CFMoto motorcycle CF150-A. Service Manual

General precautions

The personnel shall make them be aware of each other from time to time when operating, for safety

confirmation.

2.·Exhaust contains toxic ingredients. Do not run the engine in closed places or places with poor ventilation for

a long time.

3. ·No smoking or naked fire is allowed at the operation site, for the gasoline is combustible. Not only flames,

but electric sparks shall be avoided. Besides, the vapored gasoline is explosive, please operate it in the place

with nice ventilation.

4. ·Do not use gasoline to wash or clean components or parts

·5. When the engine just stops, the temperature of engine, muffler is still high; please do not touch them with

bare hands, for avoiding burn. Please wear uniform with long sleeves as well as gloves when maintaining.

· 6. In case fuel, lubricant system, cooling system or exhaust system has been repaired or maintained, it’s

necessary to inspect its marking line or any leakage.

·7. Place engine oil, coolant or waste components with proper way to protect environment.

Notes

：

1.The parts, lubricant and grease must adopt the genuine parts of CFMOTO or recommendation.
2.·The parts of each system shall be arranged and stored separately, so that the parts can be assembled
to the original places.
3. ·Proper special tools must be applied to the operations which require special tools
4. Please clean the dirt, dusts on the vehicle before maintenance.
5. The recommended lubricating grease must be applied or injected in the appointed positions.
6. The fasteners such as bolts, nuts and screws shall be pre-fastened, and then be fastened on the
diagonal according to regulated fastening torque in the principle of from big to small, from inside to outside.

7. When bolts tightened by required torque with wrench, if there’re grease or oil on bolt threads and

screws, must clean it before assembly.

8. The parts shall be washed and the cleanser shall be blown away by compressed air prior to
determination when they are disassembled and inspected. The working surface shall be lubricated before
assembly.
9. Inspect the necessary sites upon disassembly, measure the relevant data, so that the original status can
be resumed after assembly.
10. The gasket, O-ring, piston pin retainer and split pin must be renewed after disassembly.

Caution

：

Proper repair and maintenance is very important not only to worker’s safety, but

also to engine reliability and safety.

1-16

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1 Maintenance information (Engine)

1-17

Introduction of fuel, engine oil and coolant

Fuel

：

Oct ane 90# or above, unleaded

Eng ine oil

：

O il t ype (SAE10W

－

40)

Oil grade :A PI (SF or SG )

I f abov e-ment ioned oil is unav ailable, please choose

as right picture show s acc ording t o temperature.

Coolant

：

Coolant is ant i-c orros ive and anti-rust and freez ing point s houl d be 5

low er t han lowest surrounding temperature.

Recom mended co olant:- 35

℃

, anti -froz en, anti -cor rosive and hi gh-bo iling p oint

Warning

！

：

Engine coolant is toxic, do NOT drink. Keep out of reach of children and store

carefully.

Caution

：

Do not mix other brand coolant to use.

Eng ine break-i n

There’re many moving part s inside engine, suc h as piston, pist on ring, c ylinder, gears and so on. It ’s very important to break -in during

initial driv e. Break-in c an make moving component s matc h each other bett er, cont act bett er and adjust clearanc e to guarant ee engine bett er

perform ance and reliability.

Rec omm ended break-in period is 1000K m.

Notes for break-i n

：

、

Turn t hrot tl e sl owly st ep by st ep af ter st art engine. Do not t urn f ast er and sl ower.

、

Try t o drive on a good road, do not driv e in up and down road for long time.

、

Keep oil path sm ooth.

、

Try to avoid sudden acc eleration or high RP M w ith no-load c ondition.

、

Do regular repair and maint enanc e during break-in period. Remove it if any t roul bes oc cur.

、

After break-in, please change engine oil, adjust elec t ode of spark plug and valves clearance, inspec t oil pat h, and clean c arbon deposit on

head of pist on and cylinder head if needed. D o a c om plete engine inspect and maint enanc e ac cording to service manual bef ore norm al

driving.

～

500km :

Do not run engine at

≥

50% t hrottl e pos it ion; do not change speed frequently; do not run engine at a fixed thrott le posit ion;

Av oid sudden acc elerat ion; Turn t hrottl e sl owly.

