CFMoto motorcycle CF150-A. Service Manual - part 10

 

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CFMoto motorcycle CF150-A. Service Manual - part 10

 

 

(17) Electric diagram

Start relay& Fuse

CDI

Fuel sensor

Flasher relay

Rear brake switch

Fan&Motor relpay

Hand light relpay

Fuse box

Ignition switch lock

Front brake switch

Start switch

Llumination switch

Kill switch

Starting Motor

Regulator

3-Phase shift sensor    Magneto

Thermostat

Automatic switch

Clutch switch

Horn

Turning switch

Dimmer switch

Overriding switch

High beam indicator

Turning indicator(RH)

Turning indicator(LH)

Instrumert indicator

Engine rotate speed indicator

Fuel indicator

Water temperature indicator

Neutral gear indicator

Fan motor

Front turning light(RH)

Head light

Position light

Front turning light(LH)

Horn

R-Red
B-Black
G-Green
Y-Yellow
L-Blue
W-White
Gr-Grey

Br-Brown
O-Orange
P-Pale
LR-Light red
Sb-Light Blue
Lg-light green

Battery

Lgnitioncoil and spark plug

Rear turning signal(RH)

Tail light/ brake light

Rear turning signal(LH) 

water Thermostat 

Water Temperature alarm 

12v 21/5w

-49-

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 13 Troubleshooting

13-1

 13

Troubleshooting

                   

 Engine ............................. .............              13-2

                                  Carburetor............................................        13-5

                                  Cooling system/Radiator....................          13-6

                                  Ignition system........................................      13-6

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13-2

1.

Engine part

   

 Troubles

           

 Possible causes                                      Countermeasures

Cannot start or              1.

 Improper spark plug clearance   

           

  Replace or adjust

difficult to start               2. 

Spark plug dirty or wet  

                          

 Clean and dry or repair

Cylinder pressure too low

1.Cylinder wear                                              Replace

2.Piston ring wear                                          Replace

3.Air leakage of cylinder gasket                     Replace

4.Valve stem wear or unsuitable valve seat  Replace or repair

5.Spark plug loosen                                       Tighten

6.Starting motor rotate too slowly                  

 Check electric parts

7.Improper valve timing                                 Adjust

8.Improper valve clearance 

               

Adjust

Spark plug cannot ignite or weak ignition

Insufficient fuel inside carburetor

1

.Breather hole blocked  

                  

Clean or Replace

2.

Fuel switch failure or blocked

            

Clean or Replace

3.

 Valve needle failure    

                  

Replace

4.

Fuel tank blocked 

                      

Replace

5.

Carburetor blocked   

                   

Clean or Replace

1.

Improper valve clearance  

           

   Replace

2.

Unsuitalbe valve seat  

              

    Replace or repair

3.

Defective valve

                      

  Replace

4.

Rocker or rocker arm wear

            

Replace

5.

Dirty spark plug 

                      

Replace

6.

Incorrect valve clearance

              

Replace or adjust

7.

Ignition coil failure 

                    

Replace

8.

CDI failure 

                           

Replace

9

. Flywheel failure  

                      

Replace

10.

Fuel level unsuitable of float chamber

  

Adjust height of

 

float

11.

Injector blocked of carburetor 

        

 Clean

12.

Fuel switch failure 

                   

Replace

13.

Improper position of idle screw 

      

   Adjust

No idle speed or

unstable speed

Gear not in Nuetral position  

              

Shift to N postion

                    3.

Defect ignition coil                                    Replace

                    4.

Pick up short circuit or open circuit          Replace

                    5.

Defect flywheel                                         Replace

                                        6. CDI defect                                                 Replace

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 13 Troubleshooting

13-3

 13

 

 Troubles  

          

Possible causes 

                   

   Solutions

1.

Valve spring getting weak 

         

       Replace

2.

Camshaft wear 

                      

Replace

3.

Spark plug dirty

                   

      Clean or Replace

4.

Spark plug gap too narrow  

           

 Adjust or Replace

5.

Valve timing incorrect

                 

 Adjust

6.

Ignition coil failure

                     

Replace

7.

 Float too low  

              

                       Adjust height of float

8.

Air filter too dirty 

                     

Clean or Replace

9.

Fuel blocked inside carburetor 

    

        Clean

10.

Fuel switch failure 

                 

   Replace

1.

Engine oil too much

                   

Check oil level and drain

2.

Piston ring wear

                       

Replace

3.

Valve wear 

                      

          Replace

4.

Cylinder wear or scraped   

             

Replace

5.

Valve stem wear  

                      

Replace

6.

Oil seal of valve stem damaged 

         

Replace

High RPM

 

unstable

Blue or black exhaust

gas

1

.Valve clearance improper

              

 Adjust

2.

Valve spring getting weak

              

Replace

3.

Valve timing incorrect

                  

Adjust

4.

Cylinder wear 

                        

Replace

5.

Piston ring wear 

                      

Replace

6.

Improper valve seat 

                   

Replace or repair

7.

Spark plug dirty    

                     

Clean or replace

8.

