CFMoto motorcycle CF150-A. Service Manual - part 7

5-30

HUB, GEAR SHIFT DRUM  AND  SHIFT FORK

l.

Assemble gear shft drum hub 1 onto

crankcase;

2.

Install same two shift froks in correct posi-

tion  and then install guide bar 3;

3.

Install shift 4 in correct position and then in-

stall guide bar 5;

4.

Install gear shift camshaft location structure

6;

5.

Instll gearshift location spring 7;

6.

Coat oil on surface of related parts;

7.

Check if every bearing of each gear is work-

ing smoothly.

Note

:Related parts must be cleaned  and no

foreign matters or metallic fragments on

surface.

HUB, GEAR SHIFT DRUM  AND  SHIFT

FORK DRAWING

1.

Coat left crankcase 1 with sealing glue and

install two pins 2 into location holes. Rake

crankcase3 and press properly left and right

crankcases.

5-31

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

2.

Install assembly bolts and tighten bolts  two

or three times as illustrated.

Torque

:10N.m

Neutral gear stop pin and filter cover

1.I

nstall stop pin and stop spring 2, gasket

and bolt 4;

Note

: Do not mistake stop pin 1 assembly

direction;

2.Install filter cover as illustrated;

DRIVEN GEAR, GEAR SHIFT DRUM AND

GEARSHIFTING

DRIVEN GEAR, GEAR SHIFT DRUM

1.

Install driven gear, gear shift drum into

driven bearing 1, plate 2 and camshaft guide.

Note

: Assembly  direction of ratchet plate,

gear shift and driven gear, gear shift drum

can’t be wrong.

Exploded drawing for driven gear,

geashift drum

1.

DRIVEN GEAR, GEAR SHIFT DRUM

2.

RATCHET PLATE, GEAR SHIFT

3.

CAMSHAFT GUIDE, GEAR SHIFT

 

 4. RIGHT

RATCHET  5. LEFT RATCHET;6. RATCHET

PIN, GEAR SHIFT;7.RATCHET SPRING

Note: Left ratchet and right ratchet can

not be installd in wrong direction.

 

Gearshift rod

1.

Install gearshift rod as illustrated;

5-32

Put dowel 1 into crankshaft groove and install

primary drive gear 2, oil pump drive gear 3,

tightening bolt 4 and bolt 5(Torque

:

85-90N.

m

)

Note

: Bolt 5 is with left-turning thread

Oil pump

1.

Install poil pump 6 as illustrated and tighten

3 oil pump assembly bolts;

2.

Install in procedures 7, 8 and 9.

PRIMARY DRIVE GEAR AND OIL PUMP

PRIMARY DRIVE GEAR

Clutch

 

Exploded view:

5-33

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

Install clutch as illustrated;

Note:

1.

Camshaft assembly groove shold be fac-

ing right right crankcase.

2.

Coat 11 with oil before assembly;

3.

Install part 8 longer end into main shaft fac-

ing left crankcase.

Clutch bolt adjustment

1.

Loosen bolt 20 and install adjustment bolt

19 to touch slightly with clutch shaft

2.

Remove clutch adjustment bolt 1/4-1/2 and

tighten tightening bolt 20.

 

Right side cover

Install right side cover as illustrated;

Note

:Washer  6 and right side cover pater

must be new parts to avoid oil leak;

PART 

NO. 

PART NAME 

PART 

NO. 

PART NAME 

1 CAMSHAFT, 

CLUTCH  14 

WASHER  

2 WASHER 

10×2 0×1 

15 

NUT  

3 

OIL SEAL 10×2 0×6 

16 

FRICTION DIS C, CLUTCH 

4 

PLATE, OIL SEAL   

17 

PLATE, CLUTCH 

5 BOLT 

M6×10 

18 

THRUS T ROD, CLUTCH 

6 BOLT 

M6×16 

19 

ADJUS T SCREW,CLUTCH 

7 

SEPARATE ROCKER 

20 NUT 

M6 

8 

SHAFT, CLUTCH 

21 THRUST 

BEARING 

& 

BRACKET, 

CLUTCH 

889102 

9 WASHER20×3 4.5×2  22 

WASHER 

AS152801 

10 

PRIMA RY DRIVEN GEA R 

23 

PRESSURE PLATE, CLUTCH 

11 

BUSHING, PRIMARY DRIVEN 

GEAR 

24 

SPRING,CLUTCH 

12 

DAJUS T WASHER 20 

25 

BOLT COMP. M5X16 

13 

HUB, CLUTCH 

26  

 

5-34

Paper element

1.

Check O-ring and gasket 6 and replace if

necessary;

2.

Clean paper element and replace if

necessary;

3.

Install O-ring, gasket 6, paper element 5,

element spring 4 and O-ring 3, filter cover 2

and bolt 1 in order;

 

P

P

P

P

P

iston ring assembly

1.