500

～

1000km

：

Do not run engine at

≥

75% throt tle posit ion for long t im e.

Atteni on

：

· Do regular repair and maint enanc e during break-in period, if any troubles, please rem ov e it immedi at ely.

· Af ter break-i n, do a complet e m aint enanc e and dri ve normall y.

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1 Maintenance information (Engine)

Engine technical specifications

Item

No.

I tem Specificat ions

E ngine type

Single cylinder, 4 -stroke ,wa ter-c oo led, 2 v alves and

SO HC

2 B ore× Stroke

57mm ×56. 8mm

3 Dis placem ent

144.9m l

4 Co mpres sion

ratio

9.8

：

5 I dle

spe ed

1500± 150r/min

6 Sta rting

m ode

Carburetor

Ig nition ty pe

CDI

Spark plu g & g ap

CR9EP /0.8-0.9m m

E lectric

syste m

Fly whee l

3-phas e A C (ro tor and s tator)

Ty pe Tria ngular

A ir filter

Spong e elem ent

Combu stion

syste m

G asoline RQ-90

Valv es

syste m

Valve t ype

SO HC/ Cha in d rive

Ty pe Pres sure

s plash

O il pum p

Rotor drive

Filter elemen t

Fu ll-f low pap er elem ent

Lu bricatio n

syste m

O il grade

SA E10W

－

40/ SF

Coo ling type

Close-lo op recycle c ooling

Cooling

syste m

Coo lant typ e

-3 5

ant i-freezing a nd anti-corrosive

Clutc h ty pe

Wet a nd mu lti-disc ma nual clutch

Tra nsimission type

Constant me sh

Num ber of g ears s hift

5 gea rs

Ty pe and order of gear shifting

Mechanica l rec iprocatin g /1-0-2-3-4 -5-4-3-2-0-1

Prim ary ratio

3.471

1 gear

2 gear

1.857

3 gear

1.368

4 gear

1.143

Transmis sion

syste m

Tra nsimission

ratio

S econdary

ratio

5 gear

0.957

13 Dime nsion

L×W × H

（

m m

）：

386× 311× 439

Ne t weig ht

27.5k g

Drive m ode

Chain drive

Ro tatio n direction of o utput shaft

An ti-clockwise from le ft side view wh en goe s fo rward

1-19

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Service data

Valves & cylinder head (mm)

Item

Standard data

Service data

Remarks

IN. 27.5

—

Dia. Of valve stem

EX. 24

—

IN. 0.06-0.08

—

Valve clearance (cold engine)

EX. 0.1-0.13

—

IN. 0.01-0.037

—

Clearance between valve guide bush

and valve stem

EX. 0.03-0.057

—

Inner dia. Of valve guide bush

IN. & EX

5-5.012

—

IN. 4.975-4.990

—

Outer dia. Of valve stem

EX. 4.955-4.970

—

Run-out of valve stem

IN. & EX

0.03

0.05

Length of valve stem end

IN. & EX

5.3-5.5/4.8-5.0

4.8/4.3

Thickness of valve head

IN. & EX

0.5/0.8

—

Seal run-out of valve head

IN. & EX

0.03

—

Seal width of valve seat

IN. & EX

0.9-1.1

—

Inner spring

32.54

Free length of valve spring

Outer spring

34.98

32.5

Inner spring

33.7-44..3N when compressed to 26.78mm

—

Elasticity of valve spring

Outer spring

88.6-104N when compressed to 29.78mm

—

IN.

33.67 —

Height of cam.

33.314 —

Clearance between outer dia. Of

camshaft and camshaft hole

22 0.032-0.066

0.150

Outer dia. Of camshaft

22 21.959-21.980

—

Inner dia. Of camshaft hole

22 22.012-22.025

—

Run-out of camshaft

0.008

—

Dia. Of rocker arm shaft

IN. & EX

11.977-11.995

—

Inner dia. Of rocker arm shaft hole

IN. & EX

12-12.018

—

Flatness of contact surface of cylinder

head

0.03 —

Flatness of contact surface of cylinder

head cover

0.03 —

1-20

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1 Maintenance information (Engine)

Cylinder/Piston/Piston ring/Crankshaft

(mm)