Improper spark plug gap

               

Clean or replace

9.

Injector of Carb. blocked

               

Clean or replace

10

.Improper float level

              

          Adjust float level

11.

Air filter too dirty

                      

Clean or replace

12.

Rocker arm or Camshaft wear 

        

Replace

13.

Air leakage of inlet pipe

                

Tighten or replace

14

.Engine oil too much  

                

    Check oil level and change

Power not enough

1.

Carbon deposit on piston head

          

Clean

2.

Engine oil too less or too much  

         

Check and add or

 drain

3.

Fuel hose blocked 

                     

Clean

4.

Float level too low 

                      

Adjust float level

5.

Air leakage of inlet pipe

                 

Tighten or replace

6.

Unsuitable engine oil 

                   

Change oil

7

.Cooling system failure(See13-6)

Engine overheating

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13-4

Valve abnormal noise

1.

Valve clearance too big 

               

 Adjust

2.

Valve spring worn or damaged

         

  Replace

3

.Rocker arm or camshaft worn 

          

  Replace

Piston abnormal noise

1.

Piston worn

                          

 Replace

2.

Cylinder worn 

                        

 Replace

3.

Carbon deposit inside combustion

    chamber

                           

    Clean

4.

Piston pin or pin hole worn

             

 Replace

5.

Piston ring or groove worn

             

 Replace

 

Troubles 

          

 Possible causes  

                      

Solutions

Engine abnormal

noise

Timing chain abnormal noise

1.

Chain stretched out 

                   

   Replace chain and sprocket

2.

Chain sprocket worn 

                  

    Replace chain and sprocket

3.

Tensioner failure  

            

                   Repair or replace

Clutch abnormal noise

1.

Clutch gear worn or damaged

2.

Cushion rubber aging or damaged

Crankshaft abnormal noise

1.

Bearing noise 

                         

Replace

2.

Crankshaft pin bearing worn

            

Replace

3.

Clearance too big 

                     

Replace

Transmission abnormal noise

1.

Gear worn or damaged 

                

 Replace

2.

Main shaft or countershaft worn 

         

Replace

3.

Bearing worn

                          

Replace

4.

Bush worn

                             

Replace

1.

Clutch drive disc worn  

             

        Replace

2.

Clutch driven disc worn or damaged

      

Replace

3.

Clutch spring getting weak 

              

Replace

Clutch slippery

Replace clutch gear

Replace clutch gear

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 13 Troubleshooting

13-5

 13

Troubles 

            

Possible causes 

               

           Solutions

Gear shift not smooth

or locked

1.

Gear damaged

                      

    Replace

2.

Shift fork bent 

                         

Replace

3.

Shift drum worn 

                        

Replace

4

.Improper shift lever 

                   

 Adjust

2.

Carburetor

Hard to start

1.

Injector blocked 

                    

     Clean

2.

Injector chanel blocked 

             

     Clean

3

.Leakage of joint  

     

                                Tighten,adjust or replace oi

l

 seal

4.

Choke opened fully 

                 

     Close or Tune choke

1.

Air intake pipe blocked

              

      Clean

2.

By-pass air pipe blocked

            

      Clean

3.

Choke opened fully 

                 

     Close or Tune choke

4.

Unsuitable idle screw torque

         

      Adjust

5.

Float level improper 

                 

     Adjust

6.

Injector blocked 

                    

     Clean

Idle or low RPM

unstable

H i g h   R P M   u n -

stable

1.

Injector blocked

                     

    Clean

2

. Main jet blocked 

                  

        Clean

3

.Needle valve blocked

                

     Clean

4.

Choke closed fully  

                 

     Clean

5.

Fuel filter blocked

                   

     Clean

 

or replace

6.

Float level improper 

                   

Adjust

Overflow or fuel

level fluctuation

1.

Needle valve worn or damaged 

         

Replace

2.

Needle valve spring damaged

           

Replace

3.

Float work failure   

                    

  Adjust or Replace

4.

Needle valve dirty or blocked

            

Clean

Troubles 

            

Possible causes 

                   

  Solutions

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13-6

3.

Cooling system/Radiator

 

Troubles

          

Possible causes 

                      

Solutions

Engine overheating

1.

Radiator or water hose blocked 

        

Clean

2.

Air bubble inside cooling system 

       

 Remove bubble and add coolant

3.

Water pump failure

                    

Check and replace

4.

Bad quality coolant 

                 

     Replace

5.

Thermostat failure

                     

Replace

6.

Fan motor or thermo switch failure 

     

Check and replace

1.

Fan motor or thermo switch failure

       

Replace

2.

Thermostat failure

                      

Replace

Coolant  temp. too

low

4.

Ignition system

 

Troubles

      

         Possible causes

                      

Solutions

No spark or too

weak spark

1.

CDI failure 

                      

    Check and replace

2.

Spark plug failure  

                  

Check and replace

3.

Flywheel failure 

                    

Check and replace

4.

Battery voltage insufficient 

          

Check and replace

5.

Ignition coil failure 

                  

Check and replace

6.

Pick-up failure 

                    

Check and replace

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