Manual de Taller CF150 PDF

CFMOTO
CF150-3 Service Manual
WWW.CFMOTO.COM
第 1 页，共 185 页
Instruction Content
This manual introduces CF150-3 Maintenance Information 1

maintenance information，including Vehicle body .Muffler 2
disassembly procedure checking Checking &Adjustment 3
&adjustment methods, troubleshooting and
technical specifications. There are some Cooling &Lubricating system 4
illustrations, drawing to guide your operation.
Chapter 1 mainly introduces general Engine disassembly& assembly 5

operation information, tools, vehicle structure
and basic specifications. Engine disassembly 6
Chapter 2 mainly introduces checking & Front wheel, Brake, Suspension, 7

adjustment methods and how to do vehicle Steering System
maintenance. Rear wheel, Brake, Suspension 8
system
Chapter 3 mainly introduces disassembly, Electric system 9
installation, adjustment, maintenance and
troubleshooting information. Lights, 10
Instruments ,Switches
Troubleshooting 11
11
CFMOTO reserves right to make improvements

and modifications to the products without prior
notice. Overhaul and maintenance should be done
according to actual condition of vehicle.
Zhejiang CFMOTO Power Co.,Ltd
Dec.2014
第 2 页，共 185 页
Conversion table
A Ampere lb Pound
ABDC After bottom dead center m Meter
AC Alternating current min Minute
ATDC After top dead center N Newton
BBDC Before bottom dead center Pa Pascal
BDC Bottom dead center PS Metric horse power
BTDC Before top dead center psi Pound/Square Inch
°C Centigrade r Revolutions
DC Direct current rpm Revolutions per minute
F Farad TDC Top dead center
°F Fahrenheit TIR Total indicator reading
ft Feet V Volt
g Gram W Wait
h Hour Ω Ohm
L Litre in Inch
US gal Gallon(US) US qt Quart(US)
oz Ounce HP British horsepower
cm Hg Centimeter of mercury pint Pint
cu in Cubic inch mL Milliliter
第 3 页，共 185 页
Foreword
This service manual is not only specially designed for professional machinist, but
also it is used to instruct the vehicle’s user how to do maintenance work. It is necessary to
know mechanology knowledge, tools proper usage and have a well understanding of
service procedure Conversion before you perfectly solve all service problems. If no, you
should get the service support by professional machinist. Please read this service manual
and understand it before operate. No tools replaced or use temporary tools since that we
have been appointed the special service tools and equipment. All service and scheduled
maintenance should be executed base on the instructions of service manual. Any
consequences are responsible by the vehicle’s owner resulted from any rule-breaking
operations.
Long Service Life

● Scheduled Maintenance and service operations base on service manual
●Non-periodical maintenance in special situations
●Tools proper usage and use CFMOTO’s genuine parts.
Special tools has been listed into this service manual for necessary genuine parts
● Strictly operated bas on the service procedures.
● Keep fully service records and specify the date of new parts replacement.
第 4 页，共 185 页
Whenever you see the warning or warning symbol, you must keep attention and comply
with the safety operation and maintenance method
The other three symbol as following in order to distinguish the different levels of warning
information in service manual.
● Procedure or operation should be acted
○ one step of procedure or how to operate after procedure finished. Probably it is the
guidance before attention matters.
★ To take actions based on the front steps or test results from the front procedures. It
shows detail illustration including torque, lubrication oil, and lubrication grease or
tighten glue during assembling instruction.
第 5 页，共 185 页
1. Maintenance Information
Operation Attentions……………………1-1 Maintenance Parameters Table………………1-8

Disassembly&assembly Attentions…… 1-3 Fastening Torque……………………… ……1-8
VIN Number Position……………… 1-6 Lubrication and Grease………………………… 1-10
Main Parameters…………………… 1-7 Layout drawing of cables, pipes and guy cable…… 1-11
OPERATION ATTENTIONS
SAFETY ATTENTIONS
CAUTION • CAUTION
Hazardous compents in exhaust. Do not run the Don’t touch the engine or muffler with bare hands when
engine in a enclosed or poorly ventilated place for the engine has just stopped to avoid scalding. Wear
a long time. long-sleeve work clothes.
• CAUTION • CAUTION
Battery liquid (dilute sulfuric acid) is highly caustic Coolant is poisonous. Do not drink or splash to skin,
and may cause burns to skin and eyes. Flush with eyes or clothes. Flush with plenty of soap water if
water if splashed to skin and get immediate splashed to skin. Flush with water and consult the
medical attention. Flush with water if splashed to doctor. If drinking the coolant, induce vomiting and
clothes to avoid burns. Keep battery and liquid consult doctor. Keep coolant away from reach of
away from reach of children. children.
• CAUTION
• CAUTION Coolant Gasoline is highly flammable. No smoking or
Wear proper work clothes, cap and boots. If fire. Also keep against sparks. Vaporized gasoline is
necessary, were dust-glass, gloves and mask if also explosive. Operate in a well-ventilated place.
necessary.
.
第 6 页，共 185 1-1

CFMOTO
• CAUTION CAUTION
When charged, Battery may generate The asbestos dust on the brake drum is
hydrogen which is explosive. Charge the carcinogenic is breathed in. Do not clean off the
battery in a well-ventilated place. dust with compressed air. Use cleaning detergent
to avoid dust proliferation.
CAUTION
Be careful to get clamped by the turning parts like
Wheels and clutch.
1-第27 页，共 185 页

Disassembly&assembly attentions
■ Use genuine CFMOTO Parts,lubricants and
grease
■ Clean the mud,dust before overhauling
1
■ Place and store the disassembled parts

separately in order for correct assemble.
■ Replace the disassembled washers,O-rings,piston
pin circlip,cotter pin with new ones.
■ Elastic circlips might get distorted after
disassembled.Do not use the loosed circlips.
■ Clean and blow off the detergent after

disassembling the parts.Apply lubricants on
the surface of moving parts. ■ Measure the data during disassembly for correct
assembling.
■ If not know the length of screws,install the

screws one by one and tighten with same torque. ■ Pre-tighten the bolts,nuts and screws,then
tighten them according to the specified
torque,from big to small and from inner side
to outer side.
第 8 页，共 185 页
1-3
CFMOTO
■ Check if the disassembled rubber parts are ■ Apply or inject recommended lubricant to the
aged and replace it if necessary. Keep the rubber specified parts.
parts away from grease.
■ Use special tools wherever necessary. ■ If the disassembling of pressed ball bearing is
done by pressing the balls,the disassembled
should not be used again.
■ Turn the ball bearing with hands to make sure

the bearing will turn smoothly. Replace if the axial
or radial play is too big. If the surface is ■ Install the one-side dust-proof bearing in the
uneven,clean with oil and replace. if the cleaning right direction. When assembling the open type
does not help. When pressing the bearing into the or double-side dustproof bearing,install with
machine or to the shaft,replace the bearing if it manufacturer’s mark outward.
could not be pressed tight.
■Keep the bearing block still when blowing dry

the bearing after washing clean. Apply oil or ■ Install the elastic circlip after assembling to
lubricant before assembling. make sure is has been installed into the slot.
1-第49 页，共 185 页

■After assembling,check if all the tightened pats ■ Brake fluid and coolant may damage coating,plastic
are properly tightened and can move smoothly. and rubber parts.Flush these parts with water if
splashed. 1
■ Install oil seal with the side of manufacturer’s ■ When installing pipes,insert the pipe till the
mark outward. Do not fold or scratch the oil seal end.Fit the pipe clip,if any,into the rove.
lip. Apply grease to the oil seal lip before Replace the pipes or hoses that cannot be
assembling. tightened.
■ Do not mix mud or dust intoengine or the

hydraulic brake system.
■Clean the gaskets and washers of the engine

cases before assembling. Remove the
scratches on the contact surfaces by
polishing evenly with an oilstone.
■ Do not twist or bend the cables too

much.distorted or damaged cables may cause
poor operation. ■ When assembling the parts of protection
caps,insert the caps to the grooves,if any.
第 10 页，共 185 页
1-5
CFMOTO
Numbers Marking Location

Model： CF 1 50-3
VIN NUMBER： ★LCEPDKLA ×××××××××★
ENGINE NUMBER： 1 5 7 M J- 3
VIN Number
Location
1-第611 页，共 185 页

Main S pecifi cations
Item Specifications
Mo d el 1 5 0 NK CF1 5 0 -3
Length 2 0 2 5 mm
Width 7 7 0 mm
Height 1 0 7 0 mm
W h eel b a s e 1 3 6 0 mm
En g i n e m o d el 1 5 7 MJ - 3
Di s pl a c em en t 1 4 9 .4 mL
Fu el gr a d e 9 3 # or a b o v e
G ro s s wei g ht 142kg
Per s o n s 2 p e r s o n s 人(i n cl u di n g dr iv er )
Load 150kg
Ti r e F r o n t 1 0 0 /8 0 R1 7 M / C 5 2H
Rear 1 3 0 /7 0 R1 7 M / C 6 2H
Mi n . gr o u n d cl ea r a nc e 1 5 0 mm
Turning circle diameter 5 .0 m
Steering Steering angle left 32 º
right 32 º
Brake system front Disc
rear Disc
Shock suspension Front wheel telescopic
absorber
Rear wheel c a n til ev er ty p e
frame Steel tube
Item Standard
Fuel capacity 10L
Injector type: F01R00M126
Fueller Voltage：DC13.5V
Pressure：0.33±0.01MPa
Fuel pump flow：≥35L/h
Current：≤2.20A
Idle speed 1600±160rpm
第 12 页，共 185 页
1-7
CFMOTO
Front wheel
Item Standard Service limit

F r o n t w h e e l Front wheel shaft bending － 0. 2m m
Rim run-out Longitudinal 0. 8m m 2. 0m m
Horizontal 0. 8m m 2. 0m m
Tire Remaining groove － 1. 6m m
2
Tire pressure 1 75 k P a（1 .7 5 k gf ／cm ）－
Rear wheel
Rear wheel Rim run-out Longitudinal 0 2 .0 mm
Horizontal 0 2 .0 mm
Tire Remaining groove － 1 .6 mm
Tire pressure Single 2 00 k Pa （2. 0 k gf ／－
2
double 2 25 k Pa（2 . 2 5k g f ／ —
2
Brake system

Front brake Front (hand brake) free travel 10 ～ 20 m m －
Brake disc abrasion 4m m 3mm
Rear brake Rear (foot brake)free travel 10 ～ 20 m m －

Brake disc abrasion 4m m 3mm
Lighting,Dashboard,Switch
Item Standard
fuse primary 3 0A
subsidiary 10 A× 1 15A × 3
lighting, bulb Front headlight （ Hi ／ Lo ） 1 2 V3 5 W / 35 W
Brake light／Rear light LE D
Front& Rear turn signal light LE D
Dashboard light LE D
Turning Indicator light LE D
High beam indicator light LE D
Gears indicator light LCD
Neutral gear indicator light LE D
water-thermometer LE D
Trouble indicator light LE D
1-第813 页，共 185 页

Fastening Torque
扭矩 1
Item Torque N ·m (k gf ·m) 种类 N ·m (kgf ·m)
5 mm Bolt, Nut 5 （ 0 .5 ） 5 mm screw 4 （0.4 ）
6 mm Bolt, Nut 10 （ 1.0 ） 6 mm screw 9 （0.9 ）
8 mm Bolt, Nut 22 （ 2.2 ） 6m m SH Flange bolt 10 （1.0 ）
10 mm Bolt, Nut 34 （ 3.5 ） 6 mm Flange bolt, nut 12 （1.2 ）
12 mm Bolt, Nut 54 （5 .5 ） 8 mm Flange bolt, nut 26 （2.7 ）
10 mm Flange bolt, nut 39 （4.0 ）
Please use standard torque,if without torque value mentioned below table.
1.Lubrication oil should be created on screw thread and contact surface
2.Replace when self-locking bolts disassembled.
Item No. of Bolt Thread Torque Remar

Nut Dia N ·m（kgf·m） k
Engine Disassembly （ mm
Engine lifting bracket bolt 5 5 30
Engine lifting shaft nut 1 1 （3.1 ）
Front wheel, Front suspension, steering 4 100
Steering Column Locknut （ 10 .1 ）
1
Handlebar fastening screw, front wheel axle
Shock absorber fastening bolt(upper) 4 100
2
Shock absorber fastening bolt(lower) 1 （ 10 .1 ）
6
Rear wheel, Rear suspension 2 20
Rear axle shaft nut 4 （ 2 .1 ）
8
Shock absorber fixed bolt(upper)
1 65 （10 .1 ）
Shock absorber fixed bolt(lower)
1 2 20
Brake system
1 （2.1 ）
Front brake disc fixed bolt
Front brake caliper fixed bolt 1 8 20
Muffler 8 （2.1 ）
Front elbow(muffler) fixed nut 5
Muffler body fixed bolt 2 1 100
4 （ 10 .1 ）
40
2 1 （4.1 ）
0
1 40
（4.1 ）
1
第 14 页，共 185 页
1-9
CFMOTO
Lubricating grease
Application areas
Notes Type
Vehicle’s head pipe, Bearing race Multi-purposes lithium base
wheel dust-proof seal lip lubrication oil
Rear brake, Cam joint, Cam
Joint, dashboard flexible shaft
Joint, Throttle cable
Throttle handlebar part
Pivot, rear pedal(LH),
Pivot, Rear pedal(RH),
Pivot, side stand
Oil seal lip, rear fork
Gear surface and running part, Counter gear/small
gear
Axle part, main stand

Thread of Rear wheel axle nut and joint Engine oil
Rear brake, Cam sealing felt
Lip, dust-proof seal, lower part of front Absorber oil 5#
shock-absorber
Inner surrounding, handle bar Engine oil
1-第1015 页，共 185 页

1
Layout drawing of cables, pipes and guy cable
Wire harness,
Front turning light
Connector ,Dashboa
rd
Connector, Counter
Connector,
handlebar witch (Left%right) Wire harness connector, Front headlight
Fuel pump Fuel tank
High pressure
oil pipe
Auxiliary coolant box
Connector, Throttle cable

Brake switch
Auxiliary coolant pipe
Negative wire
Radiator
Positive wire
Minor-cycle Ignition coil Clutch cable Temperature sensor Inflow pipe,

water pipe
engine
第 16 页，共 185 页
1-11
CFMOTO
Throttle valve Adjustable bolt, throttle cable Main cable
Pipe negative pressure pipe Regulator
wire harness
connector(rear)
Fuse block
1-第1217 页，共 185 页

1
Flasher Battery Negative wire, Battery Relay
Battery ribbon Positive wire, Battery Auxiliary relay
30A Main fuse Fuse block wire harness sheath(rear)
第 18 页，共 185 页
1-13
CFMOTO
Gear sensor fuel strainer
喇叭
Thermostat Spark plug Roll over sensor water tank Horn Lacquer tray outlet pipe
Dashboard
Clutch handle switch ignition lock Brake handle Rear brake switch
switch
1-第1419 页，共 185 页

1. Maintenance Information 1
Fuel evaporation system
Schematic diagram
Fuel tank
Anti Roll-over valve
Engine Throttle body
Caution: To fixed the anti roll-over valve as horizontal position. Don’t change the fuel evaporation
system. Tube connection should be well connected after maintenance by disassembling without air
leakage, blocking, squeezing, broken and damage etc.
Fuel steam will be released into carbon tank by absorption tube from fuel tank. Absorbing fuel steam
by active carbon when engine stop; Fuel steam of carbon tank will follow into combustor for burning
when engine working in order to avoid environment pollution if fuel stem released into air directly.
Meanwhile, Air pressure of fuel tank should be balanced by absorption tube. If inner pressure of fuel
tank is lower than outside, it is available to replenish air pressure by air tube of carbon tank or
absorption tube. So, All tube system should be smooth running without blocking and squeezing,
otherwise fuel pump will be damaged, fuel tank will be deformed or broken
第 20 页，共 185 页
1-15
Chapter 1 Maintenance Information
General prevention measures............................. ..... ...........1-17

Fuel, engine oil and engine coolant....................... ..... ............1-18
Engine running-in.................................... ..... ..... ..... ..... .........1-18
Engine exterior and Engine number location............................1-19
Engine technical manual.................... ..... ..... ..... ..... ..............1-20
Maintenance Specification......................................... ..... .......1-21
Torque Specification...................................... ..... ..... ..... ..... .....1-25
Service tools................................... ..... ..... ..... ..... ..... ..... ........1-26
Running material and auxiliary material.................... ................1-28
第 21 页，共 185 页
1-16
CFMOTO
General prevention measures
Serviceman’s safety and engine reliability is very important. Service training and well know
service process is necessary before operating.
·Keep high safety attention and mutual remind while two or more parts working together.
·Exhaust gas should be exhausted to outside when start engine indoor

·Keep ventilation and operate base on instruction of user manual if need to use poisonous or combustibles
·Don’t take gasoline as a leaner
·Don’t touch engine oil, radiator and parts of exhaust system avoid scald if un-cooled
·Check the mark line and leakage after maintain fuel,lubrication,cooling and exhaust system.
·Don’t dispose any replaced parts at will in order to protect the natural environment
·Genuine parts should be used if any parts need to be replaced when maintaining.
·Keep all disassembled parts in order in order to any confusion if need to reuse the disassembled parts.
·Use special tools base on requirements of service manual.
·Keep clean for all assembled parts, and lubricate all parts if it must to be lubricated.
·Use specialized lubricating oil, binder and sealant.
·Tighten the big torque parts base on standard torque from inside to out while tighten the bolt, nuts and
screws.
·Use torque wrench to tighten bolt base on standard torque, and need to clean the bolt if thread with grease
and oil.
·Check all disassembled parts. Clean parts before measuring.
·Check parts running and tighten situation after assembled.
·Don’t reuse the disassembled parts such as oil seal, gasket, self-locking nut, lock washers, cotter, snap ring
etc. New parts should be assembled while assembling.
第 22 页，共 185 页
1-17
1 Maintenance information (Engine)
Introduction of fuel, engine oil and coolant
Fuel： Octane 93# or above, unleaded
Engine oil：Oil type (SAE10W－40)
Oil grade :API (SF or SG)
If above-mentioned oil is unavailable, please choose
as right picture shows according to temperature.
Coolant： Coolant is anti-corrosive and anti-rust and
freezing point should be 5℃ lower than lowest
surrounding temperature.
Recommended coolant:- 35℃ , anti-frozen, anti-corrosive and high-boiling point
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.

