CF MOTO CF125T-19 2003 Service Manual Download Page 136 | Manualshive

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9 CVT system

9

9-5

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.

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Summary of Contents for CF125T-19 2003

Page 1: ...WWW CFMOTO COM CFMOTO CF125T 19 SERVICE MANUAL CF150T VERSION A...

Page 2: ...All right reserved ZHEJIANG HONGQIAO POWER MANUFACTURING CO LTD 2003 5 WWW CFMOTO COM...

Page 3: ...m wiring diagram 19 Troubleshooting FOREWORD This manual contains an introductory descrip tion of procedures for inspection maintenance overhaul disassembly assembly removal and installation of compon...

Page 4: ...mple Conversion Pressure 200Kpa 2 00lgf cm2 33kpa 250mmHg 1kgf cm2 98 0665kpa 1kpa 1000pa 1mmHg 133 322Pa 0 133322Kps Torque 18 N 1 8kgf m 1kgf m 9 80665N m Volume 419ml 1ml 1cm3 1cc 1l 1000cm3 Force...

Page 5: ...es and gloves for operation Caution Batteryliquid dilute sulfuric acid Warning Coolant is poisonous Do not is highly causitic and may cause burns to drink or splash to skin eyes or clothes skin and ey...

Page 6: ...nic 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 Warning Be careful not to get clamped...

Page 7: ...pin with new ones Elastic circlips might get distorted after Disassembled Do not use the loosed circlips Clean and blow off the detergent Measure the data during disassembly for after disassembling t...

Page 8: ...bearing will turn smoothly The right direction When assembling the Replace if the axial or radial play is too big open type or double side dustproof bearing If the surface is uneven clean with oil in...

Page 9: ...the pipe clip if any into the do not fold or scratch the oil seal lip groove Replace the pipes that cannot be apply grease to the oil seal lip tightened beforeassembling Do not mix mud or dust into en...

Page 10: ...1 6 CFMOTO Location of serial No CF125T 19 CF150T V I N LCETDJPK LCETDKP1 Engine No 1P52MI A 1P58MJ...

Page 11: ...e 140mm Turning Radius 4 0m Starting Electric Start Engine Type 4 Stroke Gasoline Engine Cylinder Arrangement Single Cylinder Horizontal Combustion Chamber Semi spherical Valve Drive OHC Chain Drive B...

Page 12: ...pe Bevel Initial Transmission Reduction ratio 3 7700 3 13 Gear type Vertical Secondary transmission Reduction ratio 3 21 Type V type teeth belt Starting mode Auto CVT Gearing Gearbox Transmission rati...

Page 13: ...y within the following category API Category SE or SF Engine oile SAE Category Select from the left table according to the temperature Clearance of Inner Outer rotor 0 15mm 0 20mm Body Clearance 0 15...

Page 14: ...0 10 015mm 10 10mm Valve rocker Outer diameter of rocker IN EX 9 978 9 987m m 9 91mm IN 4 975 4 99mm 4 965mm External diameter of valve rod EX 4 955 4 97mm 4 945mm IN 5 5 012mm 5 04mm Inner diameter o...

Page 15: ...uter diameter of Piston 52 37 52 39 57 97 57 99 52 32 57 92 Piston pin inner diameter 15 002 15 008 15 04 Piston pin outer diameter 14 994 15 000 14 98 Shaft small end side inner diameter 15 016 15 03...

Page 16: ...e Air pressure 250kpa 2 5kgf cm3 Rear wheel Item Standard Limit Vertical 0 8mm 2 0mm Play of wheel rim Horizontal 0 8mm 2 0mm Groove 1 6mm Rear wheel Tire Air pressure 300kpa 3 0kgf cm3 Brake system I...

Page 17: ...g e I n s u ff ic ie n t c h a rg e 1 1 8 V S ta n d a r d 0 9 A 5 1 0 H B a tt e r y C h a rg in g c u r r e n t tim e Q u ic k 4 A 1 H Ignition system Light Panel Switch Pickup coil Item Standard M...

Page 18: ...justing Check Gearbox oil drain Bolt Engine oil filter cover Drain oil bolt Spark plug Lubricating system Oil plump and mounting bolt Screw oil pump plate Coolant system Water drain bolt Water tempera...

Page 19: ...sorber mounting bolt upper A bsorber mounting bolt lower R ear fork mounting bolt B rake system Front brake disc m ounting bolt R ear brake disc m ounting screw Front brake caliper m ounting bolt R ea...

Page 20: ...Charging Ignition system Peak voltage regulator 1P52MI A 922 020000 152MI 234 022300 34B 152MI 236 022301 27 152MI 236 022301 27 1P52MI A 922 040000 152MI 922 070000 152MI 921 070000 1P39MB 921 110001...

Page 21: ...ocket gear surface oil pump Oil pump comp Thread joint surface drive wheel nut Outside surrounding oil seal and press Gear surface and shaft part gear and gear shaft Camshaft surface and surrounding I...

Page 22: ...rottle cable Throttle handlebar part Pivot back bracket L Pivot back bracket R Pivot side stand Oil seal lip rear fork Gear surface and running part counter gear small gear Axle part main stand Multi...

Page 23: ...1 19 1 Overhaul Information 1 Wiring Piping Diagram...

Page 24: ...1 20 CFMOTO...

Page 25: ...1 21 1 Overhaul Information 1...

Page 26: ...1 22 CFMOTO...

Page 27: ...1 23 1 Overhaul Information 1...

Page 28: ...1 24 CFMOTO...

Page 29: ...1 25 1 Overhaul Information 1...

Page 30: ...Anti pervasion device for poisonous gas Thedeviceis tolead thepoisonous emissionfrom thecrankcasethrough air cleanerandcarburetor tothe combustion chamberfor burningso as to avoid the direct emission...

