CFMoto motorcycle CF150-A. Service Manual

4-10

Stationary Seal Ring:

Carefully check stationary seal for damage, espe-

cially the seal face.

IN case of damage or leakage,replace the station-

ary seal ring,if necessary ,replace moving seal ring.

Moving seal Ring

Carefully check Moving seal for damage, especially

the seal face

;

Water Pump Body

Check the joint surface of water pump body with

bearing and seal ,if damage, replace it .

Water Pump Impeller:

Check impeller and shaft,if damage,replace with new

impeller.

Check O-ring carfully,if it’s damaged,replace it with

a new one.

Assembly and installation of water pump

Install Oil seal 5into water pump 4 with special

tool.

Install Stationary Seal 6 into water pump 4 with

special tool.

Note

Apply sealant to side “A ” of stationary seal.

Install bearing 2 into water pump 4.

Install moving seal 7 on the impeller 8.

Note

side “A”Moving seal is outward.

Apply grease to impeller shaft

Install impeller shaft which installed Stationary

Seal to water pump body

Install new ring to water pump shaft

Install new gasket 9 to water pump body

Install water pump cover 10 and tighten the bolts

11 and bleed bolt

check impeller for smooth turning

Install new O-ring

Note

Apply engine Oil to the O-ring when install

water Pump.

Install water pump and joint waterhoses

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4-12

Schematic diagram of engine lubrication system

crankcase oil tray 2

engine oil screen 3

Oil Strainer Cover

Oil Level Mirror 5

Oil drain plug 6

Oil Pump Assy

Oil Fiter Assy. 8

Clutch 9

Countershaft 10

Mainshaft 11

Crankshaft

Cylinder Assy. 13

Piston 14

Camshaft

Engine lubrication system:most of parts inside engine which run at high speed,like

piston, Crankshaft,Camshaft all need great lubrication,the good lubrication is the base of

the good condition of engine working.

157MJ-2A engine is used pressure and splash lubrication system,Apply special engine oil for

4-Stroke engine,Engine Oil is not only used for lubrication,but also for clean rustproof,sealing

and cooling.

Inspection of Lubrication system

(see page3-12)

Inspection of engine oil pump

(see page 5-3)

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5-1

5 ENGINE REMOVAL AND ASSEMBLY

Engine removal, inspection and assembly

△

Page location

Location PARTS

REMOVAL INSPECTION ASSEMBLY

REMARK

Engine
outside

CARBURETOR 5-2

—

5-38

WATER PUMP

5-2

—

5-37

ENGINE

LEFT

LEFT SIDE COVER

5-2

—

5-38

MAIN CHAIN

5-2

—

5-38

GEAR TOUCHER

5-2

—

5-38

DUAL GEAR CHAIN

5-2

—

5-38

ENGINE

STARTOR MOTOR

5-3

—

5-37

OIL FILTER COVER AND
PAPER ELEMENT

5-3 — 5-34

RIGHT SIDE COVER

5-3

—

5-33

OIL PUMP SECONDARY
GEAR

5-3 — 5-32

OIL PUMP MAIN GEAR

5-3

—

5-32

CLUTCH 5-3

5-23

5-32

OIL PUMP

5-3

—

5-32

ENGINE

HEAD

TIMING SPROCKET
TENSIONER

5-4 — 5-37

SPARK PLUG

5-4

—

5-17

CYLINDER HEAD&COVER

5-4

5-10

5-36

CAMSHAFT 5-4

5-17

5-36

MAGNETO ROTOR

5-5

—

5-37

MAIN CHAIN

5-5

5-28

5-37

CYLINDER COVER

5-6

5-11

5-35

CYLINDER BODY

5-6

5-19

5-35

TIMING SPROCKET

5-7

—

5-36

PISTON 5-7

5-20

5-34

CRANKSHAFT

GEARSHIFT ROD

5-7

5-27

5-31

CAMSHAFT CHAIN

5-7

—

5-31

FILTER COVER

5-8

—

5-31

RIGHT CRANKSHAFT

5-8

—

5-30

GEAR BOX,FORK,MAIN
SHAFT

5-8 5-25 5-29

CRANKSHAFT 5-9

5-22

5-29

REMARK:ARROW MEANS REMOVAL PROCEDURES AND

PROCEDURE IS REVERSE FOR ASSEMBLY.

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5-2

Engine removal

Preparations

Prepare a plate for parts;

Prepare tools;

Drain all oil and coolant;

Loosen clamp 2,remove water pipe

connection, loosen 3 pieces of bolt 1, and

take out water pump.

Water pump

Engine left side

Left side cover

Remove 10 pieces of assembly bolts on left

side cover and remove left rear cover, left front

cover and left front mat.

Main drive chain

Loosen bolt 2, and remove main drive chain;

Carburetor

Loosen two bolts 1, and remove

carburetor 2.

Engine outside

Gear contactor

Use a screwdriver to loosen two pieces of

bolts 3, and remove gear contactor

DUAL GEAR

Take out dual gear axle and remove duel gear

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5-3

5 ENGINE REMOVAL AND ASSEMBLY

Oil filter cover and element:

Loosen 3 pieces of assembly bolts 3, and

remove filter cover 4 then element and other

parts;

Clutch

Loosen 5 pieces of bolt 6 and remove clutch

plate 7, then take out clutch main plate and

driven plate;

Loosen clutch tightening bolt 8, remove 9

and clutch gear 10 and then other parts;

Take out clutch main driven gear 11.