Engine Running-in
There’re many moving parts inside engine, such as piston, piston ring, cylinder, gears and
so on. It’s very important to break-in during initial drive. Break-in can make moving
components match each other better, contact better and adjust clearance to guarantee
engine better performance and reliability.
Recommended running-in period is 1000Km.
Notes for Running-in：
1、Turn throttle slowly step by step after starting engine. Do not turn faster and slower.
2、Try to drive on a good road, do not drive on up and down road for a long time.
3、Keep oil path smooth.
4、Try to avoid sudden acceleration or high RPM with no-load condition.
5、Do regular repair and maintenance during break-in period. Remove it if any troubles
occur.
6、After running-in, please change engine oil, adjust electrode of spark plug and valves
clearance, inspect oil path, and clean carbon deposit on head of piston and cylinder head
if needed. D o a complete engine inspect and maintenance according to service manual
before normal driving.
0～500km: Do not run engine at ≥50% throttle position; do not change speed frequently;
do not run engine at a fixed throttle position; Avoid sudden speed up; Turn throttle slowly.
500～1000km： Do not run engine at ≥75% throttle position for long time.
Attention：Do regular repair and maintenance during running-in period, if any troubles, please remove it
immediately.
· Maintenance After 1000km running-in, then to normally driving.
第 23 页，共 185 页
CFMOTO
ENGINE AND LOCATION OF ENGINE NUMBER
VIEW FROM LEFT
VIEW FROM RIGHT
ENGINE NUMBER
第 24 页，共 185 页
1-19
1 SERVICE INFORMATION（ENGINE）
General Specification
Item Items T ype/Specif i cati on
NO.1 Si ngl e-cyli nder、F our st roke、Liquid Cooled、
Type 2-valve、OHC
2 Bore× Stroke 57 mm× 58. 6mm
3 Displacement 149 .4m L
4 Compression Ratio 1 0.5 ：1

5 Min. Stabilized RPM (unload at idle) 16 00r/ min
6 Starting Model El ect ri c
StEart
CUer
Ignition
7 Electric Spark Plug/Pol e gap NGK CR7 E/0.7 mm～0.9 mm
System Perm anent Magnet 3-phrase AC,O ut rot or,
Magnetor f l ywheel
Combustion Chamber Triangular
8 Combustion Air Filter Sponge Element Filter
System
Gasline RQ-93 and higher leadfree gasline
9 Valve Train SOHC /Chai n Driv e

Valve Train
Lubrication Press & Splash

Oil Pump Rot or Driv e
10 Lubrication
Oil Filter Full flow, Paper Filter
System
Oil type SAE 10W－4 0/S G
Cooling Cooling Closed Loop Cooling
11
System Coolant -35℃antirust and antifreezing
Clutch Wet and multi plate manual clutch
Transmission 6-gear,constant mesh, step transmission
Gear Shift 6 gears
Gearshift type/order Mechani cal Reci procat i ng/1 -0- 2- 3- 4-5 -6-5- 4-3 -2- 0-1
Primary Ratio 3. 5
12 1st 3
2nd 1 .85 7
rd
Secondary 3 1 .36 8
Transmission Gear Ratio 4th 1 .14 3
ratio
5th 0 .95 7
6th 0 .87 5
13 Dimension L×W ×H（mm ）
：386× 312.7× 439
14 Net Weight 3 1kg
15 Driven Type Chain
16 counterclockwise,view from left,when advances
Rotation Mode forward
第 25 页，共 185 页
1-20
CFMOTO
Service Specification
Valve Train / Cylinder Cover UNIT：
(m m )
Item Standard Limit Remark
IN 27. 5 —
Dia. of Valv e Head
EX 24 —
IN 0. 08～0.10 —
Valve Clearance( cold engine)
EX 0.1 ～0. 13 —
Clearance (Valve guide Bush IN 0.0 1～0 .03 7 —
and valve stem) EX 0.0 3～0 .05 7 —
I.D of Valve guide bush IN & EX 5～5. 012 —
IN 4.975 ～4.990 —
O.D of Valv e st em
EX 4.955 ～4.970 —
Run-out of v alv ae stem IN & EX 0.0 3 0.0 5

Length, valve stem End IN & EX 5.3 ～5.5/4.8～ 5. 0 4.8/4. 3
Thickness,Valv e Head IN & EX 0.5/0.8 —
Seal run-out,Valve head IN & EX 0.0 3 —
Width,valve seat IN & EX 0.9 ～1.1 —
Inner 32.54 31
Free Length, Valve Spring
Outer 34.98 32.5
Inner 3 3. 7 N～4 4.3N when —
Valv e Spring F orce Compressed to 26.78mm
Outer 8 8. 6N～1 04N when —
compressed t o 29. 78mm
IN 33.67 —
Camshaft Lift
EX 33.3 14 —
Camshaft to hole clearance φ22 0.032 ～0.066 0.150

O.D Camshaft φ22 21.959～21.98 0 —
I.D Camshaft mating Hole φ22 22.012～22.02 5 —
Camshaft run-out 0 —
.
Dia., rocker arm shaft IN & EX 11. 977～ 11. 995 —
I.D, rocker arm shaf t hole IN & EX 12～12. 01 8 —
Cylinder Head W arpage 0 —

.
Cylinder head cover warpage 0 —
.
第 26 页，共 185 页
1-21
C yl i n d er/ Pi s to n / Pi st o n Ri n g / Co n n e cti n g R o d ( m m)
I T EM STANDARD LIMI T Remark
Cylinder pressure 10 00kPa —
Piston-to-cylinder 0.02～0.04 —
clearance
Dia.of Piston at Skirt 56.97～56.9(Measured
at 7mm to skirt end) —
I.D, Cylinder 57～57.019 —

Cylinder Warpage 0.02 —
1 Ring R 7 —
Piston Ring Free Gap
2 Ring R 7 —
1 Ring 0.15～0.25 —
Piston Ring, End Gap
2 Ring 0.15～0.25 —
1 Ring 0.0 15～0.05 —
Piston Ring to groove
clearance 2 Ring 0.015～0.05 —
1 Ring 0.97～0.99 —
Thickness,Piston Ring
2 Ring 0.97～0.99 —
1 Ring 1.0 05～1.02 —
Width,Piston Ring Groove 2 Ring 1.005～1.02 —
Oil Ring 1.86～1.96 —
I.D,Piston Pin hole 15.0 02～15.008 —
O.D,Piston Pin 14.9 94～15.000 —
I.D,Connecting Rod small 15.0 06～15.014 —
end
Connecting Rod big end side 0.15～0.45 —
clearance
Connecting Rod big end 15.95～16.00 —
thickness
Crankshaft run-out 0.04 —
LUBRICATION SYSTEM
ITEM ST A N D AR D LIMIT REMARK
Outer rotor to inner rotor 0.08 mm ～0.1 5mm —
clearance
Outer roter to pump body
clearance 0.1 5mm～0.193m m —
Oil pressure 3000 r/min, 10 ～3 0kPa —

Oil type SAE 10W－40，A PI SF or SG —
At Oil change 1200 ml —
Oil capacity At oil filter change 1250 ml —
At engine overhaul 1450 ml —
第27页，共185页
1-22
CFMOTO
Clutch/Transmission UNIT：(mm)
ITEM ST ANDER LIMIT REMARK
D
Drive Plate 2.9 ～3.1 2.8
Number of drive plate 5
Driven Plate 1.5 ～1.6 —
Driven Plate,Warpage 0.10

Number of dirven plate 4
Free Length,Clutch Spring 3 0.4 ～31 .6 29.5
Number of spring 5
NO.1 & NO.2 5～5 .1 5 —
Thickness,
Gear groove NO.3 5.5～5.6 5 —
NO.1 & NO.2 4.8 ～4.9 —

Thickness,Gear
shiftork NO.3 5.3 ～5.4 —
COOLING SYST EM UNIT： (mm )

ITEM STANDARD LI MIT REMARK
Temp.of thermostat opening 68～74℃ —
Travel,Thermostat Valve 95℃时，3.5～4.5m m —
Preesure of Radiator Cap 108k Pa —

Opening
Water Temp. (℃) Resistance（kΩ） —

Correspondence
between Resistance -20 15.0 4
of Water
Temp.Sensor and 20 2.45
Water Sensor
80 0.31 8
1 20 0.11
-35℃ high level anti-freezing,anti- —
Coolant corrsion,high boiling pont
第 28 页，共 185 页
1-23
AI R I NL ET SYST EM
ITE STANDARD REMARK
M
THROTTLE MODEL 0A80-173000
AT IDLE（r/ min） 16 00 rpm±160 r pm
AIR BY-PASS VALVE 01 8B - 172 000
El ectri cal System

I T EM STANDARD REMARK
Model NG K CR7E
Spark plug
Gap 0.7～0.9
Spark ＞8mm，1 Mpa
Primary Coil 0.45Ω

Ignition Coil
Resistance Secondary Coil 3.23 kΩ
Magneto Coil Pick-Up 100Ω～16 0Ω

Resistane
Magneto Voltage,unloading state
＞50V (AC)，5 000 r/ min
(cold engine）
Max.Power 280W，600 0 r/min
Stablizied Voltage 13.5V～ 15.0V ，5 000 r/min
Primpary Peak voltage,Ignition coil

12V
Peak Voltage,exciter coil ＞1.5V
Resistance, Starter Relay Coil 3Ω～5Ω
Resistance, Auxilliary Relay Coil 90Ω～100Ω
第 29 页，共 185 页
1-24
CFMOTO
15 7MJ-3 ENGINE TORQUE VALUE
ITEM QTY MODEL VALVE REMARK

（N·m）
BOLT,CRANKCASE 17 M6 10～12
BOLT,OIL PUMP 3 M6 10～12
Screw Cap,front left side cover 1 M26×1.5 12～15
BOLT,TENSIONER PLATE 1 M8 18～25
BOLT,OVERRUNNING CLUTCH 3 M8 28～32 Apply thread locker
BOLT,FLYWHEEL 1 M12×1.25 65～70 Apply thread locker
BOLT, Magnetor Stator 3 M5 10～12 Apply thread locker
Bolt,Pick up 2 M5 8 ～1 0 Apply thread locker
Nut,Clutch 1 M16×1 .5 38～42 Apply thread locker
Bolt,Balancer 1 M14×1 .5 47～53
Bolt,Clutch 5 M5 4.5～6 Apply thread locker
Bolt, primary drive gear 1 M16×1.5-LH 87～93
Crankcase drain bolt 1 M14×1.25 25～30
Bolt, oil pass 1 M14×1.25 25～30
Bolt, water pump 1 M6 10～12
Two-end bolt（match with left

2 YM8 7～11
crankcase）
Two-end bolt（match with right

2 YM8 7～11
crankcase）
Bolt,Cylinder Cover（T op End） 4 M8 28～32
Water Temp.Sensor 1 M12×1 .5 10～15 Apply thread locker
Water Temp.Sensor 1 R1/8 8 ～1 0 Apply thread locker
Spark Plug(NGK CR7 E) 1 M10×1 10～15
Two-end bolt,exhaust 2 M8 25～30
Bolt,Timing Chain 2 M6-10.9 15～18 Dab thread locker
Adjusting nut,Valve Clearane 4 M6×0.75 12～14
M5 4.5-6
M6 10-1 2
Other Screws,Bolts and Nuts
M8 18-2 5
第 30 页，共 185 页
1-25
1 SERVICE INFORMATION（发动机）
ME ASUING TOOLS
NO. ITEM SPECIFICATION PURPSOE REMARK
1 Vernier Caliper 0～ 150 mm Measure length,thickness

Measure O.D of rocker arm shaft,valve
2 Micrometer Scale 0～ 25m m stem,camshaft
3 Dial Gauge 25～ 50 mm Measure Max.lift travel of Camshaft
4 Dial Gauge 75～ 10 0mm Measure cylinder at skirt
5 Scale for I.D,cylinder Measure cylinder I.D

Measure rocker Arm I.D,piston pin
6 Interal quick diamter 10～ 34 mm hole,connecting rod small end
7 Dial indicator 1/1 00 Measure Jump Value
8 Knife straight Edge Measure warpage
9 Feeler gauge Measure Warpage,valve clearance
10 Plastic gauge Measure Fit clearance
11 Spring scale Measure Spring force
12 Tachometer Measure engine RPM
13 Cylinder Pressure Gauge 0～ 2MPa Measure cylinder pressure
14 Oil Pressure Gauge Measure oil pressure
15 Barometer Measure open pressure of radiator cap
16 Ohmmeter Measure resistance and voltage
17 Ammeter Measure current/switch “ON”/”OFF”
18 Thermometer Measure liquid temp.
19 Timing Light Inspect timing
20 Torque Wrench set Measure wrench torque

Common and Auxilliary Tools
22 Alcohol Burner Heating Up
23 Magnetic Stand Install Dial Gauge
24 Surface Plate Auxilliary Tool
25 V-shaped Plate Help to measure jump
26 Plier Install valve circlip
27 Circlip Plier Install/Remove circlip
28 Nipper Plier Install/Remove retainer
29 Impact Screwdriver Remove bolt,cross groove
30 Straight screwdrive
31 Cross screwdrive Remove cross groove screw
32 Wrench Sleeve SET REMOVE BOLT AND NUT
33 Inner Hexangonal Wrench
157MJ-3 E N G I N E S E R V I C E T O O L
第 31 页，共 185 页
1-26
Special Tool
NO. ITEM SPECIFICATION PURPOSE REMARK
1 Spark Plug Wrench Install/remove spark plug
Holder Wrench, Clutch Install/remove clutch nut, crankcase

2 nut
3 Removal Tool, piston Pin Remove Piston Pin

REMOVER, MAGNETO
4 Remove magneto rotor
ROTOR
5 Press Tool, Valve Spring Install/RemoveValve Spring
6 Grinder,Valve Grind valve
7 Installing Tool，Bearing set Install Bearing and Oil seal
8 Removal Tool,Bearing set Remove bearing
9 Removal Tool,Oil Seal Remove bearing
10 Holder Wrench,Flywheel Install/Remove flywheel
第 32 页，共 185 页
1-27
E ng i n e C on s um p ti on M at er i al s & A ss em b l i n g M a ter i al s
Engine consumption materials include lubricant oil(engine oil),lubricant grease (butter)
and coolant; Assembling materials include flange sealants,thread locker
ITEM SPECIFICATIO PURPOSE Remark
N
Rotation and Moving section in
cylinder
Oil Capacity
Rotation and moving section in
For 4-stroke crankcase 12 0 0 m L （at oil
Lubricant Oil motorcycle Rotation and moving section in change）
Cylinder head
SA E 1 5 W-4 0 1250 m L(at filter
Details in Lubrication System Page
A PI SF or SG （Read on 1-3 for Oil viscosity and change ）
brand ）
145 0 m L（ at engine
overhaul ）
Lubricant Piston Pin,Valve Stem, Valve Oil
Oil with Seal,Camshaft
molybdenum
Oil Seal,O-ring and rubber seal
Lubricant #3 M oS 2
grease lithium grease face,bearing with sealant
Coolant -35℃ high level anti- Capacity defined by

freezing,anti- Cooling System,Water Seal radiator tube
corrsion,high boiling
pont
Flange Crankcase faying face 、 Crankcase

Sealant and cylinder joint
Cylinder head and cylinder head
cover joint
Tread On screw or bolt thread
Locker
第 33 页，共 185 页
1-28
2 BODY/ MUFFLER
Maintenance Information …………… …2- 1 EngineCover, Radiator Cover,Front Inner
Front Fender、Seat、Rear Handgrip…2- 2 Fender……………………………………2-7
Bracket,rear fender & License Light…… 2-3 Headligt、dashboard……………………2-8
LH/RH side cover, Tail light top coverTail Muffler……………………………………2-9
Light…………………………………………2-4 Outer Parts………………………………2-10
Fuel Tank Cover………………………… 2- 5
2
Fuel Tank… …… …… …… …… ……2- 6
Maintenance Information
Warning;
Gasoline is highly flammable, therefore smoking and firing 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 introduces operation of disassembly and assembly 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.
Torque Valve
Tail Liht／Brake Light Cover Screw 1.8N·m（0.18 kgf·m）
Turn Light Cover Screw 1.8N·m（0.18kgf·m）
Troubleshooting
Too much noise of muffler
·Muffler breakage
·Exhaust Leak
Insufficient Power
·Muffler deformation
·Exhaust Leak
·Muffler Blocked
2-1
第 34 页，共 185 页
CFMOTO
Installation of front fender
Front fender is secured to position by fastening
three bolts on left and right side respectively.
BOLT,BRAKE CALIPER BRAKE CALIPER
SEAT
REMOVAL:
Insert key into seat lock
Turn the key clockwisely 90 degree to open the lock
Seat clamp
and then remove the rear seat.Loosen two bolts on
the front seat by using bushing or wrench.Slide out
front seat rearwards.
Installation: To lock the seat into position,
slide the front seat into the seat retainer,
fasten two bolts. Slide rear seat into slot, till
seat lock hook is latched; you will hear a
sound then lock the seat.
NOTICE:
When installing front seat, make sure it is positioned
into slot then push forward.Make it is secured, then
fasten two bolts. Rear seat shoule be secured and Seat
then be pressed down firmly.Shaking the seats after Lock
installation, make sure they are well positioned.
Rear fixing point seat lock

Rear Handgrip
Removal: Front Fixing Point
Remove three hexagonal bolt.
Remove rear handgrip
2-2
第 35 页，共 185 页
2 BODY/MUFFLER
License Plate Light, bolt
Rear Fender/License Plate Light
Removing
Remove rear seat and disconnect all cables
Remove four bolts on the rear fender.
License plate light is fixed on rear fender by
2
four ST4.2x9d bolts.
Remove four tapping screws and then pull out
license plate light cables.
Installing:
Skid Bolt, Fender Rear Fender Bracket
Operate removing procedures in reverse Plate and bolts
2-3
第 36 页，共 185 页
CFMOTO
TAIL C OVER Tail Cover
R em ovi ng:
Remove Seat and rear handgrip
Pull tail light top cover rearwards until it
disengages from buckle, and then remove the
tail light top cover.
I nstal li ng:
Operate removing procedures in reverse.
LH/RH SIDE PANEL

R e m o v in g :
1、Remove four hexangonal bols.
2、Remove four tapping screw
3、Remove LH/RH deco.cover,then
remove LH/RH side panel LH/RH
SIDE
Insta lling: PANEL
Operate removing procedures in
reverse. BOLTS
Notice
Adjust side panels to best position before
Installation. Tail ligth
Tail Limitor
Tail L ight light Slot
R e mo v in g : Screw
1 、Unlock rear seat
2 、Remoe rear handgrip and tail cover
3 、Disconnect tail light from main cable
4、Remove two tapping screw
4、Take off tail light
In st a ll in g : SKID
Operate removing procedures in reverse Plate
BOLTS
2-4
第 37 页，共 185 页
2 BODY/MUFFLER
F UE L TA NK CO VE R
Removing:
1、Unlock and remove tank lock.
2 、Remove lock cap and tank cover bolt
3 、Loosen tank mounting screws and remove tank
deco.cover 2
4、Revmove LH/RH deco.cover and the take off
tank cover.
Installing:
Cap,Swtich Lock Fuel Tank Lock
BOLT,TANK COVER
FUEL TANK COVER
SCREWS
2-5
第 38 页，共 185 页
CFMOTO
FUE L TAN K Roll over valve
R em ovi ng:
R em ove seat, tank l ock
and tank deco co ver MOUN
TING
MOUNTING
BOLT
Loosen four bolts BOLT
Disconnect EFI sensor connector
Disconnect fuel pump connector, raise tank up, pull
out absorption hose and high pressure fuel pipe
quick joint
Remove fuel tank
Caution Connector,oil level Connector,Fuel Pump
sensor
Don’t put fuel tank upside down,or fuel oil
will leak out from roll over valve.
Insta lling
Operate removing procedures in reverse
Caution
Prior to installing fuel tank,
Check and make sure hoses are not squeezed and/or damaged.
High
pressure
fuel pipe
filter
2-6
第 39 页，共 185 页
2 BODY/MUFFLER
ENGINE PROTECTOR COVER
R e m o v in g : remove stainless steel
hexagonal bolt on LH/Rh sides
Engine LH/RH Cover Mounting Bolt
Res er voir Ta nk Side Pa nel

Removing:
Remove tapping screws and hexagonal bolts Bolt
Reservior
Tank
LH/RH
COVER
Front inner panel

Removing:
Remove tapping screws and hexagonal bolts
Mounting Bolt,
Protector Cover
第 40 页，共 185 页
2-7
CFMOTO
HEADLIGHT ASSY.
R e m o v in g :
Remove mounting bolts and then remove
headlight.Disconnect headlight connector.
In st a ll in g : Mount
Bolts
Headlight
Turn
Dashboard
Light
Connector
Cable
Connector,
HE AD LI GH T Counter
R e m o v in g
Remove headlight mounting screws Connector,Headlight
LH/RH Handlebar Switch
Insta lling
Operate removing procedures in reverse
Headlight
Mounting
Screws
D a sh a b o a r d
Dashboard
R e m o v in g :
Disconnect dashaborad harness
Remove three mounting bolts
Remove dashboard
Mounting
Bolt
2-8
第 41 页，共 185 页
2 Vehicle Body, Muffler
Muffler
Disassembly
Remove Oxygen sensor connector
and remove oxygen sensor 2
2
Remove cap nut of and mounting
bolt of the left foot rest bracket.
Oxygen Oxygen Sensor

Assembly Sensor Connector
Reverse the removal procedure for
器接头
Cap Nut
installation.
Mounting Bolt
P42 / 185
2-9
CFMOTO
Layout of main parts
1. Deflector 13.Left panel

2. Odometer 14.Chain cover
3. Fuel tank center panel 15.Rear inner fender
4. Fuel tank lock 16.Left decorative panel
5. Fuel tank left panel 17.Engine left panel
6. Front seat 18.Left inner panel, reservoir
tank
7. Rear seat
19.Left outer panel, reservoir
8. Rear armrest
tank
9. Tail light
20.Front fender
10.Reinforcement plate, rear
21.Deflector base plate
fender
22.Deflector left panel
11.Rear fender
23.Headlight
12.Skid plate
P43 / 185 2-10