Item Stand ard

data

Service

date

Re marks

Cylind er pressure

12 00kPa

—

Clea ra nce between piston a nd cylinde r

0. 02-0.04

—

Dia. Of piston shirt

56 .97-56.9 9

7m m away from pisto n skirt end whe re

m easure d

—

Inner dia. Of cylind er

57 -5 7.019

—

Flatn ess of cylin der con tact surface

0. 02

—

1-rin g

≈

7 —

Free open cut of piston ring

2-rin g

≈

—

1-rin g

0.1 5-0 .25

—

Close cle ara nce of piston ring

2-rin g

0.1 5-0 .25

—

1-rin g

0.0 15-0.05

—

Clea ra nce be twe en pisto n ring and

piston gro ove

2-rin g

0.0 15-0.05

—

1-rin g

0.9 7-0 .99

—

Th ickn ess of p ist on ring

2-rin g

0.9 7-0 .99

—

1-rin g

1.0 05-1.02

—

2-rin g

1.0 05-1.02

—

W idth of piston groove

Oil ring

1.8 6-1 .96

—

Inner dia. Of pisto n pin hole

15 .002-15. 008

—

Ou ter dia. Of piston pin

14 .994-15. 000

—

Inner dia. Of connectin g rod sm all end

15 .006-15. 014

—

Clea ra nce of connecting ro d big end

0. 15-0.45

—

Th ickn ess of conne cting rod big en d

15 .95-16.0 0

—

Run-out o f crankshaft

0. 04

—

Lubric ati ng sys te m

Item Standa rd

data

Se rvice

da ta

Re marks

Cle arance b etween oil pump inner

rotor and outer rotor

0.0 8mm-0.15m m

—

Cle arance be twe en oil p ump outer

rotor and hole of oil pum p bod y

0.1 5mm-0.19 3mm —

Oil pressure

10-30kP a when a t 3000 r/m in

—

Oil typ e

SA E1 0W

－

4 0

，

AP I Sf o r S G

—

W hen chang e oil

1200m l

—

W hen replace oil filter

1250m l

—

Oil capa city

W hen en gine ove rh aul

1450m l

—

1-21

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C lu tch + Tra nsi mi ssio n (m m )

Item

Standa rd v alue

Serv ice limit

Re marks

Drive disc of c lutch

2.9 -3. 1

2.8

Numbe r o f driv e disc

Driven disc of c lut ch

1.5 -1. 6

—

Dis tortio n of driv en disc

0.10

Numbe r o f driv en disc

Free len gth of clutch sprin g

30. 4-3 1.6

29.5

Nume r of spring

Adjustment of clutc h s crew

Finish rotat ion o f screw and ret urn circle of 1/4 -1/2

No. 1 and No. 2 gear

5-5.15

—

Th ic kn ess of gear

slot

No. 3 gear

5.5 -5. 65

—

No. 1 and No. 2 gear

4.8 -4. 9

—

Th ic kn ess of gear

sh ifter fork

No. 3 gear

5.3 -5. 4

—

C oo lin g sys tem (m m )

Item

Sta ndard v alue

Lim it v alue

Remark s

Te mperatu re of th erm ostat

ope ning

6 8-74

℃

—

Trav el o f thermos tat valv e

W hen 95

℃ ，

3.5 -4. 5mm —

Pressu re of radiator cov er

ope ning

1 08k Pa

—

Type 0 030-0226 00

Tem perature when

S witch “O N”

116

℃

~ 120

℃

Tem perature when

S witch “O FF ”

116

℃

~ 112

℃

Alarming swit ch of wate r

tem perature

Re sistan ce

（

when

2 5

℃ ）

≥

Ω

Co olan t typ e

-30

℃

an ti-freezing and ant i-corros ive an d

h igh -bo iling p oint

—

1-22

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1 Maintenance information (Engine)

Air intake system

Item Standard

data

Remarks

Carburetor type

CPZ27

Choke size (mm)

ø24

Idle speed

（

r/min

）

1500

±150

Electric system

Item Standard

data

Remarks

Type CR9EP

Spark plug

Gap 0.8-0.9

Charicteristic of spark plug

＞

8mm

，

1 Mpa

Primary 4±0.2

Ω

Resistance of

ignition coil

Secondary 15±10

Ω

Resistance of

flywheel coil

Pick-up 110±11

Ω

Voltage with no-load of

flywheel

（

cold engine

）

＞

50V(AC)