Install piston ring onto piston;

2.

Coat  pistons rings with oil;

3.

Do not damage piston;

4.

Put piston ring with mark upside;

5.

After assembly, make sure piston ring

can turn freely and make first ring open

mouth facing air inlet.

Piston installaton

1.

Install piston 1, piston pin 2 and dowel pin

3.

2.

Put piston end with arrow mark towards to

exhuast  port.

 

5-35

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

 

Cylinder body

1.Install dowel pin 1 and new cylinder body

gasket 2.

 

2.

Coat cylinder inner surface, piston and pis-

ton ring with clean engine oil;

3.

Press piston ring, and install piston into cyl-

inder 1 and then install cyliner onto crankcase;

Note:

Do not damage piston or piston ring;

Note piston ring open not facing piston pin

with angle of 

120

 degrees.

1.

Install timing chain sprocket 2;

2.

Install guide chain 3;

3.

Intall dowel pin and new cylinder gasket 4;

4.

Turn crankcase, make piston to to stop

point.

Cylinder cover

Install cylinder cover as illustrated.

 

5-36

Camshaft assembly and cylinder head

tightening

l.

Install camshaft 1;

2.

Install sprocket onto timing chain and install

timing chain sprocket on to camshaft.

Make sure marking line of timing chain in

paralle with cylinder cover connection

surface;

Note

:Do not turn crankshaft during above

operation

1.

Tighten cylinder cover bolt 3 and bolt 4, note

that position for both is right and do  not miss

gasket;

2.

Tighten camshaft  timing chain sprocket bolt

5;

3.

Install camshaft location washer;

4.

Tighten 4 pieces of bolt 7;

Cylinder head cover

1.

Clean oil on surface between cylinder head

cover and cylinder head;

2.

Install dowel pins onto cylinder head;

3.

Coat sealing glue on cylinder head cover

connection surface;

4.

Install cylinder head cover 1 as illustraton;

5.

Install two cover bolts onto rockerarm dowel

plate hole and then install onto cylinder head

cover;

6.

Install rest bolts;

Note

:Tightn cylinder head cover bolts two or

three times(Torque:

10-12N.m

)

;

7.

Instal other assembly bolts;

Valve clearance adjustment

1.

Turn crankshaft and make pstion to stop

point. Adjust air intake and exhaust valve and

tighten clearance adjustment bolts.

Air inlet clearance

:0.06-0.08mm

Exhaust valve clerance

:0.10-0.13mm

2.

Intall valve room cover.

 

5-37

                             5 ENGINE REMOVAL AND ASSEMBLY

 5

5

5

5

5

 

Water pump

1.

Install water pump 1 as illustrated;

2.

Intall water pipe joint 3;

3.

Install water outlet pipe;

Do not forget to assemly O-ring during water

inlet pipe assembly;

T

T

T

T

T

ensioner

1.

Remove bolt 8;

2.

Press lock stop seat 2 and tensioner to bot-

tom as illustrated;

3.

Install new tensioner 1 and then tighten   bolt

4;

4.

Install tensioner spring 6, O-ring 7 and

tighten bolt 8.

 

Starting motor

Install starting motor as illustrated

 

Starting gear and magneto rotor

1.

Put 1 into grrove;

2.

Install starting gear 1 onto crankshaft;

3.

Install magneto rotor;

4.

Coat thread glue on crankshaft and then

tighten bolt 4.

 

5-38

Carburetor

Install carburetor as illustrated.

Dual gear

Install dual gear 1, axle sleeve 2 and dual gear

axle 3.

 

 

Gear connector

1.

Install spring 1 into gearsift durm hub;

2.

Install gear 

contact into hole of the hub;

3.

Install O-ring 3 and gear contact terminal 4 and

tighten bolt 5.

Front side cover and drive chain;

1.

Install dowel pin into left crankscase pin

hole;

2.

Install new left side cover gasket onto left

crankcase;

3.

Install front left cover onto left crankcase;

Note: Gasket must be clean and withou

foreign fragments. Dowel pin must not be

hit

Install drive chain sprocket;

 

 

6-1

6 Engine Disassembly and Installation

 6

6

6

6

6

 

 

Overhaul Information

.................

6-1

Engine Installation

..................

6-4

 

 Disassembly of Engine

................

6-2

Overhaul Information

Operation Cautions:

-

It requires an engine bench and coolant tube when installing and disassembling engine.

 Do not damage frame,     engine body, bolts and cables,etc.

-Following operation doesn’t require engine removed from vehicle.