3 Inspection and Adjustment (vehicle body)
Overhaul information...……………3-1 Front brake, Rear brake...……3-5

Maintenance periodic chart………3-2 Brake fluid……………………… 3-5
Fuel filter…………………………3-3 Suspension…………….……… 3-6
Throttle cable……..………………3-3 Bolt, Nut……………….………3-6 3
Chain………………………………3-4 Front & Rear wheel shaft,
Handlebar……….…….………3-6
Clutch cable...……………….… ...3-4
Overhaul Information
Operation Instruction
Note:
l It is forbidden to run engine for long time in closed place or place without
nice ventilation, because the tail gas contains poisonous elements such as
carbon monoxide (CO) etc.
l When engine just stops, the temperature of muffler and engine is still high.
They will burn the skin, if you touch it. Uniform with long sleeves and
gloves must be worn during operation. Overhaul is necessary while engine
just stops.
l Gasoline is easily combustible, so smoking or naked fire is not allowed at
the operation site. Not only flames, but also electric sparks shall be
avoided. Besides, the vapoured gasoline is explosive, please operate it in
the place with nice ventilation.
l Please be cautions that do not let the turning pieces such as driving
system as well as movable pieces clip your hands or clothes.
Note:
The vehicle must be placed in an even and stable place, raise vehicle properly
with the main support of the vehicle or maintenance bracket.
P44 / 185 3-1

CFMOTO
Periodic maintenance chart
This motorcycle must do periodical maintenance regularly. Keep motorcycle
clean before doing maintenance.
Timely inspect, clean, adjust, lubricate or replace mark “I”, Clean mark “C”,
Replace mark “R”, Lubricate mark “L”.
Without * mark item: user do maintenance by himself. Or go to
CFMOTO maintenance station to do maintenance.
With * mark item: do maintenance by CFMOTO maintenance technical
man. If user has special tool, replacements parts or maintenance
knowledge, he can do maintenance by himself.
With ** mark item: in order to ensure vehicle driving safety, only
CFMOTO maintenance technical man can do maintenance.
Remark ①: When driving this motorcycle in dust, maintenance period must
be cut short.
Remark ②: If kilometers on odometer are over the maximal number,
periodical maintenance must be done as regulated kilometers as the chart.
Remark ③: Only CFMOTO maintenance Technical man can do
maintenance and adjustment.
Frequency Kilometers (km) (Remark ②)
Interval
Item 1000km 4000km 8000km 12000km Remark
* fuel tank, fuel pipe daily Timely maintain or replace, when damage, age or blocking before use
* throttle body I I I I before use
* coolant every 2 years: R
driving each 40 hours or 1000km/I; driving each 80 hours or
air filter Remark ①
2000km/C; driving each 20000km/R
spark plug driving 80 hours or 2000km/I; driving 6000km/R
engine lubricate oil new motorcycle must replace, when kilometers on odometer 300km, 600km,
lubricate oil filter 1000km. After former maintenance, do replacement each 1500km
drive chain, sprocket Remark ① each 500km: I, L
* brake pad each 1000km: I, R
** brake fluid every 2 years: R
** front & rear brake system Remark ③ I I I I before use
* switch I I I I before use
* light, horn I I I I before use
* battery monthly I I I I
fuse or overload protector I I I I
connecting wire I I I I
initial: driving 20 hours or 200km/I; driving each 80 hours or
** throttle valve clearance Remark ③
2000km/I
* clutch driving each 80 hours or 2000km/I before use
* suspension system I I I I
* strengthen nut and bolt I I I I before use
* wheel I I I I before use
** steering column bearing Remark ③ I I I I
** engine inspection Remark ③ I I I I
P45 / 185 3-2

Fuel filter
Check high pressure fuel pipe, if aged or
broken or leakage, replace it.
Check fuel filter, if blocking or polluting,
replace it.
WARNING:
No smoke, no fire.
CAUTIONS:
Fuel filter arrow mark indicates fuel 3
flow direction.
Throttle cable
Turn the throttle handle, and check if it
can turn smoothly.
Check the outer clearance of throttle
cable.
Outer clearance: 2 ~ 6mm
Turn adjustor to adjust throttle cable

outer clearance.
The rough adjustment of Throttle cable

outer clearance: remove dust cover,
lose nut, turn the adjustor properly,
and then tighten lock nut
P46 /185 3-3

CFMOTO
Chain
Inspect transmission chain
slackness
Slackness: 10 ~ 20mm
Chain adjustment:
1. loose nut of rear axle
2. loose nut of chain adjustor,
adjust left and right chain
adjustors to same scale
3. turn rear wheel, check chain
slackness
4. fasten adjustor nut, and then
fasten rear axle nut
Caution:
After chain adjustment, must inspect
clearance of brake pedal
Clutch clearance
① check clutch clearance:
10 ~ 20mm
1. Slight adjustment: loose locking

nut, turn slight adjustment screw
and adjust clearance
2. Large adjustment: loose locking
nut, turn large adjustment screw
tube and adjust clearance
P47 / 185 3-4

Front brake, rear brake

Check brake pad, brake disk, if they
wore to the limit mark, replace it
timely. 3
Brake clearance:
Front (hand) brake clearance:
10 ~ 20 mm
Rear (hand) brake clearance:
10 ~ 20 mm
Brake fluid
Check front brake fluid
Keep steering handle straight,
inspect brake fluid level of up brake
pump and ensure the level between
up limit and down limit.
Appointed brake fluid: DOT3 or

DOT4 non-petroleum base brake
fluid
Check rear brake fluid

Keep steering handle straight,
inspect brake fluid level of up brake
pump and ensure the level between
up limit and down limit.
Appointed brake fluid: DOT3 or

DOT4 non-petroleum base brake
fluid
P48 / 185 3-5

CFMOTO
Front suspension
Hold tight front brake lever, press the front
suspension up and down several times to
check brake performance
Check if front shock absorber has oil
leakage, or every part has looseness or
abnormal noise
Rear suspension
Press rear suspension up and down
several times to check if rear shock
absorber works smoothly, and every part
has abnormal noise or looseness
Put up main support, press rear wheel and
move it side to side. And check if rear
suspension pivot has abnormal noise or
looseness
Bolt, Nut
Check if bolts or nuts loosen. If loosen,
tighten it as appointed torque
Tire
Inspect tire and check if it has crack or
damge
Check the abradability of tire. If the
abradability reach the maximum (triangle),
replace tire
Check the tire pressure as right right
illustration regulation
Caution:
check tire pressure when tire was

cooled
Front & Rear axle
Check if front axle nut loose. If loose,
Front axle nut torque: 60 ~ 80 N·m
Check if front axle nut loose. If loose,
Front axle nut torque: 80 ~ 100 N·m
Steering handle
Move steering handle side to side. And
check if wires have interference
Turn front wheel, check if it has
interference. If it does not move side to
side smoothly, check if steering axle tighten
or not
P49 / 185 3-6

3 Inspection and Adjustment (engine)
Inspection and Adjustment
Inspection period……………………………………3-8
Inspection and adjustment process……………….3-9
Valve clearance…………………………….……….3-9
Engine idling………………………………….………3-10
Spark plug……………………………………….……3-10
Air filter…………………………………………..…….3-11
Lubrication system inspection……………..……….3-13
Cooling system inspection……………….……..……3-14
Cylinder pressure inspection…….……………..……3-15
Engine oil pressure inspection…………………...….3-16
P50 / 185 3-7

CFMOTO
Inspection period confirmation
It is regular work for engine inspection. Also it is important for
normalized maintain and inspection in order to keep well performance,
reliable work, economic and durability. It is inspection period for 1 57MJ-
3 as following list.
Caution: it is made in the normal situation. Shorten

inspection period base on badly situation.
I - Inspection, adjustment. Replace if necessary

R - Replace
C - Cleaning
P51 / 185 3-8

Inspection and adjustment process
Introduce detail inspection information
base on above item list.
Valve clearance
First inspection after 20 hours
running. Hereafter, check it every
80 hours or 2000km. Must inspect
after removing cylinder cover.
Big noise if big valve clearance, valve
damage and power decrease if small 3
valve clearance.
Check valve clearance based on
inspection period. If necessary, need to
adjust it. Procedures as follows:
l Remove sight hole plug screw 1
l Remove the bolf of front cover (left) 2
l Remove valve cage cover 3
l Rotate crankshaft through the screw
hole of the front cover (left), then
adjust the TDC reticle of the flywheel
of magnetor to aim at the reticle of up
sight hole of front cover (left)
l Check the clearance between valve
bottom and adjust bolt of rocker
Valve clearance(cold state of engine)
Intake valve: 0.08 ~ 0.10mm
Exhaust valve: 0.10 ~ 0.13mm
Caution: Inspection and
adjustment of valve clearance should
proceed in the cold state of engine,
and in the TDC of piston by filler
gauge.
l If valve clearance exceed specified
value, adjust it to the prescribed limit
by special tool, Process: loosen
adjust bolt and nut, the filler gauge
(intake valve: 0.07mm thickness,
exhaust valve: 0.12mm) mat between
the top of valve and adjust bolt.
Tighten the adjust bolt, make slight
contact with filler gauge, tighten bolt
and nut.
P52 / 185 3-9

CFMOTO
l Pull out the filler gauge and
recheck the valve clearance as
prescribed limit. Otherwise,
readjust the valve clearance
conformance to requirement.
Valve adjust nut tighten torque: 10
~ 12N·m
Caution: tighten nut after fully
adjusting it.
l Assemble top valve-chamber

cover 3, left front side cover bolt
cover 2 and sight hole screw
plug 1.
Tool: screwdriver, filter, gauge
Engine Idle
Initial inspection after 20 hours
running. Then, check one time
after every 40 hours or every
1000km.
Engine idle: 1600 ± 160rpm.
Prohibit adjusting the screw of
throttle body or adjusting idle
speed by PDA.
Tool: Tachometer, PDA
Spark plug
Initial inspection after 20 hours
running. Then check one time
every 80 hours or 2000km. replace
it for every 6000km.
l Remove spark plug by special
tool
Spark plug specification: C R 7E
l Spark plug inspection: if
electrode excessive damage,
insulator breakage or thread
damage, replace it.
P53 / 185 3-10

Check carbon deposit of spark plug. If
necessary, clear it by proper tools.
Spark plug clearance: check
clearance by filler gauge. If exceed
limit, adjust it.
Spark plug clearance: 0.8 ~ 0.9mm
Caution: If replace spark plug, 3
check thread and extend distance
of new spark plug after assembly.
If short, part of spark plug hole
thread will have carbon deposit,
even damage engine.
l Spark plug assembly
Caution: Tighten spark plug by hand
avoid todamage the thread of cylinder
head. Then tighten spark plug by specail
tool.
Spark plug tighten torque: 10~ 15N·m
Tool: spark plug wrench, filler gauge
Air filter
Check air filter every 2000km,
clean or replace it, if necessary.
If air filter jamed, less air input, lower
power, increase fuel consumption.
Inspect and clean air filter as follows:
● Loosen screw 1 and 2, remove
cover 3
● remove filter element 4
● clean filter element with proper
cleaning fluid in one utensil
● compress filter element to wiping
water by hand
Caution: Do not warp and
damage filter element.
● Soak air filter 4 with engine oil, then
properly crush out enough engine oil
and keep filter element 4 as slight
oiling.
P54 / 185 3-11

CFMOTO
Warning: Do not clean filter
element by gasoline or low flask
point of solvent cleaning.
● Check filter element whether it is
broken. If broken, replace it.
Caution: Keep filter element
clean during operation. Engine
quicken damaged, if working
without, or with dirty or broken
filter. Frequently clean filter, if
working in dirty situation.
● Check the air intake, if dust in it,
clean it by cleanout fluid.
● Check oil storage pipe 4, if
with oil, clear oil after removing
strap and storage pipe.
● Reverse the disassembly
procedure for air filter assembly.
Ensure all parts be fixed and
sealed reliably.
Auxiliary material: cleanout fluid,
SAE 30 or SAE 10W/40 engine oil
Tool: cross screwdriver, cleaning
utensil
Lubrication system inspection

Change engine oil and oil filter after
300km, 600km, and 1000km. 1. Oil level window
Then change engine oil and oil 2. Screw plug of oil filter
filter every 1500km.
△ Engine oil volume inspection

● Horizontal position for engine
● Check oil volume by oil level
window, and oil height level should
keep same level with F line.
P55 / 185 3-12

l If engine oil is less than standard
volume, loosen screw plug 2, inject
engine oil. Keep oil height level as
line as F line.
Engine oil: SAE 10W/40 SG
Caution: lay engine at horizontal
position.
△Change engine oil and filter
l Put up vehicle by main stand
l Engine pre-warming by starting
l Remove drain bolt
l Quickly release all oil before 3
engine cooled
l Remove three nuts 1 of cover 2,
remover cover 2, “O” seal ring 3,
filter pressure spring 4, paper filter
5 from right side cover 6
l Change paper filter 5, put
peristome to engine and install it to
the right side cover 6
l Before installing filter cover 2,
check if “O” seal ring 3 damaged
and if filter pressure spring 4
installed
l Install filter cover and tighten nuts
properly
l Tighten up drain bolt, move screw
plug
l Fill 1000ml engine oil by oil filler
l Tighten up screw plug, running
several seconds while engine
starting
l Check oil level after engine
stopped one minute, keep oil level
in “F”, if the level is lower than “F”,
and fill little to “F”. Oil volume total
1250ml.
P56 / 185 3-13

CFMOTO
Caution: Engine oil should
change while heat engine. Change
oil filter, meanwhile change engine
oil.
Engine oil change volume
Only change engine oil: 1.2L
Meanwhile, change oil filter: 1.25L
Engine overhaul: 1.4L
Cooling system inspection

l Check radiator, subsidiary water tank, clamp situation, leaking situation
of coolant. If damaged, replace it.
l Coolant inspection: Through observe the height of coolant and up &
down scribed line. If below it, fill coolant to the up line. Meanwhile, open
radiator cap, and fill coolant into radiator.
Warning:
l Do not open radiator cap, when engine is not cooled. Otherwise you will
be hurt by water vapor or boiling coolant.
l Coolant is poisonous. Do not drink it. Do not adhere to skin and eyes.
Just in case, wash it by water at once, even go to hospital to treat in time.
l Take care of coolant. Must keep it in the safe place where child could not
take it.
1. Engine assembly
2. Water pump
3. Water pump outlet pipe
4. Radiator outlet pipe
5. Radiator assembly
6. Fan motor
7. Radiator inlet pipe
8. Reservoir tank
P57 / 185 3-14

Cylinder pressure inspection

Cylinder pressure is important
indicator for cylinder working. It
indicate engine working situation. If
necessary, check cylinder pressure.
Cylinder pressure: 1200kPa
Some situation as follows if cylinder
pressure too low:
l Cylinder over worn
l Piston or piston ring scuffing
l Piston ring block in the piston slot
l Not strictly closed for valve seat
l Cylinder head gasket damaged or
other defects 3
Caution: check above situations if
cylinder pressure too low.
Caution: before test cylinder
pressure, check if cylinder cover bolts
are tightened as special torque, valve
clearance is adjusted properly.
l Warm up engine before inspection
l Confirm battery is powered fully
l Remove spark plug 1
l Install cylinder pressure meter 2 on
spark plug hole, and tighten nuts.
l Ensure damper open fully
l Press start button, run engine for
some seconds, and record the full-
scale reading of cylinder pressure
Tool: cylinder pressure meter,
connecter
P58 / 185 3-15

CFMOTO
Engine oil pressure is important
indicator to indicate engine working
situation.
Engine oil pressure:
9.8 ~ 29.4kPa in 3000rpm
Too high or too low engine oil
pressure leads to follows abnormal
situations:
Ⅰ engine oil pressure too low
l oil pipe leakage
l oil pump defects
l above-mentioned combination
Ⅱ engine oil pressure too high

l engine oil viscosity too high
l engine oil pipe block
l engine oil filter block
l above-mentioned combination
Engine oil pressure measure
procedure
l Remove main oil pipe bolt
l connect tachometer and ignition
coil
l install oil pressure gauge and
connector into main oil pipe
l Warm up engine as follows
Summer: 10 minutes in 2000rpm
Winter: 20 minutes in 2000rpm
After engine warm up, increase
engine speed to 3000rpm, and
then record oil pressure reading.
l After measurement, apply screw
lock on main oil pipe, then screw
up main oil pipe bolt and tighten it
as special torque.
Tighten torque: 23N·m
Tool: oil pressure gauge, tachometer
P59 / 185 3-16

4 Cooling and Lubricating System
Chapter 4 Cooling and Lubrication System
4
Cooling system drawing.....................4-2
Engine coolant...........................4-3
Inspection of coolant density.................4-3
Inspection and cleaning of Radiator and hose.....4-4
Inspection of Fan COMP....................4-5
Inspection of Water Temp and Alarm Switch ......4-6
Inspection of Thermostat....................4-6
Water Pump.............................4-7
Remove and Disassemble Water Pump..........4-7
Inspection of Water Pump...................4-9
Assemble and Install Water Pump.............4-10
Lubrication system drawing.................4-14
Inspection of Lubrication system.............4-15
第 60 页，共 185 页
4-1
157M J-3 engine cooling system
1. Engine COMP.
2. Water Pump COMP.
3. Outlet hose of Water pump
4. Outlet hose of Radiator
5. Radiator Assy
6. Fan Comp.
7. Inlet hose of Radiator
8. Reservoir COMP.
4-第261 页，共 185 页

△ Engine Coolant
●Coolant used in cooling system is a mixture of
50% distilled water and 50% ethylene glycol
antifreeze. This mixture ratio provides optimized
corrosion resistance and fine heat production.
Coolant will protect cooling system from
freezing at temperature above -30 degrees,
Celsius. Mixing ratio of coolant should be 4
increased to 55% or 60% according to the figure
on the right.
Warning!
●Use high quality ethylene glycol base antifreeze
mixed with distilled water. Never mix alcohol base
anti-freeze or other different brands of antifreeze.
●The ratio of mixture should not be more than 60% or
less than 50%
● Do not use anti-leak additive
Warning!
●NEVER open radiator cap when engine is still hot.
Or you may be injured by scalding fluid or steam;
●Coolant is harmful. DO NOT swallow or stain your
skin or eyes with coolant. In case of the above, flush
with plenty of water and consult a doctor if necessary;
● Keep coolant away from reach of children
△Inspection of Cooling Cycle
● Remove radiator cap1 and connect tester2
Warning!
NEVER open radiator cap when engine is still hot to
avoid hurt by scalding fluid or steam;
●Apply pressure 105kPa and hold for 10 seconds.
●If pressure drops in 10 seconds, which indicates leakage
in cooling cycle. In this case, check the complete
system and replace parts when leakage found.
Warning!
●When removing tester, put a rag on radiator filler to
prevent splash of coolant
●DO NOT allow testing pressure to exceed radiator
cap response pressure.
4-3
△Inspection and Clean of Radiator and
Water Hoses
Inspection of Radiator cap
●Remove radiator cap1
●Connect radiator cap to barometer2
●Slowly apply pressure to 93.3~122.7kPa and

check if the cap can hold the pressure for at least
10 seconds
● If the cap cannot meet the pressure requirement,

replace with new one.
Radiator Cap Opening Pressure:

Standard: 93.3~122.9kPa
Tool: Barometer
Inspection and Clean of Radiator
●Remove dirt or trash from radiator with compressed

air
●Repair radiator fins with a small screwdriver
Inspection of Water hoses

●Check radiator hoses for leakage or damage. If
any, replace with new one.
● Check water hose clamps. Replace with new

one if any looseness found.
●After inspection and clean of radiator and hoses,

check coolant level. Fill coolant if necessary
4-第463 页，共 185 页

Inspection of Fan Motor
●Release 2 bolts from Fan Motor with socket spanner

1. Remove Fan motor from radiator 3
●Turn the vanes to check if they can turn smoothly;
●Check fan motor as the right chart: Battery: 12 volts

, motor runs at full speed with ampere not more then
3A indicating in ammeter. If the motor does not work of
the ampere exceeds the limit, replace the motor.
● Installation: Apply a little thread locker to the bolts

and tighten to the specified torque.
Fan Motor Blot Tightening Torque: 10N.m
第 64 页，共 185 页
4-5
△ Inspection of Water Temp.Alarm switch
● Remove Water Temp.Alarm switch
● Check the resistance of Water Temp.Alarm switch

as illustrated on the right, Place Water Temp.Alarm
switch “2”in a vessel with engine oil above an alcohol
burner.
Tool: ohmmeter, thermometer.

