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CBS300

发动机

维修手册

CBS300 Engine

Maintenance Manual

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Summary of Contents for CBS300

Page 1: ...50 1 Page 1 of 50 CBS300 CBS300 Engine Maintenance Manual Prepared by Checked by Reviewed by Approved by...

Page 2: ...er element Lubrication method Pressure splash Starting method Electric Max power corresponding speed 18 5 1 5 kW 8500 1 5 rpm Max torque corresponding speed 22 1 5 N m 7000 1 5 rpm Idle speed 1400 100...

Page 3: ...0 3 Page 3 of 50 Item Specification Ignition System Ignition method Capacitor discharge Spark plug CR8EB Spark plug gap 0 7mm 0 8mm Fuel Fuel grade RQ90 Engine oil Specification SJ 10W 40 Capacity 1 3...

Page 4: ...t contact surface Assembling of cylinder head Assembling of cylinder head cover Installation of cylinder head Installation of cylinder head cover Maintenance Instructions Notes The camshaft is lubrica...

Page 5: ...age 5 of 50 Item mm Standard Value mm mm Maintenance Limit Value mm Radial clearance between rocker arm and rocker arm shaft 0 016 0 045 0 08 Valve clearance 0 02 0 04 Camshaft base circle run out 0 0...

Page 6: ...ge of valve spring 2 Cylinder head Loose connection between spark plug and cylinder head Damage of cylinder head gasket Cracks and sand holes on cylinder head 3 Cylinder body piston piston ring Excess...

Page 7: ...head bolts 2 small GB T16674 M6 20 pan head bolts 1 small GB T16674 M6 32 pan head bolt 1 small GB T16674 M6 28 pan head bolt and 2 large GB5789 M6 65 pan head bolts on cylinder head cover Note 2 6 2...

Page 8: ...cket head bolts fastening the tensioner and then the tensioner and tensioner sealing gasket Note O Prevent the O ring on tensioner from falling off 4 6201 Remove camshaft bearing 6201 and bearing baff...

Page 9: ...nd the 0 intake and s well as in bling of Cyl ractor to pre ve the valve loosen the v spring retai permanent ng it shall y but as mo t can be rem rts remove as to mou cations dur er Head Co 50 NC250 r...

Page 10: ...bnormal w valve stem m 1 5 t value for surface o nly abraded valve seat sealing pe replaced ocker Arm a Shaft r arm for w m roller for a amage or fo ker arm rolle with a new o arm shaft fo e rocker ar...

Page 11: ...camshaft for crack and fracture and the reducing valve flail block and spindle for looseness if any the reducing valve flail block assembly shall be replaced Inspection of Cylinder Head 1 Check the cy...

Page 12: ...alve guide is heavily worn the cylinder head shall be replaced Width Measurement of Valve Seat Contact Surface 1 5 mm Maintenance limit value 1 5 mm If the valve measured is too wide too narrow or pit...

Page 13: ...y but as moderately as the valve collet can be mounted 2 Mount the collet properly into the circular valve groove and then tap the upper valve seat slightly and axially from the valve to ensure the co...

Page 14: ...e bolt in the corresponding hole on cylinder head cover and tighten it Note 1 During mounting of rocker arm shafts the trimmed side of rocker arm shaft shall face the top of cylinder head cover and th...

Page 15: ...n them Note 1 Prevent dust and dross from entering the cylinder 2 A B 40 45N m Tightening torque of AB bolts 40 45N m 5 6201 Mount camshaft onto cylinder head and timing chain onto timing driven sproc...

Page 16: ...d timing marks pay attention to observing whether the timing mark on timing driven sprocket and the cover closing face are on the same plane 2 3 The engine is in the correct timing position only when...

Page 17: ...e jointing faces of cylinder head cover and cylinder head and apply a layer of silicon rubber as the planar sealant on the jointing face of cylinder head cover 2 Mount cylinder head cover onto cylinde...

Page 18: ...N m Mount the valve chamber covers onto the cylinder head cover and tighten them with small GB T16674 M6 20 pan head bolts tightening torque 11 13N m 6 2 GB5789 M6 28 1 Mount the starting motor in the...

Page 19: ...l is supplied to the cylinder head through the oil hole beside the AB bolt on the right engine body before cylinder installation make sure the oil hole beside AB bolt of right body is unblocked Preven...

Page 20: ...nce between piston ring and piston ring groove Top ring 0 03 0 07 0 08 Second ring 0 02 0 06 0 08 Clearance between cylinder and piston 0 035 0 045 0 07 Outer diameter of piston pin 15 994 16 15 99 Cl...

Page 21: ...pis on of piston or cylinder w nder cylinder hea de 5789 e 2 large ts water pipe ove cylinder owel pin linder Body cylinder bo inner diame ns namely m of pisto t shall be irections 018mm value 74 Tro...

Page 22: ...8 mm e oil ring 0 0 k the piston ring groove the piston r ure the end enance limit 0 5mm rst ring 0 5m 0 5mm econd ring 0 1 4 mm g 1 4mm on on pin retain s and then r tainer from en removing ston and...

Page 23: ...limit ure the oute 15 9 enance limit out the cle pin 0 02 enance limit r diameter o 015 mm value 16 7 mm er diameter mm from pist 94 mm value 73 arance betw 7mm value 0 07 r diameter o 99 mm value 15...

Page 24: ...on Ring piston ring g ston ring maging th g when mou splacing t ngs when g ed sides o ngs shall f allation pis e of rotating etween ring h the clea uring installa ll be mounte ston piston pin IN ston...

Page 25: ...yer of engine oil on surfaces of cylinder body piston and piston ring 3 120 Stagger the opening of piston ring for 120 and then slightly mount the cylinder body in place 4 Mount the chain slide in pla...