，

5000 r/min

Max. power of flywheel

140W

，

6000 r/min

Voltage of regulator

13.5V-15.0V

，

5000

r/min

Peak voltage of primary

ignition coil

12V

Peak voltage of pick-up coil

＞

1.5V

Resistance of starter relay

Ω

-5

Ω

1-23

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157MJ-2A Engine tightening torque table

Item Qty

Dia. Of

thread

（

）

Torque

（

N.m

）

Remarks

Bolt, crankcase

～

Bolt, oil pump

～

Bolt plug, oil view hole

M12×1.25

～

Bolt cover, front left side cover

M26×1.5

～

Bolt, tensioner plate

～

Bolt, overriding clutch

～

32 Apply

locking

glues

Nut, flywheel

M10

～

Apply locking glues

Nut, crankshaft

M16×1.5

（

）

～

Nut, clutch

M16

～

Apply locking glues

Bolt, flywheel stator

～

20 Apply

locking

glues

Bolt, pick-up

～

Drain bolt, crankcase

M14×1.25

～

Retainer bolt, crankcase

M14×1.25

～

Bolt, oil pass of right side cover

M14×1.25

～

Bolt, water pump

～

Stud L (connecting crankcase)

YM8

～

Stud R (connecting crankcase)

YM8

～

Nut, cylinder head

～

Switch, water temperature

R1/8

～

10 Apply

locking

glues

Spark plug

～

Stud, exhaust

～

Bolt, timing sprocket

M6-10.9

～

18 Apply

locking

glues

Adjustable Nut, valve clrearance

M6×0.75

～

Other bolts, screws and nuts

～

1-24

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1 Maintenance information (Engine)

157MJ -2 A E ngine repai r tools

Mea uri ng gauges

Item

Tool Name

Specificat ion

Purposes

Rema rk

1 Vernier

calip er

0-150m m

Measure

length

and

widt h.

2 M icrom eter

0-25mm

Measure oute r diamete r of rocker sha ft, valve stem a nd

cam sh aft.

Dial indica tor

25-50m m

Measure Ma x. lift t ravel of camshaft

Dial indica tor

75-100 mm

Measure size of p iston skirt

Inside caliper

Measure cylind er inne r d iame ter

6 Int ernal

quick

calipe r

10-34m m

Measure inner diameter o f rocker, pisto n pin hole

and sma ll end ho le of conn ecting rod

7 Dial

indica tor

1/10 0

Measure

run-out

Knife -e dge Stee l Ruler

Measure surface flat ness

Feeler gau ge

Measure surface flat ness and adju st valve clrea rance

10 Plastigauge

Measure

clea ra nce

Spring balance

Measure spring elasticity

12 Tachomet er

Measure

en gine

RPM

13 Cylinder

pressu re

gauge

0-2MP a

Measure

cylind er

pre ssure

Oil pressure g auge

Measure oil p ressure

Baromete r

Measure op en pressure of rad iato r cap

Ohmm eter

Measure resistance and voltage

Amperem eter

Measure curre nt/switch “ON” or “OFF”

Thermom eter

Meau re coo lant temperatu re

Ig nition timing light

Check ignitio n tim ing

Torquem easuring wrench

One set

Measure tighten ing t orq ue

Common and auxilia ry tools

22 Alcohol

burner

Heating

M egnetic stand

Install

dia l

indicato r

Fla t plate

Help for measureme nt

25 V-blo ck

Measure

vibration

26 Twe ezers

Install

va lve

clips

Circlip p lie rs

Remove a nd in stall circlips

Nipper plie rs

Remove a nd in stall circlips

Shock starter

Remove cross bolts

30 Straight

screwdriver

Cross scre wdrive r

Remove cross screws

W re nch sle eve s

One set

Remove b olts and n uts

33 Int ernal

hexa gonal

wre nch

1-25

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Special tools

Item

No.

