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Crossfire CF140L, Owner'S Manual

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OPERATING INSTRUCTION MANUAL

DIRT BIKE

PIT BIKE

 CF140L OWNER’S MANUAL

Summary of Contents for CF140L

Page 1: ...OPERATING INSTRUCTION MANUAL DIRT BIKE PIT BIKE CF140L OWNER S MANUAL ...

Page 2: ...d remain ifit is resold This manual contains the latest product information available before printing Crossfire Motorcycles reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission 2013 2015 Crossfire Motorcycles OTOS 2 CF140L OWNER S MANUAL ...

Page 3: ... element ofdesign incorporated into any new vehicle for the purpose ofnoise and or emissions control prior to its sale or delivery to the ultimate purchaser or while it is in use and B The use ofthe vehicle after such devise or element of design has been removed or rendered inoperative by any person Crossfire Motorcycles reserves the right to modify any equipment technical specifications colors ma...

Page 4: ...or broken frame or swing arm due to abuse Bent or broken wheels due to abuse Bent or broken plastic shrouds due to abuse Any sign of impact accident spin outs or roll over not caused by the condition for which the warranty coverage is sought TO GET SERVICE Contact your nearest Crossfire Motorcycles service center and or dealer The cost of transportation of the product to and from the service cente...

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Page 6: ...eceded by a Ht n lj jj symbol This information is intended to help you avoid damage to your motorcycle and or prope1ty around you This manual covers basic maintenance procedures A detailed parts diagram manual is available and it can be purchased separately from Crossfire Motorcycles The parts manual will be helpful to those with the mechanical skills and tools required to service their own motorc...

Page 7: ...ycle You must use your own good judgment Safety infonnation will come in a variety ofdifferent fonns including Safety Labels on the Motorcycle Safety Messages preceded by a safety symbol Aand one of these signal words Below are the definitions ofthese three words A DANGER You WILL be KILLED or SERIOUSLY INJURED ifyou do not follow instructions _A WARNING You CAN be KILLED or SERIOUSLY INJURED ifyo...

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Page 9: ... questions Does your child think through problems and come to logical conclusions Does your child obey your rules when they ride their bicycle If your child makes bad judgments takes un warranted risks and or does not obey your rules they should not ride this motorcycle Ifyou have decided that your child is ready to ride please remember the following points and never let your child ride without a ...

Page 10: ...e read them carefully and do not remove them If your label wears off from riding or becomes hard to read contact your Crossfire Motorcycles dealer for a replacement 1 1 Tn 1rq 1 1tu ric 11 Ju 11 c ftJ tt11 IT I I J l c H O fl Cl H t HI n 1l1C 111 JH h JI I 11 p JIJ f r _ i o1 _ Lt s sd_c _ _ Wl JIR 11 COlDTlltf 91 SSUllf R1um 41 FronlanctRear 1 18ps1 1031241ijla Neqr 111or n re1Jelo t 1r1tt e I In...

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Page 12: ...X COMPONENT LOCATIONS 12 CDI Box J ...

Page 13: ... on page 3 Engine Model Serial Number The engine model number and serial number is stamped on the left side of the engine under the countershaft sprocket Write this number is the Engine Number box on page 3 HANDLEBAR LEVER CONTROLS Clutch Lever The clutch leverO is located on the left side of the handlebar Hand Brake Lever Throttle The hand brake lever Qand throttleC is mounted on the right side o...

Page 14: ...fuel tap is closed No fuel can flow to the carburetor ON In this position the fuel tap in open This means fuel can flow to the carburetor With the lever in this position the tank will be emptied Choke Lever When pulling the choke lever fully toward the topG a cylinder in the carburetor is opened Through this cylinder the engine can take in additional fuel This results in a rich fuel and air mixtur...

Page 15: ...ht side of the engine Its basic operation is to apply the rear brake to slow or stop the motorcycle Kick Start Lever The kick start leverOis mounted on the right side of the engine It is used to start the engine in case the electrical starter system is non functional Side Stand Push the side standOto the ground and tilt the motorcycle to the left Make sure the bike is on solid ground and the posit...

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Page 17: ...gine Oil Check the level of engine oil and add if needed For better performance Xmotos recommends using 10W40 or lOWSO ONLY for off road riding or racing Fuel Check the level of fuel in the gas tank Add if needed Be sure the gas cap is tightened securely Drive Chain Inspect the drive chain condition and slack Adjust and lubricate if needed Also check the chain guide s and roller s for wear and rep...

