CFMoto motorcycle CF150-A. Service Manual - part 6

5-14

Valve stem jump

z

As illustrated,use a V-shape to support valve,

use a micrometer to measure the jump.

Tool:micrometer and  V-shape support

 

Valve head jump

z

As illustrated,use a micrometer gauge to

meausre valve head jump. If the jump is over

limit,replace valve.

Limit

:0.03

mm

.

Tool:Megnetic clock seat, micrometer gauge

(1/100)and V-shape seat.

Valve head surface wearing

z

Check wearing of every valve head surface,

replace a new valve in case of wearing or

damage.Measure valve head width T, if valve

head depth

 

is smaller  than  limit,replace

valve.

Valve head limit

:0.5

mm

Tool:Feeler gauge

External diameter of valve stem

z

Measure with a micrometergauge

Valve intake

 4.975-4.990

mm

Valve exhaust

 4.955-4.970

mm

Tool:Micrometer gauge

(0-25

mm

)

 

 

 

 

 

Valve step end status

z

Check valve step end surface for corrosion

and wearing. If A is less than the limit,repair

it.

Valve stem length limit

:4.5

mm

Tool:feeler gauge;

5-15

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

Valve spring

Valve spring is for sealing between valve and

valve seat. Loss of spring power will cause

engine power output and lead to valve

mechanic nosie.

z

Measure free travel and replace spring if

limit is below limit.

z

Measure power of compressed spring and

replace standard limit of inner spring  of valve

if the spring power out of limit.

Compressed from

 26.8

mmto

 33.7N-44.3N

Valve external standard(valve intake and

exhaust

):

Compress to

 29.8

mm is 

88.6N-104N

Tool: Spring balance

z

Measure spring leaning,and replace spring

in case of leaning out of limit.

Valve spring length limit

(

valve intake and

valve exhaust

):31

mm

Tool:Feeler gauge.

Valve external spring free travel limit

(

valve in-

take and valve exhaust

):32.5mm

5-16

z

Install valve inner and external spring, little

end 6 close to cylinder head and big end with

mark upwards.

z

Place valve spring upper seat

2 

and com-

press spring with special tool. Put two valve

clamps

1 

at

  3 £¬

and then release com-

pressed tool.

Note:Use a hammer slightly knocks

at valve end, and make sure valve clamp

is already fixed in valve groove.

Cylinder head assembly

z

Install all valve spring seat 1;

z

Coat every valve step sealing with

lubricant and then install valve cap end.

Material:molybdenum lubricant

Warning: Valve step sealing can not be

re-used.

z

Insert valve 3 and 4, coat a layer of

molybdenum  lubricant on valve step round

surface

Wa r n i n g :   D o   n o t   d a m a g e   s e a l i n g

of valve step during valve  installation

 

5-17

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

Camshaft

Tool: Valve spring compressed tool, and

tweezers.

z

Check sealing of cylinder cover:inject clean-

ing liquid into air inlet

 ¢Ù 

and air outlet and

stop for a while,check valve seat

 ¢Ú 

for leak.

z

Install spark plug and water sensor,thermo-

stat and thermostat kit and cylinder cover re-

lated parts.

z

In case of abnormal noise or vibration or

power output too low from engine cylinder

cover,lift of camshaft or assembly must be

checked. Wearing of camshaft will also lead

to mentioned breakdown.

5-18

 

During cam shaft assembly , measure clear-

ance  between camshaft and bearing hole

tojudge if the cleearance is within the limit.

 Camshaft work-out clearance limit:

0.15mm

Measurement method:

z

Clean cylinder head and cover.

z

Put plastic clearance gauge external surface

of camshaft touching position and then as-

semble it with cylinder head cover;

z

Install cylinder head cover and tighten bolt

with proper torque

z

Disassemble cylinder cover and then read

data on the gauge.

Tool: Plastic clerance gauge.

Tool:Plastic gauge

Note:Do not turn camshaft during plas-

tic gauge assembly.

If oil clerance exceeds the limit, measure di-

ameter of camshaft, replace camshaft in case

of over limit or replace cylinder head and head

cover.

Wearing of camshaft will defect valve perfor-

mance and lower engine power output.Wear-

ing of inlet and outlet  limit uses a to clarify.

A n d   u s e   a   m i c r o m e t e r   g a u g e   f o r

measurement. Replace camshaft in case

over wearing;

The limit of camshaft travel

Inlet camshaft

:5.6695

mm

V

alve exhaust camshaft

:5.314mm

Tool: Micrometer gauge

(0-25mm)

z

Wearing of camshaft

z

Camshaft bearing wearing

z

Camshaft assembly external diameter

Use a micrometer  gauge to measure exter-

nal diameter A on camshaft assembly posi-

tion and replace camshaft in case of exceed-

ing limit.

Standard A limit

:

 21.959mm-21.98mm

Tool:micrometer  gauge

(0-25mm)

5-19

                             5 ENGINE REMOVAL AND ASSEMBLY

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5

5

5

5

Cylinder body:

 Cylinder 

body deformation:

z

 

Use a knife straight ege and a feeler gauge

to inspect 7 points and read the limitdata and

replace cylinder body if limit is exceeded.

