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Summary of Contents for CF125T-22A

Page 1: ...WWW CFMOTO COM CF150T 6A CF125T 22A Service Manual All manuals and user guides at all guides com a l l g u i d e s c o m...

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Page 5: ...clothes please suds it immediately When it contacts the eyes please wash it thoroughly with a great deal of clear water immediately and receive medical treatment in hospital In case the coolant is dr...

Page 6: ...ase charge it in the place with nice ventilation DXWLRQV R QRW OHW WKH WXUQLQJ RU PRYDOEH SLHFHV VXFK DV UHDU ZKHHO FOXWFK HWF FOLS RXU KDQGV RU FORWKHV ZKHQ PDLQWDLQLQJ Cautions The personnel shall m...

Page 7: ...en the bolt length is unidentified Please clean the dirt dusts on the vehicle before maintenance The gasket O ring piston pin retainer and split pin must be renewed after disassembly The elastic retai...

Page 8: ...hen blowing the ball bearing by compressed air after washing If the bearing race turns back its high back turning speed will be beyond the limit that may result in damage of bearing The bearing shall...

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Page 10: ...0272 CF150T 6A CF125T 22A LCETDKP6 LCETDJPM 1P58MJ A 2 1P52MI B 2 All manuals and user guides at all guides com...

Page 11: ...e Gasoline Engine Cylinder quantity and distribution Single cylinder horizontal Model of combustion chamber Hemisphere Valve drive model OHC Chain Drive Bore Stroke 58 57 8mm 52 4 57 8mm Compression r...

Page 12: ...l Initial Transmission Gear Type Bevel Gear ratio 3 13 3 77 Secondary transmission Gear Type Bevel Gear ratio 3 21 CVT Type V type teeth belt Starting mode Automatic CVT Transmission Ratio range 2 500...

Page 13: ...rade engine oil SAE specification select from the table at right according to the outdoor temperature Oil pump rotor Gap between external rotor and internal rotor 0 15mm 0 20mm The body Gap 0 15 0 23m...

Page 14: ...9mm 4 965mm EX 4 955 4 97 mm 4 945mm Internal diameter of valve IN 5 5 012mm 5 04mm EX 5 5 012mm 5 04mm Clearance between valve rod and guide IN 0 01 0 037mm 0 075mm EX 0 03 0 057mm 0 095mm Thrown hei...

Page 15: ...9 2 Piston pin inner diameter 15 0 02 15 008 15 04 Piston pin outer diameter 14 9 94 15 000 14 98 Shaft small end side inner diameter 15 0 16 15 034 15 05 Clearance of cylinder between piston 0 02 0...

Page 16: ...m Standard Service Limit Rear wheel Play of wheel rim Vertical 0 8mm 2 0mm Horizontal 0 8mm 2 0mm Tire Groove 1 6mm Air pressure 225kPa 2 25kgf cm 2 Item Standard Service Limit Front brake Brake handl...

Page 17: ...d 0 9A 5 10h Quick 4A 1h Item Standard Ignition ECU Spark Plug Type NGK Standard DPR7EA 9 Optional Clearance 0 8 1 0mm Ignition Timing Max Advanced Angle 43 BTDC Peak Voltage Ignition Coil 150V Pulse...

Page 18: ...1 8 36 1 5 12 1 5 12 1 5 22 2 2 18 1 8 25 2 5 18 1 8 Lubricating system Oil plump and mounting bolt Screw oil pump plate 2 1 6 3 15 1 5 2 0 2 Cooling system Water drain bolt Water temperaturesensor Im...

Page 19: ...Rear wheel Rear suspension Rear wheel axle nut Shock absorber mounting bolt upper Shock absorber mounting bolt lower Rear fork mounting bolt 1 2 2 2 16 10 8 10 140 14 3 55 5 6 30 3 1 55 5 6 Brake sys...

Page 20: ...ess driven shaft bearing Disassemble bearing Install drive shaft bearing Install final shaft bearing Ac generator starting motor Rotor puller 152MI 922 030000 Disassemble stator Front wheel Front susp...

Page 21: ...p 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 Inner surface valve arm roc...

Page 22: ...t Pivot rear pedal L Pivot rear pedal R Pivot side stand Oil seal lip rear fork Gear surface and running part counter gear small gear Axle part main stand Multi purpose lubrication oil Lip dust proof...

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Page 30: ...eplace the gasket with a new one When muffler is installed check if there is any exhaust leakage Tightening torque Tail light brake light screw 1 8 N m 0 18kgf m Screw Rear turning indicator cover 1 8...