Page 31: ...f the exhaust gas will be turned into harmless carbon dioxide and water To keep theexhaust gas in theexhaust pipefrom flowingbackwards aone waytonguevalve is set inthe Secondaryairinlet gateway innerc...

Page 32: ...y also be explosive when it is vaporized so operation should be done in a well ventilated place Muffler can t be disassembled and installed until it is fully cooled l This chapter is on the disassembl...

Page 33: ...y 2 3 Remove circlip pull out seat pin and remove big seat Mounting Install the big seat in the reverse order of disassembly Note After installation of the big seat rock it up and down back and forwar...

Page 34: ...w2 Screw out fuel tank cover Lift central trunk big seat assembly Remove bolt5 bolt6 and nut1 nut2 Remove seat lock and cable seat comp Take down seat box big seat comp Disconnect seat box big seat co...

Page 35: ...ly 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 Remove small...

Page 36: ...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 Re...

Page 37: ...ighten the tapping screw Install front seat bracket Install rear carrier and small seat Right protecting plate Disassembly Remove small seat 2 2 Remove seat box big seat comp 2 3 Remove middle protect...

Page 38: ...e 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 Rem...

Page 39: ...ough 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 Front emblem plate Disa...

Page 40: ...ont 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...

Page 41: ...n 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 Remove front left and right winker and take o...

Page 42: ...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...

Page 43: ...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 Instal...

Page 44: ...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...

Page 45: ...nect 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 Mounti...

Page 46: ...rrier 2 4 Remove left protecting plate 2 5 Remove right protecting plate 2 6 Remove bolt1 Remove bolt2 bolt3 bolt4 and bolt5 take down trunk rear mounting plate and mat Remove fuel sensor 2p Socket Re...

Page 47: ...wn 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 Torque Front elbow...

Page 48: ...2 17 2 Vehicle body muffler 2 Outer Components...

Page 49: ...ess contact maycause seriousburn Besuretowearfatiguedresswithandglovesiftheworkhastobedonewhentheengine is just stopped l Gasolineis highlyflammable smokingis strictlyforbiddenintheworkplace Keepalert...

Page 50: ...s k b r a k e d i s k D a m a g e a n d w e a r R e p l a c e w h e n t h e t h i c k n e s s o f b r a k e d i s k i s l e s s t h a n 3 m m D r i v i n g d e v i c e T i r e T i r e p r e s s u r e...

Page 51: ...t e r m i n a l s E l e c t r i c a l d e v i c e E l e c t r i c w i r i n g S l a c k a n d d a m a g e o f j o i n t s S t a r t in g s t a t u s a n d a b n o r m a l n o i s e t i m i n g C h a...

Page 52: ...ors function Alarm and lock device function instruments function Slack or damage when installing Exhaust pipe and muffler Function of muffler frame Slack and damage Others Lubrication grease status of...

Page 53: ...ayof the steering column tighten the locknutordismantlethesteeringcolumnforfurther check Lift the front wheel slowlyturn the handle bar left and right to see if it can turn freely Incasethereisanyhind...

Page 54: ...r parts Keep the fluid away from these parts l Slightly turn the handlebar left and right till the brake pump comp Is in the horizontal status then remove the oil cup cap Brake disk Brake flake Wear o...

Page 55: ...ge Note Check tire pressure when tires are cooled Driving under improper tire pressure will reduce thecomfortofoperationandriding andmaycause deflected wear of the tires Tire pressure parameter Frontw...

Page 56: ...f any rocking dismantle the front wheel and check the bearing Suspension system Checkingmethod Front suspension Hold tight the front brake handle press the front suspension up anddownseveral times In...

Page 57: ...rication oil in the gearbox Checkifthereisanyoilleakagearoundthegearbox Park the scooter with main stand and Stoptheengine takeouttheoilcheckboltandcheck ifthe oil level is bythescrew hole Incaseoflow...

Page 58: ...ent 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 electromag...

Page 59: ...nthehorizontal position Insert the oil dip rod DO NOT screw in and check engineoillevel2 3minutesaftertheenginestopped If oil is between the upper and lower limit oil is sufficient If oil is close to...

Page 60: ...akage Stop the engine andcheckoil level again Washing of the oil filter Draintheengineoil Removetheengineoilfiltercover Removethespring filter andwashthefilternet Check O ring of filter cover if neces...

Page 61: ...on 1 Status of the air filter and small air filter filter 2 Status of spark plug Useanenginetachometer whichcanreaderrorof50r min andinstallproperlyaccordingtooperationmanual Anyinclineofthevehiclebod...

Page 62: ...the rated value readjustaccordingtofollowingsteps Clipthesecondaryairsupplyinghosewithclampto cut the supply of secondaryair Start the engine and adjust idle speed if necessary Idle speed 1600 150r m...

Page 63: ...andcheckifitcanturnsmoothly In casethe turningof the throttle handle is not smooth enough Checkifthereisdamagewiththethrottlecable or rust with the steel wire or any stickness with the throttlehandle...

Page 64: ...lant gets into eyes rinse with plenty of water and go to see the doctor Keep the coolant in a safe place and away from the reach of the children In case of drinking the coolant induce vomit and got to...

Page 65: ...fillingcoolant Coolant Leakage Checkradiatorpipeline waterpump waterpipesand jointsforleakage Incaseofanyleakage dismantleanddofurthercheck Refer to Part 6 Check the radiator pipeline for aging damage...

Page 66: ...cylinderheadcover to see if there is drop agingor damage Replace in case of anyabnormal Check thecontrolvalvevacuumtubetoseeifthere is drop aging or damage Replace in case of any abnormal Checkthehose...

Page 67: ...een air filter body and secondaryair control valve If now air is sucked check if there is blockage in the tube between air filter body and secondary air controlvalve Input 450mmHg vacuum pressure to t...