Engine right side

Starting motor

Loosen two pieces of bolt 1 and remove start-

ing motor 2.

Right side cover

Loosen right side cover bolts 5 & 6, remove

right side cover 7 and right side cover mat.

Driven gear oil pump

Use special tool to remove clamp 1 and then

remove driven gear 2;

Main gear oil pump

Use chisel to loosen bolt 4 and remove

main gear 5;

Oil pump

Loosen 3 pieces of bolt 12, and then remove

oil pump 13.

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5-4

Camshaft

Engine head

Timing sprocket tensoioner

Remove bolt 1 and take out tensioner spring;

Remove tensioner bolt and then the

tensioner.

Use a special tool to remove spark plug 1.

Spark plug

Note:Do not let dowel pin fall into

crankcase.

Remove valve room cover 1;

Remove cover bolt;

Remove cylinder cover;

Remove cylinder cover pin.

Remove timing sprocket bolt 1;

Remove camshaft spacer 3;

Remove timing sprocket 2 from camshaft;

Take out camshaft 1;

N o t e : D o n o t l e t s p a c e r f a l l i n t o

crankcase. Hook the timing sprocket

during removal to avoid drom into

crankcase.

Cylinder cover

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5-7

5 ENGINE REMOVAL AND ASSEMBLY

Timing chain

Remove dowel pin;

Remove gasket 2;

Remove timing chain;

Piston

Use clipper to remove piston pin 4;

Remove pistion pin 5;

Remove piston.

Note:

Keep order with cylinder during piston

assembly;

During piston removal, clear pin or groove

surface, and use too to remove piston if

necessary. Do not use knock out the piston

with hammer

Tool:Piston pin removal tool

Engine crankcase

Gearshift rod unit

Remove gearshift rod unit 1;

Gearshift camshaft driven gear

Use a screwdriver to loosen 4 pieces of

bolts 2;

Remove gearshift camshaft driver gear

Note:

During removal of driven gear 3, do not

loosen 4 and 5, spring 6 and pin 7.

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5-8

Right crankcase

Loosen bolts on crankcase;

Put left crankcase downwards and right one

upward, use tool to separate left and right

crankcases, then remove right crankcase.

Filter element cover

Loosen bolt 1 and take out spacer pin spring

and neutral spacer pin.

Loosen 3 pieces of bolts 2;

Remove cover 3.

Gearbox,shifting fork axle and shifting

fork,main and driven axle

Remove shifting fork axle 1;

Remove shiting fork 2;

Remove shifting fork axle 3;

Remove shiting fork 4;

Remove main gear 6 and driven gear 5;

Remove gearbox.

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5-10

Engine parts inspection

Cylinder head cover

Disassembly

Warning:during

disassembly, make sure

each part position so assembly can be made

just same as done in factory.

Remove 2 valve covers;

Disassemble spacer 2;

Disassemble two rocker arms 2;

Disassemble two rocker arms 4.

Cylinder cover surface

Clean glue on cylinder cover and put it plain,

use a feeler gauge to check surface situation.

Limit:0.05mm

Tool: feeler gauge.

Replace with new parts if limit is exceeded.

Rocker arm

Use a micrometer to measure external

diameter.

External diameter:Rocker arm(air inlet and

outlet)

Standard

: 11.977~11.995mm

Tool: Micrometer

(0~ 25mm)

Note:Cylinder head and cover are an

assy,and should be replaced as a set.

Touching surface of cylinder cover

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5-11

5 ENGINE REMOVAL AND ASSEMBLY

Rocker arm

During valve rocker arm, check also surface

1 and adjustment bolt for wearing ;

Valve rocker arm inner diameter:standard

12.000¡«12.018mm

Tool:Innter diameter gauge

Assembly

Coat rocker inner hole and rocker arm with

oil and assemble rocker arm as illustrated.

Install rocker arm O-ring, make sure rocker

arm surface in line with spacer position A.

Note:

Replace O-ring for every rocker arm inspec-

tion

Cylinder cover

Disassembly

Remove air inlet pipe.

Remove thermostat cover 1, water

temperature sensor 2 and chain tensioner 3.

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5-13

5 ENGINE REMOVAL AND ASSEMBLY

Cylinder deformation

Clear burning room and touching surface.

Use gauge to measure cylinder head and

touching deformation.Replace cylinder head

cover if necessary.

Cylinder head deforming limit

:0.03mm

Tool: Feel gauge, kinfe feeler

;

V a l v e s t e p a n d g u i d e b u s h i n g

composition.

Raise valve seat 10 mm higher from valve,

and use micrometer gauge to measure the

deviation at X and Y vertical position.Replace

valve or cylinder if limit is exceeded.

Deviation limit

(

Valve intake and exhaust

)£º

0.25

Tools:Micrometer gauge and magnetic clock

seat.

Valve width

Coat a layer of color on A and then insert

valve and turn gently,in order to get clear trace

use tool to fix valve head.

Coating trace on valve head must be con-

tinuous and strip width must be within follow

limit. Repair if nenessary.

Standard valve seat width

.:0.9-1.1

Tool:Valve repair.

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CFMoto motorcycle CF150-A. Service Manual - part 5