Limit: 0.02mm

Tool:knife straight edge and feeler gauge.

Cylinder body inner diameter inspection.

z

Check cylinder inner surface for scratch, or

any other damage and replace new parts if

necessary

;

z

Measure inner diameter with spotted three

points, upper position,middle position and

bottom position, in vertical position between

each two points;

Cylinder body inner standard limit

:57-57.

019mm

Tool:Cylinder body inner diameter gauge.

TENSIONER SET, CHAIN,GUIDE CHAIN.

z

Inspection

Check touching surface for wearing and

damage, replace if necessary.

5-20

Piston

:

:

:

:

:

Piston diameter

.

.

.

.

.

Use a micrometer gauge to measured diam-

eter at position 7mm. Replace piston in case

of lower limit

Piston external standard

:56.97-56.99mm

External diameter limit

:56.94mm

Tool:Micrometer gauge(

50-75mm)

Measure clearace between piston and cylin-

der body based on above measurement.

Repalce cylinder or piston or both if clearance

is exceeding 0.15mm.

Piston groove clearance

Use a feeler gauge to measure clerance be-

tween ring 1 and 2. And replace piston and

piston rings in case clearance exceeds the

limit.

  

  

  

  

       

First ring

:0.15mm

Second ring

: 0.13mm

Piston groove width standard:

First ring

:1.005-1.02mm

Second ring

: 1.005-1.02mm

Oil ring

: 2.005-2.02mm

Piston ring thickness standard:

First ring

:0.970-0.990mm

Second ring

: 0.970-0.990mm

Tool; Feeler gauge
Micrometer gauge

(0-25mm)

f

5-21

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

Piston free open and working open

Before piston ring assembly,use feelergauge

to measure free open of each ring and then

install pinton on cylinder body. Then measure

working open of each ring, replace piston ring

in case of incorrect limit.

First ring

:7.5mm

Second ring

:7.5mm

Piston ring working open limit:

First ring

:0.25mm

Second ring

:0.25mm

Tool:vernier cliper and feeler gauge

Piston pin and pin hole

z

Measure piston pin hole inner diameter with

a inner micrometer gauge, and mesaure ex-

ternal diameter with micrometer gauge. Re-

place piston and piston pin in case limit is

exceeded.

Piston pin hole limit

:15.030mm

z

Use a micrometer gauge to measure exter-

nal diameter at three points.

Piston pin external diameter limit: 14.980mm

Tool:Micrometer gauge

(0-25mm)

5-22

2 ¼ì²é £º

Crankshaft

Crankshaft little end innerdiameter

z

Replace crankshaft in case limit is

exceeded.

Little end limit

 :

Tool:percentile scale

(0-18mm)

z

Crankshaft big end wearing can be checked

by checking little end beat.

Beat  limit of little end :3mm .

Crankshaft beat

Tool: percentile scale, magneto seat and V-

shape seat.

Crankshaft big end side clearance:

z

Push big end to another end and use feeler

gauge to measure clearance£¨Standard:0.

10-0.45mm, limit:1.00mm);replace crank-

case if clearance is exceeding limit

Crankshaft jump

z

As illustrated, put crankshaft on V-shape

support,turn slowly and use percentile scale

to measure jump, replace or repair crankshaft

if jump exceeds limit

Jump limit:0.04mm

Tool:Percentile gauge, magneto seat and V-

shape support

15.014mm

Tool: Feeler gauge

5-23

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

Clutch

Primary clutch:

z

Check bearing teeth and replace bearing A

in case of wearing or damage.

Secondary cltuch

z

Inner rubber wearing will cause movement

or noise between bearing and clutch. Replace

secondary B in case of serious movement

z

Replace two bearings in case of wearing or

damage.

z

Replace two bearings in case of abnormal

noise.

FRICTION DISC, CLUTCH

z

Use feeler gauge to measure clutch disc

thickness and replace friction disc clutch in

case limit is exceeded.

Thickness standard:2.9-3.1mm

Limit:2.8mm

Plate clutch

z

Use plain panel and thickess gauge

1 to

measure deforming data

(Limit 0.1mm),

re-

place clutch plate if measurement exceeds

limit.

5-24

Clutch spring

z

Measure free travel of each spring with a

feeler  gauge(Limit:29.5mm) Replace all

springs in case any length of spring is below

limit.

THRUST BEARING & BRACKET,CLUTCH

z

Check 

THRUST BEARING & BRACKET, CLUTCH

for abnormal status, such as broken, wearing

or damage, and replace if necessary.

Crankcase bearing.

z

Feel clearance of crankshaft bearing inside,

and check for noise or smooth turn with hand,

replace bearing if necessary.

5-25

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

GEARSHIFTING

GEARSHIFTING

GEARSHIFTING

GEARSHIFTING

GEARSHIFTING

PART

 

NO.