Page 68: ...20 CFMOTO Others Lubrication state of frame parts Turn the movableparts of vehicle body and check thelubricationcondition In case of anystickness applyrecommended lubrication oil or grease to the part...

Page 69: ...lo w in g ra n g e A P I S E o r S F ty p e e n g in e o il S A E s e le c t fro m le ft ta b le a c c o rd in g to e x te rn a l te m p e ra tu re C le a ra n c e o f in n e r a n d o u te r ro to rs...

Page 70: ...n dismantling and installing the oil pump Dismantling Remove right sidecover 11 2 Remove the rotor comp driven gear comp 11 3 Remove separate plate oil pump comp B Removeshaftcirclip Remove sprocket a...

Page 71: ...rotor and outer rotor of oil pump Note Measurement should be done multi spots and choose the max measured value Replace the oil pump assy If the measured values exceed the service limit Body clearance...

Page 72: ...orandouterrotorontheoilpumpbody measure the clearance between inner rotor and outer rotor with a plug ruler Service limit 0 20mm Terminal surface clearance Installinnerrotorandouterrotortotheoilpumpbo...

Page 73: ...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 Installation Make sure that the two mounting holes of the oil pump...

Page 74: ...in 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 In...

Page 75: ...t over twist or bend the cables The twisted cables may cause poor operation l Check the installation position of o rings replace if necessary l Remove the drainage screw of the float bowl before disma...

Page 76: ...isnotworkingnormally Over concentrated mixture l Floatvalveisfunctioning l Airnozzleisnotfunctioning l Filterelementisnotfunctioning l Carburetoroverflow l Difficult to start or engine stops after sta...

Page 77: ...ly of carburetor Remove seat box 2 3 Removecouplerofstartingenrichingvalve Loosen locknut remove adjusting nut and remove the cable from throttle Loosen clamp of air intake pipe and air filter remove...

Page 78: ...and the start ing enriching device Check the starting enriching device for damage and float needle valve and O ring for wear Vacuumchamber Remove screw vacuum chamber cover spring septum and vacuum pi...

Page 79: ...nd 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 necessa...

Page 80: ...n 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 Clean carburetor body with compressed air...

Page 81: ...atvalve floatandfloatpin Checking the oil level Note Fuel level gauge should bevertical against thefloat chambermountingsurface andmeasurethedistance tomainmeasuringhole Incline carburetor so that the...

Page 82: ...ing to carburetor body Caution Unite the protruding part of sep tum with groove of carburetor body Toavoidtheseptumbeingclipped installthevacuum chamber cover while maintaining the status of the vacuu...

Page 83: ...n air inlet connection pipe and air filter tighten clamps on both sides of the carburetor Installvacuumtube Connect cable rear end to throttle and fit the cable into the bracket Adjustclearanceofthrot...

Page 84: ...5 10 CFMOTO Air filter removal Remove leftshield 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...

Page 85: ...ter secondary air inlet 5 Loosen bolt remove air filter bracket Dismantling of air filter Loosen screw removeair filterconnectionpipe Removeexhaustgasrecyclingcover Removeexhaustfilterelement Removenu...

Page 86: ...the dust on the filter element with com pressed air Replace in casethere is damage orseri ousstainsonthefilling Assembly of air filter Installfilterelementcomp andairfiltersealring Cover the air filt...

Page 87: ...nd connectairfilterjoint pipe Airfilter installation Securethefilterbracket Itotheinstallationsurfaceof carburetorbodyand tightenwith bolt Secure the filter bracket II to the installation surface of c...

Page 88: ...Installleftandrightshields 2 Disassembly of control valve Remove footrest deck 2 12 Remove control valve breather pipe reed valve breatherpipeandvacuumtubefromcontrolvalve removecontrolvalvefixingcol...

Page 89: ...mp Open the clip place of small air filter comp before dismantling Refer to the right picture for the dismantled small air filter Assemble order is from left to right Caution Blow off the dust on the...

Page 90: ...the breather hose Installation of control valve Set control valve on the control valve comp Connect control valveair intake pipe reed valve air intake pipe vacuum tube tothe control valve andfix Fix t...

Page 91: ...5 17 5 carburetor air filter secondary air inlet 5 Air cleaner Assembly...

Page 92: ...s swallowed vomit immediately and see a physician Store the coolant properly and keep it away from reach of children Theoverhaulingofthewaterpumpcandonewithoutremovingtheengine Coolantfillingiscarried...

Page 93: ...osed l Blockage of radiator pipe or cooling pipe l Coolantisnotenough No rise or slow rise of water temperature Malfunctionofthermostat thermostatisn tclosed Water leakage l Water pump seal is not goo...

Page 94: ...tureofusingplace Check coolant for stains Inspection of radiator cap Caution Open the radiator cap after the coolant is cooled down Removefrontemblemplate 2 8 Remove radiator cap refertoprevious item...

Page 95: ...washyoureyeswithwaterandconsultadoctor If coolant splashes on your clothes quickly washitawaywithwaterandthenwithsoapand water If coolant is swallowed vomit immediately and see a physician Store the...

Page 96: ...washer and drainbolt andtighten Secondary water tank Remove front top cover 2 9 Remove the bolt and tapping screw of secondary water tank Remove water pipe of secondarywater tank Removesecondarywatert...

Page 97: ...rlimit Note Place the scooter upright on a flat sur face when checking the coolant level Air removal Removetheairbythefollowingsteps 1 Startengine runforafewminutesatidlespeed 2 Turnthethrottle3 4time...

Page 98: ...3 Overhauling Note l The thermostat must be replaced even if it is a bit open at normal temperature l There is time lag due to the small temperature sensing area of the thermostat So check the rising...

Page 99: ...ater 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 6 4 Water pump 11 4 Overha...

