Remove oil seal. Install the remover head on the rim Install the bearing remover shaft on the remover head from the reserve side, strike in and remove the bearing.
Page 160 All manuals and user guides at all-guides.com &)0272 Remove five bolts from brake disc, and remove brake disc. Inspection Brake disc thickness: 3mm Replace Remove bolt1, bolt2 and brake calipers comp. Inspection Brake caliper: check brake calipers for cracks or oil leakagefrom thetighteningparts.Replace,ifany.
Page 161: Special Tools
All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP VVHPEO\ Assemble spacer Apply lubrication grease to the running part of new bearings, press the left side bearing first. Install spacer. Install right side bearing. Special tools: Handle A , press tool A 519-922-070003 Press tool outer sleeve 28x30 519-922-070004 Guide tool 12mm...
Page 162: Installation
All manuals and user guides at all-guides.com &)0272 Apply grease to the protruding part of odometer gear guard ring. Apply grease to de gearing and sliding parts of odometer gear. Install with the groove part of odometer gear in line with the protruding part of guard ring.
Page 163: Front Shock Absorbers
All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Front Shock Absorbers Disassembly Remove: Front wheel ( 13-3) Two Bolt 1 Four fixing screws(L&R), sealing cover and seal ring. Caution: There should be no damage with the seal ring. Remove shock absorbers Caution: Do not put the shock absorber upside down in case...
Page 164 All manuals and user guides at all-guides.com &)0272 Installation Install the shock absorber. Install the seal cover and seal ring of shock absorber. Tighten according to the specified torque. TighteningTorque: 50N m (5.1kgf m) Install the tightening bolt 2 of absorber, and tighten it according specified torque.
Page 165 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Handlebar rear cover Removal: Handlebar front cover ( 13-10) Two tapping screws Screw 3 Handlebar rear cover Installation: Reverse the removal procedure for installation.
Page 166: Rear View Mirror
All manuals and user guides at all-guides.com &)0272 Rear View Mirror Disassembly Turn up jacket, loosen nut counter clock-wise, re- move left rear view mirror by turning it counter clockwise. Turn up jacket, loosen nut clock-wise, remove right rear view mirror by turning it clockwise. Installation: Reverse the removal procedure for installation...
Page 167 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Master Cylinders Removal: Rear View Mirror Handlebar front cover Handlebar rear cover Bolt Loosen brake cable coupler, remove left master cylinder efer to above for removal of right master cylinder. Caution: 1.
Page 168 All manuals and user guides at all-guides.com &)0272 Installation Reverse the removal procedure for installation Caution: 1. Tightening torque for handlebar bolt: 50~60N•m 2. Main cable, throttle cable, brake hose, etc should be routed properly 3. Couplers and plugs should be plugged properly. 4.
Page 169: Front Fork
All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Front Fork Remove: Front top cover Front Wheel Front Fender Front shock absorbers Handlebar Steering column locknut Special tool: Locknut spanner: 519-922-050002...
Page 170 All manuals and user guides at all-guides.com &)0272 Remove thrust washer. Remove bearing retainer. Special tool: Steering column adjusting spanner 519-922-050002 Remove: Upper ball retainer Front fork Lower ball retainer Set special tool to the frame standpipe and remove lower bearing race. Special tool: Bearing remover comp 519-922-050000 Rotor puller 519-922-050010...
Page 171 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Install special tool on the rectangular tube of the stand and remove upper ball race. Special tool Bearing remover comp 519-922-050000 Rotor puller 519-922-050010 Remover shaft 519-922-050003 Remover hammer 519-922-050004 Installation Install new lower ball race and special tools as listed below to the steering column.
Page 172 All manuals and user guides at all-guides.com &)0272 Install new upper ball race on the steering column with tools listed below: Special tools: Tool A, steering column bearing retainer 519-922-050005 Tool shaft 519-922-050006 Tool B, steering column bearing retainer 519-922-050007 Tool shaft 519-922-050008 Hold installation tool shaft, tighten the locknut while...
Page 173 All manuals and user guides at all-guides.com )URQW ZKHHOEUDNLQJVXVSHQVLRQ DQG VWHHULQJ V\VWHP Press new lower bearing retainer onto front fork with special tool and press machine. 6SHFLDO WRRO Front fork cover, press tool 519-922-050009 ,QVWDOODWLRQ Apply lubrication grease on new lower bearing, and then install front fork.
Page 174 All manuals and user guides at all-guides.com &)0272 Install upper bearing retainer, Tighten it according to the specified torque Special tool Adjustingwrench,steeringcolumnbearing: 519-922-050002 Torque: 10N m (1.0kgf m) Turn front fork left and right several times to the blocks (limit position), and make block and bearing match well.
Page 175: Tightening Torque
All manuals and user guides at all-guides.com 5HDU ZKHHO%UDNH6XVSHQWLRQ Overhaul information 14-1 Rear fork 14-4 Troubleshooting 14-2 Rear shock absorber . 14-5 Rear wheel 14-3 Overhaul information Operating notes Notes Securely support the scooter when overhauling the rear wheel and suspension system. Use genuine parts of bolts and nuts for rear shock absorber.
Page 176: Troubleshooting
All manuals and user guides at all-guides.com &)0272 Troubleshooting Rear Wheel wobbles rim warpage. faultytire. lower tire air pressure improper wheel balance faultytighteningof wheel axle nut. Rear shock absorber is too soft weak spring. oil leakage with rear shock absorber Rear shock absorber is too hard.