●Warm the ant freezing, and check
the display of Ohmmeter and
thermometer.
Table of Water temperature and resistance value
For1 and 3
Temp（℃） 50 80 110
Resistance 318±8 141.7±
（Ω） 811
1.8
Table of Composited Water temperature sensor and
resistance value
For 2 and grounding
Temp（℃） 50 120
Resistance 176±40 17.9±1.5
（Ω）
Installment of Composited water

temperature sensor：Apply a few of
Thread-locking Adhesives on the
Thread，and install it into cylinder head
according to specific process.
Torque tightening for Composited water

temperature sensor installment:
10～15N·m
Note：
●To prevent the damage of water temperature sensor, it is not allow to crash the flint.
●Composited water temperature sensor and thermometer and not allow to contact with dish.
● Inspect the coolant liquid after installed
Composited water temperature sensor. Add coolant
liquid if necessary.
△Inspection of Thermostat
●remove 2bolts”1” from Thermostat cover Assy.
●Remove thermostat cover”2”
●Remove thermostat
4-第665 页，共 185 页

●check the thermostat pellet “3”if any broken ,replace
it.
●test thermostat as the following steps:
☆Pass a string through thermostat flange as illustrated

on the right； 4
☆Immerse thermostat in a beaker with water. Make

sure thermostat is in the suspended position without
contacting to the beaker.
Heat water with an alcohol burner and observe the
temp. Rise on the thermometer.；
☆Take temperature reading from thermometer when

thermostat valve opens
Thermostat Valve Opening Temp.:68-74℃
☆Keep heating water to specified degree,

thermostat valve should have been lifted by
3.5～4.5mm；
☆If higher of thermostat opening temperature or thermostat

valve lift does not reach the standards, replace it .
●Installation: Reverse the removal procedures for installation

☆Apply coolant to the rubber seal of
thermostat before
Assembling the mounting hole.
Tighten to the specified torque to install
thermostat cover.
Tightening Torques:10N/m
△Water Pump
Removal and Disassembly
●Release hose clamp 1remove hose 2 to drain coolant.
Note：Before draining coolant, check water pump

for oil or coolant leakage. In case of oil leakage, check
water pump oil seal, O-ring, In case of coolant leakage,
check water seal .
第 66 页，共 185 页
4-7
●Release clamp”1”remove water hose “2”
●Remove bolts”3”of water pump
●Remove Water Pump”4”
●Remove O-Ring”5” and checking, replace a

new one if broken.
●Release water pump cover screws”6”
●Remove water pump gasket”8” and cover”9”

from water pump body”7”,check the gasket ,replace
a new one if broken.
Note：It should be clean up the contact surface

of water pump body and cover ,in order to affect the
sealing of gasket.
●Release shaft clip “10” which on the water

pump shaft with Circlip pliers.
4-第867 页，共 185 页

Note: shaft clip must replaced with new one

after disassembling.
●Remove Water Pump Impeller Assy.11;

4
●Remove moving ring seal “12” from impeller.
●Remove stationary ring “13” with special tool.
Note: stationary ring does not need to be removed

if no abnormal condition
●Remove oil seal with special tool “14”
Note: Oil seal does not need to be removed if

no abnormal condition.
●Inspect bearing of water pump if it can work

well. In case any problems like blocked, replace
it. When do replacement, use bearing puller tool
to remove bearing
Note: shaft must be replaced with a new one

after disassembling.
Inspection of Water Pump

☆Bearing:
● Check bearing clearance by hand while it is
still in the water pump body.
● Turn inner race of bearing to check for abnormal
noise and smooth rotation.
● Replace bearing if any abnormal condition
第 68 页，共 185 页
4-9
☆ Stationary Seal Ring:
●Carefully check stationary seal for damage,
especially the seal face.
●In case of damage or leakage, replace the

stationary 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 .
9
☆ Water Pump Impeller:
●Check impeller and shaft, if damage, replace with
new impeller. 6
4 13
☆ O-ring 3 11
8
●Check O-ring carfully,if it’s damaged, replace it 14 2
with a new one. 16
Assembly and installation of water pump 1

●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 1
●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 water hoses
4-第1609 页，共 185 页

Lubricant system drawing

1 5 7MJ -3 ENGINE LUBRICANT SYSTEM DRAWING
第 70 页，共 185 页
4-11
●Schematic diagram of engine lubrication system：
1. Crankcase oil tray 2.engine oil screen 3.Oil Strainer Cover
4. Oil Level Mirror 5.Oil drain plug 6.Oil Pump Assy
7. Oil Filter Assy. 8.Clutch 9.Countershaft 10.Mainshaft 11.Crankshaft
12. 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-3 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.
4-第1721 页，共 185 页

5 Engine removal, inspection and assembly
Engine removal, inspection and assembly

△Engine removal/assembly and page location
Location Parts name Removal Inspection Assembly Remark
Injector, throttle 5-2 — 5-40
Engine
Outside Water pump 5-2 — 5-38
5
Starting motor 5-2 — 5-40
Left side cover 5-2 — 5-39

Engine 5-3 5-39
Main chain wheel —
left 5-3 5-39
Gear contactor —
Dual gear 5-3 — 5-38
Oil filter cover and element 5-4 — 5-35
Right side cover 5-4 — 5-34

Engine Driven gear Oil pump 5-4 — 5-33
right Main gear Oil pump 5-4 — 5-33
Mounting nut balance shaft 5-4 — 5-33
Clutch 5-4 5-24 5-33
Oil pump 5-4 — 5-33
Timing sprocket tensoioner 5-5 — 5-38
Spark plug 5-5 — 5-18
Cylinder head cover 5-5 5-11 5-37

Engine Camshaft 5-5 5-18 5-37
head Magneto Rotor 5-6 — 5-38
Main gear 5-6 5-29 5-38
Cylinder cover 5-7 5-12 5-36
Cylinder 5-7 5-20 5-36
Timing chain 5-8 — 5-36
Piston 5-8 5-21 5-35
Shift god 5-8 5-28 5-32
Gear, Cam driven 5-8 — 5-32
Oil screen cover 5-9 — 5-32
Right crankcase 5-9 — 5-31
Engine gearbox hub, Gear shift lever,

5-9 5-26 5-30
shifting fork, Main and driven
Crankcase
gear
Balancer shaft 5-9 5-25 5-31
Crankshaft 5-10 5-23 5-30
第 72 页，共 185 页
5-1
Ⅰ Engine removal
△Preparations
●Prepare a plate for parts;
● Prepare tools;
●Drain all oil and coolant;
△Engine outside
Injector, Throttle
●Remove the two bolts 1, and remove cap of Injector 4
and Injector 5 by socket head wrench.
Loosen the Throttle 3
Water pump
●Loosen clamp 2,remove water pipe

connection, loosen 3 pieces of bolt 1, and
take out water pump.
Starting motor
●Loosen two Nut 1 and remove Starting motor.
△Engine left side
Left side cover
●Loosen Bolt 1 and 3, Remove rear left cover

2 and Gear cover of Front left cover.
5-第273 页，共 185 页

Take out dual gear axle and

remove duel gear 1.
5
Loosen the 9 pcs of front left cover nuts,

Remove the front left cover.
DUAL GEAR I I
Take out dual gear axle and remove duel
gear 4.
Main drive chain

Loosen 2 pcs of bolt 1, and remove
mounting plate 2 and main drive chain;
Gear contactor
Use a screwdriver to loosen two pieces of
bolts 3, and remove gear contactor
5-3
第 74 页，共 185 页
△Engine right side
Oil filter cover and element
Loosen 3 pieces of assembly bolts 1, and
remove filter cover 2 then element and other
parts;
Right side cover

Loosen right side cover bolts 3, 4 & 5, remove
right side cover 5 and right side cover mat.
Mounting nut balance shaft

Loosen balance shaft mounting nut1,
Remove washer 2
Main gear Oil pump

Use chisel to reveres and beat away the lock washer
and loosen Nut 4 and remove Main gear 5.
Driven gear Oil pump

Use special tool to remove clamp 6 and then
remove driven gear 7;
Clutch
● Loosen 5 pieces of bolt 8 and remove clutch
plate 9, then take out clutch main plate and
driven plate；
●Loosen clutch tightening bolt 10, remove 11
and clutch gear 12 and then other parts;
●Take out clutch main driven gear 13 and
Then other parts.
Oil pump
●Loosen 3 pieces of bolt 14, and then remove
oil pump 15.
5-第475 页，共 185

△ Engine head
Timing sprocket tensoioner
● Remove bolt 1 and take out tensioner spring;
● Remove tensioner bolt and then the tensioner.
5
Spark plug
●Use special tool to remove spark
plug 1. Turn the crankshaft, and stop
when groove of crankshaft parallel
with the plane of cylinder head.
Cylinder cover
●Remove valve room cover 1;

● Remove cover bolt;
●Remove cylinder cover 2;
● Remove cylinder cover pin.
Note: Do not let dowel pin fall into

crankcase.
Camshaft
●Remove timing sprocket bolt 1;

● Remove camshaft spacer 3;
●Remove timing sprocket 2 from camshaft;
● Take out camshaft 1;
Note: Do not let spacer fall into

crankcase. Hook the timing sprocket
during removal to avoid drom into
crankcase.
第 76 页，共 185 页
5-5
MAGNETO ROTOR
●Remove tightening nut 1 ；
●Use tool to fix on the outer thread and

Remove the rotor and get off the woodruff key.
Tool: Rotor puller
Main gear
●Remove the Main gear 1
5-第677 页，共 185 页

5 ENGINE REMOVAL AND ASSEMBLY
Cylinder tightening bolt
●Loosen 4 pieces of tightening bolts. 5
Cylinder head
●Loosen 4 pieces of cylinder cover

bolts and copper mat.
●Remove cylinder cover 1.
Cylinder body
●Remove pin 1;
● Remove gasket 2;
●Remove timing chain guide;
● Remove cylinder 4;
第 78 页，共 185 页
5-7
CFMOTO
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 pins or groove

surface, and use tool 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.
5-第879 页，共 185 页

●Loosen bolt 1 and take out spacer pin

spring and neutral spacer pin.
Filter element cover

5
●Loosen 3 pieces of bolts 2;
●Remove cover 3.
Right crankcase
●Loosen bolts on crankcase;
●Put left crankcase downwards and right one
upward, use tool to separate left and right
crankcases, and then remove right
crankcase.
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.
第 80 页，共 185 页
5-9
CFMOTO
Crankshaft
● Use tool to separate crankshaft from left crankcase;
Tool: Crankshaft separating tool
5-第1801 页，共 185 页

Ⅱ Engine parts inspection

Cylinder head cover
△ Disassembly
Warning: during disassembly, make sure

each part position so assembly can be made 5
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.
Touching surface of cylinder cover
Limit: 0.05mm
Tool: feeler gauge.

Replace with new parts if limit is exceeded.
Note: Cylinder head and cover

are an assy, and should be replaced
as a set.
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)
第 82 页，共 185 页
5-11
CFMOTO
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 inspection
Cylinder cover
△ Assembly
●Remove air inlet pipe.
●Remove thermostat cover 1, water

temperature sensor 2 and chain tensioner3.
5-第1823 页，共 185 页

●Take out thermostat;
● Use a special tool to compress valve spring

and then remove clamp 1.
Tool: Valve compress tool.
●Take out valve spring upper seat 2 and then

outer spring 3 and inner spring 4.
● Remove outlet valve 5 and inlet 6;
● Take out sealing 7;
●Remove seat valve spring.
第 84 页，共 185 页
5-13
CFMOTO
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;
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
continuous and strip width must be within
follow limit. Repair if nenessary.
Standard valve seat width.:0.9-1.1mm
Tool: Valve repair.
Valve step and guide bushing

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

0.25mm
Tools: Micrometer gauge and magnetic clock
seat.
5-第1845 页，共 185 页

External diameter of valve stem

●Measure with a micrometer gauge
Standard external diameter of valve stem:
Valve intake 4.975-4.990mm
Valve exhaust 4.955-4.970mm
Tool: Micrometer gauge(0-25mm)
Valve stem jump

●As illustrated, use a V-shape to support valve,
use a micrometer to measure the jump.
Limit: 0. 05 mm
Tool: micrometer and V-shape support
Valve head jump

●As illustrated, use a micrometer gauge to
measure valve head jump. If the jump is over
limit, replace valve.
Limit: 0.03mm.
Tool: Megnetic clock seat, micrometer gauge
(1/100) and V-shape seat.
Valve head surface wearing

●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.
Limit: 0.5mm
Tool: Feeler gauge
Valve step end status

●Check valve step end surface for corrosion
and wearing. If A is less than the limit, repair it.
Limit: 4 .5mm
Tool: feeler gauge;
第 86 页，共 185 页
5-15
CFMOTO
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 noise
●Measure free travel and replace spring if limit is
below limit.
Valve spring length limit (valve intake and valve
exhaust):31mm
Valve external spring free travel limit (valve intake
and valve exhaust):32.5mm
Tool: Feeler gauge.
● Measure power of compressed spring and

replace standard limit of inner spring of valve if
the spring power out of limit.
Compressed from 26.8mmto 33.7N-44.3N
Valve external standard (valve intake and
exhaust):
Compress to 29.8mm is 88.6N-104N
Tool: Spring balance
● Measure spring leaning, and replace spring in

case of leaning out of limit.
Spring leaning limit: 2 °
5-第1867 页，共 185 页

△ Cylinder head assembly

●Install all valve spring seat 1;
●Coat every valve step sealing with lubricant
and then install valve cap end.
Material: molybdenum lubricant 5

Warning: Valve step sealing can not
be re-used
●Insert valve 3 and 4, coat a layer of

molybdenum lubricant on valve step round
surface
Warning: Do not damage sealing of valve

step during valve installation
●Install valve inner and external spring, little

end b close to cylinder head and big end a
with mark upwards.
●Place valve spring upper seat② and

compress spring with special tool. Put two
valve clamps① at ③ and then release
compressed tool.
Note: Use a hammer slightly knocks at

valve end, and make sure valve clamp
is already fixed in valve groove.
第 88 页，共 185 页
5-17
CFMOTO
Tool: Valve spring compressed tool, and

tweezers.
● Check sealing of cylinder cover: inject

cleaning liquid into air inlet ① and air
outlet and stop for a while, check valve
seat ② for leak.
●Install spark plug and water sensor,

thermostat and thermostat kit and
cylinder cover related parts.
Camshaft
● 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-第1889 页，共 185 页

●Wearing of camshaft
Wearing of camshaft will defect valve
performance and lower engine power output.
Wearing of inlet and outlet limit uses a to
clarify. And use a micrometer gauge for
measurement. Replace camshaft in case
over wearing; 5
The limit of camshaft travel Inlet camshaft:
5.6695mm
Valve exhaust camshaft: 5.314mm
Tool: Micrometer gauge (0-25mm)
●Camshaft bearing wearing

During cam shaft assembly, measure
clearance between camshaft and bearing
hole to judge if the clearance is within the
limit.
Camshaft work-out clearance limit: 0.15mm
Measurement method:
●Clean cylinder head and cover.
●Put plastic clearance gauge external
surface of camshaft touching position and
then assemble it with cylinder head cover;
●Install cylinder head cover and tighten bolt
with proper torque
●Disassemble cylinder cover and then read
data on the gauge.
Tool: Plastic clearance gauge.
• Note: Do not turn camshaft during

plastic gauge assembly.
If oil clearance exceeds the limit, measure
diameter of camshaft, replace camshaft in
case of over limit or replace cylinder head
and head cover.
●Camshaft assembly external diameter

Use a micrometer gauge to measure external
diameter A on camshaft assembly position
and replace camshaft in case of exceeding
limit.
Standard A limit:
21.959mm-21.98mm
Tool: micrometer gauge (0-25mm)
第 90 页，共 185 页
5-19
CFMOTO
TENSIONER SET, CHAIN, GUIDE CHAIN.

● Inspection
Check touching surface for wearing and
damage, replace if necessary.
Cylinder body:
△ Inspection Cylinder body deformation:
●Use a knife straight ege and a feeler
gauge to inspect 7 points and read the
limit data and replace cylinder body if
limit is exceeded.
Limit: 0.02mm
Tool: knife straight edge and feeler gauge.
Cylinder body inner diameter inspection.
● Check cylinder inner surface for scratch or

any other damage and replace new parts if
necessary;
●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.
5-第2901 页，共 185 页

Piston:
Piston diameter.
Use a micrometer gauge to measured
diameter at position 7mm. Replace piston in
case of lower limit
Piston external standard: 56.97-56.99mm

5
External diameter limit: 56.94mm
Tool: Micrometer gauge (50-75mm)
Measure clearance between piston and

cylinder body based on above
measurement. Replace cylinder or piston or
both if clearance is exceeding 0.15mm.
Piston groove clearance

Use a feeler gauge to measure clearance
between 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)
第 92 页，共 185 页
5-21
CFMOTO
Piston free open and working open

Before piston ring assembly, use feeler
gauge 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
● Measure piston pin hole inner diameter

with a inner micrometer gauge, and
measure external diameter with micrometer
gauge. Replace piston and piston pin in
case limit is exceeded.
Piston pin hole limit: 15.030mm
●Use a micrometer gauge to measure

external diameter at three points.
Piston pin external diameter limit: 14.980mm
Tool: Inner scale（18～35mm) Micrometer

gauge(0-25mm)
5-第2923 页，共 185 页

Crankshaft
Crankshaft little end inner diameter
●Measure crankshaft little end inner
diameter inner diameter with a inner
micrometer gauge，Replace crankshaft in
：5.014mm 5
Little end limit : 1
Tool: percentile scale (0-18mm)
Crankshaft beat
●Crankshaft big end wearing can be
checked by checking little end beat.
Beat limit of little end: 3mm.

Tool: percentile scale, magneto seat and
V shape seat.
Crankshaft big end side clearance:

●Push big end to another end and use
feeler gauge to measure
clearance£¨Standard:0. 10-0.45mm, limit:
1.00mm); replace crankcase if clearance
is exceeding limit 1.00mm).
Tool: Feeler gauge
Crankshaft jump
●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
第 94 页，共 185 页
5-23
CFMOTO
Clutch
Primary clutch:
●Check bearing teeth and replace bearing A
in case of wearing or damage.
Note: Dot mark aligning with key slot.
Secondary clutch
●Inner rubber wearing will cause movement
or noise between bearing and clutch.
Replace secondary B in case of serious
movement.
●Replace two bearings in case of wearing or

damage.
●Replace two bearings in case of abnormal

noise.
FRICTION DISC, CLUTCH

●Use feeler gauge to measure clutch disc
thickness and replace friction disc clutch in
Thickness standard: 2.9-3.1mm
Limit: 2.8mm
Plate clutch
● Use plain panel and thickess gauge1 to
measure deforming data (Limit 0.1mm),
replace clutch plate if measurement
exceeds limit.
5-第2945 页，共 185 页

5 Engine removal, inspection & assembly
Clutch spring
●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.
5
THRUST BEARING & BRACKET, CLUTCH

●Check thrust bearing & clutch bracket
for abnormal status, such as broken, wearing
or damage, and replace if necessary
Crankcase bearing.
●Feel clearance of crankshaft bearing inside,
and check for noise or smooth turn with hand,
replace bearing if necessary.
Shaft, balancer
●Remove circle no.1;
Remove balancer shaft gear no.2, spring
no.4, pad no.3 & gasket no.5;
Note：Check the spring and the gasket if
any damage, replace if necessary.
●Installation
Orderly put the gasket no.5, balancer gear
no.2, cushion block no.3 & spring no. 4 on
the balancer shaft no.6, then put on the
circle no.1。
第 96 页，共 185 页
5-25
CFMOTO
GEARSHIFT
30 Shift fork shaft(middle) 45 Main shaft

29 Shift fork (middle) 44 Bolt M6*10
28 Shift fork 43 Plate,Chain
27 Shift fork shaft 42 Main chain sprocket
26 Bolt M6*12 41 Secondary shaft
25 Plate, Camshaft 40 Second gear,secondary shaft
24 Rachet plate,gearshift 39 Sixth gear, secondary shaft
23 Rachet spring 38 Third gear, secondary shaft
22 Rachet pin, gearshift 37 Fourth gear, secondary shaft
21 Left Rachet 36 Washer
20 Right Rachet 35 Retainer
19 Driven gear, gear shift drum 34 Fifth gear, secondary shaft
18 Hub,gear shift drum 33 First gear, secondary shaft
17 Pin 4*6 32 Bush
16 Contact spring 31 Washer 15*25*15
5-第2967 页，共 185 页

Fork
●Check position 1
●Check position2
Repalce in case of scrach, bending or
damage.
5
HUB, GEAR SHIFT DRUM

●Check groove of hub
●Check position A of hub
Replace in case of wearing or damage
Shift fork
●Check shift fork 1 & 2
Replace in case scratch, wearing or
damage.
●Shift fork inspection