Page 100: ...6 9 6 cooling system 6 Cooling System...

Page 101: ...om the vehicle oil pump 4chapter carburetor air filter secondary air inlet 5chapter cylinder head cover cylinder head cylinder body camshaft 8chapter CVT system left side cover 9chapter gearbox 10chap...

Page 102: ...3 air filter 5 10 Drain coolant 6 4 Remove starting enriching coupler Removestartingenrichingvalvewirefrom tiedown band Remove AC magneto 3P 2P coupler Remove water temperature alarm coupler Remove s...

Page 103: ...ondaryairinletsystem Loosenlocknut Remove throttlecable clampandsmall cyclingwaterpipe clamp andwater inlet pipe Remove clamp and water outer pipe Removeexhaustingmufflercomp Remove bolt1 bolt2 and r...

Page 104: ...rear fork 14 4 5 Remove rear wheel 14 3 6 Removemainstandspring mainstandboltand bush Removemainstand Engine Installation Note Cables and electrical wires and cables should be fitted properly accordi...

Page 105: ...ketontheengine andtightenthenut 4 Installenginesuspensionbracketboltandbush installtheengineontheframe 5 Install rear shock absorber 6 Tighten following bolts and nuts according to thespecifiedtorque...

Page 106: ...er outlet pipe water inlet pipe and small cycling water pipe and tighten with clamp accordingly Note There should not be any cracks or other dam ages with each water pipe There should be no leakage or...

Page 107: ...coupler Install magneto 2P and 3P coupler fill into shield and tie with tiedownband Installstartingenrichingcoupler tiethestartingen richingvalvewirewithtiedownband Install exhaustingmufflercomp 2 16...

Page 108: ...comp and cylinder cover l Lubricating channels of the cylinder head cover cylinder head comp and cylinder body comp must be cleaned before assembling of these parts Overhauling standard S ta n d a rd...

Page 109: ...rn broken or jammed Unstable idle speed Abnormal noise Lowcompression pressure Damage or wear with Cam surface of camshaft comp Air Leakage at carburetor joint Improper adjustment of valve clearance B...

Page 110: ...there should not be pressure leakage in the joint Electrical starting will cause overflow of battery Do not run the starting motor for over 5 seconds continuously Compression pressure 700kPa 7kgf cm2...

Page 111: ...with the cylinder head machining surface and the trough ofcamshaft neckupwards Insert ruler between rocker arm and valve and in spect valve clearance Valve clearance when engine is in cold condition I...

Page 112: ...Rotate gearbox driving gear by two rounds and check again whether the valve clearance is in con formitywiththespecifiedstandard Installleftsidecover Installcylinderheadcover Disassembly of reed valve...

Page 113: ...g plate Remove left and right protecting plate footrest deck Reed valve inletpipe andcylinder cover bolt seal ring comp and cylinder cover Note Be careful not to damage the joint face when disassembli...

Page 114: ...earbox driving gear anti clockwise and keep the mark lines on the camshaft sprocket inparallelwiththemachiningsurfaceofcylin der head and the trough of camshaft neck upwards Remove tensionerspringseat...

Page 115: ...8 8 CFMOTO Remove camshaft bracket comp threeretainersintherockerarmshaftholeandcam shafthole valve rocker arm Note Pull out rocker arm shaft with a M5 bolt Disassembly of camshaft Removecamshaftcomp...

Page 116: ...eightwithmicrometer Service limit IN 30 69mm EX 30 28mm Note Check rocker arm when there is damage or wear with cam surface Rocker arm rocker arm shaft Check sliding part of rocker arm and contact sur...

Page 117: ...dy and securely support the scooter Removemuffler 2 15 Drain coolant 6 4 Remove carburetor 5 3 cylinder head cover 8 6 camshaft bracket comp 8 7 dowelpin Removevacuumtube Loosen bolt remove carburetor...

Page 118: ...vecylinderheadbolt andfixingplateof controlvalve Removecylinderheadcomp Note Support scooter with main stand press rear vehicle downwards and remove cylinder head Removecylinder head gasket anddowel p...

Page 119: ...tool 1P52MI A 922 020000 Remove valve springpress tool take out valve spring seat valve spring valve valve stem sealingsetandvalvespringretainer Theremoved valve stem sealingset should not be reused R...

Page 120: ...limit IN 4 965mm EX 4 945mm Remove the carbon deposit with reamer before measuringtheinnerdiameterofvalveguide Caution Insert the reamer from the combustion chamber Keep the reamer turning clockwise a...

Page 121: ...e cylinderhead is cooled insert the reamerfrom combustion chamberside andream valveguideaccurately Caution l Insert reamer from the combustion chamber l Do not deflect the reamer so as to avoid leakag...

Page 122: ...ontact surface is on the higher side or lowerside correct thevalveseat withamilling cutter Measure seal width of valve face Standard 0 9 1 1mm Service limit 1 8mm In case the seal width is uneven too...

Page 123: ...o remove the scrapes or cracks Caution Lapper the valve seat face when replace with valve guide Be careful not to lapper excessively Use 32o millingcutterto correct out side face slowly Use 60o millin...

Page 124: ...specifiedwidth with 45o milling cutter After correction applygrinding paste evenlyonthe valve seat and use a hammer to adjust the valve Note Slightlystrikethehammerwhileadjusting Do not over press or...

Page 125: ...ringseat Press the valve springs with press tools and install thevalvelockclip Warning To prevent weakening of the spring do not press thespringmorethantherequiredlength Inspection of cylinder body Ch...

Page 126: ...s damages or de flectedwear Clean the stains and impurities onthe joint surface Checkthecoolingpipesystem oilchannelsandbolt holesforimpurities Install cylinder gasket cylinder water inlet hose dowelp...

