CF MOTO CF125T-19 2003 Service Manual
  1. Manuals
  2. Brands
  3. CF MOTO Manuals
  4. Scooter
  5. CF125T-19 2003
  6. Service manual

CF MOTO CF125T-19 2003 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CFMOTO
CF125T-19
SERVICE MANUAL
CF150T
VERSION A
WWW.CFMOTO.COM

Advertisement

Table of Contents
loading

Related Manuals for CF MOTO CF125T-19 2003

Summary of Contents for CF MOTO CF125T-19 2003

  • Page 1 CFMOTO CF125T-19 SERVICE MANUAL CF150T VERSION A WWW.CFMOTO.COM...
  • Page 2 WWW.CFMOTO.COM All right reserved ZHEJIANG HONGQIAO POWER MANUFACTURING CO.,LTD. 2003 年 5 月...
  • Page 3 INDEX FOREWORD Servicing information This manual contains an introductory descrip- Vehicle body、 muffler tion of procedures for inspection， maintenance, Inspection & Adjustment overhaul， disassembly & assembly， removal Lubricating system and installation of components and parts, trouble- Carburetor 、 air filter shooting and service data together with illustra- Cooling system tions of our scooters CF125T-19/150t。...
  • Page 4 Conversion Table Item Example Conversion Pressure 200Kpa 1kgf/cm =98.0665kpa 1kpa=1000pa (2.00lgf/cm 1mmHg=133.322Pa=0.133322Kps 33kpa(250mmHg) Torque 18 · N(1.8kgf-m) 1kgf· m=9.80665N · m Volume 419ml 1ml=1cm =1cc 1l=1000cm Force 12N (1.2kgf) 1kgf=9.80665N...
  • Page 5 1 Overhaul Information Cautions… … … … … … … … … … … … … 1-1 Special Tools… … .… … … .… … … .1-16 Cautions for Disassembling and Assembling..1-3 Lubricant, Sealing Agent… … … … . 1-18 VIN Number &...
  • Page 6 CFMOTO Caution: When charged, Battery may Warning: The asbestos dust on the brake generate hydrogen which is explosive. drum is carcinogenic is breathed in. Charge the battery in a well-ventilated Do not clean off the dust with compressed air. place. Use cleaning detergent to avoid dust proliferation.
  • Page 7 1 Overhaul Information Cautions for Disassembling and Assembling ■ Use genuine CFMOTO parts, ■ Clean the mud, dust before over hauling lubricants and grease ■ Place and store the disassembled parts ■ Replace the disassembled washers, o-rings, Separately in order for correct assemble. ■...
  • Page 8 CFMOTO ■ Check if the disassembled rubber parts ■ Apply or inject recommended lubricant to are aged and replace if necessary. Keep the the specified parts. rubber parts away from grease. ■ Use special tools wherever necessary ■ If the disassembling of pressed ball bearing is done by pressing the balls, do not use the disassembled bearing.
  • Page 9 1 Overhaul Information ■ After assembling, check if all the tightened ■ Brake fluid and coolant may damage parts are properly tightened and can move coating, plastic and rubber parts. Flush smoothly. these parts with water if splashed. ■ Install oil seal with the side of ■...
  • Page 10 CFMOTO Location of serial No CF125T-19 CF150T V.I.N： LCETDJPK～ LCETDKP1～ Engine No： 1P52MI-A ～ 1P58MJ～...
  • Page 11 1 Overhaul Information Main Technical Parameter Item Parameters Models CF125T-19 CF150T Length 2034mm Width 700mm Height 1186mm Wheel Base 1353mm Engine Model 1P52MI-A 1P58MJ Displacement 124.6ml 152.7ml Fuel 90 Octane or above Dry Weight 126kg Number of Passengers 2 人 (Inl. Driver) Max.
  • Page 12 CFMOTO Item Param eter A ir Filter type Paper filter elem ent Fuel device Type Vacuum D iaphragm Carburetor D iam eter of valve 26m m Type D ry, auto-centrifugal Clutch Starting m ode A uto-centrifugal G ear type Bevel Initial Transm ission R eduction ratio 3.7700/3.13...
  • Page 13 1 Overhaul Information Troubleshooting Datasheet Lubricating device Item Standard S ervice Lim it O il C apacity R eplacing 0.8l － Full C apacity 1.0 l － S pecial 4 -stroke · M otorcycle S A E -10W -40、 20W-50 U se substitute oil only w ith in the following category。...
  • Page 14 CFMOTO Cooling Device I t e m S t a n d a r d F u l l v o l u m e 0 . 8 8 l V o l u m e s e c o n d a r y w a t e r 0 .
  • Page 15 1 Overhaul Information Deceleration Device Item Standard Engine oil Replacement 0.15L Disassembly 0.15L Recommended deceleration engine oil SAE15W-40/SF Starting motor Item Standard Limit Starting motor Brush length 10mm Crankshaft 、 Piston、 Cylinder Item Standard （ mm） Limit （ mm） CF125T CF150 Crankshaft Shaft big...
  • Page 16 CFMOTO Front wheel Item Standard Limit Front wheel Bending, front wheel shaft 0.2mm Play of wheel rim Vertical 0.8mm 2.0mm Horizontal 0.8mm 2.0mm Tire Groove 1.6mm Air pressure 250kpa(2.5kgf/cm Rear wheel Item Standard Limit Rear wheel Play of wheel rim Vertical 0.8mm 2.0mm...
  • Page 17 1 Overhaul Information Battery、 Charging system I t e m S t a n d a r d A C m a g n e t o M o t o r M o d e l P e r m a n e n t m a g n e t A C t y p e O u t p u t 3 - p h a s e A C...
  • Page 18 CFMOTO Tightening torque Item Torque N· m(kgf· m) Item Torque N· m(kgf· m) Bolt, nut 5mm 5(0.5) Screw 5mm 4(0.4) Bolt, nut 6mm 10(1.0) Screw 6mm 9(0.9) Bolt, nut 8mm 22(2.2) Bolt with flange, 6mmSH 10(1.0) Bolt, nut 10mm 34(3.5) Bolt with flange, nut 12(1.2) Bolt, nut 12mm...
  • Page 19 1 Overhaul Information Frame body Typ e N o . of D iam e te r T ig h ten in g to rq u e R e m a rks B o lt & (m m ) N ·m (k g f·m ) N u t E n g in e d isassem bly E n g in e su sp en sio n m o u n tin g b o lt...
  • Page 20 CFMOTO Special tools Tool name Tool No. Usage Fuel system Adjusting tool for mixed gas screw Adjusting mixed gas screw Cylinder cover comp, Valve Disassemble valve system Valve assembly clipper 1P52MI-A-922-020000 Repair/clean the valve guide Valve guide reamer 5mm 152MI-234-022300-34B Amend the valve seat Valve seat cutter Valve lapper 27mm(45°...
  • Page 21 1 Overhaul Information Lubricant, Sealant Application Areas Notes Grease type Inner surface, cylinder cover special Joint cone installation, generator rotor SAE standard of Bearing/side, connection rod big end cylinder Inner side, connection rod small end motor: classify Drive bearing surface, crankshaft of 10w-40 API: Timing sprocket gear surface, crankshaft SE or SF engine...
  • Page 22 CFMOTO Lubricant, Sealant A pplication areas N otes Types Bearing seat, motor head pipe M ulti-purpose lubrication oil Lip part, front wheel dust-proof seal Running part and camp part, rear brake comp. Joint, meter flexible cable Joint, throttle cable Throttle handlebar part Pivot, back bracket(L) Pivot, back bracket( R ) Pivot, side stand...
  • Page 23 1 Overhaul Information Wiring, Piping Diagram 1-19...
  • Page 24 CFMOTO 1-20...
  • Page 25 1 Overhaul Information 1-21...
  • Page 26 CFMOTO 1-22...
  • Page 27 1 Overhaul Information 1-23...
  • Page 28 CFMOTO 1-24...
  • Page 29 1 Overhaul Information 1-25...
  • Page 30 CFMOTO Anti-pervasion device for poisonous gas The device is to lead the poisonous emission from the crankcase through air cleaner and carburetor to the combustion chamber for burning so as to avoid the direct emission to the air. 1-26...
  • Page 31 1 Overhaul Information Secondary air inlet supplying device Secondary air inlet supplying device sends the fresh air from the secondary air filter to the exhaust pipe, where the not-fully-combusted mixed-gas in the exhaust gas can continue to burn. In this way the main contents of HC¡¢...