In case not smooth, replace shift fork.
Note: Do not try to repair deformed
shift fork.。
●Use a slide caliper to measure

thickness of shift fork composition
Shift fork thickness standard: 4.80-

4.90mm
Fork (Middle) standard: 5.30-5.40mm
第 98 页，共 185 页
5-27
CFMOTO
Main, secondary shaft

2
●Check main shaft 1 and secondary shaft 2.
Replace set in case of deforming, wearing or
damage.
1
●Check bearing teeth

Replace bearing in case of blue points,
wearing or damage.
Replace in case of wearing, crack or
misplacement.
Shift rod
●Check 1 and replace in case of deforming,
wearing or damage.
Reset spring
●Check 1 and replace in case of deforming,
wearing or damage.
Shaft collar
●Check shaft collar 3 and replace in case
of damage or wearing.
DOWEL SPRING, GEAR SHIFT
●Check spring no. 4
and replace in case of wearing or damage.
Gearshift unit camshaft location
structure.
●Check gearshift camshaft location structure
5 and replace in case of damage, wearing.
5-第2989 页，共 185 页

Starting driven bearing, dual gear and

dual shaft axle.
5
△Inspection
●Inspection driven bearing 1 for wearing
or damage.
● Measure inner and external diameter s of
driven bearing 1.
Limit:
Inner; replace if over 22.10mm
External; replace if below 54.15mm
●Check dual bearing no.2 & no. 3 for

wearing or damage;
● Check dual bearing no.4 & no. 5 for
wearing or damage;
Overriding clutch
△Inspection
●Check working status of overriding clutch
after installing starting driven gear onto
overriding clutch as illustrated.
●Hold flywheel, and status is good if
starting driven gear turns smoothly anti-
clockwise.
5-29
第 100 页，共 185 页
CFMOTO
Ⅲ Engine assembly
Assemble engine in reverse procedures of
removal. And pay attention to following
points:
1 . Clean related parts;
2. Every parts should be checked no damage.
3 . Lubricate parts before assembly;
4. Oil lips and O-ring should be lubricated.
Crankcase assembly
Left crankcase
●Clean oil and sealing glue on crankcase
sealing surface;
●Lubricate oil seal lip;
Crankshaft rod
●1.Use special tool to pull rod into left

crankcase
Note ：
●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.
5-第31001 页，共 185 页

HUB, GEAR SHIFT DRUM AND SHIFT FORK
●Assemble gear shift drum hub 1 onto

crankcase;
●Install same two shift forks in correct position
and then install shift fork 3; 5
●Install shift 4 in correct position and then install
Shift fork 5;
●Install gear shift camshaft location structure 6 ;
●Install gearshift location spring 7 。
●Coat oil on surface of related parts;
●Check if every bearing of each gear is working
smoothly.
Note: Related parts must be cleaned and no
foreign matters or metallic fragments on surface.
HUB, GEAR SHIFT DRUM AND SHIFT

FORK DRAWING
Main, Secondary shaft

● Install the balancer shaft as illustrated
Note: make sure the spot marked on the
balancer shaft gear should be on the spot of
crankshaft gear.
Balancer shaft
●Coat left crankcase 1 with sealing glue and
install two pins 2 into location holes. Take
crankcase3 and press properly left and right
crankcases.
第 102 页，共 185 页

5-31
CFMOTO
●Install assembly bolts and tighten bolts two

or three times as illustrated.
Torque: 10N.m
Neutral gear stop pin and filter cover
●Install stop pin 1 and stop spring 2, gasket

3 and bolt 4; 。
Note: Do not mistake stop pin 1 assembly

direction;
●Install filter cover as illustrated.
DRIVEN GEAR, GEAR SHIFT DRUM AND

GEARSHIFTING shift lever assy
DRIVEN GEAR, GEAR SHIFT DRUM
●Install driven gear, gear shift drum into
driven bearing 1, plate 2 and camshaft guide3.
Note: Assembly direction of ratchet plate,

gear shift and driven gear, gear shift drum
can’t be wrong.
Exploded drawing for driven gear,
gearshift drum
1.DRIVEN GEAR, GEAR SHIFT DRUM Driven gear, shift cam
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 installed in wrong direction.
Gearshift rod
●Install gearshift rod as illustrated;
5-第31203 页，共 185 页

PRIMARY DRIVE GEAR AND OIL PUMP
PRIMARY DRIVE GEAR

●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
●Install poil pump 6 as illustrated and tighten
3 oil pump assembly bolts;
●Install in procedures 7, 8 and 9.
Nut, balancer shaft

●Put on washer 10,tighten nut 11;
torque ：4 7 ～5 3 N ·m 。
Clutch
Exploded view:
第 104 页，共 185 页

5-33
CFMOTO
Item Part Name Item Part Name
10 Head rod, Clutch 20 Washer, Thrust
9 Nut 19 Bolt M6*16
8 Locking Washer 18 Separate Rocker
7 Driven Pad, Clutch 17 Oil seal 10*20*6
6 Driven Pad, Clutch 2 16 Washer 10*20*1
5 Driven Pad, Clutch 1 15 Rod, Clutch
4 Hub, Cluth 14
Bolt M5*16
3 Bushing, Primary Driven Gear 13 Spring, Clutch
2 Primary Driven Gear 12 Platen, Clutch
1 Washer 20*34.5*2 11 Thrust Bearing & Bracket, Clutch
● Reverse the removal procedure for

install clutch as illustrated.
Note：
●Coat 11 with oil before assembly;
●Install part 8 longer end into main shaft facing
left crankcase.
Clutch bolt adjustment

●Loosen bolt 20 and install adjustment bolt
19 to touch slightly with clutch shaft;
●Remove clutch adjustment bolt 1/4-1/2 and
tighten tightening bolt 20.
Right side cover

●Install right side cover as illustrated;
Note：Use new right side cover paper

to avoid oil leak;
5-第31405 页，共 185 页

Paper Element
●Check O-ring 3 and gasket 6 and replace
if necessary;
● Clean paper element and replace if
necessary;
5
●Install O-ring 6, gasket 6, paper element 5,
element spring 4 and O-ring 3, filter cover 2
and bolt 1 in order;
Piston Ring Assembly

●Install piston ring onto piston;
●Coat pistons rings with oil;
●Do not damage piston;
●Put piston ring with mark upside;
●After assembly, make sure piston ring
can turn freely and make first ring open
mouth facing air inlet.
Piston installation
●Install piston 1, piston pin 2 and dowel
pin 3;
● Put piston end with arrow mark

towards to exhaust port.
5-35
第 106 页，共 185 页
CFMOTO
Cylinder body
● Install two dowel pin 1 and new cylinder body
gasket 2.
● Coat cylinder inner surface, piston and piston

ring with clean engine oil;
●Press piston ring, and install piston into cylinder
1 and then install cylinder onto crankcase;
■Note: Do not damage piston or piston ring;
■Note piston ring open not facing piston pin
with angle of 120 degrees.
● Install timing chain sprocket 2;
●Install guide chain 3;
●Install dowel pin and new cylinder gasket 4;
●Turn crankcase, make piston to stop
point.
Cylinder cover
● Install cylinder cover as illustrated.
5-第31607 页，共 185 页

Camshaft assembly and cylinder head

tightening
●l.Install camshaft 1;
●Install sprocket onto timing chain and
install timing chain sprocket 2 on to
camshaft. Make sure marking line of timing
chain in parallel with cylinder cover 5
connection surface;
Note: Do not turn crankshaft during above
operation
●Tighten cylinder cover bolt 3 and bolt 4,

note that position for both is right and do
not miss gasket;
●Tighten camshaft timing chain sprocket
bolt 5;
● Install camshaft location washer;
●Tighten 4 pieces of bolt 7;
Bolt, cylinder head
Cylinder head cover

●Clean oil on surface between cylinder
head cover and cylinder head;
●Install dowel pins onto cylinder head;
●Coat sealing glue on cylinder head cover
connection surface;
●Install cylinder head cover 1 as illustraton;
●Install two cover bolts onto rocker arm
dowel plate hole and then install onto
cylinder head cover;
●Install rest bolts;
Note:Tightn cylinder head cover bolts two
or three times(Torque:10-12N.m);
●Install other assembly bolts.
Exhaust valve intake valve
Valve clearance adjustment

●Turn crankshaft and make piston to stop
point. Adjust air intake and exhaust valve
and tighten clearance adjustment bolts.
Air inlet clearance:0.08-0.10mm
Exhaust valve clerance:0.10-0.13mm
● Install valve room cover.

Cover, valve
第 108 页，共 185 页 5-37

CFMOTO
Water pump
●Install water pump 1 as illustrated;

●Install water pipe joint 3;
●Install water outlet pipe 2 ;
Note：Do not forget to assembly O-ring during
water inlet pipe 3 assembly;
Tensioner
●Remove bolt 8;。
● Press lock stop seat 2 and tensioner to bottom
as illustrated;
●Install new tensioner 1 &5,then tighten bolt
4;
●Install tensioner spring 6, O-ring 7 and
tighten bolt 8.
Starting gear and magneto rotor
●Put 1 into groove;

●Install starting gear 2 onto crankshaft;
●Install magneto rotor 3;
●Coat thread glue on crankshaft and then
tighten bolt 4.
Dual gear
●Install dual gear 1, axle sleeve 2 and dual gear

axle 3.
5-第31809 页，共 185 页

Gear connector
●Install spring 1 into gearshift drum hub;

●Install gear contact into hole of the hub;
●Install O-ring 3 and gear contact terminal 4 and
tighten bolt 5.
5
Side cover,LH and dual gear I

●Install location pin into left crankcase pin
hole;
●Install new left side cover gasket onto left
crankcase;
● Install front left cover onto left crankcase;
Note: Gasket must be clean and without
foreign fragments. Dowel pin must not be
hit.
●Install the dual gear I &dual gear shaft I
as illustrated。
●Install location pin, side cover,LH 4 & the bolt;
Note： Side cover 4 must be clean and without

foreign fragments, coating with glue 5699 before installation.
Drive chain sprocket
●Install drive chain sprocket1, chain

holder 3 & bolt 3 as illustrated.
第 110 页，共 185 页
5-39
CFMOTO
Starting Moto
●Install starting moto1 & bolt 2 as illustrated.
I n j e c t o r , T h r o tt l e b od y
●Install injector 1, injector cap 2

and throttle body 3 as illustrated.
5-第41011 页，共 185 页

6 Engine Disassembly and Installation
Overhaul Information…………6-1 Engine Installation……6-4

Disassembly of Engine……………………………6-2
Note:
·It requires an engine bench and coolant tube when installing and disassembling engine.
Do not damage frame, engine body, bolts and cables,etc.
Tightening Torque:
Engine suspension tightening nut: M8 ：20 ～30N ·m
M10：34～40N·m
Fork shaft tightening nut: M 14 ：50 ～8 0N ·m
Rear wheel axle tightening nut: M 14 ：50 ～8 0N ·m
第 112 页，共 185 页

6-1
CFMOTO
Disassembly of Engine
Use the special stand to support the rear
wheel off the ground;
Remove seat;
Remove front protection cover (LH&RH)
Remove fuel tank;
Remove water sensor connector;
Remove the cables that connected with
engine;
Remove muffler;
Remove three bolts and three nuts on
engine; Mounting Spark Outlet clamp
Remove 2 water pipe clamps, drain coolant. bolt plug water pipe water pipe
Pull out spark plug cap;

Remove flue gas pipe connect with crankcase
and air filter;
Remove air filter.
Clamp inlet water pipe, engine

Loosen chain adjust nut & bolt; Water pipe
Loosen rear wheel shaft nut.
Loosen chain snaps with pliers and remove

chain
Rear wheel nut
6-第2 113 页，共 185 页

6 ENGINE REMOVAL/INSTALLATION (VEVEICLE)
Removal injector Injector

Removal the air filter water leak
Loosen fastening screw,
removal throttle body
Loosen clutch cable
Removal rear shock
Removal rear fork shaft
Removal rear fork
Removal negative & positive
cable of starting motor
Removal throttle cable
Loosen bolt & nut of engine front
6
Throttle clip
Negative cable Positive cable
Removal shift level

Loosen bolt & nut of engine rear side
Removal engine
Gear pedal Rear fork shaft
第 114 页，共 185 页

6-3
CFMOTO
Engine Installation
Attention: Do not damage bolt thread,
wirings and flexible 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 installation.
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 cooling system)
6-第4 115 页，共 185 页

7 F r o n t w h e e l , Br a k i n g , Su s p e n s i o n a n d St e e r i n g S y s t em
Overhaul information ……………7-1 Front shock absorber…………………7-8
Troubleshooting……………………7-2 Steering column………………………7-9
Handle bar……………………………7-3 Front brake……………………………7-11
Front wheel…………………………7-6
Operation Attention
Attention
·Securely support the scooter when overhauling front wheel and suspension system.
·Do not overexert on the wheel. Avoid any damage to the wheels.
·When removing tire, use the special tire lever and rim protector.
Overhaul Standard
Camber of front wheel shaft － 0. 2mm

7
Rim run- Longitudinal 0.8mm 2. 0mm
Front wheel
ou t Horizontal 0.8mm 2. 0mm
Tire Groove left － 1. 6mm
2
Air pressure 175kPa（ 1. 75kgf／cm ）－
Front brake Free play of brake lever 10 ～20mm －
Tightening Torque
Mounting nut, steering bar 10～14 N·m

Nut, front wheel shaft 50 ～ 80N ·m
Upper fixing nut, front shock absorber10～14 N·m
Lower fixing bolt, front shock absorber 20～25N·m
第 116 页，共 185 页

7-1
CFMOTO
Troubleshooting Spongy brake lever

Heavy steering (steering too tight) ·air enter into brake system
·Upper thread is over tightened. ·brake oil level too low
·Steering bearing is damaged or worn out. ·oil leakage in brake system
· Inner & outer bearing seats are damaged,
worn out or stepped. Poor brake
·Steering column is distorted ·dirty brake disc
·Tire pressure is too low. ·brake disc unparallel with wheels
·Worn tire
Abnormal noise with disc brake
Loosened Handlebar ·dirty brake disc
·Front right and left shock absorbers are not ·eccentric disc brake disc
matched. ·disc brake pump wrong assembly
·Front shock absorbers are distorted ·brake disc unparallel with wheels
··Front wheel shaft is distorted, wrong
assembly of front wheel
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
·front shock absorber not tighten enough
·oil insufficiency, front shock absorber
·steering bearing worn out
·oil insufficiency, counter gear
第 117 页，共 185 页

7-2
Steering bar
Disassembly
Remove 2 pcs mounting nut, 1
right handlebar switch
1. Right handlebar switch 2. Screw
Remove throttle cable and throttle grip,

remove right handlebar switch
3 .Throttle cable 4 .Throttle grip
7
Loosen fixing screw 1, balance block,
remove balance block and throttle grip.
5 .Balance block 6 .Screw 1
Remove fixing 2 pcs screws, Front brake main pump, 8

remove Front brake main pump
9
7. Front brake main pump 8. Window hole 9. Bolt 2
第 118 页，共 185 页
7-3
CFMOTO
Loosen 2 pcs mounting screw,
remove left handlebar switch
Left handlebar
switch
Clutch lever
Loosen 2 pcs fixing bolt 1, clutch lever, remove clutch lever
Handlebar tube Mounting screw
Loosen2 pcs fixing screw, loosen 2 pcs locknut,

Remove left/right handlebar.
Installation
Reverse the disassembly procedure for installation
Dowel pin
Fastening screw
Insert dowel pin into position hole when
assembling
left handlebar.
第 119 页，共 185 页

7-4
7 Fr o n t w h e e l , Br a k i n g , Su s p e n s i o n a n d St e e r i n g S y s t em
When assembling right handlebar switch,
insert throttle grip into right handlebar,
install throttle cable.
1 .Throttle grip 2 . Throttle cable
Insert dowel pin into position hole, assemble

right handlebar.
3
4 6
5
3 .Dowel pin 4 .Right handlebar switch

5 .Throttle grip 6 、Position hole
第 120 页，共 185 页

7-5
CFMOTO
Front Wheel
Support main stand, put a jack under engine or put a
heavy thing on rack, raise front wheel.
Loosen cable, speedometer
Loosen front wheel shaft, remove front wheel shaft
Remove front wheel
Front wheel shaft inspection Front Front wheel shaft

Put front wheel shaft on V block, wheel
check curvature. shaft
Service limit: >0.2mm replace
Front rim inspection

Put front wheel on turntable, turn wheel to check
wheel beating with dial indicator..
Service limit:
Axial direction: 2.0 m m
Radial direction: 2.0m m
Check wheel bearing for looseness; turn bearing

inner ring to check for flexible rotation; Check if any
looseness when assembled on rim. If any above
problem, replace with a new bearing.
第 121 页，共 185 页

7-6
Disassembly
Remove front wheel Front brake disc Fixing bolt
Remove sleeve,
front wheel shaft
Head, bearing Counter induction plate

removal tool
Remove sleeve, front wheel
shaft
Remove dust seal
Remove bolt, front brake
disc
Front disc thickness service
limit: 3mm
7
Shaft, bearing removal tool
第 122 页，共 185 页

7-7
CFMOTO
Front shock absorber
Remove
Front fender
Front wheel
Loosen 6 pcs fixing hexagon socket bolt
Remove front shock absorber(LH&RH).
Inspection
Oil leakage, aged or damaged oil seal -Replace
Locking bolt Hexagon socket bolt
Locking & adjusting bolt, Steering

Column
Hexagon socket bolt
第 123 页，共 185 页

7-8
7F r o n t w h e e l , B r a k i n g , S u s p e n s i o n a n d S t e e r i n g S y s t em
Steering
Column
Remove:
Remove front
fender
Remove front
wheel, front
shock
Remove
handlebar
Remove big
light cover
Locking bolt, upper connecting plate
Remove locking bolt, upper connecting plate
Locknut
Dust
cover
Loosen nut with wrench, remove dust cover and

lower joint plate, front fork.
Remove circlip, upper bearing, top and bottom ball.
Connection
plate, bottom
7
Top bearing race
Remove top and bottom bearing race with impact

tool.
Circlip, upper bearing

Bottom bearing race
Top ball
Bottom ball
Remove bottom ball

Circlip, lower
bearing
第 124 页，共 185 页

7-9
CFMOTO
Installation
Put bottom ball into lower joint Locknut

plate, front fork.
Dust
cover
Connection
Install top and bottom bearing race to frame riser
with impact tool, apply enough grease. plate, bottom
上轴承钢碗
Put top ball into top bearing race.
Top bearing
Bottom
race ring
Install lower joint plate to frame riser, bearing race
insert top bearing race and dust cover.
Lock up lower joint plate with nut, adjust tightness to Top bearing
proper position(standard: plate do not move up and race
down, flexible move left and right)
Lock up nut tightening torque:60 ～ 9 0 N ·m Bottom bearing race
Bottom bearing race ring
Install upper joint plate, lock up with bolt,

tightening torque: 6 0 ～ 9 0 N ·m
Install dash board.
Remove front wheel, front shock absorber
Install big light cover.
Install front fender
Install handlebar(LH&RH).
Locking bolt, top connection plate
第 125 页，共 185 页

7-10
Front Brake
Fluid reservoir
Fluid Reservoir
Removal
Remove rear mirror (LH)

Remove 2 pcs fixing bolt
Separate fluid reservoir from handlebar, do not
remove fluid reservoir from handlebar without
changing hydraulic brake. Cover
Attention
Cover bolt
1 Do not hang brake pump on brake hose.
2 Remove master cylinder first before fluid reservoir;
install fluid reservoir first before master cylinder, do
not reverse the procedure in case air enter into
hydraulic system. Fixing
bolt
Removal front brake caliper
Remove 2 pcs fixing bolt
remove master cylinder from front shock absorber(LH) Brake

caliper
Attention
Do not pinch front brake lever after removal of brake
pump. 7
Front brake caliper Installation
Reverse removal procedure for installation of fluid
reservoir
第 126 页，共 185 页

7-11
CFMOTO
Replace brake Fluid,
drain out air
Support main stand on flat ground, correct handlebar.
remove 2 pcs fixing screw, fluid cup cover
Attention：
Cover coating and plastic parts with cloth to avoid brake fluid.
Connect a transparent hose with relief valve, master

cylinder, loosen relief valve.
Suck out brake oil with injection syringes,
Brake Fluid Injection Connect a transparent hose and injection tube with
relief valve, master cylinder, loosen relief valve bolt.
Inject brake oil into fluid cup, suck out air with injection
tube until no air in the hose, lock up relief valve.
Attention：
1. Oil level in fluid cup should keep at least half when
sucking in case of sucking in air.入
2. Use recommended brake oil(DOT3 or DOT4 nonpetroleum
base brake fluid)
Drain out Air Connect a transparent hose with relief valve, pinch front
brake lever without loosening, open relief valve to drain air, repeat several times until no air.
Attention：
Oil level should keep at least half when draining air.
第 127 页，共 185 页