Page 31: ...lprocedurefor installation Caution Make sure there is no deviation of the seat byshakingit afterinstallation Waterproof Cover Dissassembly Open seat with ignition key Remove 4 tapping screws 1 Waterpr...

Page 32: ...LHFHV RI ROW 5HPRYH 7UXQN Installation Reverse the removalprocedurefor installation DWHUSURRI RYHSODWH IRU OHFWURQLFH SDUWV 6HDW 6RFNHW L LQJ 3ODWH SLHFHV ROW 6HDW 6RFNHW L LQJ 3ODWH SLHFHV ROW All ma...

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Page 34: ...Installation Reversetheremovalprocedurefor installation 5HPRYH ROW 5HPRYH 8SSHU RYHU 7DLO LJKW 5HYHUVH WKH UHPRYDO SURFHGXUH IRU LQVWDOODWLRQ 5HPRYH WDSSLQJ VFUHZ RZHU RYHU 7DLO LJKW 5HYHUVH WKH UHPR...

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Page 41: ...paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place 5HPRYH URQW 9HQWLODWLRQ URQW 3URWHFWLRQ RYHU URQW 7RS RYHU 5HDU XHO 7DQN RYHU...

Page 42: ...W 5HPRYH DLU WHPSHUDWXUH 5HPRYH 0XIIOHUV TighteningTorque Nuts front elbow 30N m 3 0kgf m Bolts muffler 40N m 40 5kgf m Notice Replace the sealing gasket when install ing the muffler All manuals and u...

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Page 44: ...s and gloves if the work has to be done when the engine is just stopped Gasoline is highly flammable smoking is strictly forbidden in the work place Keep alert on the electrical sparks Besides vaporiz...

Page 45: ...e and wear Replace when the thickness of front or rear brake disk is less than 3mm Tire pressure Front wheel 225kPa 2 25kgf cm2 Rear wheel 225kPa 2 25kgf cm2 Chap and damage Groove depth and abnormal...

Page 46: ...dle speed 1700 170r min exhaust body Filter element Oil leakage Lubricatio n device Oil defiling and oil level Dip stick type oil level should be between the upper and lower limits Fuel leakage Joint...

Page 47: ...ock device Function Instruments Function Slack or damage caused by installation Exhaust pipe and muffler Function of muffler Frame Slack and damage Others Lubrication grease of frame parts Abnormal pa...

Page 48: ...hten the locknut or disassemble the steering column for further check Lift the front wheel slowly turn the handlebar left and right to see if it can turn freely In case there is any hindrance check if...

Page 49: ...e fluid away from these parts 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 Pad Wear of brake Pad Check t...

Page 50: ...Driving under improper tire pressure will reduce the comfort of operation and riding and may cause deflected wear of the tires Tire pressure parameter Indicated pressure tire Front wheel Rear wheel P...

Page 51: ...ay disassemble the front wheel and check the bearing 13 4 Suspension system Front suspension Hold tight the front brake lever press the front suspension up and down several times In case of any rockin...

Page 52: ...ck the lubrication oil in the gearbox Check if there is any oil leakage around the gearbox Park the scooter with main stand and Stop the engine remove the oil bolt and check if the oil level reaches t...

Page 53: ...to prevent dust from entering the combustion chamber Remove spark plug Check the central and side electrodes of the spark plug to see if there is nay erosion burning or damage of theinsulate electroma...

Page 54: ...il dip rod DO NOT screw in and check engine oil level 2 3 minutes after the engine stopped If oil is between the upper and lower limit oil is sufficient If oil is near the lower limit add oil till the...

Page 55: ...evel again Cleaning the oil filter screen Drain the engine oil Remove the engine oil filter screen cover Remove the spring filter and wash the filter screen Check O ring of filter cover if necessary r...

Page 56: ...ove 2 bolt 1 as shown in pictures Remove air box Remove air filter element and replace Reverse the removal order for installation Idle speed inspection RPM of Idle speed inspection 1700 170rpm All man...

Page 57: ...sor 60cm use a connector and connect it to the muffler After strictly adjusting the idle speed measure the density of CO CO and HC HC CO at Idle speed below 3 8 HC at idle speed below 800ppm RPM at id...

Page 58: ...le is not smooth enough Check if there is damage with the throttle cable or rust with the steel wire or any stickness with the throttle handle Check the outer clearance of throttle handle Clearance 1...

Page 59: ...t the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach of children Coolant level Coolant might get less due to natural...

Page 60: ...hose water pump water pipes and joints for leakage In case of any leakage disassemble and do further check Refer to Chapter 6 Check the radiator hose for aging damages or cracks The rubber hose will n...