Tightening Torque:

Engine suspension tightening nut: 

 

 M8: 20-30N

.

m

     

M10: 30-40N

.

m

Rear arm shaft tightening nut:  

        

80-100N

.

m

Rear wheel axle tightening nut:    

     

80-100N

.

m

6-2

CFMOTO

Disassembly of Engine

Remove:

 -Seat

 Front protection cover(LH&RH)

 -Middle protection plate(LH&RH)

 Fuel tank

 -Air pipe,fuel pipe water pipe and cables

 connected with engine

 -Wirings connected with engine

 -Muffler

 -2 water pipe clamps,drain coolant.

 Remove ignition coil high tension cap from spark

plug.

 Loosen rear wheel shaft nut

 Loosen chain snaps with pliers and remove

chain

6-3

6 Engine Disassembly and Installation

 6

6

6

6

6

 Loosen:

-Clamp to seperate carburetor and air filter.

-Clutch cable and throttle cable

 Loosen 4 pcs engine mounting nut

 Loosen 3 pcs engine mounting nut

 Loosen:

-gear shift rod bolt

-1pc engine mounting nut

-rear arm shaft nut

 Remove engine

6-4

CFMOTO

Engine installation

Note:

Do not damage bolt thread, wirings and

flexibale cables,etc.when connecting

engine with frame,

Make sure gear shift rod installed to

a comfortable position for usage,

Use recommended coolant,drain out air

in engine cooling pipe.

Check clutch and chain free clearance

after installation.

Reverse the disassembly procedure for

engine instalation.

Carefully install engine to the original position

by jack or other tools to support engine.

Add coolant before fuel tank installation.

(refer to Chapter 4)

7 

Front wheel,Braking,Suspension  and Steering System

 7

7

7

7

7

7-1

Overhaul information

.................

7-1

Troubleshooting

......................

7-2

Handle bar

...........................

7-3

Front wheel

..........................

7-6

Front shock absorber

..................

7-9

Steering column

......................

7-10

Front brake

...........................

7-12

Overhaul Information

Note

1.

Securely support the scooter when overhauling front wheel and suspension system.

2.

Do not overexert on the wheel. Avoid any damage to the wheels.

3.

When removing tire, use the special tire lever and rim protector.

Overhaul Standard

It e m S t a nd a rd  

Se r vi c e  

l i mi t  

Ca mbe r  o f  f ro nt   w h e el  
sh af t  

－

 0. 2m m 

Lon gi t u da l   0. 8 mm  2. 0m m 

Ri m 
ru n- ou t  

Ho ri z on t a l 0. 8 mm  2. 0m m 

Gr oo ve  l ef t  

－

 1. 6m m 

Fro nt  
wh ee l  

Ti re  

Ai r   p re su re  

1 75 kP a

（

1. 75 kg f

／

c m

2

）

 

－

 

Fro nt  
bra k e 

F r ee   pl a y  of  b ra ke   l e ve r 

10

－

20 mm 

－

 

 

Tightening Torque

Mounting nut, steering bar                            10-14 N.

m

Nut, front wheel shaft

    60-80N

.

m

Upper fixing nut, front shock absorber            20-30 N

.

m

Lower fixing bolt, front shock absorber           30-40 N

.

m

7-2

CFMOTO

Troubleshooting

Heavy steering(steering too tight

·Upper thread is over tightened.

·Steering bearing is damaged or worn out.

·Inner & outer bearing seats are damaged,

 worn out or stepped.

·Steering column is distorted

·Tire pressure is too low.

·Worn tire

Loosened Handlebar

·Front right and left shock absorbers are not matched.

·Front shock absorbers are distorted

·Front wheel shaft is distorted,

 wrong assembly of front wheel

Spongy brake lever

·

 air enter into brake system

·

 brake oil level too low

·

 oil leakage in brake system

Poor brake

·

 dirty brake disc

·

 brake disc unparalle with wheels

Abnormal noise with disc brake

·

 dirty brake disc

·

 eccentri disc brake disc

·

 disc brake pump wrong assembly

·

 brake disc unparalle with wheels

Front wheel wobbles

·Deformed  rim

·Faulty  wheel  bearing

·Faulty  tire

·Improper tightening of wheel shaft

Front suspension too soft

·

 Loosened spring,front shock absorber

·

 oil insufficiency,front shock absorber

Front suspension too hard

·

 improper oil,front shock absorber

·

 front shock absorber deformed

·

 oil channel blocked,front shock absorber

Abnormal noise with Front absorber

·slipping parts distorted

·oil insufficiency,front shock absorber

·outer oil seal broken

·steering bearing worn out

·oil insufficiency,counter gear

7 

Front wheel,Braking,Suspension  and Steering System

 7

7

7

7

7

7-3

Steering bar

Disassembly

Remove 2 pcs mounting nut, right handlebar switch

Remove throttle cable and throttle grip,

remove right handlebar switch

Loosen fixing screw, balance block,

remove balance block and throttle grip.

Loosen 2pcs half cover bolt, fluid reservoir,

remove fluid reservoir