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Page 19: ...he 5 minute warm up you are ready to go Starting When the Engine Is Warm I Repeat steps 1 2 3 5 6 7 and 8 in section Starting when the engine is cold STARTING PROCEDURE KICK START Starting When the Engine Is Cold I Turn the key switch to the ON position 2 Make sure the transmission is in the neutral position 3 Turn the fuel tap to the ON position 4 Lift the choke lever up 5 Press and hold the brak...

Page 20: ...Y for a few times STOPPING THE ENGINE To stop the engine shift into neutral and push the engine stop switch Oon the left side of the handle bar 20 A DO NOT ride your motorcycle with full load and DO NOT rev up the engine when cold Since the piston warms up and expands faster than the water cooled cylinder this might cause engine damage Always let the engine idle until warm or ride it warm at low R...

Page 21: ...er smoothly Remember to close the throttle before shifting gears Improper shifting may damage the engine transmission and drive train learning when to shift gears will come with riding experience Up shift into a higher gear when you hear the engine speed rpm get too high When the engine rpm gets too high in a gear you will feel the motorcycle stop accelerating This is another way to know when to u...

Page 22: ...s happens release the brake controls and steer straight ahead until you regain control of the motorcycle Once you have control reapply the brakes with less force Generally reduce your speed and complete your braking before you begin a tum Avoid braking or closing the throttle quickly while turning Either of these actions may cause one or both of the wheels to slip Any wheel slip will reduce your c...

Page 23: ...ance recommendations and schedules in this manual 4_ As a parent it is up to you to make sure the motorcycle is properly maintained and kept in safe operating condition For youngsters learning how to take care of a motorcycle and perform basic maintenance can be an important part of their riding experience However if you allow a youngster to perform or assist in any maintenance task s such as fill...

Page 24: ... will ensure the best quality and reliability for your motorcycle Always perform the pre ride inspection described on page 17 at each scheduled maintenance interval Each item on the maintenance schedule requires some mechanical knowledge You will find that some items in the table marked and may require a higher level of mechanical skill and special tools If you do not feel capable of performing an...

Page 25: ... be sure you are using the proper octane rating Use ofunleaded fuel is recommended because it produces fewer engine deposits and extends the life of the engine and exhaust components Never use stale or contaminated gasoline Never use gasoline that has been mixed with oil Avoid getting dust dirt and water into the fuel tank INSPECTION REFUELING PROCEDURE I Before refueling your motorcycle check the...

Page 26: ... molybdenum additives they may adversely affect the clutch operation DO NOT use motor oils that display the API circular logo that is labeled energy conserving they may affect the lubrication and clutch performance CHECKING ADDING OIL Fig 1 I Start and run the engine at idle for 3 5 minutes then stop it 2 Wait about 2 3 minutes to allow the oil to properly distribute itself in the engine 3 Stand t...

Page 27: ... motorcycle on a straight level surface so that it is not leaning to either the right or left support it 3 Remove the oil filler cap Pg 26 4 Place the oil drain pan under the engine 5 Remove the oil drain bolt Oand sealing washer G 6 As the oil is draining out press and hold the engine stop button and the starter button The engine will turn but will not start This will allow all the oil to be drai...

Page 28: ... Loosen the clamp that is holding the air filter on to the carburetor 2 Once you have loosened the clamp take out the air filter 3 If the filter has a tear or break in the filter element it must be replaced 4 Once the filter is removed wash it clean with a non flammable cleaning solvent Then wash in hot soapy water rinse well Then allow the filter to dry well 5 When the filter is thoroughly dry sp...

Page 29: ...e 0direction will decrease free play Turning the adjuster in the direction will increase free play 5 Operate the throttle to ensure that it is functioning smoothly and when released it returns completely from fully open to fully closed in all steering positions 6 Inspect the condition of the throttle cable from the throttle down to the carburetor If the cable is kinked or chafed it must be replace...

Page 30: ...arm up for 3 5 minutes then shut it off 2 Connect a tachometer to the engine 3 Make sure the transmission is in neutral gear 4 Keep the motorcycle in an upright position S Adjust the idle speed with the stop screw O 6 To increase the idle turn the screw to O 7 To decrease the idle turn the screw to 8 The idle screw might look like and located on different sides of the motorcycle depending on which...