7-12
Brake disc / Front
brake disc
Brake disc replace
Remove brake disc
Press bracket, brake disc until inner pads can be get
as illustrated per picture. Exhaust port Inner/outer brake pads
Remove outer brake pads after getting inner brake

pads. Remove spring 1 and 2. Install new inner and
outer brake pads by reversing the procedure for
removal.
Attention：
Brake disc must be adjustment after installing
before usage.
Front brake disc
7
Measure Brake Disc Thickness
Measure brake disc thickness with micrometer or
caliper. Replace with a new one if over service limit.
Service limit: 3mm
第 128 页，共 185 页

7-13
8 Rear Wheel, Rear Brake & Suspension
Overhaul information…………………8-1 Rear fork……………………… …………8-4
Troubleshooting………………………8-1 Rear brake…………………… …… … 8-4
Rear wheel……………………………8-2
Overhaul information
Operation Attention
Attention
·Assemble the fender driving chain, make gap to the opposite way from the wheel.
·Adjust the driving chain, double confirm the brake if need to do adjustment accordingly.
Overhaul standard

Rear wheel Camber of rear wheel shaft － 0.2m m
Rim run-out Longitudinal － 0.5m m

Horizontal － 0.5m m
Tire pressure S in g le person： 2 0 0 k P a（ 2 . 0 k g f －
2
／ cm ）
Two persons：2 2 5 k P a（ 2 . 2 5 k g f ／
cm 2）
Rear brake Thickness of rear brake 5mm 2mm
shoes
Tightening torque
Mounting nut, REAR ARM 50～80N·m
Fixing bolt/nut, Front shock absorber 35～45 N·m
Nut, front wheel axle 50～80N·m
第 129 页，共 185 页

8-1
CFMOTO
Rear wheel
Removal 1 2
Support the frame with jack, lift the front wheel,
Remove rear wheel chain adjusting nut.
Remove rear wheel axle nut, remove rear wheel axle,
take out rear wheel axle and front wheel
5 4 3
1. Rear brake disc 2. Chain adjuster 3. Nut, rear
Inspection wheel shaft 4. Rear brake caliper 5.Chain
Rear wheel axle
Set axle on a V block, measure axle vibration
with centesimal gauge.
Service Limit: 0. 2 mm
Set rear wheel on the rotating stage, check the

rims vibration
Service Limit:
Horizontal: 0.5mm
Vertical: 0.5mm
Check rear axle clearance; change if clearance

is too big.
Check rear chain wheel, replace if worn.
Check driving chain, replace if necessary.
8-第2130 页，共 185 页

8Rear Wheel, Rear Brake &
Dissemble Suspension
rear wheel
Remove SHAFT
Rear brake disc
SLEEVE,REAR
WHEEL (LH)
Remove oil
seal
Remove chain
comp. Rear brake caliper
Remove rubber cushion, check if there is any

looseness or worn to replace in time.
Rear wheel bush
Rubber cushion
Rearwheel axle bush
Remove rear brake comp.
Chain wheel
Rear wheel bush

Inspection rear wheel axle bush,
change if the clearance too big.
Use special tool to dissemble rear wheel axle bush.
(LH&RH) Oil seal
Assemble
Follow the opposite way of dissemble when Assemble
rear wheel.
Use butter when assemble dust boot.
Rear wheel axle nut torque:50～80N ·m
第 131 页，共 185 页

8-3
REAR FORK Botls,
rear shock
Re mo va l absorber
Remove rear wheel.Remove the bolts, rear
shock absorber and rear shock absorber.
Remove the clip and rear brake hose. rear
Loosen bolts M6 , remove chain cover. shock
absorber
Loosen lock nuts, rear fork.
Remove shaft, rear swing arm, and then
remove rear fork.
Ins t a l l a t i o n
Reverse the removal procedure for
Installation.
REAR BRAKE
Ins p e c t i o n
Check thickness of
rear brake disc.
Replace the brake disc if the wear has reached
the position of wear limit trough.
BRAKE FLUID
Connect the brake caliper deflation valve to a
transparent hose and injection syringe, Shaft, rear swing arm lock nuts
loosen the bleeder screw, add the brake fluid
into the oil cup, use the injection syringe to
purge the air until there is no air in the Outer brake
transparent hose, then tighten the screw.
disc
CAUTION:
Inner brake
1.When add the brake fluid into the oil cup
with the injection syringe,the brake fluid level disc
of the oil cup should be between upper and
lower limit, to avoid the entrance of the air. Air outlet
2.Use only the recommended brake fluid(DOT3
or DOT4)
AIR PURGE OF BRAKE SYST EM

Connect hose to deflation valve, hold the brake
lever, loosen deflation valve and bleed the
air.Repeat the operation until there is no air.
CAUTION：
The brake fluid level of the oil cup should be
between upper and lower limit when bleeding air
BRAKE DISC T HICKNESS
Measure the thickness of the b rake disc
with m icrom eter or calip er, rep lace the
b rake disc if exceed the use lim it.
Min. limited thickness of brake disc:3mm
Hole, oil pump
8-第4132 页，共 185 页

9 ELECTRIC SYSTEM/WIRING DIAGRAM
一 Charging system………........9-1
二 Electric starting system…...9-3
三 EFI system………………….... 9-8 9
1. The structure of EFI system…… 9-8
2.EFI system wiring diagram…… 9-9
3.Maintenance of EFI system…... 9-9
4.Service tool………………….....9-10
5.The structure and function of EFI
spare parts…................................9-12
ECU…………………………....... 9-12
Throttle body………………....... 9-13
Intake pressure sensor…............ 9-14
Inlet air temperature sensor....9-15
Water temperature sensor…9-16
Oxygen sensor……………….....9-17
Pick up…………………………... 9-18
Speed sensor…………………......9-19
Gearshift sensor………………..9-20
Fuel pump………………….......9-21
Fuel injector………………....... 9-22
Air by-pass valve……………..... 9-23
Ignition coil……………................9-24
Roll-over senor……………....... 9-25
6.Inspection of EFI system……... 9-26
FI indicator light………………. 9-26
PDA………………………............9-27
Error code…………………….....9-28
7.Electrical wring diagram………... 9-29
第 133 页，共 185 页 9-1

△CHARGING SYSTEM
Charging Diagram
Magneto Coil Resistance

● Measure the resistance of 3-phase magneto stator coil.
● Replace a new charging coil in case of the resistance is out
of specified range.
● Check whether stator coil and stator center is
Insulated or not.
Turn multimeter on 1X10 Ω range
Magneto coil resistance:0.5 ～1.5 Ω

（Yellow-Yellow）
Insulation resistance: ∞Ω (Yellow-Ground)
Performance of Magneto Without Load

● Start the engine and keep it at 5000rpm
Measure the voltage among 3 out put lines
of magneto stator coil by multimeter.
● If the v ol tag e i s l ow er than
specified range,please replace
a new m ag neto.
Turn multimeter on AC voltage
range.
The voltage rate of coil when
magneto is without load >50V(AC
voltage) at 5000rpm
第 134 页，共 185 页

9-2
RECTIFIER
●Start engine, check voltage of fully charged battery’s terminals(red,green) which is usually between 13.5V-
15V when the engine speed reaches specified speed 5000rpm. Replace the rectifier if the charging voltage is
out of the service limit.
第 135 页，共 185 页

9-3
△STARTING SYSTEM
第 136 页，共 185 页

9-4
STARTING MOTOR
1. Front cover
2. Brush holder
3. Brushing spring
4. O-ring
5. Brush terminal
6. Motor housing
7. Washer
8. Armature
9. Washer
10. Rear cover
11. O-ring
第 137 页，共 185 页

9-5
BRUSH
●In brush holder, check the abnormal damage
crack or matte of brush.
●Replace the brush,if any damage.
COMMUTATOR
●Check commutator color and abnormal
damage or over-wear.
●Replace the armature if any abnormal damage.
●If commutator color changes,polish it with
sand paper and wipe it with dry clean cloth
●If over-wear,saw the part of insulatorB,
The distance between A and part of insulator B is d:
d ≥ 1.5mm
ARMATURE COIL
Check the connection of armature coil with
the multimeter.Make sure the armature coil
are well connected, otherwise,replace the
armature.
OIL SEAL
Replace a new starting motor if any damage or
leakage of oil seal lip.
第 138 页，共 185 页

9-6
STARTER RELAY
●Connect the “+”pole and “-” pole of a 12V battery with
starter relay coil. And use multimeter to check
2 terminators are well connected or not.
●If the clatter sound can be heard, starter relay coil is normal.
●The terminators of starter relay are not conducted when
disconnected with 12V battery.
●If the above 2 conditions happen, starter relay is ok.
Turn multimeter on diode.
CAUTION：Load voltage on the
starter relay should not exceed 2
minutes,otherwise, it may cause relay
overheated and coil blown.
●Measure the resistance of starter relay

coil with multimeter.Replace a starter
reply if the resistance is out of
specification.
●Turn multimeter on1X 10 Ω range

Resistance of Auxiliary relay coil:3～
5 Ω
Auxiliary Relay、Oil Pump Relay

● Load 12V voltage between the anode and
cathode of starter relay coil,and use
multimeter to check connections A and B are
well connected or not.
Turn multimeter on diode.
●If starter relay connections tick,2 connections are connected.
●Unload 12V voltage on coil, and 2 connections disconnect.
●If the above 2 conditions happen, the relay is ok.
●Turn multimeter on 1X100 Ω range.

Resistance of Auxiliary starter relay ：
9 0 ～1 0 0 Ω
CAUTION：
In the back of Auxiliary relay, the anode of
relay coil is in the same direction of diode.
第 139 页，共 185 页

9-7
Caution when starting engine
●Connect the lines according to circut diagram.
●Check whether parts are connected properly before starting.Connection of EFI parts see the
EFI part below.
●Check air circulation system.
●Check fuel system.
If blocked，clean clogged parts and ensure
smooth fuel system.
If leakage, try to reconnect the leaked
parts and ensure leakless fuel system.
●Check the oil pressure with the oil pressure gauge.
Oil pressure of fuel pump outlet ：

0 . 3 3 ±0 . 0 1 B a r ；
●Turn the gear at neutral.

●Diagnose the faulty with PDA，if any，
eliminate the faulty according to the erro code.
●Release throttle and turn off ignition switch.
Push starting switch with 3-5 seconds. Oil pressure gauge
●After starting engine,warm up engine, check
the idle speed after it’s stable.
Idle speed：1 6 0 0 ±1 6 0 r p m ；
第 140 页，共 185 页

9-8
△ EFI SYSTEM
Structure of EFI System Ignition coil
Air by-pass valve
Air filter
Fuel injector
9
Oxygen sensor
Inlet air temperature sensor
Throttle body
Water temperature sensor
Pick up sensor
Roll-over sensor
Fuel pump
EFI SYSTEM consists of 3 parts：
( 1) Sensor:
( 3) Actuator:
Transfer different knds of non-electrical quantity
Implement the instruction from ECU.It is the hands of
of engine into electrical signal,and send the
information to ECU. It is the eyes and ears of ECU.The main actuator :
ECU,including the sensors below: ●Fuel pump (Provide high pressure fuel)
●Inlet air pressure sensor(load
●Fuel injector ( Inject fuel quantitatively,atomize
information)
fuel better)
●Inlet air temperature sensor(air density)
●TPS (load information load range ●Ignition coil (Provide ignition energy to spark plug in
accelerate and decelerate information) high pressure condition)
●Pick up (Crankshaft phase information) ●Air by-pass valve( Provide idle air inflow）
●Water temperature sensor (engine
temperature information)
●Speed sensor (RPM of output shaft)
●Gearshift sensor (g earshif t inf ormation)
●Oxygen sensor (Excess air coefficient>1 or <1 information）

●Roll over sensor(prevent vehicle dumping)
( 2 )E C U:
Electronic control unit , is the brain of EFI system.
It analyzes and cope with the information provided
by sensors, and send the conclusion in the form of
instruction to actuator, then make the engine run
in the optimal condition.
第 141 页，共 185 页

9-9
喷 EFI System Wiring Diagram
电
Maintenance of EFI System

● Use CFMOTO spare parts to do maintenance, ●When inspect the ignition system, and only
otherwise, can not ensure the EFI system working when necessary, to do the spark-over test,
normally. and the time should be as short as
●Do not decompose the EFI parts during possible.Do not open the throttle boday,
maintenance. otherwise,it can lead large amount of
unburned gasoline into the exhaust pipe,
●Handle with care for the EFI parts during damage the TWC.
the maintenance.
●EFI system adjusts the idle speed of the
●Whenever the EFI electrical connections are to engine，do not need manual adjustment.
be connected or disconnected, do not turn on the Do not remove or adjust the throttle limit screw since
ignition switch, otherwise , it may damage the EFI parts. it has been adjusted and set with precision at the
●Do not charge the fuel pump，to avoid causing factory.
electric sparks and fire, when remove the
electric fuel pump from the fuel tank. ●To prevent damage to the electrical
components, do not reverse the battery cable
● Do not operate the fuel pump if the pump is connections. this system adopts negative iron.
completely dry or operate it in the water,
otherwise, it will reduce its service life. Do not ●Do not remove the battery cable when the
reverse the cable connections of fuel pump. engine is running.
●Fuel supply pressure of EFI system is high(about
3 3 0 k P a),fuel pipes adopt resistant high pressure
●Remove the positive and negative of Battery
pipe. do not remove fuel pipe during maintenance cable and ECU before welding the vehicle.
because fuel pipes still keep higher oil pressure even
the engine is not running. ●Do not use the method of puncturing wire to test the
Release the pressure of fuel system before removing the input and output electric signal of the parts.
fuel pipe, when maintain the fuel system, method of
pressure relief is below:
Remove fuel pump relay, start engine ●Establish the environment awareness, cope
in idle speed,let it stop by itself. with the garbage during the maintenance
Remove fuel pipe and change the oil filter in a effectively.
well-ventilated area.
第 142 页，共 185 页
9-10
Maintenance Tool
9
T o o l ：PDA
Function ：
Read/ erase trouble code of EFI system,
observe data flow and accessories test etc.
Tool：D igit al m ult im et er
Function ：
Inspect the parameter of EFI system like voltage,
current and resistant ect.
T o o l ：Vacuum Gauge
Function ：
Inspect the pressure of air inlet hose.
第 143 页，共 185 页 9-11

T o o l： I g n i t io n t im i ng l i g h t
Function ：
Inspect ignition timing of the engine.
T o o l： C y l i n d e r c om p r e s s i o n g a u g e
Function ：Inspect the cylinder pressure of the
engine.
T o o l： O i l p r e s s u r e g a u g e
Function ：
Check the pressure of fuel system and judge
the working condition of fuel pump and oil
pressure regulating valve in fuel system.
T o o l： F u e l i n j e c t o r
cleaning analyz er
Function ：
Analyze the cleaning of fuel injector.
第 144 页，共 185 页

9-12
St ruc t ure a nd Pe rf o r ma nc e o f EF I Pa rt s
( 1 )E C U:
Electronic control unit , is the brain of EFI system.
It analyzes and cope with the information
provided by sensors, and send the conclusion in
the form of instruction to actuator, then make the
engine run in the optimal condition.
9
ECU Pin Function ：
1. Ignition coil control signal
2. Ground to ECU
3. Speed signal
4. FI indicator light
5. Ignition switch power +
6. Inlet air temperature sensor signal
7. Neutral switch
8. Roll-over sensor signal
9. Mode switch signal
10. +5V Power supply
11. Ignition switch power +
12. Pick up A
13. Pick up B
14. Fuel injector
15. Oxygen sensor heating
16. Auxiliary relay
17.Air by-pass valve （canister control valve）
18. Water temperature sensor signal
19. Intake air pressure sensor signal
20. TPS sensor
21. Ground to sensor
22. Fuel pump relay
23. Battery power +
24. Oxygen sensor signal
25. RPM output
26. Cable K diagnosis.
Lim it Data：
Value
Item unit
Minimum Typical Maximum
Nomal
9.0 14+0.1 16.0 V
Battery voltage working
Limit function 6.0-9.0 16.0-18.0 V
Limit and time of Keep part of function,
battery over- 26.0V can diagnose the 5 min
voltage trouble
working temperature -40 +70 ℃
storage temperature -40 +90 ℃
● Do not allow to increase the load on the cover or cap of ECU

● Handle with care，should not drop it on the ground 。
第 145 页，共 185 页

9-13
( 2) Throttle Body:
Connect with air filter and the engine, control
the on-off angle of throttle by throttle cable. Send
out the angle signal through TPS.
TPS Pin Function：

1. Connect 5V power
2. Connect to ground
3. Output voltage signal
4. Inlet air temperature and pressure sensor
The wiring diagram of connecting to ECU,

See the right picture.
Do not adjust idle limit bolt
●Do not adjust idle limit bolt manually

because EFI system adjusts the idle speed
of the engine.
第 146 页，共 185 页

9-14
( 3) Intake Air Pressure Sensor:

Supervise the pressure of air inlet pipe, provide the engine load to ECU.
Pin
Function ： 43 21
1. Output 9
voltage signal
2. Connect 5V
power
3.Connect to
the ground
The wiring diagram of connecting to ECU,

Allow ed installation range is in the

right picure.It can make sure no
codansate water in the sensor, because
the codansate water will damage the
pressure sensitive units of the sensor.
The diagram of pressure and output voltage is below:

Supervised pressure range：10 ～11 5 k P a
第 147 页，共 185 页

9-15
( 4) Inlet Air Temperature Sensor:
It is a NTC thermistor, the resistance value
decreases with increase of the coolant
temperature, but it is not a linear relation.
Temperature sensor is packed together with
the pressure sensor.
43 21
The wiring diagram of

connecting to ECU,
Temperature-Resistance Table
60000
50000
40000
30000
20000
10000
0
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
-10000
温度（℃）标称阻值（OHM)
第 148 页，共 185 页

9-16
(5) Water Temperature Sensor:
It is two sets NTC thermistors. the resistance value decreases with increase of the coolant temperature, but it is not a
linear relation. One set provides for ECU, supervises the heat condition of the engine. Another provides for dashboard,
supervises water temperature.
A & C group: provide the water temperature signal
B & Threaded part group: provide water temperature signal to dashboard
Wiring diagram of this sensor and ECU

Resistance between Terminal B and

Chassis ground . Send signal to dashboard.
See the right table
Resistance between Terminal A and

Terminal C . Send signal to ECU.
See the right table.
第 149 页，共 185 页

9
Temperature(˚C) Resistance (Ω)
9-17
CFMOTO
(6) Oxygen sensor:
This sensor is used in closed-loop feedback-
controlled fuel injection to improve the
air-to-fuel ratio accuracy and control the
emission. It’s located in the exhaust stream to
measure the amount of oxygen in
exhaust and send the signal to ECU, which
can revise the fuel injector output,so as to
reduce the amounts of unburnt fuel and
make catalytic converter convert HC, CO and
oxides of Nitrogen efficiently.
Pins and Function：

1. Connected with positive terminal,
heating power(white)
2. Connected with negative terminal,
heating power(white)
3 . Connected with negative terminal,
signal output(grey)
4. Connected with positive terminal,
signal output(black)
Right figure is circuit of sensors and ECU
The following table explains the oxygen sensor working parameters.
第 150 页，共 185 页

9-18
(7) Pick-up:
Pick up transfers signal of engine speed to ECU and by
which ECU to confirm engine speed ignition angle and
injecting phase.
Pick-up
Right is diagram of pick-up and ECU
Measure pick-up resistance value
● Set multimeter to 1X 100 Ωrange；

pick up coil resistance：1 0 0 ～1 6 0 Ω (2 0 C)
●Replace a new one when resistance is not within
above value range.
Measure pick up peak voltage

●Connect multimeter and peak voltage adaptor as
shown as right picture：
+ Probe：Green (B) cable
- Probe：Blue (A) cable
9
Note：
Refer to owner manual when use peak value voltage adaptor
● Set multimeter to AC V range.
● Set engine to Netrual gear, turn on ignition switch
● Press starter button and keep engine running for seconds,
then measure pick up coil peak value voltage
● Repeat a few times and record the highest value
Pick up coil peak value voltage ：≥2 V（3 0 0 r p m ）
● Replace a new one when peak value voltage is not within above value range
第 151 页，共 185 页