Page 61: ...sit in the discharge duct at right bottom of air filter If there s deposit remove the discharge plug drain the deposit from the duct Install the discharge plug and fix it with the clamp All manuals an...

Page 62: ...spection Adjustment Lighting Device Optic Axis adjustment of Front head light Adjust Optic Axis adjustment bolt with cross banner to adjust lenght of lighting All manuals and user guides at all guides...

Page 63: ...ot bee seen Others Lubrication of frame parts Turn the movable parts of vehicle body and check the lubrication condition In case of any stickness apply recommended lubri cation oil or grease to the pa...

Page 64: ...lation of piston ring Mixture of oil with coolant Wearing of valve guide or stem Poor sealing of water seal comp Damaged oil seal of valve stem Poor sealing of cylinder gasket Wearing of cylinder pist...

Page 65: ...alling the oil pump Dismountling Remove right side cover 11 2 rotor comp driven gear comp 11 3 IsolationplateB oil pumpcomp Removeshaftcirclip Remove sprocket and chain Check if there is anywear or da...

Page 66: ...Multi spots should be measured and choose the max measured value Replace the oil pump assy if the measured values exceed the service limit Body clearance Measure the out diameter of oil pump outer ro...

Page 67: ...etheclearancebetweeninnerrotorandouter rotor withapluggauge Service limit 0 20mm Installation of Oil Pump End face clearance Install inner rotor and outer rotor to the oil pump body measure the cleara...

Page 68: ...tighten cover plate after assembly install oil pump shaft and make sure the shaft can turn freely Installation Make sure that the two mounting holes of the oil pump comp are in line with the that of t...

Page 69: ...y installed Install shaft circlip into the shaft groove Check if the circlip is properly installed Join isolation plate B with isolation plate A and tighten with bolt Install rotor comp driven gear co...

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Page 155: ...ches 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 ITEMS STANDARD SERVICE LIMIT Front wheel axle bend 0...

Page 156: ...tire pressure Front suspension is too hard Front shock absorber is bended Tirepressuretoohigh Abnormal noise with Front absorber Faultyfront shock absorber Looseningoftighteningpartsoffront shock abso...

Page 157: ...V VWHP Frontwheel Removal Support the frame with jack raisethe front wheel removefrontwheel axlenut Remove front wheel axle remove brake disk from brake calipers remove front wheel Remove counter All...

Page 158: ...lowly turn the wheel and measure the tire wobblewithacentesimalmeter Servicelimit Axial 2 0mm Radial 2 0mm Wheel bearing Turn the inner ring of the bearing with finger to check if it can turn smoothly...

Page 159: ...thebearingremovershaft onthe remover head from the reserve side strike in and remove the bearing Remove spacer Special tool Bearing remover shaft 519 922 070001 Bearing remover head 12mm 519 922 07000...

Page 160: ...brake disc Inspection Brake disc thickness 3mm Replace Remove bolt1 bolt2 and brake calipers comp Inspection Brake caliper check brake calipers for cracks or oilleakagefromthetighteningparts Replace i...

Page 161: ...bearings press the left side bearingfirst Installspacer Installrightsidebearing Special tools Handle A press tool A 519 922 070003 Press tool outer sleeve 28x30 519 922 070004 Guide tool 12mm 519 922...

Page 162: ...t ofguardring Installation Install front wheel with the brake disk in line with brake bracket Note Make sure counter comp is in line with front fork block Installfrontwheelaxleandtightennut Install od...

Page 163: ...olt 1 Fourfixingscrews L R sealingcoverandseal ring Remove shock absorbers Caution Donot put theshock absorberupsidedown incase oil leakagefrom inner absorber Inspection Oil leakage aged or damaged oi...

Page 164: ...1kgf m Install front wheel 13 3 Install brakecalipercomp Set the brake clipper on the brake disk install bolt 2 and tighten brake clipper comp according to the specifiedtorque Tightening Torque N m 4...

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Page 166: ...k wise re move left rear view mirror by turning it counter clockwise Turnupjacket loosennutclock wise removeright rearviewmirrorbyturningitclockwise Installation Reversetheremovalprocedureforinstallat...

Page 167: ...positionandfixthemontothehandlebar Placingthemastercylinders upsidedownmaycause entranceofair intothehydraulicsystem Installation Reversetheremovalprocedureforinstallation Note Keep the UP mark of bra...

Page 168: ...urn open the dust cap and drop some lubricant oil along the steel wire Pull the steel wire back and forth for lubricating purpose and then tighten Locknut 5 When installing throttle grip apply lubrica...