Page 177: Rear Wheel
All manuals and user guides at all-guides.com 5HDU ZKHHO%UDNH6XVSHQWLRQ Rear Wheel Removal Securely support the scooter with main stand. Remove: Rear wheel fender 2-11 Muffler 2-13 Rear right shock absorber Rear brake caliper Rear fork Remove Rear fork inner collar Remove rear wheel.
Page 178 All manuals and user guides at all-guides.com &)0272 Rear Fork Removal: Muffler Bolt 4, Rear right absorber Nut 1, rear wheel axle Bolt 2 (2 pcs) Bolt 3 (2 pcs) Remove rear fork. Disassembly of rear fork Remove front oil seal 1, rear oil seal 6 and clamp 5. Remove bearing 4 with special tool.
Page 179: Rear Shock Absorber
All manuals and user guides at all-guides.com 5HDU ZKHHO%UDNH6XVSHQWLRQ Rear Shock Absorber Rear Left Absorber Removal: Securely support scooter with main stand. Maintenance cover (2-2) Seat (2-2) Storage compartment (2-3) Rear bracket (2-4) Rear Joint plate (2-5) Left protecting plate (2-5) Remove Bolt 1 and Bolt 2 of rear left absorber.
Page 180 All manuals and user guides at all-guides.com &)0272 Inspection Check shock absorbers for oil leakage and rubber spacer for aging. Replace with new ones if any. Reverse the removal procedure for installation. Tighten the bolts according to the specified torque. Upperfixingbolt: Torque: 55N•m (5.6kgf•m) Lowerfixingbolt:...
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Page 183: Fault Diagnosis
All manuals and user guides at all-guides.com Overhauling standard It e m St andard AC Magneto typ e Pe r ma n ent ma gn e t AC system output Three phase current Charge coil r es i stance 0. 5 Re ctifie r t yp e Th re e p h as e circu lar c om mute, it can control p a ral lel volt a ge...
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Page 197 All manuals and user guides at all-guides.com Electrical starting system,overriding clutch Overhaul information Starter relay 17-1 17-2 Troubleshooting Starting motor Comp 17-1 17-2 Overriding clutch 17-5 Overhaul Information Notice: Bundle the wires of the same color. Wires of different colors should be connected with the wires of the same color.
Page 198 All manuals and user guides at all-guides.com &)0272 Starter Relay Notes • Check and confirm battery is in good status before inspection. •In case of faulty starting, check each brake switch and starter relay. (Chapter 16) Disconnect 4P coupler of starter relay and remove starter relay.
Page 199 All manuals and user guides at all-guides.com Electrical starting system,overriding clutch Note: • Check and confirm battery is in good status before inspection. • In case of faulty starting, check each brake switch and starter auxiliary relay. (Chapter 16). Keep ignition switch in the position.
Page 200 All manuals and user guides at all-guides.com &)0272 Starter motor comp. Disassembly Remove air filter; Remove fixing bolt of starter motor and remove starter motor comp. Disassembly of starter motor comp Remove tightening screw of starter motor housing and remove motor housing and motor seat. Inspection Measure brush length Service Limit:Replace if the brush less than 7mm.
Page 201 All manuals and user guides at all-guides.com Electrical starting system,overriding clutch Make sure rotor shaft is not conducted with commutators. Installation Set O-ring in the groove of starter motor seat. Apply some grease on the O-ring.
Page 202 All manuals and user guides at all-guides.com &)0272 Apply some lubricant on rotor shaft ends. Install rotor into motor housing. Press brush into the brush holder, while install brush holder on the commutator. Align the cam part of motor housing with groove of motor seat.
Page 203 All manuals and user guides at all-guides.com Electrical starting system,overriding clutch Loosen bolt, remove fixing plate and driven gear comp. Installation Reverse the removal procedure for installation Apply some lubricant on the dual gear shaft in the right case. Tighten the three inner hex bolts of overriding clutch according to the specified torque.
Page 204 All manuals and user guides at all-guides.com &)0272 Refer to chaper 19 for specific electrical circuit diagram...
Page 205 All manuals and user guides at all-guides.com Overhaul information ......18-1 Brake light switch ......18-8 Troubleshooting ......18-2 Electrical horn ......18-8 Bulb replacement ......1 8-3 Odometer .......18-9 Head light ......18-5 Fuel sensor .....18-10 Ignition switch lock ......18-6 Water temperature sensor ....18-12 Handlebar switch ......18-7 Overhaul information...
Page 206 All manuals and user guides at all-guides.com Troubleshooting Head light cannot turn on Fuse break Open circuit with main cable Bulb burnt Night switch is damaged.
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Page 208 All manuals and user guides at all-guides.com Brake light/Tail light bulb Remove tapping screw 9, tail light cover 1 Turn brake light/tail light bulb5 counter clockwise and remove it Replacelight/taillightbulb Bulb Specification: 12V-21/5W Reverse the removal procedure for installation. Rear turning light bulb Remove screw9 Remove tail light cover1 Remove rear right turning light cover7...
Page 209 All manuals and user guides at all-guides.com ,QVWUXPHQW OLJKW 1RWH +($' /,*+7 +HDG OLJKW $VV\ Remove front cover of handlebar Remove the 4P-insert connector on headlight. Remove the 4 bolts. Remove head light...
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