Page 26: ...of clutch housing Inspection of driving gear Inspection of oil pump Inspection of gearshift mechanism Assembling of water pump Installation of driving gear Assembling of gearshift mechanism Assemblin...

Page 27: ...free stroke 1 Excessive free stroke 2 Bending of clutch driven plate 2 Bending of clutch driven plate Difficulty in clutch operation Excessive pressure of handle 1 Clutch housing sliding groove havin...

Page 28: ...and take out the oil screen assembly or remove the bleeding bolt on the bottom and wait until the oil is completely discharged 2 10 GB16674 M6 40 1 GB16674 M6 50 Remove the 10 small GB16674 M6 40 pan...

Page 29: ...gs 9 4 2 4 Removal of Gearshift Mechanism 1 Remove the shift arm components 2 GB119 1 4 10 Remove the pentagram shaped plate fastening bolt and spring shim and then remove the pentagram shaped plate a...

Page 30: ...cove he copper g water pum of expans water pump g water pump g of Clutch Assembly clutch cover spring and move the frict f Right Cran crankshaft over for dam replaced wi to the follow g the crank het...

Page 31: ...nspection o k the locatin e rotation h driven pl arance gaug mm value 0 11 nce betwee mm value 0 6m n of Clutch grooves on d y gap and sc or serious g replaced on of Drivin g gear for w ous wear a be...

Page 32: ...water pump cover 4 2 Mount 2 dowel pins and mount the water pump cover onto the water pump 5 3 GB16674 M6 45 6 2 1 12 Fasten the water pump cover with 3 small GB16674 M6 45 pan head bolts and pay att...

Page 33: ...ing gear locknut 50 65 N m Assembling of Gearshift Mechanism 1 Mount the locating plate assembly onto the right body and tighten it 2 Mount the pentagram shaped plate in the gear shift drum and pay at...

Page 34: ...1 2 O 9 4 2 4 Put 2 O rings 9 4 2 4 into corresponding holes 2 Mount the oil pump to the corresponding position and pay attention to arrow which shall point to the main shaft O 9 4 2 4 O ring 9 4 2 4...

Page 35: ...bush washer onto the main shaft Note Evenly apply lubricating grease on inner ring of clutch shaft sleeve 2 Mount the retainer in the corresponding groove on main shaft 3 Mount bearing and pushrod on...

Page 36: ...ing and driven balance gears Installation of driving and driven balance gears Installation of magnetor rotor Installation of magnetor stator Installation of gear indication harness Installation of lef...

Page 37: ...3 5 GB16674 M6 40 2 GB16674 M6 50 1 GB16674 M6 25 Remove the left cover bolts 5 small GB16674 M6 40 pan head bolts 2 small GB16674 M6 50 pan head bolts and 1 small GB16674 M6 25 pan head bolt 4 2 Rem...

Page 38: ...ed that the magnetor rotor is impacted by accident during removing and assembling such as falling onto the ground or being knocked by a foreign object it shall be replaced with a new one Removal of Dr...

Page 39: ...e gear indication harness Note O Take out the gear indicator together with its O ring Inspection of Left Crankcase Cover Check the left crankcase cover for breakage etc Inspection of Magnetor Stator a...

Page 40: ...e driving gear locknut Note 1 Oil on driving gear locknut and left crank threads shall be cleaned up 2 M24 1 3 4 263 Apply the Loctite 263 thread locker on 3 4 threads whole circle of balance shaft lo...

Page 41: ...unting the driving and driven balance gears namely the driving and driven balance gear teeth with timing marks shall mesh with each other 2 3 4 263 Apply the Loctite 263 thread locker on 3 4 threads w...

Page 42: ...end of the duplicate gear II has one gasket 10 5 0 5 18 2 Mount the magnetor rotor onto the left crank and fasten it with the locknut Note 1 3 5 7262 Apply the HUITIAN 7262 anaerobic thread locker on...

Page 43: ...n Note O Before installation make sure the O ring is intact on the gear indicator and replace it in case of damage 2 2 Fasten the gear indicator with 2 pieces of gear indicator bolts 5 7N m Torque of...

Page 44: ...with the cable crimping board 5 GB16674 M6 12 Fasten the cable crimping board with GB16674 M6 12 bolts Note 8 12 N m Tightening torque 8 12 N m Installation of Duplicate Gear Cover 1 Mount the duplic...

Page 45: ...Assembling of oil screen Assembling of transmission crankshaft balance shaft Crankcase assembling Maintenance Instructions This section describes the installation and detection of transmission cranks...

Page 46: ...learance on big end side of connecting rod Axial 0 1 0 3 0 5 Radial 0 008 0 016 0 02 Balance shaft Shaft diameter 19 98 19 993 19 96 Troubleshooting Difficulty in gear shifting Crankshaft having noise...

Page 47: ...ead bolt M6 100 pa 2 rd and re and then rem and the 2 d nkshaft Bal Counter Sh e fork shaft and cou crankshaft a parts are le main and tion of Cran V rankshaft b n radial run auge rance on th th a fee...

Page 48: ...well as e bearings or flexible ro ation or seiz aced with th her the oil hift arm on se of damag h those on of Shift For Gear Shift fork for wea measure the 12 020 mm value of for shaft for w asure i...

Page 49: ...Check the oil screen for damage if any replace it with a new one Assembling of Oil Screen 1 Mount the oil screen and spring in corresponding holes on the left case body 2 Mount the oil screen cover N...

Page 50: ...se body Note The left crankshaft bearing requires interference fit with the crankshaft hole and shall be mounted in a shrinkage fitting way namely before installation bake hot the left crankshaft hole...

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