Page 127: ...eaches the upper dead point till piston surfaceisinparallelwiththecylinderjointface Caution Installation ofcylinderhead gasket anddowel pin Installation of cylinder head Installcylinderheadcomp Instal...

Page 128: ...and rocker arm as well Install retainer to rocker arm shaft hole and cam shaftretainergroove Applylubricatingoiltocamsurface Install camshaft with cam top towards the side of crankcase Press tight wi...

Page 129: ...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 Press the block on the tensioner and push the tensioning...

Page 130: ...m 8 Installthermostatcomp Installwatertemperaturealarmcoupler Installation of cylinder head cover Assemblesealring dowel pin sealringfor secondaryairinlet to the cylinder head cover Installreed valvec...

Page 131: ...hespringtotheoilchannel joint theninsert it to thepin in thecamshaft hole Install theassembledcylinderheadcover Install theseal ring ofcover bolt Install thereedvalveairintake Fill coolant and removea...

Page 132: ...scooter Do not damage the joint faces Keep the impurities mud and sand from entering the engine Overhaul standard Tightening torque Left side cover bolt 10 N m 1 0kgf m Gearbox nut 59 N m 6 0kgf m Cl...

Page 133: ...Slider Cam Worn damaged Clutch shoe Worn damaged Clutchspring Damaged Engine stops or beats when the scooter starts to run Clutchreturnspring damaged Poor speed performance V belt worn damaged Clutch...

Page 134: ...not damage the joint faces Remove the cap bolt and the air inlet port cover Remove thefourofthefivetighteningbolts from the left side cover Remove the rest bolt with the socket wrench Remove left side...

Page 135: ...ver Removethesleeve Break open theclamp andseparate theair inlet port cover from airinlet port Removetheelement wipeoff thedustandimpurities Forassembly installtheelementfirst keeprightthe insertposit...

Page 136: ...earbox and clutch well with jig loosen the tightening nut and washer for gearbox with socket wrench Specialtools Special jig 1P52MI A 922 040000 Remove primarysheave andV belt Holdtheinnersideofprimar...

Page 137: ...liding sheare face Removerollerweight Check V belt Cracks wear scaling chipping Measure theV belt width Service limit 20 7 mm Roller weight Wear damage Measure the outer diameter of roller weight Serv...

Page 138: ...9 CVT system 9 9 7 Primary sliding sheave Measureinnerdiameterofslidingsheave Service limit 24 07 mm Check collar for any wear or damage Measure the outer diameterof collar Service limit 23 92 mm...

Page 139: ...rollerweight terminalsurfacealignmentinthedirectionasshown inthepicture Installprimarysheavecap Install collar into the bush hole of primary sliding sheave Installationcaution Never smear grease to th...

Page 140: ...ified torque Torque 59 N m 6 0kgf m Clutch Disassembly Remove left side cover 9 3 drive face 9 5 Holdtheclutchwiththejigandremovethelocknut RemoveClutch Dismantling Attach the protruding part of clutc...

Page 141: ...ove the following parts from clutch spring compressor Clutchcomp Secondaryfixed sheave Clutchspring Socket Bufferwasher Plasticwasher Dismantleclutchcomp and secondaryfixedsheave separately Dismantlin...

Page 142: ...Remove guide pin roller remove secondaryfixed sheave Check guide pin and roller for damage or wear Remove oil seal and O ring from secondary fixed sheave Replacewithnewones forinstallation Check the n...

Page 143: ...ondary sliding sheave Remove the needle bearing with bearing removal tool Removecirclip andtakeout the ball bearing Applylubricant tothenewball bearing Striketheballbearingwithits countermarkupward in...

Page 144: ...the secondaryfixed sheave Check Clutch housing Check the clutch housing for wear and damage Measure inner diameter of clutch hous ing Service limit 125 mm Clutch shoe Check clutch shoe for wear and da...

Page 145: ...er Service limit 33 92 mm Secondary sliding sheave Check for wear and damage Measuretheinnerdiameter Service limit 34 06 mm Assembly of clutch Caution Whileassembling cleaninganddegreasingfrom sliding...

Page 146: ...innersideof secondaryslidingsheave ApplylubricantgreasetotheO ringandinstallitto secondaryfixedsheave Applylubricant greaseto the oil seal lip and install theoilseal withthelipfacingthesecondaryslidin...

Page 147: ...9 16 CFMOTO Assemble clutch comp Install damper rubber to the base plate of secondary fixedsheave Payattentiontothemountingdirectionofreturnspring Installcentrifugalweightsandreturnspring...

Page 148: ...9 CVT system 9 9 17 Installcirclip Assembly Assemble the following parts Clutch comp Socket Clutch spring Damper washer Plastic washer Secondary sliding sheave...

Page 149: ...with pliers or the like Installnut forsecondaryfixedsheave Tightentheclutchlocknut accordingtothespecified torque with socket wrench Torque 59 N m 6 0kgf m Removeclutchspringcompressor Installation o...

Page 150: ...9 9 19 Install left side cover tighten according to the specified torque Torque 10 N m 1 0kgf m Reversetheremovalprocedureforinstallation Install air inlet cover comp Tightentheboltaccordingtothespec...

Page 151: ...special tools Fix the inner side of bearing and press it into the drive shaft Troubleshooting standard Item Standard For replacing 0 15l Oil capacity For dismantling 0 15l Recommended oil SAE15W 40 S...

Page 152: ...ricant from gearbox 3 10 Remove Rear wheel 4 3 Clutch assy 9 9 Removebolt Removegearbox Removedowel pinandgearbox sealinggasket Wipe off the attached sealant on the joint face Removefinalshaftcomp Rem...

Page 153: ...with fingers check whether they turn smoothly without block or not Replace the old if not with newones Checkiftherearedamagesorscrapeswiththebear ings in thegearbox and left crankcase Check final shaf...