Page 31: ...terclockwise to remove free play A second adjustment may be needed if the clutch is slipping or if the clutch will not engage Follow the steps below carefully to perform the adjustment If the clutch is slipping you will need to decrease the amount of clutch engagement Ifyou squeeze the clutch lever all the way and the clutch still will not engage you need to increase the engagement Clutch Free pla...

Page 32: ...ed at your local auto parts store The spark plug gap should be 02 03 in 0 6 0 7mm Always check the gap of a new spark plug before you install it 8 Be sure all dirt has been cleaned from the threads Install the spark plug by hand This will prevent stripping and or cross threading ofthe threads Use a 5 8 in socket or wrench to securely tighten the spark plug Do not over or under tighten the spark pl...

Page 33: ...terclockwise inse11 the brake lever back in to the coupler insert the pin and check the lever height Ifit is the desiredheight tighten the lock nut reinstall the pin and then the cotter pin Make sure the cotter pin is opened so that the pin does not fall out BRAKE FLUID LEVEL CHECK FRONT I Check the level ofthe brake fluid by looking in the sight glass Operiodically with the motorcycle in the upri...

Page 34: ...akes are working properly 7 Check the brake hose and brake caliper for leaks ADDING BRAKE FLUID PROCEDURE REAR I Clean all dirt and dust from the master cylinder cap f 2 Remove the cap screws Owith a Phillips head screwdriver 3 Remove the cap Be careful not to damage the diaphragm gasket that is seated under the cap 4 Add the required amount in to the master cylinder DO NOT OVERFILL Always use fre...

Page 35: ...se contact your nearest Crossfire Motorcycles dealer for 1 mm assistance or schedule your motorcycle for servicing BLEEDING THE BRAKE SYSTEM Because the brake system utilizes fluid any air bubbles inside the brake system will cause you to lose braking efficiency Air generally enters the brake system when the motorcycle sits unused for long periods of time Air will also enter the system if you have...

Page 36: ...le bars several times The suspension should feel clean and smooth 3 Check the lower end of the forks near the wheel for oil leaks 4 Inspect the upperf and lower triple clampsQfor tightness 5 Be sure all the triple clamp boltsO are tight 6 Examine the metal for any cracks wear or other damage 7 Be sure there is no free play in the steering head e ADJUSTABLE SUSPENSION FRONT I On the top of the fork...

Page 37: ...cles dealer for service and or inspection Your Crossfire Motorcycles dealer is the most qualified to determine whether or not replacement parts or service is required Your motorcycle is new Break it in for about 2 hours with the original settings before attempting adjustments DO NOT TRY TO REPAIR TflE SflOCK IF REPAIR IS NECESSARY TAKE TflE MOTORCYCLE TO AN XMOTOS DEALER SUSPENSION INSPECTION REAR...

Page 38: ... familiar with the settings on your suspension you can quickly and easily adjust them to suit different te1rnin For example you make the setting position for when you ride in the sand dunes But when you are riding on your local motocross track you know to tune it to a different setting ADJUSTABLE SUSPENSION REAR A The rear shock absorber has one adjuster for both compression and rebound O B By tur...

Page 39: ... or local motorcycle shop for inspection Properly inflated tires will provide you with the best combination of handling tread life and riding comfort Generally speaking underinflated tires will wear unevenly and adversely affect handling Underinflated tires are also more likely to fail from being overheated and can cause wheel damage on rocky terrain Overinflated tires will cause the motorcycle to...

Page 40: ...owever a repaired tube may not have the same reliability as a new one and could fail while riding For more information on a temporary repair see the section titled Resolvingthe Unexpected Always use replacement tubes that are the same size as the 01iginal We recommend tbat you have tubes changed at your local Crossfire Motorcycles dealer or your local motorcycle shop Replacing a tube requires remo...

Page 41: ...ry to remove or replace the chain to perfonn recommended maintenance service CHAIN INSPECTION I Check the slack in the lower drive chain midway between the sprockets 0 Push upward on the chai11 with your finger The vertical movement should measure between 08 IO 111111 2 Repeat step I along several points ofthe drive chain The slack should remain constant through out Ifit is not some links may be k...

Page 42: ...ged Teeth REPLACE GOOD CHAIN ROLLER INSPECTION I Check the lower O roller for wear and damage 2 If the roller is worn or damaged it must be replaced before your next ride 3 If the roller has been worn down then the roller must be replaced 4 If you cannot or do not know how to replace the roller take the motorcycle to an Crossfire Motorcycles dealer for service 42 A NEVER RIDE YOUR MOTORCYCLE IF TH...