9-19
CFMOTO
( 8 ) SPEED SENSOR:
This sensor is used to detect speed
of engine output shaft and provide signal
for ECU to judge vehicle speed.It belongs
to Hall effect sensor,that varies its output
voltage in response to a magnetic field.
Pins and Function:

1. Ground
2. Output voltage signal (>80% input
power voltage)
3. Power+DC12V
Right figure is circuit of sensor and ECU
Speed Sensor Test:

● Ground pin 1and connect pin 3 with +12V
power;
● Fix a gear 2.5mm away from a speed
sensor as the right figure illustrates;
● Turn multimeter to DCV range;
● Slowly turn the gear and measure the
voltage between pin 2 and pin 3 to
determine that if the reading varies from
0V～12V;
● If the reading does not vary, that indicates
the sensor is defective and needs to
be replaced.
第 152 页，共 185 页

9-20
(9) Gear position sensor:
This sensor is used to provide the gear
position signal for meter display.Meanwhile,
it cooperates with cable as starting
protection.
Pins and Function:

White/Yellow-(1st Gear)
Red/Black-(2nd Gear)
Green/Blue-(3rd Gear)
Yellow/Blue-(4th gear)
Brown/Red-5th gear
Green/Red-6th gear
Blue –Neutral
●When each pin at a certain gear position,

there is continuity between this pin and
engine.Otherwise, no continuity.
第 153 页，共 185 页

9-21
9
(10)Fuel pump:
The Fuel pump assy includes fuel pump,
plastic support, preliminary filter, fine filter
and pressure regulator. It supplies fuel for
engine under a certain pressure and flow.
Functions of the pins:

1. Blue (Ground)
2. Red (connectted with fuel pump relay
output terminal)
Parameters:
Pressure regulator opening pressure:
0 .3±0. 01M Pa
Flow: ＞35 L/H
● This fuel pump is located in fuel tank.
● Do not operate the fuel pump in dry
condition in order to prevent damage.
● Always handle the fuel pump gently.
Never drop the fuel pump onto ground.
Fuel Pump Wiring
●Battery supplies power for fuel pump

assembly via fuel pump relay, which connects
the fuel pump circuit only with engine
started.
Fuel pressure test:

●Connect the fuel pressure gauge with
fuel outlet and tighten the joint with a
clamp to prevent fuel leaks.
● Route accords to the right circuit.
●Turn on ignition switch and engine stop switch;
●At this moment, fuel pump will keep working
for 5 seconds. After the fuel pump stops, fuel
pressure should be in specification, otherwise, replace it.
●After fuel pump stops running, the holding pressure
should be at 0.25MPa for at least 5 minutes, otherwise, replace it
Pressure relief of fuel pipe:
In an EFI model, the pressure in fuel system is very high, so all the line is high pressure resistant.
Even though the engine is not started, the pressure in fuel system remains high. Therefore, it is not
recommended to remove fuel lines before pressure relief.
Follow the procedure below to perform pressure relief:
Remove fuel pump reply, start the engine and allow it to idle unitil the engine
stops automatically.
第 154 页，共 185 页

9-22
9 Electrical System
(12)Fuel Injector:
One end of fuel injector mounts into fuel
injector seat, and the other end attaches
to the injector cap, which connects with a
fuel line. Fuel injector is controlled by
ECU to inject fuel at stated time into the
engine.
This injector nozzle is a 4-hole style.
Don’t turn injector after the joint between
injector and injector cap is installed.
9
Pins and Function:
● Connector with the mark ”+” connected

with fuel pump relay output
terminal.
Fuel Injector Resistance:12±1Ω（20℃）
Fuel Injector Circuit:

Installing：
●Install fuel injector manually. Never
knock fuel injector with a hammer.
When removing and installing fuel
injector, the O-rings on both ends must be
replaced;
● Perform pressure relief before fuel
injector removal if necessary;
● Test the fuel injector sealing after
installation to ensure no leaks.
第 155 页，共 185 页
9-23
CFMOTO
(12) Idle Air Control vale (Canister

Control vale):
IACV is used to control the air flow of Conenct with
by-pass.ECU calculates the engine load Throttle Body
and controls IACV through electrical pulse
duration and frequency (commonly known
as duty ratio). IACV allows different air
flows passed through under different
pressure. Therefore, it should be connected
properly. Otherwise, idle speed
may be incorrect. When there is no electrical
Connect with Air flow
pulse, IACV would be closed.
Air Filter Direction
Pins and Function: Connect with

1. Connect with 17 pins of ECU Fuel pump relay
2. Connect with outlet end of fuel pump
relay.
Idle Air Control Valve Circuit:
Idel air control valve
●To avoid electronic component

damages, please do not plummet the
connector as right diagram when fixing the
IACV.
● To avoid solid-borne sound transmission
you can install the IACV suspended
in the tube, or fix it on engine or frame by
rubber boot.
Idle Air Control Valve Parameters: Wrong installation
第 156 页，共 185 页

9-24
9 Electrical system
( 1 3 ) Ignition coil：
Ignition coil transforms the low voltage
of primary coil to high voltage of secondary Connect with High-tension Cable
coil needed to spark the spark plug and ignite
the mixture of air and fuel in cylinder.
9
Pins and Function:
1. Ground;
2. Connect power +;
3. Connect ECU pin;
Ignition Coil
Ground
Secondary
Ignition Coil Circuit:
Power
Primary
ECU
1ST PIN
High Voltage
Ignition Coil
Output
Peak Voltage Tester
Secondary Ignition Voltage Test:
● Connect the engine according to EFI
wiring diagram;
● Connect the peak voltage tester
according to the right diagram;
Battery
● Start the enigne;

● Secondary ignition voltage should be
＞15000V; Spark Plug
Ignition Coil Parameters:
第 157 页，共 185 页

9-25
( 13 ) Tilt sensor：
Tilt sensor is used for preventing vehicle from tilting. When vehicle’s tilt angle is larger than setted tilt angle,
an “OUT” signal will be transferred to ECU. ECU will stop the engine.
Tilt Angle
VCC connect with +12V

OUT connect with ECU 8 pins
GND connect with negative terminal
第 158 页，共 185 页

9-26
9 Electrical System
EFI self-diagnosis
ECU contains about monitors sensors, actuators, circuits, MIL and battery voltage, etc,
even itself. It also tests sensors output signal, actuator drive signal and inner signal
(such as closed-loop control, coolant temp. signal, idle speed control and battery
voltage control, etc for reliability ).If any malfunction or suspectable signal found, ECU
would record the fault information in RAM.
Fault information comes in form of fault codes, which are then displayed on PDA, in
sequence of which fault comes first.
Faults can be divided into “steady fault” and “occasional fault” (such as a
fault caused by harness short or loose connection.)
PDA or MIL can be used to locate the part in trouble immediately after fault happens.
(1) MIL (or FI Indicator):

MIL is a light-emitting diode and located on instrument panel. It indicates different
fault codes through the flashes in different frequency
MIL Circuit: The current in pin 4, ECU should be less than 0.5A.
MIL Flash principles:
a. In flash code model, trouble-free in Trouble memory

When ECU monitors MIL in flash code model, MIL flashes to indicate a fault code
according to the fault P-code from Trouble memory.
From the beginning of ECU ignition,MIL lights up for 5 seconds. And after 1 second
interval, MIL flashes in 2 HZ flash frequency. It indicates troublefree until turn ignition
b. In flash code model, trouble

faulted in Trouble memory.
When ECU monitors MIL in flash code
model, MIL flashes to indicate a fault code
according to the fault P-code from Trouble
memory.
From the beginning of ECU ignition,
MIL lights up for 5 seconds. And after 1
second iinterval, MIL flashes to indicate P-code of memory. MIL lights up until exit the
flash code model after indicate all of fault code entered into memory. Flash code
model requires that cable K to ground.
c. Read the troubles by flash code.

Turn the ignition on, and K line to ground after 2.5 seconds. If ECU Trouble
memory has fault code, the output code of engine MIL means P-code.
Take fault code P0203 for example: MIL lights flashes for 10 times-Interval- flashes
for 10 times-Interval- flashes for 2 times-Interval- flashes for 10 times-Interval-flashes
for 3 times
第 159 页，共 185 页

9-27
CFMOTO
（ 2 ） P D A：
PDA has 3 pins, power, ground wire and
data cable K. These pins are connected
with related ECU pins. The right photo
refers to operation panel of PDA. When it
comes to detailed keys function, refer to PDA
manual.
Pins and Function:
1. Connect with ECU pin 26 ECU
2. Ground
3. Connect with +12V power
Keys and Function:
LH Key: Page up
UP Key: Scroll up
RH Key: Page down
Down Key: Scroll down
OK Key: Entrance
Exit Key: Exit
PDA Function:
(1)Version Information Display
PDA can display engine, ECU hardware and soft ware
information.
(2)Fault Display
PDA monitors IAP sensor, IAT sensor, water
temperature sensor, TPS, Oxygen
sensor,Oxygen sensor heating circuit, air-to-fuel ratio
revision, fuel injector, fuel
pump relay, CPS, speed signal, idle speed, idle air
control valve, system voltage,
ECU,FI indicator and displays the fault code.
(3)Engine Parameters Display
PDA can display battery voltage, RPM, desired idle speed, vehicle speed, coolant
temperature, water temperature sensor signal voltage, inlet air temperature, IAT
sensor signal voltage, inlet air pressure, inlet air flow, IACV target position, TPS
signal voltage, throttle body position, throttle body relative position, canister duty,
charging time, FI pulse width, park advance angle, Oxygen sensor voltage, engine
relative load, canister load, IACV position, atmospheric pressure, altitude multiplier,
engine operation time.
(4)EFI Status Display
Starter switch, main relay, fuel pump relay, idle speed, idle speed, full load status,
deceleration activation, acceleration activation, FI close loop activation, lambda
control activation, canister control valve activation, MIL status.
(5)Actuator Test Function
MIL, fuel pump, IACV, canister control valve, ignition and fuel injection.
第 160 页，共 185 页

9-28
9 Electrical System
Fault code table：
REF Fault code Instruction

NO
1 P0030 Oxygen sensor heating control circuit open
2 P0031 Oxygen sensor heating control circuit short to ground
3 P0032 Oxygen sensor heating control circuit short to battery
4 P0107 Intake air pressure sensor short to ground
5 P0108 Intake air pressure sensor short to battery
6 P0112 Intake air temp.sensor low voltage
7 P0113 Intake air temp.sensor high voltage
8 P0117 Engine water temp.sensro circuit voltage too low
9 P0118 Engine water temp.sensro circuit voltage too high
10 P0122 TPS circuit voltage lower than min.voltage
11 P0123 TPS circuit voltage higher than max. voltage
12 P0130 Oxygen sensor singal improper
13 P0131 Oxygen sensor circuit voltage too low
14 P0132 Oxygen sensor circuit voltage too high
15 P0134 Oxygen sensor signal malfunctin
16 P0201 Injector control circuit open
17 P0261 Injector control circuit short to ground
18 P0262 Injector control circuit short to battery
19 P0321 RPM signal reference point malfunction
20 P0332 No pick-up(speed) pulse signal (open or short)
21 P0501 Speed sensor singal improper
22 P0560 Battery voltage signal improper
23 P0562 Battery voltage too low
24 P0563 Battery voltage too high
25 P0627 Fuel pump relay control circuit open
26 P0628 Fuel pump relay control circuit short to ground
27 P0629 Fuel pump relay control circuit short to battery
28 P0650 MIL circuit malfunction
29 P1105 IACV control circuit short to battery
30 P1099 Tilt sensor malfunction
31 P1117 IACV TEV circuit short to ground
32 P1118 IACV TEV circuit open
第 161 页，共 185 页

9-29
第 162 页，共 185 页
9-30
9 电器系统/电器原理图
第 163 页，共 185 页

9-31
1 0 Lights/Dashboard/Switch
Maintenance Info… ……………10-1 Rear brake switch………………10-5
Troubleshooting/dashboard… 10-2 Handlebar switch, horn……… 10-5
Bulb replacement……………… 10-3 Fuel sensor………………10-6
Igniton switch/tail light… 10-4
10
Maintenance Information
Operation instructions
Warning:
·Headlight bulb will be very hot when it is turned on. Do not touch it after it is just
turned off. Operation should be done when the bulb is cooled down.
· The temperature of headlight is quite high when turned on. Replacing with bare hand
or stained glove willcause oil stains on the glass face which may form hot spot and
cause deformation of glass face and damage to bulb.
·Pay attention to the following when replacing the bulb.

·Pay attention to the following when replacing the bulb.
Do not replace the bulb when it is turned on. Keep ignition switch in the OFF position,
and replace after the bulb is cooled down.
-Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface.
-Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil
stains on the glass surface.
·If the Inspection has to be done check if the battery is normal.
·Inspection of switch continuity can be done without removing the switches from the
vehicle.
· After the inspecting and overhauling of each part, cables and wires should be routed
properly (chapter1) .
·Refer to Chapter 2 for removal and installation of taillight and rear turning lights.
Check standard
ITEM Standard
Main 20 A
Fuse Auxilliary 1 ×5 A 3 ×10A
headlight（ Hi ／ Lo ） 12 V- 35 / 3 5W ×2
Light & Bulb Position light LE D
Brakelight／ tail light LE D
Turn light LE D
Speedmeter indicator LE D
第 164 页，共 185 页

10-1
CFMOTO
7.1 Troubleshooting
Head Light Cannot Turn On, no reaction on Hi/Lo switch
·Blow n f use
·Sw itch dam ag ed
·Burnt b ulb
·Battery bad connection or no battery power
·W ire connector loosen
Da s hb o a rd
Re mo va l
Remove headlight and disconnect
connector
Remove dashboard connector
Remove bolt
Remove dashboard
Check dashboard and replace when necessary
Ins t a l l i ng
Operate removal procedures in reverse
第 165 页，共 185 页

10-2
10 Light/Dashboard/Switch
Bulb Replacment
Headliht bulb
Cautions
Headlight bulb will be very hot when it is
turned on. Do not touch it after it is just turned off.
Operation should be done when the bulb is
cooled down.
Remove headlight
10
Remove waterproof cover and press the clamp
Take out headlight bulb
Replace a new one when it is broken
Position light：L ED
Headlight bulb：12V 35/35W
Ins t a l l i ng
Operate the removal procedures in reverse
Wa
Turn light（Front/Rear）
Loosen nut
Disconnector turn light connector
Turn light is LED, must replace the whole turn
light when it is damaged
Installing
第 166 页，共 185 页
10-3
Tail light/ Brake light
Removal
Unlock rear seat
Remove rear grip Screw Clamp
Remove rear deco.plate
Check bulb and replace new tail light/brake light

bulb when it is broken Tail
Tail light: LED Light
Installing
License Light Bulb

Removal
Take out license light seat
Remove its bulb
Check bulb and replace one when it is broken
License light bulb: LED
License Light
Ignition switch
Removal
Loosen 2 mounting nut
Disconnect ignition switch connector
Inspection
Check continuity of circuit of each connector
Ignition Switch Mounting Bolt
Front brake ligh switch

Remove front brake light switch plug
Check light continuity status
Apply the front brake: brake light works Brake Switch
Release the front brake: brake light doesn’t work
1 0 Lights&Instruments&Switches
Rear brake switch
Disaasemble rear brake switch wire, inspect the
conection of wire
Inspection 1
Push Brake Pedal: rear brake light works
Release brake pedal: Rear brake light doesn’t
work. 1
Left handlebar switch 10

Remove fuel tank( →2-4）
Disassemble the connection of lef t
handlebar switch harness (→1-12）
Check according to the following table if the 1 、Switch, rear brake light
coupler terminals are connected.
2 3
4 5
2 、switch,Hi&Lo beam 3 、Switch,

passing light 4 、Switch, turn light 5 、
Button, Horn
Left handlebar Switch

Remove f uel tank( →2-4） 6
Disassemble the connection of lef t
handlebar switch harness (→1-12）Check
according to the following table if the coupler
terminals are connected.
8 7
6 、 Kill Switch 7 、switch,position
light&headlight 8 、Start Button
9 、Plug,Speaker Harness
Ho rn
Remove harness plug and connect with
12V battery and check if the horn can
make sounds.if dumb, replace the horn
with a new one.If sounds bad, turn the
adjusting screw to adjust the sound
quality
第 168 页，共 185 页

10-5
CFMOTO
Fuel sensor
Di s a s s e mb l y
Remove seat and fuel tank
Remove 4 mounting nuts and take out the
fuel sensor
N ot i c e ： Take out the fuel sensor
slowly to prevent guide stem from
Fuel Sensor
Ins p e c t i o n
Please replace a new seal of fuel sensor if it is
buckled, damaged or sclerotic
Inspect high-to-low pole of fuel sensor’s High fuel level Middel fuel level
resistance.
Resistance：High：4～10 Ω
Low：90 ～100 Ω
Connect Fuel sensor harness with main cable. Seal ring Low fuel level
Turn on Ignition switch.
Swing the floater slowly, and check the needle on
the oil gauge.
If the needle can not reach F or E point, please
replace new oil gauge.
If the needle swings instability, please replace new
fuel sensor.
Ins t a l l a t i o n
Reverse the removal procedures for installation
Caution：
Install the fuel sensor properly into fuel tank hole.
There should be no fuel leakage Fuel Meter
第 169 页，共 185 页

10-6
11 Troubleshooting
1 Engine………………………………11-2
2 E F I ……………………………… 11-5
11
11-1
第 170 页，共 185 页
CFMOTO
1. ENGINE BODY
Troubles Possible Cause Countermeasures
C yl i nd er pr e s s ur e t oo l ow
1.Cyinder worn Replace
2.Piston ring worn
Replace
3.Air leakage of cyclinder gasket
Repair or replace
4.Valve stem worn or unsuitable valveseat
Tighten
5.Spark plug loosen
6.Starting motor rotate too slowy Check electrical parts
7.Improper vavle timing Adjust
8. Improper valve clearance Adjust
Spark plug cannot ignite or weak
ignition
1.Improper spark plug clearance Adjust or repair
2.Spark plug dirty or wet Clean & dry or repair
Cannot start or 3.Defect ignition coil Replace
difficult to start 4.Pick-up short circuit or open circuit Repalce
5.Magnetor malfunction Replace
Insufficient fuel inside throttle body

1.Breather hole block
2.Injector blocked or failure Clean or reair
3.High Pressure oil pump failure Clean or reair
4.Low pressure,oil pump Inspect or repair
5.Oil pump Filter net blockd Inspect or repair
Clean or reair
1.Improper valve clearance Adjust

2.Unsuitalbe valve seat Repair or replace
3.Defective valve Replace
4.Rocker or rocker arm wear Replace
5.Dirty spark plug Replace
6.Incorrect valve clearance Replace or adjust
No idle speed or 7.Ignition coil failure
Replace
unstable speed Adjust or replace
8. In & Ex a air hose blocked, idle valve
Replace
9. Magnetor failure
11-2
第 171 页，共 185 页
11 T r o u b l e s h o o t i n g
Troubles Possible Cause Countermeasure
1.Valve spring getting wea Replace

2.Camshaft wea Replace
3.Spark plug dirty Clean or repair
High RPM unstable 4.Spark plug gap too narrow Adjust or repair
5.Valve timing incorrectt
6.Ignition coil failure
Adjust 11
Repair
7.Low pressure,oil pump Adjust or repair
8.Air filter too dirty
Clean or repair
1.Engine oil too much Check oil level and drain

2.Piston ring worn Replace
Blue or black exhaust 3.Valve woren Replace
gas 4.Cylinder worn or scraped Replace
5.Valve stem worn Replace
6.Oil seal of valve stem damaged Replace
1.Valve clearance improper Adjust

2.Valve spring getting weak Replace
3.Valve timing incorrect Adjust
4.Cylidner worn Replace
5.Piston ring worn Replace
6.Improper valve seat Replace or repair
7.Spark plug dirty Clean or replace
Engine Power not 8.Improper spark plug gap Clean or replace
enough Clean or replace
9.Injector blocked
Adjust or repair
10.Insufficient pressure,oil pump
Clean or replace
11.Air filter too dirty
Replace
12.Rocker arm or camshaft worn Tighten or replace
13.Air leakage of inlet pipe Check oil level and change
14.Enginge oil too much
1.Carbon deposit on piston head Clean