  • Page 32: Table Of Contents

    2 Vehicle body muffler Overhaul info… … … … … … … … … … … … . 2-1 front fender, front decoration plate… … … … … … … … 2-8 Trouble shooting… … … … … … … … … … … … … … front top cover …...
  • Page 33 cfmoto Seat Small seat Disassembly Open up the big seat with ignition switch lock. Remove bolt1 and bolt2, and remove the small seat Mounting Install the small seat in the reverse order of disassem- Big seat Disassembly Remove the central trunk/big seat assembly (2-3) Remove circlip;...

  • Page 34: Central Trunk

    2 Vehicle body muffler Central Trunk Disassembly Open up the big seat with ignition key. Remove battery cover(2-2) Remove battery(15-4) Remove bolt1, bolt2, bolt3, bolt4 and tapping screw1, tapping screw2 Screw out fuel tank cover Lift central trunk/big seat assembly. Remove bolt5, bolt6 and nut1, nut2 Remove seat lock and cable seat comp.
  • Page 35 cfmoto Mounting Install seat lock cable as indicated in the drawing. Middle protecting plate Disassembly Remove central trunk/big seat assembly. (2-3) Remove tapping screw1 Remove tapping screw2 Remove Middle protecting plate Mounting Install the middle protecting plate in the reverse order of disassembly Rear carrier Disassembly...

  • Page 36: Left Protecting Plate

    2 Vehicle body muffler Left protecting plate Disassembly Remove Small seat(2-2) Remove central trunk/big seat assembly (2-3) Remove Middle protecting plate(2-4) Remove Rear carrier(2-4) Remove bolt1, bolt2, and seat front bracket Remove tapping screw1 Remove tapping screw2 Remove tapping screw3 Take off Left protecting plate and seat lock cable comp.

  • Page 37: Right Protecting Plate

    cfmoto Mounting Install seat cable, seat lock plate and seat lock to the left protecting plate Install the left protecting plate assembled with seat lock comp. In symmetry with right protect- ing plate¡¢ fender and rear fender . Tighten the tapping screw Install front seat bracket Install rear carrier and small seat Right protecting plate...

  • Page 38: Vehicle Body Muffler

    2 Vehicle body muffler Middle protecting skirt(R) Disassembly Remove tapping screw Remove screw1, screw2 Remove Middle protecting skirt (R) Mounting Reverse the disassembly procedure of Middle protecting skirt (R) for installation. Middle protecting skirt (L) Disassembly Remove tapping screw Remove screw1, screw2 Remove middle protecting skirt(L) Mounting Install the middle protecting plate (L) in the re-...
  • Page 39 cfmoto Front Fender Disassembly Remove screw, bolt1, and bolt2 Remove screw1, screw2 Loosen clip of front side, front fender from the trough of rear side. Remove front and rear parts of front fender. Loosen bolt1 and bolt2 Remove fender, front fork Mounting Install front fender in the reverse order of disas- sembly...

  • Page 40: Front Top Cover

    2 Vehicle body muffler Front top cover Disassembly Remove front emblem plate (2-8) Remove tapping screw1, tapping screw2, tapping screw3 and tapping screw4 Remove the bolt on the ventilation port plate Remove tapping screw5 and tapping screw6 which joint front top cover and footrest deck Separate front top cover with front trunk...

  • Page 41: Front Trunk

    cfmoto Remove the four tapping screws (tapping screw7, tapping screw8, tapping screw9, tapping screw10) which joint front top cover and venti- lation port plate Separate front top cover with ventilation port plate, and take down ventilation port plate Separate front winker left coupler with front winker right coupler Take down winker front top cover comp.
  • Page 42 2 Vehicle body muffler Take down the front trunk cover, Pull down the dowel plate¡¢ lock cover and the mounting screw of ignition switch lock Disassemble the mounting screw of front trunk and frame Remove front trunk Mounting Install front trunk in the reverse order of disas- sembly 2-11...
  • Page 43 cfmoto Footrest deck Disassembly Remove small seat(2-2) Remove seat box big seat comp. (2-3) Remove middle protecting plate(2-4) Remove rear carrier(2-4) Remove left protecting plate(2-5) Remove right protecting plate(2-6) Remove middle protecting skirt (L&R)(2-7) Remove front top cover(2-9) Remove front trunk(2-10) Remove bolt1, bolt2, bolt3 and bolt4 Take down footrest deck Mounting...

  • Page 44: Rear Fender ,Tail Light

    2 Vehicle body muffler Rear fender¡¢tail light Disassembly Remove small seat(2-2) Remove seat box big seat comp. (2-3) Remove middle protecting plate(2-4) Remove rear carrier(2-4) Remove left protecting plate (2-5) Remove right protecting plate(2-6) Remove bolt1, and disconnect tail light 6p socket Remove bolt2 Remove bolt3 and bolt4 Take down rear fender tail light comp.
  • Page 45 cfmoto Dismantle of tail light comp., rear fender Remove screw1; disconnect tail light2 and rear fender4 Remove screw8, take down cover7, tail light, take out bulb9, Remove screw6, take down cover5, and take out bulb3; Remove screw10, take down cover11, and take out bulb12 Mounting Install rear fender and tail light in the reverse order of disassembly 2-14...

  • Page 46: Fuel Tank

    2 Vehicle body muffler Fuel tank Disassembly Warning Gasoline is highly flammable, smoking is strictly forbidden in the work place. Keep alert on the electrical sparks. Besides, vapor- ized gasoline is highly explosive, so work should be done in a well-ventilated place. Remove small seat(2-2) Remove seat box big seat comp.

  • Page 47: Muffler

    cfmoto Muffler Disassembly Warning The dismantling and installation work of muffler can only be done when it is cooled down! Remove joint nut1 and nut2 of muffler front elbow Remove bolt1, bolt2, take down clamp ring, muffler and rubber cushion. Mounting Install muffler in the reverse order of disassembly.
  • Page 48 2 Vehicle body muffler Outer Components 2-17...
  • Page 49 3 Inspection, Adjustment Overhaul info … … … … … … 3-1 Ignition device… … … … … … … … … … … … … … … … 3-11 Replacement of parts … … … 3-1 Lubricating device… … … … … … … … … … … … … … … 3-13 Inspection Instruction…...
  • Page 50 CFMOTO C h e c k & a i n t e n a n c e o d e i n t e r v a l ○ C h e c k & a i n t e n a n c e i t e m I n t e r v a l s J u d g i n g...
  • Page 51 3 Inspection, Adjustment C h e c k & M a i n t e n a n c e m o d e ○ : i n t e r v a l s C h e c k & M a i n t e n a n c e i t e m i n t e r v a l s J u d g i n g p a r t...
  • Page 52 CFMOTO Check & maintenance item intervals Judging part item daily Half Every standard year year Lighting device and function ○ ○ ○ indictors Alarm lock function ○ device instruments function ○ Exhaust pipe Slack or damage when ○ muffler installing Function of muffler frame Slack and damage...

  • Page 53: Steering Column

    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 sway. In case of a sway, determine if it is the problem of the steering column or other parts and then do the maintenance accordingly.
  • Page 54 CFMOTO Brake pump comp. <Fluid level> Check the brake fluid level When the brake fluid level is near to the lower limit line, 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 upper limit line.
  • Page 55 3 Inspection, Adjustment Tire Tire pressure Check the pressure of the tires 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 56: Suspension System

    CFMOTO Slacking of wheel nut and wheel shaft Check slacking of front wheel shaft and rear wheel shaft nuts. Tighten the nuts in case of any slacking according to the specified torques. Tightening torque: Front wheel shaft nut: 80N.m(8.2kgf.m) Rear wheel shaft nut: 140N.m(14.3kgf.m) Rocking of wheel bearing Park the scooter with the main stand, and lift the front wheel.

  • Page 57: Gearbox

    3 Inspection, Adjustment Rocking of the joining part Park the scooter with main stand and wave engine left and right to check if there is damage or rocking with the hanging cushion. In case of any, replace it with a new one. Gearbox Check the lubrication oil in the gearbox Check if there is any oil leakage around the gearbox.
  • Page 58 CFMOTO Remove the spark plug cap. When removing the spark plug, clean the joint face of spark plug with compressed air to pre- vent dust from entering the combustion chamber. Remove the spark plug. Check the central and side electrodes of the spark plug to see if there is nay erosion, burn- ing or damage of the insulate electromagnet.

  • Page 59: Lubricating Device

    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. If the spark plug is a new one, screw by one-quarter after the sealing gasket contacts the joint face.