Page 154: ...ck 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 Removethefinalshaftoils...

Page 155: ...ools for bearing 1P52MI A 922 050000 060000 080000 Press a new drive shaft bearing vertically with its countermark side upwards into the gearbox housing till it is stopped by the bottom sidestep of be...

Page 156: ...a new bearing vertically with its countermark side upwards into the left crankcase until it is stopped Repeat above step for installation of bear ings of drive shaft countershaft and final shaft Inst...

Page 157: ...that adjustingwasher is on the shaft Installfinalshaft Installdowelpin Dip thegearbox gasket into kerosene install it onto the joint face of left crankcase Installgearbox Installtheboltandtightenit T...

Page 158: ...10 8 CFMOTO...

Page 159: ...over 11 7 Overhaul information Operation caution Note Disassembly of right side cover stator assy and flywheel should be done when the engine is cool Overhaul of right side cover could be done without...

Page 160: ...ion 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 pumpgasket Removerightsidecover Disassembly...

Page 161: ...l tools for disassembly of flywheel comp 152MI 922 030000 Disassembly of driven gear Removebolt fixingplateanddrivengearcomp Disassembly of stator assy Remove stator comp andtrigger Removecirclip Remo...

Page 162: ...all theshaftintoshaftholeofrightsidecover 2 Install bearing6000 P6 towaterpump shaft andclipwithcirclip Applysealant toouter surfaceofoil seal install it intoright sidecover 3 Install water seal assy...

Page 163: ...Right side cover magneto water pump 11 11 5 Assembly of right side cover Install water pump comp as indicated Install upper inspection cover and seal ring oillevelgauge oilfiltercomp oil bolt and wash...

Page 164: ...1 and 2 Caution Apply sealant Assembly of driven gear comp Install driven gear comp ontocrankshaft set the fixing plateto driven gearandtighten it Adjust fixingplateso that it does not conflict orhave...

Page 165: ...n the bolt by 2 or 3 timesintheoppositeangles Torque 12 N m 1 2kgf m Caution Waterpumpshaftopeningmustbeinbuttjoint with oil pump shaft otherwise otherwisetherewill be installation failure Installdowe...

Page 166: ...a l g a p 0 1 6 0 3 0 4 m m 0 5 0 m m B ig e n d o f c o n n e c tin g r o d R a d ia l g a p 0 0 0 5 0 0 1 7 m m 0 0 5 m m C r a n k s h a f t V ib r a tio n o f c r a n k s h a f t 0 1 0 m m In s ta...

Page 167: ...ston ring Compression pressure is too high Carbon deposit at piston end or in combustion chamber Blue smoke from exhaust muffler Wearingofconnectingrod s small end wearingof cylinder piston ringor pis...

Page 168: ...Remove crankcase bolt Keep theright crankcase downwards and remove leftcrankcase Remove crankcase gasket and dowel pin Removecrankshaftoilseal Caution Do not pry crankcase mating surface with screwdri...

Page 169: ...piston Expand pistonringgap andremovepistonring Caution Piston ring is easy to be broken Do not ex pand gap too wide Keep piston ring from scraping the piston Scrape off carbon deposit from piston Rem...

Page 170: ...ion 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 Measurevibrationofcrankshaft Measureinnerdiametero...

Page 171: ...clearance between piston and cylinder inner diameterofcylinder 8 12 Service limit 0 08 mm Measure the inner diameter of the piston pin hole in the directionofXandYrespectivelyandtakethemax value asfi...

Page 172: ...ge piston ring or piston when assembling piston Assemblepistonringontopiston withmarks upwards Caution Top ring and 2nd cannot be interchanged Make sure to install piston rings so that the manufacture...

Page 173: ...ghtenac cordingtospecifiedtorque Specified torque 13 N m 1 3kgf m Caution Make sure not to damage piston or piston rings Donotdamagecrankcasematingsurfacewhile installing Match left and right crankcas...

Page 174: ...ights instruments and switches Do not overexert on the wheel Avoid any damage to the wheels When removing tire use the special tire lever and rim protector Overhaul standard Item Standard Service Limi...

Page 175: ...er bearing seats are damaged worn out or stepped Steeringcolumnisdistorted Tire pressure is too low Worntire Loosened Handlebar Steeringbearingisdamaged ornotwelltightened Right and left shock absorbe...

Page 176: ...el Brake Suspension Steering system Frontwheel Removal Support the frame with jack raise the front wheel removefrontwheelaxlenut Removefront wheel axle removebrake diskfrom brake calipers removefront...

Page 177: ...ion Wheel axle Set axle on a V block measure axle wobble with centesimalgauge ServiceLimit 0 2mm Wheel bearing Turntheinnerringofthebearingwithfingertocheck if it can turn smoothly Check if there is a...

Page 178: ...l headon therim Install the bearing remover shaft on the tool head from the reserve side strike in and removethe bearing Remove spacer Special tool Bearing remover shaft 519 922 070001 Bearing remover...

Page 179: ...rake face Inspection Check thickness ofbrakedisk Replacewithanew one in case thethickness is less than 3mm Remove bolt and brake calipers comp Inspection Brake clipper check brake calipers for cracks...

Page 180: ...lubrication grease on the running part of new bearings press intotheleft sidefirst Installspacer Installrightsidebearing Special tools Handle A press tool A 519 922 070003 Press tool outer sleeve 28x...

Page 181: ...rinline with theprotrudingpart ofguardring Installation Installwiththebrakediskinlinewithbrakebracket Note Make sure counter comp is in line with front fork block Install front wheel axle and tighten...

Page 182: ...se oil leakage from inner absorber Inspection Checkshockabsorberforoilleakage oilseal agingor damage Replace if any Front shock absorber Disassembly Remove front fender 2 8 Removefront wheel 13 3 Remo...