2.Engine oil too less or too much Check and add or drain
3.Oil pump failure Replace
4.Fuel hose blocked Clean
5.Air leakage of inlet pipe Tighten or replace
Engine Overheating 6.Unsuitable engine oil Change oil
7.Cooling system failure(see7-5)
11-3
第 172 页，共 185 页
CFMOTO
Troubles Possible Causes Solutions
Val v e ab n o r m al n o i s e
1.Valve clearance too big Adjust
2.valve spring worn or broken Replace
3.rockerm arm or camshaft worn Replace
Pisto n abn ormal noi se

1.Piston worn Replace
2.Cylinder worn Replace
3.Carbon deposit inside combustion Clean
chamber Replace
4.Piston pin or pin hole worn Replace
5.Piston ring or groove worn
T iming ch ain abn ormal noi se

1.Chain stretched out Replace chain and sprocket
2.Chain sprocket worn Replace chain and sprocket
3.Tensioner failure Repair or replace
Engine abnormal
noise Cl u t ch ab n o r m al n o i s e
1.Clutch gear worn or damaged Replace clutch gear
.2.Cushion rubber aging or damaged Replace clutch gear
C ra n k sh af t a b n o r m al n o i s e
1.Bearing noise Replace
2.Crankshaft pin bearing down Replace
3.Clearance too big Replace
T ransmi ssion abno rmal noi se

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
Clutch slippery 3.Clutch spring getting weak Replace
11-4
第 173 页，共 185 页
2、Diagnose in accordance with engine error
Prior to diagnosing failures according to engine error this step, preliminarily
inspections should be carried out:
1、Make sure engine error signal work normally 11
2、Connect PDA,make sure no error record exists
3、Confirm errors exist and conditions in which errors happened.
Then check vehicle appearance：
（1）Check if any leakage of fuel hose
（2） Check if vaccum pipe was broken, twisted or properly connected；
（3） Check if air intake pipe is blocked,air leaked,squashed or broken;
（4） Check if high tension cable of ignition system is broken, aging or correct ingnition
order
（5） Check if wiring close to ground is clean and tight；
（6） Check if connectors of sensors or other electronic components are loosen or
improperly connected. Important notice: If above-mentioned errors exist, then
repair above errors. Ohtherwise it will affect following diagnosis work and
maintenance.
Diagnosis Help：
1、Confirm engine is without any error records;
2、Confirm claimed errors exist；
3、During vehicle maintenance, never ignore affects which could be arose by vehicle
maintenance conditions、cylinder pressure、timing and fuel；
4、Replace ECU and test; If error could be eliminated, then it is ECU error.If error
exists yet, and then installs previous ECU and repeat maintenance.
Troubleshooting and Maintenance：
l When starting，engine doesn’t work or rotate slowly.
l When starting, engine can rotate but cannot start.
l Difficult to start hot engine.
l Difficult to start cold engine.
l Difficult to start in any conditions.
l Idle speed unstable at any time whilst engine starts normally
l Idle speed unstable during warming while engine starts normally
l Idle speed unstable after warming while engine starts normally
l Idle speed unstable or engine stopped while it is partial loaded( headlight is on)
l Idle speed is too high while engine starts normally
l RPM cannot increase or engine stops when accelerates.
l Slow reaction to accelerate
l Difficult to accelerate and bad performance.
11-5
第 174 页，共 185 页
CFMOTO
（1）Engine cannot start or rotate slowly

General failure part：1、Battery；2、Starter Motor；3、Wiring or ignition
switch；4、Mechanical parts of engine
General diagnosis procedures：

Item Procedures Results Next
Use multi-meter to test battery voltage YES Next Step
1 whether is between 8-12V when engine NO Replace battery
starts
Turn on ignition switch, stop switch side YES Next step
stand switch and check if voltage of ECU
2 pin 14 is around 12V
NO R e p a i r s wi t c h e s o r
change harness
Keep ignition switch “on”, use multi-meter YES Next step
3 to check if voltage of starting motor anode Repair or change
is over 8V. NO
harness
Disassemble starting motor and check its YES Repair or replace
4 working status, especially whether there
st a r t i n g m o t o r
was broken circuit or jammed by bad
lubrication. NO Next step
If error only occur in Winter, check if starting Change to prober oil
motor resistance is too big because YES
5 improper oil used NO Next step
C h e c k r e si st a n c e i n si d e
YES
engine
6 Check if mechanical resistance is too big
inside engine NO Repeat above procedures
（2）When starting,engine can rotate but cannot start

General failure part:1、No fuel； 2、Fuel pump；3、Pick up；4、
Ignition coil；5、Mechanical parts of engine

Item Procedures Result Next
YES
Connect fuel pressure gauge, turn on ignition Next step
1 switch or start engine, check if fuel pressure
NO Repair fuel supply
is around 300kpa
system
YES Next step
Connect PDA,check if there’s signal of
2 NO Check and repair RPM
RPM data after starting engine
sensor circuit
YES
Disconnect high-tension cable, connect Next step
3 spark plug and set its electrode 5mm to
engine body, then start engine to check if NO Check and repair ignition
blue and white spark appears system
11-6
第 175 页，共 185 页

Eliminate engine
Test cylinder pressure and check if pressure YES
4 Mechanical failures
is enough
NO Next step
Use PDA to test, turn on ignition switch, YES Use PDA to check
11
5 check if power supply of ECU pin 1 and pin
2 is normal; check if pin 2 and pin 17 works Repair related
NO
circuit
normally
（3）Diffcult to start hot engine

General failure part ：1、Water in fuel tank；2、fuel pump；3、water temp.
sensor；4、Ignition coil.

YES Next step
1 Connect fuel pump gauge,start engine,check if
pressure is around 300kpa NO Repair fuel supply
system
YES Next step
Disconnect high-tension cable, connect spark
2 plug and set its electrode 5mm to engine body,
then start engine to check if blue and white NO Repair ignition
spark appears system
YES Repair wiring or
Disconnect water temp.sensor connector and replace sensor
start engine to check if engine can start.(or use
3 one 300ohm resistance to replace water NO Next step
temp.sensor)
NO Next step
Check whether the failure happens right after YES Change fuel oil
4
filling fuel oil NO Next step
YES Use PDA to check
Connect PDA , turn on ignition switch, check if
5 power supply of ECU pin 1 and pin 2 is normal; NO Repair related
check if pin 2 and pin 17 works normally circuit
（4）Difficult to start cold engine.

General failure part：1、water in fuel tank；2、Fuel pump；3、
Engine temp.sensor；4、Injector；5、Ignition coil；6、Throttle
body and by-pass；7、Mechanical parts of engine

11-7
第 176 页，共 185 页
CFMOTO

YES
Next step
1 Connect fuel pump gauge,start engine,check if
pressure is around 300kpa NO Repair fuel supply
system
YES
Disconnect high-tension cable, connect spark Next step
then start engine to check if blue and white spark NO Repair ignition
appears
System
Repair circuit or
Disconnect water temp.sensor connector and YES
start engine to check if engine can start.(or use replace sensor
3 one 2500ohm resistance to replace water
temp.sensor) NO Next step
Clean throttle body

Slightly draw throttle cable and check if engine YES
and by-pass
4 could start easily
NO Next step
YES Replace
Disassemble injector and use special tool to
5 injector
check if there is leakage or block
NO Next step
6
Eliminate engine
Check if cylinder pressure is insufficient YES mechanic failures
7 NO Next step
（5）Difficult to start in any conditions.
General failure part：1 、Water in fuel tank；2、Fuel pump；3、

Water temp.sensor；4、Injector；5、Ignition coil；6、Throttle
body and by-pass；7、Air intake pipe；8、Ignition timing；9、
Spark plug；10、Mechanical part of engine。

YES Repair air intake
Check if air filter is blocked or air intake pipe
1 system
leaks
NO Next step
11-8
第 177 页，共 185 页

YES
Next step
2 Connect fuel pump gauge,start engine,check
if pressure is around 330kpa NO Repair fuel
Supply system
11 Disconnect high-tension cable, connect spark
YES
Next step
then start engine to check if blue and white NO Repair ignition
spark appears
System
YES Next step
4 Check if spark plug is suitable for
requirement(including its type and clearance) NO
Adjust or replace
YES
5 Disconnect water temp.sensor connector and Repair or replacesensor
start engine to check if engine can start. NO Next step
YES Clean throttle body and by-
6 Slightly draw throttle cable and check if engine pass
could start easily NO Next step
Disassemble injector and use special tool to YES Replace injector
7
check if there is leakage or blocked. NO Next step
8
YES Eliminate mechanical
9 Check if cylinder pressure is insufficient failures
NO Next step
YES Next step
10 Check if ignition timing complies with standard NO
regulation Adjust ignition timing
（6）Normal starting，but unstable idle speed
General failure part：1、Water in fuel tank；2、Injector；

3、Spark plug；4、Throttle body and by-pass；5、Air intake
pipe；6、Air control valve；7、Ignition timing；8、Spark
plug；9、Mechanical part of engine

Check if air filter is blocked or air intake system
1
pipe leaks
NO Next step
11-9
第 178 页，共 185 页
CFMOTO
Item Procuedures Result Next

YES Clean or replace
2 Check if air control valve is blocked
NO Next step
Check if spark plug is suitable for YES Next step
3 requirement(including its type and clearance) NO Adjust or replace
Check if there is carbon deposit inside throttle body YES Clean

4
and air control valve NO Next step
Disassemble injector and use special tool to check YES Replace
5 if there is leakage or blocked or wrong fuel flow
NO Next step
Check whether the failure happens right after filling YES Change fuel oil
6 fuel oil NO Next step
Eliminate mechanical
YES failures
Check if cylinder pressure is insufficient
7
NO Next step
YES Next step
8 Check if ignition timing complies with standard Repair ignition timing
regulation NO
（7）Noral starting,but unstable idele spped during

engine warming
General failure part：1、Water in fuel tank；2、Injector；3、Spark
plug；4、Throttle body and by-pass；5、Air intake pipe；6、Air
control valve；7、Ignition timing；8、Spark plug；9、Mechanical
part of engine

YES Repair air intake system
Check if air filter is blocked or air intake pipe leaks
1
NO Next step
NO Next step
Check if there is carbon deposit inside throttle body YES Clean
4
and air control valve
NO Next step
YES Replace
Disassemble injector and use special tool to check
5
if there is leakage or blocked or wrong fuel flow NO Next step
11-10
第 179 页，共 185 页
11 Troubleshooting
Check whether the failure happens right after filling YES Change fuel oil
6
fuel oil NO Next step
Eliminate mechanical
YES failures
Check if cylinder pressure is insufficient
7
NO Next step
11
（8）Normal starting,but unstable idle seepd after enging warming
General failure part：1、Water in fuel tank；2、Injector；3、Spark

control valve；7、Mechanical part of engine

Item Procuedures Result Next
NO Next step
Check if there is carbon deposit inside throttle YES Clean

4 body and air control valve NO Next step
Disassemble injector and use special tool to YES Replace
5 check if there is leakage or blocked or wrong NO Next step
fuel flow
6 filling fuel oil NO Next step
Eliminate
Check if cylinder pressure is insufficient YES mechanical failures
7 NO Next step
（9）Normal starting,unstable idle speed or engine stop when it is

electronic loaded (e.g. headlight is on)
11-11
第 180 页，共 185 页
CFMOTO
General failure part： 1、Air control valve；2、Injector.

Disassemble air control valve and check if YES Clean related
1 there is carbon deposit inside throttle
parts
body,idle adjustment and by-pass
NO Next step
YES Jump to item 4
Check if output power increases when lighting,
by using PDA to test if ignition advance angl, NO Next step
2 fuel spray and air intake volume is normal
NO Repair air intake
System
Disassemble injector and use special tool to YES Replace injector
3 check if there is leakage or blocked or wrong NO Next step
fuel flow
（10）Engine starts normally,but idle speed is too high

General failure part：1、Throttle body and by-pass； 2、Injector
seat；3、Air control valve；4、Water temp.sensor；5、Ignition
timing.

Check if throttle cable is jammed or too tight YES Adjust
1
NO Next step
Check if there’s leakage between air intake pip
2 system
and injector seat
NO Next step
Remove air control valve and check if there s YES Clean related
3 carbon deposit inside throttle body, air control Parts
valve and by-pass NO Next step
YES Repair wiring or
Remove water temp.sensor connector, start
4 replace sensor
engine to check if idle speed is too high
NO Next step
YES Next step
5 Check if ignition timing complies with standard
regulation NO Repair ignition
Timing
11-12
第 181 页，共 185 页
（11）RPM cannot increase or engine stop when accelerating

11
General failure part：1、Water in fuel tank；2、TPS；3、Spark plug；

4、Throttle body and by-pass；5、Air intake pipe；6、Air control valve；
7、Injector； 8、Ignition timing;9、Exhuast pipe


system
1 Check if air filter is blocked NO Next step
YES Next step

2 Connect fuel pressure gauge, start engine to
NO Repair fuel supply
check if pressure is around 300kpa at idle system
YES Clean related

Remove air control valve and check if there is parts
4 carbon deposit inside throttle body, air control
YES Next step
Repair circuit or
5 Check if TPS and its ciruit is normal NO replace TPS
YES Replace
6
check if there is leakage or blocked NO Next step
YES Change fuel oil
Check whether the failure happens right after
YES Next step
8 Check if ignition timing and timing order NO Adjust ignition

comply with standard regulation timing
YES Next step
9 NO Repair or replace
Check if exhaust gas exhale smoothly Exhaust pipe
11-13
第 182 页，共 185 页
CFMOTO
（12）Low acceleration
General failure part：1、Water in fuel tank；2、TPS；3、Spark
control valve；7、Injector； 8、Ignition timing;9、Exhuast pipe

Repair air intake
YES system
1 Check if air filter is blocked
NO Next step
YES Next step

Connect fuel pressure gauge, start engine to
check if pressure is around 300kpa at idle Repair fuel supply
2 NO system

Clean related
Remove air control valve and check if there is YES parts
4 carbon deposit inside throttle body, air control
valve and by-pass Next step
NO
YES Next step
Check if TPS and its ciruit is normal Repair circuit or
5
NO replace TPS
YES Replace
6
check if there is leakage or blocked NO Next step
YES Change fuel oil

Check whether the failure happens right after
YES Next step

Check if ignition timing and timing order comply Adjust ignition
8 with standard regulation
NO timing
YES Next step

Check if exhaust gas exhale smoothly Repair or replace
9 NO Exhaust pipe
（13）Difficult to accelerate and bad performance

General failure part：1、Water in fuel tank；2、TPS；3、Spark
plug；4、Ignition coil; 5 、Throttle body and by-pass；6、Air
intake pipe；7、Air control valve；8、Injector； 9、Ignition
timing;10、Exhuast pipe
11-14
第 183 页，共 185 页

Check if clutch slideing,low tire pressure,bad YES Repair
1 brake or wrong tire size NO Next step 11
Repair air intake
YES system
2 Check if air filter is blocked
NO Next step
YES Next stp

Connect fuel pressure gauge, start engine to
3 check if pressure is around 300kpa at idle Repair fuel supply
NO system
Disconnect high-tension cable, connect spark YES Next step

plug and set its electrode 5mm to engine body,
4 then start engine to check if spark is strong Repair ignition
enough NO system
YES Next step
Check if spark plug is suitable for
requirement(including its type and clearance) Adjust or
5 NO
replace
Remove air control valve and check if there is Clean relate
YES Part
carbon deposit inside throttle body, air control
6
YES Next step
Check if TPS and its ciruit is normal Repair circuit or
7 NO Replace sensor
Disassemble injector and use special tool to YES Replace

8 check if there is leakage or blocked NO Next step
YES Next step
Check if ignition timing complies with standard Repair ignition
10 regulation NO
Timing
YES Next step
Check if exhaust gas exhale smoothly
11 NO Repair or replace
11-15
第 184 页，共 185 页
WWW.CFMOTO.COM
All right reserved

Z HE JI AN G C FM OT O PO WE R C O. ,L
TD.
第 185 页，共 185 页 2 014 年1 2 月
M o de s t a r t e r r el ay a n d f u s e
T ur n ing sw itc h B a t t e ry
o v er r i d i n g H o r n D im m e r sw itc h
s t a rt s w i tc h L i g h t sw i t c h k i l l s w i t c h fr o n t b r ak e s w i t c h
C l utc h sw itc h f u e l p u m p re l a y F a n R e la y S i d e s t a n d r el ay
s w i t ch s w i t c h sw itc h h ea d l i g h t
D R L r e la y
r e la y
W/L
M O DE
F use bo ?
12V6Ah
R /G
B /B r
W /L
W
Gr
B /B r
G
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L
Lg
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G r /W
I gn itio n lo c k
7. 5 A
10A
15A
15A
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M a gn e tor R e g u l at o r
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T u r n i n g i n d i c a t o r (R H )
B
R
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G /P
R/ G
G/ B
B/ R
R
Ho r n
W/ L
W/ G
B r/ B
B / Br
R /B
B
G /Y
Y /R
G
G /P
R
Y /R
B /W
s t a r t mo t o r
G /W
T u r n i n g i n d i c at o r (L H )
G
Y
Y
Y
M
R
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L L
O O
B r /G B r /G
Br B /B r B /B r
In s t r u m en t i n d i c a t o r Y /B Y /B G
G /L G /L
Br L /W L /W
G G
P/ W P/ W
S ide s ta nd ind ic a tor Y/W Y/W Y /W N e u tr a l g e ar s w i tc h
W /P W/P
G r/ W Gr/W
W a t e r t e m p . i n d i c at o r B /B r
B /B r
P /W
G
F u el i n d i c a t o r B /B r
Sb Sb
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G G
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S pe e d ind ic a tor
G/P Y /W G /B B/Br
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M od e S (E )
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G G T ai l l i g h t / b ra k e l i g h t
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B
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R /L
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G
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P /B
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I Id l e m a g e n t i c v a l v ei n t a k e a i r
TP S t em p . p r e s s u re in j e c tor Fuel Pum p
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w a te r te m p .se n sor s en s o r
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Manual de Taller CF150 PDF

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Manual de Taller CF150 PDF

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CFMOTO

CF150-3 Service Manual

This manual introduces CF150-3 Maintenance Information 1

Chapter 1 mainly introduces general Engine disassembly& assembly 5

Chapter 2 mainly introduces checking & Front wheel, Brake, Suspension, 7

CFMOTO reserves right to make improvements

Zhejiang CFMOTO Power Co.,Ltd

Long Service Life

● Procedure or operation should be acted

Operation Attentions……………………1-1 Maintenance Parameters Table………………1-8

第 6 页，共 185 1-1

1-第27 页，共 185 页

■ Place and store the disassembled parts

■ Clean and blow off the detergent after

■ If not know the length of screws,install the

■ Turn the ball bearing with hands to make sure

■Keep the bearing block still when blowing dry

1-第49 页，共 185 页

■ Do not mix mud or dust intoengine or the

■Clean the gaskets and washers of the engine

■ Do not twist or bend the cables too

Numbers Marking Location

1-第611 页，共 185 页

Item Standard Service limit

Item Standard Service limit

Brake disc abrasion 4m m 3mm

Rear brake Rear (foot brake)free travel 10 ～ 20 m m －

1-第813 页，共 185 页

Item No. of Bolt Thread Torque Remar

Axle part, main stand

1-第1015 页，共 185 页

Fuel pump Fuel tank

Auxiliary coolant box

Connector, Throttle cable

Auxiliary coolant pipe

Minor-cycle Ignition coil Clutch cable Temperature sensor Inflow pipe,

Throttle valve Adjustable bolt, throttle cable Main cable

Pipe negative pressure pipe Regulator

1-第1217 页，共 185 页

Battery ribbon Positive wire, Battery Auxiliary relay

30A Main fuse Fuse block wire harness sheath(rear)

Gear sensor fuel strainer

1-第1419 页，共 185 页

Anti Roll-over valve

Engine Throttle body

Chapter 1 Maintenance Information

General prevention measures............................. ..... ...........1-17

General prevention measures

·Exhaust gas should be exhausted to outside when start engine indoor

·Don’t take gasoline as a leaner

·Use special tools base on requirements of service manual.

·Use specialized lubricating oil, binder and sealant.

·Check parts running and tighten situation after assembled.

Caution： Do not mix other brand coolant to use.

ENGINE AND LOCATION OF ENGINE NUMBER

VIEW FROM LEFT

VIEW FROM RIGHT

4 Compression Ratio 1 0.5 ：1

9 Valve Train SOHC /Chai n Driv e

Lubrication Press & Splash

Clearance (Valve guide Bush IN 0.0 1～0 .03 7 —

and valve stem) EX 0.0 3～0 .05 7 —

I.D of Valve guide bush IN & EX 5～5. 012 —