  • Page 60: Fuel Device

    CFMOTO 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. Engine oil capacity: 0.8L(for replacing) 1.0L(for disassembling) Check the oil level with the dip rod while adding till the oil level reached the upper limit.
  • Page 61 3 Inspection, Adjustment Replacing air filter element Remove the two bolts and rear brake oil pipe. Loosen the butterfly nut on the right side of air filter and remove the right side cover of air filter. Remove air filer filling and replace with a new one. Assemble the removed parts in the reverse order.
  • Page 62 CFMOTO Checking the 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 4.5% HC% at idle speed: below 1200ppm If the density of CO/HC exceeds the rated value, readjust according to following steps:...
  • Page 63 3 Inspection, Adjustment In case the density of CO/HC is more than the rated value, turn the adjust screw and check the density of CO/HC till the value is under the rated standard. Special tool Mixture screw adjusting tool: 07KMA-MS60101 Target value of CO density at idle speed:<4.5% Remove the clamp of secondary air inlet pipe.

  • Page 64: Cooling Device

    CFMOTO Cooling device Caution Check of liquid level should be done on the secondary water tank instead of the radiator. If the radiator cover is opened while the en- gine is hot (over 100¡æ), the pressure of the cooling system will come down and the coolant will become boiled rapidly.
  • Page 65 3 Inspection, Adjustment When the coolant level is below the lower limit, re- move the two tapping screws of the front emblem plate, and then the front emblem plate. Remove sec- ondary water tank’s cover, add coolant till the up- per limit (coolant or diluted original liquid).

  • Page 66: Exhaust Gas Recycling Device

    CFMOTO Exhaust gas recycling device Check if there’s any deposit in the discharge duct for exhaust gas/mist separation. (at right bottom of air filter). If there’s deposit, remove the discharge plug; drain the deposit in pipe. Install the discharge plug and fix it with the clamp.

  • Page 67: Lighting Device

    3 Inspection, Adjustment Remove the joint hose between air filter body and control valve of secondary air intake. Remove the vacuum tube of control valve of sec- ondary air inlet from the T joint. Install block on T joint. Connect vacuum tube of control valve of second- ary air intake to vacuum pump.

  • Page 68: Others

    CFMOTO Others Lubrication state of frame parts Turn the movable parts of vehicle body, and check the lubrication condition. In case of any stickness, apply recommended lubrication oil or grease to the parts. 3-20...
  • Page 69 4 lubricating system Overhaul info… … … … … … … … 4-1 Failure diagnosis… … … … … … 4-1 oil pump… … … … … … … … … … 4-2 Overhaul info Caution l The maintenance of the oil pump shall be done after dismantling the right side cover. (→ l When the measured values exceed the service limit, replace the oil pump.
  • Page 70 CFMOTO Oil pump Caution Do not let impurities into the inside of the engine when dismantling and installing the oil pump. Dismantling Remove right side cover(11-2) Remove the rotor comp, driven gear comp. (11-3) Remove separate plate, oil pump comp B. Remove shaft circlip.
  • Page 71 4 lubricating system Remove oil pump comp., and the oil pump shaft. Check oil pump comp. for any damage or wear. Dismantling Remove screw and oil pump cover plate. Remove inner rotor and outer rotor of oil pump. Note Measurement should be done multi spots and choose the max measured value.
  • Page 72 CFMOTO Clearance between inner rotor and outer rotor of oil pump Install inner rotor and outer rotor on the oil pump body, measure the clearance between inner rotor and outer rotor with a plug ruler. . Service limit: 0.20mm Terminal surface clearance Install inner rotor and outer rotor to the oil pump body, measure the clearance between rotor and oil pump body with a plug ruler.
  • Page 73 4 lubricating system Caution Wash and clean each part with clean kero- sene before assembly. Assemble inner rotor and outer rotor to oil pump body. Install cover plate oil pump, tighten the screw ac- cording to the stated torque. Torque: 2N.m(0.2kgf.m) Pre-tighten cover plate after assembly, install oil pump shaft, and make sure the shaft can turn smoothly.
  • Page 74 CFMOTO Install oil pump sprocket and chain. Note: Sprocket and chain should be prop- erly installed Install shaft circlip into the shaft groove. Check if the circlip is properly installed Fold separate plate oil pump B with separate oil pump A, and tighten with bolt. Install rotor comp, driven gear comp.
  • Page 75 5 carburetor air filter secondary air inlet Overhaul info … … … … … … … 5-1 air filter assembly… … … … … … 5-12 Failure diagnosis… … … … … 5-2 air filter installation… … … … … … 5-13 Carburetor disassembly…...
  • Page 76 CFMOTO Failure diagnosis Engine can’t be started l Too much fuel in the engine — air filter blockage — carburetor overflow Air leakage between carburetor and joint plate l Deteriorated fuel l No fuel in carburetor — fuel cleaner blockage —...
  • Page 77 5 carburetor air filter secondary air inlet Disassembly of carburetor Remove seat box(2-3) Remove coupler of starting enriching valve. Loosen locknut, remove adjusting nut, and remove the cable from throttle. Loosen clamp of air intake pipe and air filter, remove carburetor. Remove the vacuum tube connected with carburetor.
  • Page 78 CFMOTO Dismantling of carburetor Starting enriching device Remove screw and retainer, and the start- ing enriching device. Check the starting enriching device for damage, and float needle valve and O-ring for wear. Vacuum chamber Remove screw, vacuum chamber cover, spring, septum and vacuum piston. Turn the oil pin retainer counter clockwise, remove retainer, spring and float needle.
  • Page 79 5 carburetor air filter secondary air inlet Check septum, vacuum piston and float needle for any damage. Float chamber Remove the four screws; remove float chamber and O-ring. Take out float pin, remove float and float valve. Check the float for distortion and damage, if necessary, replace the float.
  • Page 80 CFMOTO Dismantling following parts — main jet — main nozzle — low-speed jet — mixture ratio screw/O-ring/washer/ spring Caution Before removing the mixture ratio screw, turn the mixture ratio screw till it contacts valve base slightly and write down the turns. Caution Don’t screw in too hard to avoid damage of valve base surface.
  • Page 81 5 carburetor air filter secondary air inlet Assembly of carburetor Assemble following parts -Low-speed jet main noain jet -o-ring/washer/spring /mixture ratio screw Note Screw the mixture ratio screw to till it slightly contacts valve base, screw back according to the turns of disassembly. Assemble float valve, float and float pin.
  • Page 82 CFMOTO Assemble oil pin, spring and retainer to the throttle. Rotate oil pin retainer clockwise and fix it. Assemble vacuum piston/septum, spring to carburetor body. Caution Unite the protruding part of sep- tum with groove of carburetor body. To avoid the septum being clipped, install the vacuum chamber cover while maintaining the status of the vacuum piston with fingers.
  • Page 83 5 carburetor air filter secondary air inlet Assembly of carburetor Install carburetor between air inlet connection pipe and air filter; tighten clamps on both sides of the carburetor. Install vacuum tube. Connect cable rear end to throttle and fit the cable into the bracket.
  • Page 84 CFMOTO Air filter removal Remove left shield(2-5) right shield(2-6) carburetor(5-3) left side bolt right side bolt air intake pipe Loosen clamp Loosen bolt; remove air filter bracket¢ ñ 5-10...
  • Page 85 5 carburetor air filter secondary air inlet Loosen bolt; remove air filter bracket¢ ò Dismantling of air filter Loosen screw; remove air filter connection pipe. Remove exhaust gas recycling cover. Remove exhaust filter element. Remove nut and air filter end cover. 5-11...
  • Page 86 CFMOTO remove filter element comp. and air filter seal ring. Blow off the dust on the filter element with com- pressed air. Replace in case there is damage or seri- ous stains on the filling. Assembly of air filter Install filter element comp. and air filter seal ring. Cover the air filter end cover and lock with the nut.
  • Page 87 5 carburetor air filter secondary air inlet Cover exhaust gas recycling cover, tighten with screw and connect air filter joint pipe. Air filter installation Secure the filter bracket I to the installation surface of carburetor body and tighten with bolt. Secure the filter bracket II to the installation surface of carburetor body and tighten with bolt.
  • Page 88 CFMOTO Tighten right side bolt. Install breather hose. Tighten clamp. Install carburetor. (5-9) Install left and right shields. (2) Disassembly of control valve Remove footrest deck(2-12) Remove control valve breather pipe, reed valve breather pipe and vacuum tube from control valve. remove control valve fixing collar with control valve from fixing plate.
  • Page 89 5 carburetor air filter secondary air inlet Removal of Small air filter comp. Remove small air filter breather hose and bolt; Remove Small air filter from bracket. Dismantling of small air filter comp. Open the clip place of small air filter comp., before dismantling.
  • Page 90 CFMOTO Installation of small air filter Install the assembled small air filter comp. to the bracket with bolt, and connect the breather hose. Installation of control valve Set control valve on the control valve comp.. Connect control valve air intake pipe, reed valve air intake pipe, vacuum tube to the control valve and fix.
  • Page 91 5 carburetor air filter secondary air inlet Air cleaner Assembly 5-17...
  • Page 92 6 cooling system Overhauling info......6-1 thermostat.......6-7 Trouble shooting......6-2 radiator........6-8 Performance overhauling....-6-3 oil pump........6-8 Secondary water tank....6-5 cooling system drawing¡...6-9 Caution Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap.