Tool name

Specifications

Purpose

Remarks

Special wrench for spark

plug

Remove/install

spark

plug

Rotation stopper wrench

for clutch

Remove/install nut of clutch or

nut of crankshaft

Remover for piston pin

Remove piston pin

Puller for flywheel rotor

Remove flywheel rotor

Compression tool for

valve spring

Remove/install

valve

spring

6 Grinder

for

valve

Grind

valve

Install tool for bearing

One set

Install bearing and oil seal

Remove tool for bearing

One set

Remove bearing

Remove tool for oil seal

Remove oil seal

Stopper wrench for

flywheel

Remove

flywheel

1-26

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1 Maintenance information (Engine)

E ngine lubricating materials and other materials

Th ere are lub rican ts (such as oil), greas e (bu tte r) , c o olan t, se ala nt and glue s.

Item S pecifications

Ap plie d

are as

Re m a rks

En gin e oil

G ra de :

S AE 15 W -40

O r A PI: S F or S G

Mo vin g pa rts in sid e cylind er

Mo vin g pa rts in sid e cran kcase

Mo vin g pa rts in sid e cylind er h ea d

L ub ricating d iag ra m p lea se see pag e 4-11

O il g ra de p leas e s ee p ag e 1-17

Oil Ca pacity

12 00m L

（

C ha nge oil

）

12 50 m L

（

R epla ce oil

fi lte r

）

14 50 m L

（

Eng ine

overha ul

）

L ub rican t o il

with

m o lyb de num

Piston pin , va lve stem , v alve se al,

ca m sh aft

Gre ase/b utte r

# 3 grease w ith M oS

lith iu m

Se al lip s, o -ring an d o th er rubb er seals,

b ea rin g

Co ola nt - 35

℃

a nti-fre ezing ,

a nti-c o rro si ve a nd

h igh -b oiling p oin t

C oo ling sys te m

Volu me de fined b y

ra dia to r

Se ala nts

C on ta ct surfa ce b etwe en c rankc ase,

cylinde r a nd cylin de r he ad

Locking glue s

of scre w

So m e screw o r bo lt threa ds

1-27

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2-1

2 VEHICLE BODY & MUFFLER

Overhaul information

Caution

Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.

Special attention should also be paid to sparks. Gasoline may also be explosive when it is

vaporized, so operation should be done in a well-ventilated place.

Remove and Install muffler after it is fully cold.

1.This chapter here introduce operation of disassemble and assemble for cover material

muffler and fuel tank .

2.Hoses, cables and wiring should be routed properly.

3.Replace the gasket with a new one after muffler is removed.

4.After muffler is installed, check if there is any exhaust leakage.

Tightening torque

Bolt of tailight/brake light cover 1.8N.m(0.18kgf.m)

Bolt of turning light cover 1.8N.m(0.18kgf.m)

Trouble shooting

Too big noise of muffler

1.Muffler breakage

2.Exhaust gas leakage

Not powerful

1.Muffler deformation

2.Exhaust gas leakage

3.Muffler blocked

Overhaul information............2-1

Front fenderchain cover..............................2-7

Seat

，

rear rack………………..2 -2

Lock seat,helmet lock……… ………… ……… ….2-8

Front protective cover(LH&RH)

、

Headlight cover…… ……… ………… ………… …2-9

side cover(LH&RH)…… 2-3

Muffler,(L/R)triangular panel……………………2-10

Fuel tank ………………… 2-4

Cable,plastic parts… ……… ……… ……… ……..2-11

Top cover of tail Light ……2-5

Rear license bracket

、

rear flector

、

rear mudguard……………2-6

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2-3

2 VEHICLE BODY & MUFFLER

Left,Right front protect cover

Remove

--2 bolt

Pull along protect cover,until break away from

hanger of fuel tank ,then renmove left¡¢right front protect

cover .

Installation

Reverse the removal procedure for installation

Caution

Adjusting front cover in perfect position

before installation.

Middle guard board(left)

Remove

Remove seat

Opening fix point 1

Opening fix point 2

Pull back,up left middle guard board,

until break away from fix point 3,then remove

left middle guard board.

Installation

Reverse the removal procedures

for installation.

Middle guard board(right)

Remove

Remove seat

Opening fix point 1

Opening fix point 2

Pull back,up right middle guard board,

until break away from fix point 3,then remove

right middle guard board.

Installation

Reverse the removal procedure for installation.

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CFMoto motorcycle CF150-A. Service Manual - part 2