Page 183: ...stall bolt 2 and tighten brake clipper comp according to the specifiedtorque TighteningTorque 30N m 3 1kgf m Install bolt 1 and fix front brake hose comp Install front fender 2 8 Handlebar Handlebar u...

Page 184: ...ehandlebar lowercover Installation Install throttlecable 13 14 Install handlebar lower cover 13 14 Handlebar switch Right Disassembly Removeheadlight comp 18 5 Remove handlebar upper cover 13 10 Loose...

Page 185: ...cover from vehicle Remove screw1 and screw 2 Remove connection withlefthandlebarswitchcoupler Removelefthandlebarswitch Installation Install left handle bar switch 13 14 Rear mirror Disassembly Remove...

Page 186: ...leftmastercylinder Removeright master cylinder inthe abovesteps Note 1 Do not hang the master cylinders with brake hoses 2 Maintain the mastercylinders in the instal lation position and fix them onto...

Page 187: ...ip Install throttlegriptothe steeringbar Installthrottlecableonthefrontpartofrighthandle barswitch Applylubricationgreaseon throttle mountingpart of throttle grip and end of throttle cable Connectthro...

Page 188: ...er 13 10 Install head light lower cover 13 10 Install odometer 18 9 Installheadlightcomp 18 5 Front fork Disassembly Remove front fender 2 8 front decorative plate 2 8 cowling plate 2 9 front wheel 13...

Page 189: ...ench Steering column bearing 519 922 050002 Remove upper bracket frontfork lower bracket Install special tool on the frame bodystandpipe Removelowerball race Special tool Bearing remover comp 519 922...

Page 190: ...over shaft 519 922 050003 Remover hammer 519 922 050004 Installation Install newlower ball race andspecial tools as listed belowtothesteeringcolumn Special tools Tool A steering column bearing bracket...

Page 191: ...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 p...

Page 192: ...lower bearing retainer on to front fork with special tool andpress machine Special tool Front fork cover press tool 519 922 050009 Installation Applylubricationgreaseonnewlowerbearing and theninstall...

Page 193: ...umnupperbearingretainer Tightenupperbearingretainer withhand thenloosen turn back by 1 8 circle Set lock washer claw with front fork groove and in stall lockwasher Installsteeringcolumnlocknut Special...

Page 194: ...t on the wheels and do not damage the wheels When removing tire from tube use special tire lever and rim protector to avoid damage to the rim Overhaul standard Item Standard Limit Vertical 2 0mm Vibra...

Page 195: ...lbalance faultytighteningofwheelaxlenut Rear shock absorber is too soft weakenedspring oil leakage with rear shock absorber Rear shock absorber is too hard bended rear shock absorber highertire airpre...

Page 196: ...moverearwheel Inspect Rim Check rim for damage deform or scrapes Refer to page 13 4 and measure the play of wheel ring by centesimal meter Replace rim in case of any damage deform or scrapes Service L...

Page 197: ...rear wheel axle nut bolt 6 and bolt 7 Remove rear fork comp Disassemble rear fork Remove front and rear oil seal Remove clamp Remove bearingwith special tool Inspection Check if bearing can turn smoot...

Page 198: ...comp 2 3 middle protection plate 2 4 rear bracket 2 4 left protection plate 2 5 right protectione plate 2 6 Removeupperfixingbolt1forleftshockabsorbers Removelowerfixingbolt2forleftshockabsorbers Remo...

Page 199: ...dle protection plate 2 4 rear bracket 2 4 trunk big seat washer assemblycomp 2 3 small seat 2 2 Rear brake Rear brake caliper Disassembly Remove bolt 1 Remove bolt 2 Removenut Remove rear brake calipe...

Page 200: ...15 Battery Charging system 15 15 1 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...

Page 201: ...switch OFF when disassembling electrical parts Remove negative connecting harness of battery when storing the battery on the vehicle Fast charging is not recommended as it may reduce the life of batte...

Page 202: ...ect monomer voltage of battery and record it 15 4 Start engine turn on headlight Inspect battery s voltage between terminals at the engine speed of 5000r mi 15 5 Standard monomer voltage charge voltag...

Page 203: ...r installation Inspection Measure voltage between battery terminals and inspecttestsituation Complete test 12 8V Insufficienttest lessthan11 8V Rechargewhenchargeisnotsufficient Note When recharging a...

Page 204: ...rging situation Remove battery 15 4 and install a fully charged battery Keepignitionswitchinthe OFF position Connect voltmeter betweenbattery s terminals af ter engine is started and warmed up Notes D...

Page 205: ...the large to the small measurement Do not turn on the ignition switch when measur ingthecurrent Current Leakage less than 3mA Whenleakagecurrentishigherthanspecifiedlimit thereisfaultwiththereturncir...

Page 206: ...t2 Disconnectthetworectifiercouplers Removevoltagerectifier Reversetheremovalprocedureforinstallation Notes Routing of wires hoses cables should pass properly 1 20 Item Result Battery wire red V oltag...

Page 207: ...ACmagneto yellow yellow yellow andtriggercoil black white green Measure the resistance between the yellow termi nals of theAC magneto 3Pcoupler Resistance 0 2 0 3 20 Make sure the yellow terminal ofAC...

Page 208: ...15 Battery Charging system 15 15 9...

Page 209: ...ntroubleshootingtable Refer to 16 7 fordispositionof ignition system parts IgnitionadvancerisplacedintheCDI sotheignitionsystemwillautomaticallyadjustignitiontime Be careful with CDI overhaul Dropping...

Page 210: ...r with digital muitimeter available in the market with input resistance over 10M DCV Item Standard Ignition CDI battery ignition NGK Standard DPR7EA 9 Optional Spark plug Spark plug gap 0 8 0 9mm Igni...