  • Page 93: Trouble Shooting

    CFMOTO Trouble shooting Water temperature rises too fast Radiator cap is not good Air mixes into cooling system pipe Malfunction of water pump Malfunction of thermostat (thermostat is closed) Blockage of radiator pipe or cooling pipe Coolant is not enough No rise or slow rise of water temperature.
  • Page 94 6 cooling system Function check Inspection of coolant density Caution Open the radiator cap after cool ant is cooled down. Remove front emblem plate(2-8) Remove radiator cap Check with a densimeter if the density of coolant fits the temperature of using place Check coolant for stains Inspection of radiator cap Caution...
  • Page 95 CFMOTO Pressure test of radiator Apply the specified pressure and make sure there is no pressure drop for 6 seconds. Caution Do not apply pressure over the specified pressure [108kpa(1.1kgf/cm )], or the cooling system may be damaged. In case there is any pressure leakage, check the pipe, joint parts, joints of water pump and water drain- age leakage(6-8).

  • Page 96: Secondary Water Tank

    6 cooling system Remove drain bolt Remove drain bolt and seal washer of the water pump, and drain coolant After draining the coolant, assemble new seal washer and drain bolt and tighten. Secondary water tank Remove front top cover(2-9) Remove the bolt and tapping screw of secondary water tank.
  • Page 97 CFMOTO Coolant filling Fill coolant to filler port. Start engine; and remove air from the cooling sys- Check from filler port and see if air in the cooling system has been completely removed and then install radiator cap. Remove secondary water tank cap, fill coolant to the upper limit .

  • Page 98: Thermostat

    6 cooling system Thermostat Disassembly and installation Note Open the radiator cap after the coolant is cooled down. Remove footrest deck. (2-12) Drain coolant. (6-4) Remove carburetor. (5-3) Remove bolt, lower and upper cases of thermostat. Remove the thermostat. Reverse the removal procedure for installation. Install footrest deck.

  • Page 99: Radiator

    CFMOTO Radiator Note Don’t damage radiator fins Remove plastic parts. (2chapter) Drain coolant(6-4) Remove rubber plate, wind channel. Loosen clamp, remove water inlet and outlet hoses under radiator. Remove bolt and radiator. Reverse the removal procedure for installation. Install plastic parts. (2chapter) Fill coolant and remove air.
  • Page 100 6 cooling system Cooling System...

  • Page 101: Oil Pump

    7 disassembly and mounting of engine Overhauling info......7-1 mounting of engine......7-4 Disassembly of engine....7-2 Overhauling info Operation cautions Securely support the scooter with jack when installing and disassembling engine. Do not damage frame, engine body, bolts and cables. Wrap the frame to avoid any possible damage when installing and disassem- bling the engine.
  • Page 102 CFMOTO Disassembly of engine Remove — Plastic parts. (2chapter) — carburetor. (5-3) — air filter. (5-10) Drain coolant. (6-4) Remove starting enriching coupler Remove starting enriching valve wire from tiedown band Remove AC magneto 3P、 2P coupler Remove water temperature alarm coupler Remove spark plug cap Loosen starting motor positive terminal and negative terminal.
  • Page 103 7 disassembly and mounting of engine Remove tiedown band and breather hose for sec- ondary air inlet system. Loosen locknut, Remove — throttle cable. — clamp and small cycling water pipe. — clamp and water inlet pipe. Remove clamp and water outer pipe. Remove exhausting muffler comp..
  • Page 104 CFMOTO Remove engine from frame in the following procedure. 1. Remove rear shock absorber 2. Remove suspension bracket bolt and bush, and remove engine. 3. Remove engine suspension bracket shaft nut , pull out bracket shaft, and take down suspen- sion bracket 4.
  • Page 105 7 disassembly and mounting of engine Install engine to the frame in the following procedure: 1. Install real wheel to the engine 2. Install rear fork to the engine, and assemble rear shaft nut and rear fork bolt and tighten accord- ing to the specified torque.
  • Page 106 CFMOTO Install rear brake caliper comp., and tighten bolt1 and bolt2 to the specified torque. Torque:30N· m(3.1kgf· m) Install rear brake hose comp., tighten bolt3 and bolt4. Note Rear brake hose should be fitted properly, and it should not be intervened with rear wheel, rear brake disk and other parts.
  • Page 107 7 disassembly and mounting of engine Install spark plug cap. Install water temperature alarm coupler. Install magneto 2P and 3P coupler; fill into shield, and tie with tiedown band. Install starting enriching coupler, tie the starting en- riching valve wire with tiedown band. Install —...
  • Page 108 8 Cylinder cover Cylinder head Cylinder body valving system Overhauling info......... Dismantling of cylinder head....8-11 Trouble shooting........ Replacement of valve guide...... 8-15 Cylinder compression pressure ..8-4 Inspection & Correction of valve-seat ring 8-15 Valve clearance adjustment ....8-5 Assembly of cylinder head ......
  • Page 109 CFMOTO Tightening torque Cylinder cover bolt 10N· m(1.0kgf· m) Cylinder head nut 35N· m(3.5kgf· m) Timing chain bolt 9N· m(0.9kgf· m) Tensioner spring bolt 10N· m(1.0kgf· m) Cylinder head bolt 10N· m(1.0kgf· m) Tensioner bolt 10N· m(1.0kgf· m) Cylinder body cover bolt 10N·...
  • Page 110 8 Cylinder cover Cylinder head Cylinder body valving system Cylinder compression pressure Note Measuring must be done after the engine is warmed up Remove spark plug cap, spark plug. Select proper compression pressure gauge; install it to cylinder head spark plug. Full throttle Measure compression pressure of cylinder by using electrical starting.
  • Page 111 CFMOTO Adjustment of valve clearance Inspection Note The inspection and adjustment of valve clearance should be done when the engine is in cold condition. Remove — cylinder head cover( 8-6) — left side cover (9-3) Rotate gearbox driving gear and keep the two par- allel mark lines on the camshaft sprocket in parallel with the cylinder head machining surface and the trough of camshaft neck upwards.
  • Page 112 8 Cylinder cover Cylinder head Cylinder body valving system Apply lubricating oil to the contact surface of rocker arm and make the rocker arm return. Rotate gearbox driving gear by two rounds and check again whether the valve clearance is in con- formity with the specified standard.
  • Page 113 CFMOTO Disassembly of cylinder cover Note Operation will be easy when removing the middle protecting plate. Remove: — left and right protecting plate, footrest deck. — Reed valve inlet pipe and cylinder cover bolt. — seal ring comp. and cylinder cover. Note Be careful not to damage the joint face when disassembling the cylinder cover.
  • Page 114 8 Cylinder cover Cylinder head Cylinder body valving system Disassembly of camshaft bracket comp. Remove: — left side cover (9-3) — cylinder head cover(8-6) Rotate gearbox driving gear anti-clockwise and keep the mark lines on the camshaft sprocket in parallel with the machining surface of cylin- der head, and the trough of camshaft neck upwards.
  • Page 115 CFMOTO Remove: — camshaft bracket comp.. — three retainers in the rocker arm shaft hole and cam- shaft hole. — valve rocker arm. Note: Pull out rocker arm shaft with a M5 bolt. Disassembly of camshaft Remove camshaft comp.
  • Page 116 8 Cylinder cover Cylinder head Cylinder body valving system Inspection Camshaft Rotate outer circle of bearing with finger; check whether it can turn freely. Replace the camshaft in case of rocking or blocked turning. Check the cam surface for any damage or strips. Measure cam top height with micrometer.
  • Page 117 CFMOTO Disassembly of cylinder head Note Hook the chain with a steel wire in case it drops into cylinder body, and securely support the scooter. Remove muffler. (2-15) Drain coolant. (6-4) Remove — carburetor.(5-3) — cylinder head cover. (8-6) — camshaft bracket comp..(8-7) —...
  • Page 118 8 Cylinder cover Cylinder head Cylinder body valving system Remove cylinder head bolt, and fixing plate of control valve. Remove cylinder head comp. Note Support scooter with main stand, press rear vehicle downwards, and remove cylinder head. Remove cylinder head gasket and dowel pin. Disassembly of cylinder body Remove guide chain.
  • Page 119 CFMOTO Remove water inlet hose and cylinder body comp.. Dismantling of cylinder head. Note The dismantled parts should be stored sepa- rately and installed to the original places. Take out the valve lock clip with valve spring press tool. Caution To protect the valve spring, just press the valve spring down to the length enough for removal of the valve lock clip.
  • Page 120 8 Cylinder cover Cylinder head Cylinder body valving system Valve spring Check the valve spring for weakening and damage. Measure the free length of outer valve spring. Service limit: 33.5mm Measure the free length of inner valve spring. Service limit: 30.8mm Valve stem Check the valve for distortion (valve deflection), damage and burn, and the end of valve stem for...
  • Page 121 CFMOTO Replacement of valve guide Caution The valve works with valve guide as axis. Re- placement of valve guide may cause poor sealing between valve and valve seat. So the valve seat should also be adjusted after replacement. Heat up the cylinder head homogeneously to 100-150℃...
  • Page 122 8 Cylinder cover Cylinder head Cylinder body valving system Remove valve; check valve seat sealing face through the attached red lead oil on the valve face. Correct the valve seat in case of any scrapes. If valve inclines, check clearance between valve guide and valve stem, if the clearance is not proper, replace it with a new valve guide.
  • Page 123 CFMOTO In case there are scrapes or cracks on the valve seat surface, use a 45 milling cutter to remove the scrapes or cracks. Caution Lapper the valve seat face when replace with valve guide. Be careful not to lapper excessively. Use 32 milling cutter to correct out side face slowly.
  • Page 124 8 Cylinder cover Cylinder head Cylinder body valving system Check again the valve-seat face. In case the valve-seat face is higher, grinds and pares with 32o milling 。 cutter first, and then correct to the specified width with 45o milling cutter. 。...
  • Page 125 CFMOTO Set the lower spring seat and the new valve stem gas- ket to the valve guide. Apply lubricant to valve stem and inner guide valve. Turn the valve slowly into the valve guide. Be careful not to damage the valve stem sealing comp. Install the inner/outer springs with the small ends to- wards the combustion chamber.
  • Page 126 8 Cylinder cover Cylinder head Cylinder body valving system Installation of cylinder Check the chain guide for scrapes, damages or de- flected wear. Clean the stains and impurities on the joint surface. Check the cooling pipe system, oil channels and bolt holes for impurities.
  • Page 127 CFMOTO Install the chain guide Turn the crankshaft (gearbox driving gear), till piston till piston reaches the upper dead point. (till piston surface is in parallel with the cylinder joint face) Caution: Installation of cylinder head gasket and dowel pin. Installation of cylinder head Install cylinder head comp.
  • Page 128 8 Cylinder cover Cylinder head Cylinder body valving system Installation of camshaft bracket comp. Installation of camshaft comp Install the camshaft into the hole in cam- shaft in camshaft bracket. Apply some lubricating oil to rocker arm shaft end and insert it into rocker arm hole and rocker arm as well.
  • Page 129 CFMOTO Install the sprocket to camshaft, keep the mark on sprocket in parallel with cylinder head surface. Install timing chain to the sprocket. Install tightening bolt for camshaft sprocket. Torque: 9 N. m (0.9kgf.m) Caution Before adjusting the valve clearance, check if the mark on the sprocket is in parallel with cylinder head surface and the groove opening of camshaft neck is upwards.
  • Page 130 8 Cylinder cover Cylinder head Cylinder body valving system Install thermostat comp. Install water temperature alarm coupler. Installation of cylinder head cover Assemble seal ring, dowel pin, seal ring for secondary air inlet to the cylinder head cover. Install reed valve comp. Install the R ＆...
  • Page 131 CFMOTO Install reed valve cover and tighten. Torque： 10 N. m (1.0kgf.m) Set the spring to the oil channel joint then insert it to the pin in the camshaft hole. Install the assembled cylinder head cover. Install the seal ring of cover bolt. Install the reed valve air intake.