 

PART

 

NAME

 

P/N

 

PART

 

NAME

 

1

 

SCREW

   

M6×12

 

21

 

O-RING 

26.2×2.4

 

2

 

RAT CHETPLATE,GEAR SHIFT 

22

 

SWITCHSEAT,GEAR POSITION 

3

 

CAMSHAFT  GUIDE, GEAR SHIFT 

23

 

SCREW 

M5×20

 

4

 

RIGHT  RAT CHET 

24

 

WASHER

 

6

 

5

 

RAT CHET  PIN, GEAR SHIFT 

25

 

LIMIT, GEAR SHIFT  DRUM 

6

 

RAT CHET  SPRING 

26

 

DOWEL SPRING, GEAR SHIFT 

7

 

DRIVEN GEAR, GEAR SHIFT  DRUM 

27

 

BOLT

 

8

 

LEFT RAT CHET 

28

 

SHIFT FORK 

9

 

CENT ER SHAFT, SHIFT  FORK 

29

 

SHAFT, SHIFT  FORK 

10

 

SHIFT FORK (CENTER) 

30

 

MAIN SHAFT 

11

 

BOLT

 

M14×1.25×12

 

31

 

COUNT ERSHAFT 

12

 

WASHER

 

14

 

32

 

DRIVE CHAIN SPROCKET 

13

 

DOWEL SPRING, NUET RAL GEAR 

33

 

LOCK WASHER, CHAIN 

SPROCKET 

14

 

STOP PIN, NUET RAL GEAR 

34

 

NUT

 

M16×1.5

 

15

 

PIN  4X6 

35

 

ROD ASSY,  GEAR SHIFT 

16

 

HUB, GEAR SHIFT DRUM 

36

 

ROD,

 

GEAR

 

SHIFT

 

17

 

CONTACT  SPRING 

37

 

RETURN

 

SPRING

 

18

 

SWIT CH CONTACT, GEAR POSIT ION 

38

 

SHAFT COLLAR 

19

 

WASHER

 

25×40×1

 

39

 

BUSH,DRIVECHAINSPROCKET 

20

 

DOWEL PLAT E, GEAR SHIFT  DRUM 

40

 

O-RING 

 

5-26

Fork

z

Check position 1

z

 

Check position2

Repalce in case of scrach, bending or

damage.

HUB, GEAR SHIFT DRUM

z

Check groove of HUB, GEAR SHIFT DRUM

z

Check position A of HUB, GEAR SHIFT

DRUM

Replace in case of wearing or damage

Shift fork

z

l

Check shift fork and 2

Replace in case scrach, wearing or damage.

z

Shift fork inspection:

In case not smooth, replace shift fork.

Note: Do not try to repair deformed

shiftfork.

  

  

z

Use a slide caliper to measure thicknes of

shift fork composition.

Shift fork thickness standard:4.80-4.90mm

Fork(Middle)standard:5.30-5.40mm

5-27

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

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5

5

z

Check bearing teeth

Replace bearing in case of blue points, wear-

ing or damage.

Replace in case of

 

wearing, crack or

misplacement.

Shift rod

z

Check 1 and replce in case of deforming,

wearing or damage.

Back spring

z

Check spring 2 and replace in case of

damage, deforming.

Shaft collar

Check shaft collar 3 and replacein case

of damage or wearing.

DOWEL SPRING, GEAR SHIFT

z

Check DOWEL SPRING, GEAR SHIFT 4

and replace in case of wearing or damage.

G e a r s h i f t   u n i t   c a m s h a f t   l o c a t i o n

structure.

z

Check gearshift camshaft location structure

5 and replace in case of damage, wearing.

Main,secondary shaft

z

Check main shaft 1 and secondary shaft 2.

Replace set in case of deforming, wearing or

damage.

5-28

 

Starting driven bearing, dual gear and

dual shaft axle.

  

  

  

  

  

Inspection

 

l.

 Inspection driven bearing 1 for wearing or

damage.

2. 

Measure inner and external diameter s of

driven bearing 1.

Limit:

    Inner;replace if over 22.10mm

    External;replace if below 54.15mm

1.

Check dual bearing 2 for wearing or

damage;

2.

Check dual gear shaft axle 3 for wearing or

damage.

Overriding clutch

 

 

 

 

 

Inspection

l.

Check working status of overriding cltuch

after installing starting driven gear onto over-

riding clutch as illustrated.

2.

Hold flywheel, and status is good if starting

driven gear turns smoothly anti-clockwise.

5-29

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

 Engine assembly

Assemble engine in reverse procedures of

assembly removal.and pay attention to follow-

ing points:

1

.Clean related parts;

2.Every parts should be checked without no

damage.

3.Lubricate parts before assembly;

4.Oil lips and O-ring should be lubricated.

Crankcase assembly

Left crankcase

l.

Clean oil and sealing glue on crankcase

sealing surface;

2.

Lubricate oil seal lip;

Crankshaft rod

1.

Use tool to pull rod into left crankcase

Note:

2.

Do not let crankshaft by plastic hammer fall

into crankcase, tool must be used to keep left

and right crankcase in same concentric.

Tool: Crankshaft  assembly  tool.

Main, counter shaft

 

Assemble main, counter shaft as illustrated.