Page 211: ...e and thread or positive pole andinput end 2 Faulty spark includes no spark and weak spark Inspect the following aspects if there is no spark 1 Inspectignitioncoilinsubstitutionwaywithmultimeterormeas...

Page 212: ...ngterminals black yellow frame body earth wire Turn ignition switch to the ON position and start engine Peak voltage above 150V Note Whenmeasuringthevoltage donottouchtheterminalwith fingerto avoidele...

Page 213: ...r Connectpeakvoltageoscillographterminalwiththe followingterminalofmaincable Special tools Peak voltage oscillograph 07HGJ 0020100 Use it together with digital universal meter availablefromthemarketwi...

Page 214: ...et of rotor Be careful not to hurt the fingers when removing Loosen bolt remove AC magneto stator and trigger Installation Reversetheremovalprocedureforinstallation Ignition coil Disassembly Removal R...

Page 215: ...16 16 7 16 Ignition system...

Page 216: ...should be connected with couplers of the same colors Maintenance Standard Item Standard ServiceLimit Brushlength 10mm 7mm Troubleshooting Starting motor does not run Insufficient charging of battery F...

Page 217: ...e makesure there is battery voltage between red white and framebodyearthingwire If there are anyabnormals inthe above inspection checkignitionswitch brakeswitch mainfuse 15A secondary fuse 10A If all...

Page 218: ...Inspection Measurelength ofeachbrush Service Limit Replace if the brush less than6 5mm Check color of rectifier rotor If more than two rectifier rotors have changed color shortcircuitwillbecaused Repl...

Page 219: ...17 4 CFMOTO Makesuretherotorshaftisnotconductedwitheach rectifierrotor Installation Set O ring in the groove of starter motor Applysome grease on the O ring...

Page 220: ...oove of motorholder Install motorholder in thecase Tightenthebolt SetO ringsealintothegrooveofmotorpositioning camshoulder Installation Notes Connect the wire and confirm the rotating direc tionbefore...

Page 221: ...allation Reverse the disassemblyprocedure forassembly Apply some lubricant on the gear compound shaft in theright case Tighten the three inner hex bolts of overriding clutch according to the specified...

Page 222: ...ause oil stains on the glass cover which may form heat points and cause deformation of glass and damage to bulb Pay attention to the following points when replacing the bulb Do not replace the bulb wh...

Page 223: ...18 2 CFMOTO Troubleshooting Head light cannot turn on Fuse break Open circuit with main cable Bulb burnt Night switch is damaged...

Page 224: ...Wear clean gloves when replacing bulb Oil stains on the glass surface may cause break of bulb Clean the stained surface with alcohol Make sure that the three positioning pins of the bulb should be in...

Page 225: ...fication 12V 21 5W Reverse the removal procedure for installation Rear turning light bulb Remove screw 10 red brake tail light cover4 screw8 rear turning indicator right cover3 Replace rear turning in...

Page 226: ...1 20 Reverse the removal procedure for installation Odometer bulb Remove odometer 18 9 Remove high beam socket and replace with a new bulb Bulb specification 12V 3 4W Replace the instrument illuminat...

Page 227: ...installation Note Be careful not to damage main cable when mounting After replacing adjust the headlight beam 3 19 Note Routing of wires cables and hoses should pass properly 1 20 Ignition switch loc...

Page 228: ...nect ignition switch 4p coupler Loosen bolt and remove ignition switch lock Reverse the removal procedure for installation Handlebar switch Remove head light comp 18 5 Remove handlebar upper cover 13...

Page 229: ...ght switch coupler and check coupler terminals for conducting Check if the brake light is connected when hold ing the brake handle and the brake light is not connected when releasing brake handle In c...

Page 230: ...t the front wheel with repairing bracket Rotate front wheel quickly and check if the odometer pointer turns Replace with a new one in case of any problems Removal and installation Remove head light co...

Page 231: ...or from fuel tank with a flat screwdriver Inspection Remove fuel sensor refer to above steps Connect fuel sensor 2p coupler Turn ignition switch to ON Rock the fuel sensor float check if the float pos...

Page 232: ...n up 10 2 20 Down 90 4 below 20 Replace the fuel sensor in case of any problems found Installation Press fuel sensor into fuel tank installation hole install it properly and there should be no fuel le...

Page 233: ...seat box with big seat comp 2 3 middle panel 2 4 rear carrier 2 4 left side panel 2 5 right side panel 2 6 Drain coolant 6 4 Disconnect water temperature sensor coupler and remove water temperature s...

Page 234: ...ting enrich ing device Measure resistance between coupler ter minals Standard value 19 5 21 5 20 Inspection Remove carburetor 5 3 Connect ethylene pipe etc to fuel increment loop Check that when the c...

Page 235: ...19 1 CFMOTO 19 Electrical Diagram...

Page 236: ...19 Electrical Diagram 19 2 CFMOTO...

Page 237: ...lug No spark Stained or damaged Spark plug strong spark Broken high tension coil or short circuit Broken Ignition coil or short circuit Faulty ignition switch Low or no Faulty CDI unit Compression Fau...

Page 238: ...ow or no Worn or damaged Cylinder and compression piston ring pressure Broken cylinder gasket with compression pressure Incorrect faulty trigger coil Faulty CDI unit correct Improper adjustment Refer...

Page 239: ...not clogged Stained damaged or color changed Stained or damaged spark plug Improper spark plug heat value No stain damage or color change Overheated thinner mixture Deteriorated fuel Carbon deposit in...

Page 240: ...t circuit Strong spark Faultyignition switch Faulty CDI unit Not conducted tarting enriching cable breaks Faulty starting enriching device Conducted With Air current Faulty starting enriching device N...

Page 241: ...ting enriching cable breaks Faulty starting enriching device Conducted With Air current Faulty starting enriching device No air current check ignition timing check carburetor jet for clogging Disconne...

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