  • Page 132: Overhaul Information

    9 CVT system Overhaul information· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-1 Removal of clutch· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-9 Troubleshooting·...

  • Page 133: Troubleshooting

    CFMOTO Troubleshooting When engine is running, scooter does not run V.-belt • worn Slider, Cam • Worn/damaged Clutch shoe • Worn/damaged Clutch spring • Damaged Engine stops or beats when the scooter starts to run Clutch return spring •damaged Poor speed performance V-belt •worn/damaged Clutch spring...
  • Page 134 9 CVT system Removal of left side cover *Caution Do not damage the joint faces Remove the cap bolt and the air inlet port cover. Remove the four of the five tightening bolts from the left side cover. Remove the rest bolt with the socket wrench.
  • Page 135 CFMOTO Removal and assembly of air inlet port cover Remove the sleeve. Break open the clamp and separate the air inlet port cover from air inlet port. Remove the element, wipe off the dust and impurities. For assembly, install the element first, keep right the insert position and reverse the procedure of removal for installation.
  • Page 136 9 CVT system Gearbox assy. Disassembly Remove left side cover.(9-3) Fix the gearbox and clutch well with jig, loosen the tightening nut and washer for gearbox with socket wrench.. Special tools: Special jig: 1P52MI-A-922-040000 Remove primary sheave and V-belt. Hold the inner side of primary sliding sheave, remove the collar for slider Dismantling Remove the collar for slider.
  • Page 137 CFMOTO Remove sliding sheare face Remove roller weight. Check V-belt Cracks/wear/scaling/chipping Measure the V-belt width. Service limit: 20.7 mm Roller weight Wear/damage Measure the outer diameter of roller weight. Service limit: 19.45 mm...
  • Page 138 9 CVT system Primary sliding sheave Measure inner diameter of sliding sheave. Service limit: 24.07 mm Check collar for any wear or damage. Measure the outer diameter of collar. Service limit: 23.92 mm...
  • Page 139 CFMOTO Install the roller weight comp. to the sliding groove of the primary sliding sheave. Keep the roller weight terminal surface alignment in the direction as shown in the picture. Install primary sheave cap. Install collar into the bush hole of primary sliding sheave.

  • Page 140: Assembly Of Clutch

    9 CVT system Install V-belt. Install primary sheave, washer, nut. Apply glue to the nut screw part, install the nut and tighten it. Tighten the primary sheave nut with pneumatic wrench according to the specified torque. Torque: 59 N. m (6.0kgf.m) Clutch Disassembly Remove:...
  • Page 141 CFMOTO Fix the clutch spring compressor with a pliers or the like. Remove the nut from clutch with socket wrench. Remove the following parts from clutch spring compressor: -Clutch comp. -Secondary fixed sheave -Clutch spring -Socket -Buffer washer -Plastic washer Dismantle clutch comp.and secondary fixed sheave separately.
  • Page 142 9 CVT system Remove damper rubber. Dismantling of secondary fixed sheave Remove sealing bush. Remove guide pin, roller, remove secondary fixed sheave Check guide pin and roller for damage or wear. Remove oil seal and O-ring from secondary fixed sheave ( Replace with new ones for installation) Check the needle bearing and ball bearing of sec- ondary fixed sheave Replace in case of poor rotat- ing or jam.
  • Page 143 CFMOTO Replacement of bearing for secondary sliding sheave.. Remove the needle bearing with bearing removal tool. Remove circlip, and take out the ball bearing. Apply lubricant to the new ball bearing. Strike the ball bearing with its countermark upward into the secondary fixed sheave. Install circlip.
  • Page 144 9 CVT system Apply lubricant to the inner side of the secondary fixed sheave. Apply lubricant to the new needle bearing. Press the needle bearing with is countermark up- wards into the secondary fixed sheave. Check Clutch housing Check the clutch housing for wear and damage Measure inner diameter of clutch hous- Service limit: 125 mm...
  • Page 145 CFMOTO Secondary fixed sheave Check for wear and damage. Measure the outer diameter Service limit: 33.92 mm Secondary sliding sheave Check for wear and damage. Measure the inner diameter. Service limit: 34.06 mm Assembly of clutch Caution While assembling, cleaning and degreasing from sliding surface and inner secondary fixed sheave must be performed.
  • Page 146 9 CVT system Degrease and clean the belt sliding surface of sec- ondary fixed sheave Apply lubricating grease to the lip of oil seal and install the oil seal with the lip facing the inner side of secondary sliding sheave Apply lubricant grease to the O-ring and install it to secondary fixed sheave Apply lubricant grease to the oil seal lip and install...
  • Page 147 CFMOTO Assemble clutch comp. Install damper rubber to the base plate of secondary fixed sheave. Pay attention to the mounting direction of return spring. Install centrifugal weights and return spring. 9-16...
  • Page 148 9 CVT system Install circlip Assembly Assemble the following parts -Clutch comp. -Socket -Clutch spring -Damper washer -Plastic washer -Secondary sliding sheave. 9-17...