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Page 44: ...n the chain or clockwise to increase slack 4 Make sure the gap4D between the adjusting plateG and swing arm are the same on both left and right sides 5 Tighten the axle nut Oto 85ft lbs 115 Nm 6 Re check chain slack and readjust if necessary CHAIN LUBRICATION Commercially prepared chain lubricants may be purchased at most motorcycle shops and should be used instead of motor oil Chain lube or gear ...

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Page 46: ...bly Broken or shorted engine stop switch DO NOT TOUCH THE SPARK PLUG OR PLUG CAP WHILE TRYING TO START THE ENGINE YOU WILL RECEIVE AND ELECTRICAL SHOCK WHICH COULD RESULT IN SERIOUS INJURY OR DEATH Loose or corroded wires and or connectors always clean bad electrical connections Yes SEE STEP 4 4 Cylinder Compressio11 Test Perform a simple compression test by kick starting the engine slowly Be sure...

Page 47: ...elerate lightly Docs the engine speed increase No Clogged air filter Restricted or clogged fuel line and or fuel filter Clogged mufficr spark arrester Choke valve is closed Clogged fuel tank breather hose Yes SEE STEP 5 5 Spark Plug i11spectio11 Remove the spark plug and inspect Is the spark plug in good working condition No Spark plug is not serviced frequently enough Incorrect spark plug heat ra...

Page 48: ...mber 11 Jg11itio11 Timing 11spectio11 See your local Crossfire Motorcycles dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected Only attempt these procedures if you are qualified and have the proper tools needed Is the ignition timing normal Timing is non adjustable No Faulty CDI ignition box Faulty ignition pulse generator Yes SEE STEP 12 12 Lubrica...

Page 49: ...11spe tio11 See your local Crossfire Motorcycles dealer or motorcycle repair shop to have the ignition timing inspected Only attempt these procedures if you are qualified and have the proper tools needed Is the ignition timing normal Timing is non adjustable No Faulty CDI ignition box Faulty ignition pulse generalor Yes Sec your Xmotos dealer to have your motorcycle serviced POOR PERFORMANCE AT HI...

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Page 51: ...e to make permanent repairs as soon as possible 3 Do not continue riding if you are hurt or if your motorcycle is not in safe riding condition Recommendations for specific problems follow IF THE ENGINE QUITS or WILL NOT START If the engine was not making unusual noises before it quit running and it feels nonnal when you operate the kick starter you can probably rule out a major mechanical problem ...

Page 52: ...fely carefully inspect the motorcycle for damage Check the tightness of critical nuts and bolts such as the handle bars control levers brakes and wheels If there is minor damage or you are not sure about possible damage but decide to ride back to your base ride slowly and cautiously Sometimes crash damage is hidden or not immediately apparent Once you get home go over your motorcycle thoroughly an...

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Page 54: ... 6 Chain Roller Bracket Bolt 17 6 13 3 K Handle Bar Clamp Nut 20 14 8 7 Foot Stand Bolt 23 17 3 Triple Clamp Bolt Mounting Plate Bolts lower 20 15 3 8 bottom 23 17 3 M Front Fender Bolt 6 7 5 7P Shift Lever Bolt 14 10 3 N Front Axle Nut 61 45 3 0 Exhaust Nut 16 12 4Z Caliper Bracket Bolt 20 15 3 p Engine Mount Bolt top 29 8 22 3 6V Brake Disc Bolt front 13 5 10 3 Q Oil Drain Bolt 18 9 14 SS Spark ...

Page 55: ... Nut Riser Bolts Steering Stem Nut Notes TORQUE SPECIFICATIONS Torque Notes N m ft lbs 4 5 3 3 5 4 4 10 8 8 3 20 14 8 3 27 20 3 I Apply oil to threads 2 Apply loctite 271 liquid to threads 3 Apply loctite 243 liquid to threads 4 Apply grease to bolt NOT threads 55 ...

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Page 57: ...NOTES X 57 ...

Page 58: ...x NOTES I 58 ...

Page 59: ...59 phone 61 2 9822 8899 email sales crossfiremotorcycles com address No 4 26 Kelso Cresent Moorebank Sydney NSW 2170 Australia ...

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