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Page 170: ...Remove Upperballretainer Front fork Lowerball retainer Set special tool to the frame standpipe and remove lower bearingrace Special tool Bearing remover comp 519 922 050000 Rotor puller 519 922 05001...

Page 171: ...hammer 519 922 050004 Installation Install new lower ball race and special tools as listed belowtothesteeringcolumn Special tools ToolA steeringcolumn bearingretainer 519 922 050005 Tool shaft 519 922...

Page 172: ...er 519 922 050005 Tool shaft 519 922 050006 Tool B steering column bearing retainer 519 922 050007 Tool shaft 519 922 050008 Holdinstallationtoolshaft tightenthelocknutwhile pressingtheupper ball race...

Page 173: ...ingretainer onto front fork with special tool and press machine Front fork cover press tool 519 922 050009 Applylubricationgreaseonnewlowerbearing andtheninstallfrontfork Applyinglubricationgreaseonne...

Page 174: ...ghtenupperbearingretainerwithhand thenloosen turn back by1 8 circle Set lock washer claw with front fork groove and installlockwasher Installsteeringcolumnlocknut Special tool Locknut spanner 07916 KM...

Page 175: ...use special tire leverand rim protector to avoid damage to the rim Overhaul standard Tightening torque Rear wheel axle nut 140N m 14 3kgf m Shock absorber upper mounting bolt 55N m 5 6kgf m Shock abso...

Page 176: ...enut Rear shock absorber is too soft weakspring oil leakage with rear shock absorber Rear shock absorber is too hard bent rear shock absorber highertire airpressure Poor brake effect faultybrakeadjust...

Page 177: ...ion Rim Check rim for damage deform or scrapes Refer to page 13 4 and measure the play of rim by centesimal meter Replace rim in case of anydamage deform or scrapes Service Limit Axial 2 0mm Radial 2...

Page 178: ...h a new one if any Installation Press inthebearingwithspecial tool Install Clamp 5 Oil seal 1 and Oil Seal 6 Reversetheremovalprocedureforinstallation of rear fork Tightenthebolts andnuts accordingtot...

Page 179: ...te 2 5 Remove Bolt 1 and Bolt 2 of rear left absorber Remove rear left absorber Rear RightAbsorber Removal Securelysupport scooterwith mainstand Maintenance cover 2 2 Seat 2 2 Storage compartment 2 3...

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Page 183: ...ntle rectifier connector s connect test leakage current once again test battery s leakage current 15 5 abnormal current below 1mA current below 1mA abnormal normal normal main cable short circuit insp...

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Page 197: ...ith those of the same colors Maintenance Standard Troubleshooting Starting motor does not run Insufficient charging of battery Faulty contact of main switch Faulty contact of starting switch Faulty st...

Page 198: ...n switch brake switch main fuse 15A sub fuse 10A side sensor If all these items are normal replace starter relay Earthing wire return circuit Disconnect 4P coupler of starter relay and remove starter...

Page 199: ...fuse 15A sub fuse 10A side sensor ECU If all these items are normal replace starter auxiliary relay Capability of starter auxiliary relay Remove starter auxiliary relay measure the resistance between...

Page 200: ...ngscrewofstartermotorhousingand remove motor housingand motor seat Inspection Measure brush length Service Limit Replace if the brush less than 7mm Check color of commutators If there color changes wi...

Page 201: ...riding clutch Make sure rotor shaft is not conducted with commutators Installation Set O ring in the groove of starter motor seat Apply some grease on the O ring All manuals and user guides at all gui...

Page 202: ...ve of motor positioning cam shoulder Installation Notes Connect the wire and confirm the rotating direc tion before installing the starter motor on the engine Reverse the removal procedure for install...

Page 203: ...edual gearshaft in theright case Tightenthethreeinnerhexboltsofoverriding clutch accordingtothe specifiedtorque Tightening Torque 18N m apply some thread tightening glue 3 FRXSOHU FRQQHFWRU ZKHQ VFRRW...

Page 204: ...0272 Refer to chaper 19 for specific electrical circuit diagram All manuals and user guides at all guides com...

Page 205: ...s and cause deformation of glass face and damage to bulb Payattentiontothefollowingpoints whenreplacingthebulb Do not replace thebulb when it is turnedon Keep ignitionswitch inthe position andreplace...

Page 206: ...Troubleshooting Head light cannot turn on Fuse break Opencircuit withmaincable Bulbburnt Nightswitchisdamaged All manuals and user guides at all guides com a l l g u i d e s c o m...

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CF MOTO CF125T-22A, Service Manual

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