  • Page 149: Installation Of Clutch

    CFMOTO Install with the hole of secondary fixed sheave facing the protruding part of clutch spring compressor. Caution Do not tighten the clutch spring com- pressor more than the specified torque. Fix the clutch spring compressor with pliers or the like. Install nut for secondary fixed sheave.

  • Page 150: Cvt System

    9 CVT system Install left side cover, tighten according to the specified torque. Torque: 10 N. m (1.0kgf.m) Reverse the removal procedure for installation Install air inlet cover comp. Tighten the bolt according to the specified torque. 9-19...
  • Page 151 10 Gearbox Overhaul information· · · · · · · · · · · · · · · · · · 10-1 Bearing arrangement· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-4 Troubleshooting·...
  • Page 152 CFMOTO Disassembly of gearbox Drain lubricant from gearbox.(→ 3-10) Remove: -Rear wheel( 4-3 ) -Clutch assy.( 9-9 ) Remove bolt Remove gearbox. Remove dowel pin and gearbox sealing gasket Wipe off the attached sealant on the joint face. Remove final shaft comp. Remove countershaft and gear.
  • Page 153 10 Gearbox Disassembly of drive shaft Strike the terminal shaft with wooden hammer, and remove drive shaft Inspection of gearbox Turn inner circles of bearings in the gearbox and left crankcase with fingers, check whether they turn smoothly without block or not. Replace the old, if not, with new ones.
  • Page 154 CFMOTO Check countershaft and bearing for wear or damage. Replace with new ones in case of any dam- age or wear. Bearing arrangement Removal and installation of gearbox bearing and oil seal Remove the final shaft oil seal from gearbox. 10-4...
  • Page 155 10 Gearbox Remove final shaft bearing with special tools. Use the same tools and reverse the re- moval procedure for installation. Remove the drive shaft bearing and coun- tershaft bearing at the gearbox’s side, with the same special tool. Special tools: Disassembly tools for bearing: 1P52MI- A-922-050000...
  • Page 156 CFMOTO Removal and installation of left crankcase. Remove drive shaft oil seal. Refer to 10-5 for removal for removal of left crankcase drive shaft bearing, counter- shaft bearing and final shaft bearing. Press a new bearing vertically, with its countermark side upwards, into the left crankcase until it is stopped.
  • Page 157 10 Gearbox Gearbox assembly Install adjusting washer Install countershaft gear and countershaft to gearbox, make sure that adjusting washer is on the shaft. Install final shaft. nstall dowel pin. Dip the gearbox gasket into kerosene, install it onto the joint face of left crankcase. Install gearbox Install the bolt and tighten it.
  • Page 158 CFMOTO 10-8...
  • Page 159 11 Right side cover magneto water pump Overhaul information· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 11-1 Installation of water pump·...
  • Page 160 CFMOTO Removal of right side cover Remove plastic parts(2) Drain coolant(6-4) Drain crankcase lubricant.(3-11) Caution Removal of right side cover should be done when the engine is cold. Remove water inlet hose and breather hose. Remove water pump cover, dowel pin and water pump gasket.
  • Page 161 11 Right side cover magneto water pump Fix flywheel comp. with special tool and remove fly- wheel comp with spanner. Special tool: Special tools for disassembly of flywheel comp.: 152MI-922-030000 Disassembly of driven gear Remove bolt, fixing plate and driven gear comp. Disassembly of stator assy.
  • Page 162 CFMOTO Assembly of water pump Assembly steps 1. Install bearing 6901/P6 to water pump shaft, and then install the shaft into shaft hole of right side cover. 2. Install bearing 6000/P6 to water pump shaft, and clip with circlip; Apply sealant to outer surface of oil seal install it into right side cover. 3.
  • Page 163 11 Right side cover magneto water pump Assembly of right side cover Install water pump comp. as indicated. Install: — upper inspection cover and seal ring. — oil level gauge. — oil filter comp. — oil bolt and washer. 11-5...
  • Page 164 CFMOTO Installation of stator comp. Install stator comp. , trigger, and tighten with bolt. Caution: Fix wires for stator comp and trigger with clamp. Apply tightening glue to the tightened bolt. Install the two wires seal block into clip groove in the order of 1 and 2.
  • Page 165 11 Right side cover magneto water pump Install compound gear, compound gear shaft, oil channel joint and joint spring. Install dowel pin, right side cover gasket. Installation of right side cover Install right side cover, tighten the bolt by 2 or 3 times in the opposite angles.
  • Page 166 12 Crankcase crankshaft piston Overhaul information· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12-1 Crankshaft/piston· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12-4 Troubleshooting·...
  • Page 167 CFMOTO Troubleshooting Compression pressure is too low • Wearing and damages of piston ring • Wearing of cylinder and piston • Poor sealing of cylinder and valve. •Burnt, broken or jamed piston ring. Compression pressure is too high • Carbon deposit at piston end or in combustion chamber Blue smoke from exhaust muffler •...
  • Page 168 12 Crankcase crankshaft piston Dismantling of crankcase. Remove engine from scooter.(chapter 7) Refer to 12-1 for removing the relevant parts before crankcase dismantling. Remove thread pin and tensioning plate comp. Remove crankcase bolt. Keep the right crankcase downwards and remove left crankcase.
  • Page 169 CFMOTO Crankcase/piston Dismantling of crankcase and piston Refer to 12-1 for removal of relevant parts from engine. Remove piston pin retainer. Remove piston pin and piston. Expand piston ring gap and remove piston ring. Caution • Piston ring is easy to be broken. Do not ex- pand gap too wide.
  • Page 170 12 Crankcase crankshaft piston Inspection Crankshaft Measure side gap of big end of connecting rod. Service limit: 0.5mm Measure radial gap of big end of connecting rod. Service limit: 0.05mm Measure vibration of crankshaft. Measure inner diameter of small end of connecting rod. Service limit: 15.05mm 12-5...
  • Page 171 CFMOTO Turn crankshaft bearing, check if there is any abnormal knocking or rocking. In case of any, replace it with a new one. Piston、 cylinder Check the outer surface for scrapes. Check piston groove for wear or blockage of oil hole. Measure outer diameter of piston at 6mm above piston bottom, and at the angle of 90°...
  • Page 172 12 Crankcase crankshaft piston Check piston ring for wear or scrapes. Assemble piston ring into the right groove, and then press till it reaches the position close to the side surface of piston. Measure the clearance between piston ring and groove with a plug ruler.
  • Page 173 CFMOTO Installation of crankcase Apply lubricating grease to the inner lip of the new oil seal and sealant to the outer lip, install it to the left crankcase. Install dowel pin and crankcase gasket. Install crankcase and piston. Install tensioning plate and thread pin, tighten ac- cording to specified torque.
  • Page 174 13 Front wheel, Brake, Suspension ,Steering system Overhaul information 13-1 Front shock absorber 13-9 Troubleshooting 13-2 Steering bar 13-10 Front wheel 13-3 Front fork 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 175 CFMOTO Special tools Shaft, bearing remover 07746-0050100 Remover head 10mm, bearing remover 07746-0050100 Handle A , press tool 00749-0010000 Press tool outer sleeve 07946-1870100 Guide tool 10mm 07746-0040100 Locknut spanner 07916-KM10000 Bearing adjusting spanner, steering column 07SMA-GBC0100 Bearing remover set, 07JAC-PH80000 Rotor puller 07JAC-PH80100...
  • Page 176 13 Front wheel, Brake, Suspension ,Steering system 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. Remove counter. 13-3...
  • Page 177 CFMOTO Remove axle collar from front wheel left side. Inspection Wheel axle Set axle on a V block, measure axle wobble with centesimal gauge. Service Limit: 0.2mm Inspection Wheel axle Set axle on a V block, measure axle wobble with centesimal gauge.
  • Page 178 13 Front wheel, Brake, Suspension ,Steering system Dismantling Remove the oil seal. Install the tool head on the rim Install the bearing remover shaft on the tool head from the reserve side, strike in and remove the bearing Remove spacer. Special tool: Bearing remover shaft 519-922-070001...
  • Page 179 CFMOTO Remove five bolts of brake face, and remove brake face. Inspection Check thickness of brake disk. Replace with a new one in case the thickness is less than 3mm. Remove bolt and brake calipers comp. Inspection Brake clipper: check brake calipers for cracks or oil leakage from the tightening parts.
  • Page 180 13 Front wheel, Brake, Suspension ,Steering system Assembly Assemble spacer Apply lubrication grease on the running part of new bearings, press into the left side 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 519-922-070005...
  • Page 181 CFMOTO 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. Installation Install with the brake disk in line with brake bracket.
  • Page 182 13 Front wheel, Brake, Suspension ,Steering system Front shock absorber Disassembly Remove front fender? (2-8) Remove front wheel? (13-3) Remove bolt1 and bolt2 Remove the four upper fixed bolts, seal cover and seal ring Note There should be no damage with seal ring Remove shock absorber Note Do not put the shock absorber upside down in case...
  • Page 183 CFMOTO Installation Install the shock absorber. Install the seal cover and seal ring of shock absorber. Tighten it according to the specified torque. Tightening Torque: 50N•m (5.1kgf•m) Install the tightening bolt 1 of absorber, and tighten it according specified torque. Tightening Torque: 40N•m (4.1kgf•m) Install front wheel.
  • Page 184 13 Front wheel, Brake, Suspension ,Steering system Handle bar lower cover Disassembly Remove head light comp (18-5) Remove handlebar upper cover (13-10) Loosen handlebar fixing bolt and nut, remove handlebar comp. Remove bolt 1, bolt 2, bolt 3, and bolt 4 of handle bar lower cover Loosen throttle cable.
  • Page 185 CFMOTO Left handle bar switch Disassembly Remove head light comp (18-5) Remove handlebar upper cover (13-10) Loosen the four screws fixing handlebar lower cover and frame, loosen handle bar lower cover. No need to remove handle bar lower cover from vehicle. Remove screw1 and screw 2.
  • Page 186 13 Front wheel, Brake, Suspension ,Steering system Master Cylinder Disassembly Remove head light comp (18-5) Remove handle bar upper cover (13-10) Loosen the four screws fixing handlebar lower cover and frame, loosen handle bar lower cover. No need to remove handle bar lower cover from vehicle. (13- Remove bolt1 and bolt 2.
  • Page 187 CFMOTO Note Main cable comp, throttle cable, brake hose, cable wiring should be corrected routed. Install handlebar lower cover Install handlebar lower cover to the handlebar, tighten the four screws. Install handlebar Install handlebar with lower cover onto the scooter. Tighten fixing bolt and nut according to the speci- fied torque and direction.
  • Page 188 13 Front wheel, Brake, Suspension ,Steering system Install rear view mirror (13-12) Install handlebar upper cover (13-10) Install head light lower cover (13-10) Install odometer (?18-9) Install headlight comp. (18-5) Front fork Disassembly Remove: — front fender (2-8) — front decorative plate (2-8) —...
  • Page 189 CFMOTO Remove thrust washer Remove steering column bearing retainer Special tool Adjusting wrench, Steering column bearing 519-922-050002 Remove: — upper bracket — front fork — lower bracket Install special tool on the frame body standpipe Remove lower ball race Special tool Bearing remover comp 519-922-050000 Rotor puller 519-922-050010 Remover shaft 519-922-050003...
  • Page 190 13 Front wheel, Brake, Suspension ,Steering system 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 191 CFMOTO Install new upper ball race on the steering col- umn with tools listed below: Special tools Tool A, steering column bearing bracket 519-922-050005 Tool shaft 519-922-050006 Tool B, steering column bearing bracket 519-922-050007 Tool shaft 519-922-050008 Hold installation tool shaft, tighten the locknut while pressing the upper ball race into steering column.
  • Page 192 13 Front wheel, Brake, Suspension ,Steering system Press new lower bearing retainer on to front fork with special tool and press machine. Special tool Front fork cover, press tool 519-922-050009 Installation Apply lubrication grease on new lower bearing, and then install front fork Install after applying lubrication grease on new up- per bearing 13-19...
  • Page 193 CFMOTO Install upper bearing retainer, Tighten it according to the specified torque Special tool Adjusting wrench, steering column bearing: 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. Loosen steering column upper bearing retainer.
  • Page 194 14 Rear wheel Brake Suspension 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. •Do not overexert on the wheels and do not damage the wheels.
  • Page 195 CFMOTO Troubleshooting Rear Wheel wobbles •deformed rim. •faulty tire. •lower tire air pressure •improper wheel balance •faulty tightening of wheel axle nut. Rear shock absorber is too soft •weakened spring. •oil leakage with rear shock absorber Rear shock absorber is too hard. •bended rear shock absorber •higher tire air pressure Poor brake effect...
  • Page 196 14 Rear wheel Brake Suspension Rear wheel Disassembly Securely support the vehicle with main stand. Remove: — muffler (2-16) — rear shock absorber (right)(14-5) — rear brake caliper (14-6) — rear fork (14-4) Remove rear fork inner collar Remove rear wheel Inspect Check rim for damage, deform or scrapes.
  • Page 197 CFMOTO Rear fork Disassembly Remove muffler （ 2 － 16） Remove bolt 1、 bolt 2、 bolt 3 and nut， and then loosen rear brake hose and lower end of right rear shock absorber Remove bolt 4 and bolt 5，and remove rear brake caliper comp。...
  • Page 198 14 Rear wheel Brake Suspension Rear shock absorber Rear shock absorber (L) Disassembly Securely support the vehicle with main stand. Remove : — small seat (2-2) — trunk & big seat assembly comp (2-3) — middle protection plate (2-4) — rear bracket (2-4) —...
  • Page 199 CFMOTO Inspection Inspect shock absorbers for oil leakage、aging of rubber spacer or damage. Replace in case of any. Installation Install absorber upper fixing bolt, and tighten ac- cording to specified torque. Torque: 55N•m (5.6kgf•m) Install absorber lower fixing bolt, and tighten ac- cording to specified torque.
  • Page 200 15 Battery Charging system Charging system 15-1 Charging system inspection 15-5 Overhaul information 15-2 Rectifier 15-6 Troubleshooting 15-3 AC magneto inspection 15-8 Battery 15-4 15-1...
  • Page 201 CFMOTO Overhaul information Operation notes Warning •Usually no hydrogen will be generated during charging except when overcharged. Do not smoke when charging. •Electrolyte is highly corrosive, splash to clothes, skin or eyes will cause burn or loss of sight. Wash with plenty of water if splashed. In case of splash into eyes, wash with plenty of water and consult the doctor.
  • Page 202 15 Battery Charging system Overhaul standard I t e m S ta n d a r d A C m a g n e to M o d e l P e r m a n e n t m a g n e t a lte r n a to r O u tp u t 3 - p h a s e A C R e s is ta n c e o f c h a rg in g c o il (2 0 ℃...
  • Page 203 CFMOTO Battery Disassembly Notes Keep switch OFF before operation. Open the seat with ignition key. Remove battery cover. (2-2) Loosen terminal screws, and remove battery’ nega- tive harness joint. Remove terminal cover and screw. Remove battery’ positive harness joint. Installation Reverse the removal procedure for installation.
  • Page 204 15 Battery Charging system Connect charger’ positive harness with battery’s positive terminal. Connect charger’ negative harness with battery’s negative terminal. Charging current/time: standard: 0.9A/5- 10hours Fast charge: 4A/60mins Notes •Keep the battery’s liquid temperature under than 45℃ . Reduce current to adjust the temperature if it is too high.
  • Page 205 CFMOTO Remove fuse. Connect ammeter between negative terminals and negative harness of battery. Measure current leakage with ignition switch in the “OFF” position. Notes •If the measured current is higher than the limit, the fuse of multimeter will be burnt. Therefore, measure the current by shifting from the large to the small measurement.
  • Page 206 15 Battery Charging system Check the coupling terminals for loosening, bending, rust break. Check the following items of the main cable termi- nals of the two rectifier couplers: Item Result Battery wire (red) V oltage between red terminal(+) and frame body earthing wire Earthing wire (green) Green terminal must be connected with frame body earthing wire Ω...
  • Page 207 CFMOTO Inspection of AC magneto Remove left protection plate (2-5) Remove right protection plate (2-6) Disconnect couplers of AC magneto (yellow, yellow, yellow), and trigger coil (black/white/green). Measure the resistance between the yellow termi- nals of the AC magneto 3P coupler. Ω...
  • Page 208 15 Battery Charging system 15-9...
  • Page 209 16 Ignition system Overhaul information 16-1 Trigger coil 16-6 Trouble shooting 16-3 Ignition coil 16-6 Inspect ignition system 16-4 Ignition system disposition 16-7 Overhaul information Operating notes Notes Exhaust contains toxicant, DO NOT keep the engine run for a long time in a closed or poorly ventilated place.
  • Page 210 CFMOTO Overhaul standard Item Standard Ignition CDI battery ignition Spark plug Standard DPR7EA-9 Optional Spark plug gap 0.8-0.9mm Ignition timing Maximum advance angle 33°BTDC Peak voltage Ignition coil 150V ≥ Impulse generator ≥ 0.8V Special tool Peak voltage oscillograph 07HGJ-0020100 (Use it together with digital muitimeter available in the market with input resistance over 10M/ DCV) 16-2...
  • Page 211 16 Ignition system Troubleshooting •Engine cannot be started. Check fuel and air gateways for any faults; If the fuel and air gateways are normal, check the ignition system. •Inspect of ignition system for the following items: 1. Spark inspection: Check in the following steps: Take off spark plug Remove spark plug cap Set high tension flexible cable end to earthing...
  • Page 212 CFMOTO Inspection of ignition system Notes •If the spark plug generates no spark, check first if there is break, loosening or poor contact with the wiring, then measure the peak voltage. •Different universal meter has different input resis- tance and shows different readings. Thus it is impos- sible to obtain the correct reading.
  • Page 213 16 Ignition system Trigger coil Notes • Measurement should be done after all the wires are correctly connected. • Inspect with compression pressure in the cylinder, spark plug and spark plug cap are properly installed. If the spark plug is removed and then do the measurement, the peak volt- age will rise.
  • Page 214 CFMOTO Trigger Disassembly Remove: — AC magneto coupler — water pump inlet hose and outlet hose, and drain coolant water. (Chapter 6) — crankcase breather hose. (Chapter 11) — exhaust muffler. (Chapter 2) — right side cover. (Chapter 11) Notes Stator is installed on the right side cover and is attached by the magnet of rotor.
  • Page 215 16 Ignition system 16-7...
  • Page 216 7 Electrical start ignition Overriding clutch Maintenance information 17-1 Starter relay 17-2 Troubleshooting 17-1 Starting motor comp 17-2 Overriding clutch 17-5 Maintenance information Notice: • Bundle the wires of the same color. Wires of different colors should be connected with the wires of the same color.
  • Page 217 CFMOTO Starter relay Notes • Check and confirm battery is in good status before inspection. •In case of poor starting, check each brake switch and starter relay. (Chapter 16) Disconnect 4P coupler of starter relay and remove starter relay. Input voltage Keep ignition switch in the ON position.
  • Page 218 7 Electrical start ignition Overriding clutch Inspection Measure length of each brush Service Limit£ ºReplace if the brush less than 6.5mm Check color of rectifier rotor¡£ If more than two rectifier rotors have changed color£¬short circuit will be caused¡£Replace them¡£ Make sure rectifier rotors are well connected。...
  • Page 219 CFMOTO Make sure the rotor shaft is not conducted with each rectifier rotor. Installation Set O-ring in the groove of starter motor Apply some grease on the O-ring. 17-4...
  • Page 220 7 Electrical start ignition Overriding clutch Apply some lubricant on bearing part of rotor’ two ends. Install rotor into case of starter motor. Press brush into the brush holder, while install brush holder on the rectifier. Align the cam part of motor case with groove of motor holder.
  • Page 221 CFMOTO Loosen bolt, remove fixing plate and driven gear comp. Installation Reverse the disassembly procedure for assembly. Apply some lubricant on the gear compound shaft in the right case. Tighten the three inner hex bolts of overriding clutch according to the specified torque. Tightening Torque: 12-14N•m (apply some thread tightening glue) 17-6...
  • Page 222 18Light, Instrument, Switch Overhaul information 18-1 Brake light switch 18-8 Troubleshooting 18-2 Electrical horn 18-8 Bulb replacement 18-3 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 Starting enriching device 18-13 Overhaul information Notes on operation...
  • Page 223 CFMOTO Troubleshooting Head light cannot turn on •Fuse break • Open circuit with main cable •Bulb burnt •Night switch is damaged 18-2...
  • Page 224 18Light, Instrument, Switch Replacement of bulb Head light bulb Note Headlight bulb has larger power and the tem- perature is very high when it si turned on. Do not touch it after it is just turned off. Opera- tion should be done when the bulb is cooled down Remove head light comp.
  • Page 225 CFMOTO Brake/tail light bulb Remove screw 10, and tail light cover4 Rotate brake/tail light bulb 7 counterclockwise and remove it. Replace the brake/tail light bulb. Bulb specification: 12V-21/5W Reverse the removal procedure for installation. Rear turning light bulb Remove — screw 10 —...
  • Page 226 18Light, Instrument, Switch Fuel level gauge illuminator light Remove front top cover(2-9) Remove tapping screw1 and tapping screw2 Remove fuel level gauge Pull out socket from fuel level gauge and re- place with a new bulb. Bulb specification: 12V-1.7W Note Routing of wires, cables and hoses should pass properly(¡ú...
  • Page 227 CFMOTO Disconnect head light 4p coupler Reverse the removal procedure for installation. Note Be careful not to damage main cable when mounting. After replacing, adjust the headlight beam. (3- Note Routing of wires, cables and hoses should pass properly(1-20) Ignition switch lock Inspection Remove front top cover(2-9) Disconnect ignition switch 4p coupler.
  • Page 228 18Light, Instrument, Switch Check the terminals between ignition switch cou- pler for conducting according to following table. l-l means normal. Disassembly and mounting Remove front top cover comp. (2-9) Disconnect ignition switch 4p coupler Loosen bolt and remove ignition switch lock. Reverse the removal procedure for installation.
  • Page 229 CFMOTO Turning indicator switch Overtaking switch Electric horn switch If inspection of above items have any problems, replace the handlebar switch. Brake light switch Remove head light comp. (18-5) Remove handlebar upper cover(13-10) Disconnect brake light switch coupler and check coupler terminals for conducting.
  • Page 230 18Light, Instrument, Switch Removal and installation Disconnect electronic horn coupler. Remove mounting bolt horn. Reverse the removal procedure for installation. Odometer Note Check if odometer flexible shaft is broken or loosen. Securely lift the front wheel with repairing bracket. Rotate front wheel quickly and check if the odometer pointer turns.
  • Page 231 CFMOTO Fuel sensorDisassembly Remove: — small seat(2-2) — middle side panel(2-4) — rear carrier(2-4) — left side panel(2-5) — right side panel(2-6) — seat box with big seat comp(2-3) Disconnect fuel sensor 2p coupler. Pry fuel sensor from fuel tank with a flat screwdriver.
  • Page 232 18Light, Instrument, Switch Remove fuel sensor 2p coupler Connect universal meter between fuel sensor 2p coupler terminals. Rock fuel sensor float with hand, and measure resistance of each position. Connection terminal: yellow/white-green ± Ω ℃ Float position: up:10 ± Ω ℃...
  • Page 233 CFMOTO Water temperature sensor Warning: Be careful not to get scalded and do not place flammables nearby. Note Coolant must reach the switch thread, and the depth from vessel bottom to sensor top should be over 40mm. Keep liquid temperature for three minutes before measuring, and do not raise tem- perature sharply.
  • Page 234 18Light, Instrument, Switch Starting enriching device System inspection Note Exhaust contains toxic contents. Do not run the engine for a long time in a closed or poorly ventilated place. Note Inspection should be done after the en- gine is cooled down. Unit inspection Inspection of Resistance The inspection of resistance can be...
  • Page 235 CFMOTO 19 Electrical Diagram 19-1...
  • Page 236 19 Electrical Diagram CFMOTO 19-2...
  • Page 237 20 Troubleshooting Operation notice… … … … … … … … … … … … … … … … … … … … … … 20-1 Starting failure/Hard starting… … … … … … … … … … … … … … … … … … 20-1 Unstable engine running or engine stops…...
  • Page 238 CFMOTO Unstable engine running or engine stops Not reached No fuel in fuel tank Loosen drain screw, and check if fuel Clogged fuel hose has reached carburetor Clogged float valve Reached clogged fuel filter Clogged fuel tank cap breather ho le Stained, damaged or color changed Remove spark plug and Stained or damaged spark plug...
  • Page 239 20 Troubleshooting (20 — 2) Connect starting enriching cable with With Air current battery for 5 Faulty starting enriching device Minutes. Connect ethylene pipe with fuel increment loop and blow. No air current Clog ged carburetor Poor engine performance in high-speed range Engine speed does Clogged air filter Slightly try running engine at...
  • Page 240 CFMOTO Idle speed performance improper Faulty pulse generator check ignition time Faulty CDI unit proper improper adjustment check caburetor mixture Fuel system chapter (chapter 5) screw Properly adjusted intake Faulty tightening of carburetor and inlet pipe Check if secondary air Faulty reed valve seal washer intake into air intake No elasticity of inlet pipe joint...
  • Page 241 20 Troubleshooting Poor engine performance at middle or high speed improper Faulty pulse generator check ignition timing Faulty CDI unit proper Clogged check carburetor jet for clean clogging Not clogged Disconnect starting Not conducted starting enriching cable breaks enriching device and check Faulty starting enriching device if it is conducted.

This manual is also suitable for:

Cf150t 2003

Table of Contents