Cf Moto V5 Service Manual - Download Free Apps
. CF250T-5 SERVICE MANUAL WWW.CFMOTO.COM. WWW.CFMOTO.COM All rights reserved CHUNFENG HOLDING GROUP CO.LTD. Inspection & Adjustm ent together with illustrations of our motorcycle Lubricating system Model: CF250T-5(V5).
Chapter 1: general service information, tools, Carburetor 、 Air Cleaner vehicle structure and technical data. Cooling system Chapter 2:. Conversion Table Item Example Conversion 1kgf/cm =98.0665kPa ) 200 kPa( 2.00kgf/cm Pressure 1kPa=1000Pa 33kPa (250mmHg) 1mmHg=133.322Pa=0.133322kPs Torque 18N m( 1.8kgf m) 1kgf m=9.80665N m 1ml=1cm =1cc 419ml Volume 1l=1000cm 1kgf=9.80665N Force 12N( 1.2kgf). 1 Service information Cautions 1-1 Overhaul Data Table 1-9 Tightening Torque 1-14 Cautions for Disassembling and Assembling.
Caution: When charged, Battery may generate hydrogen Warning: The asbestos dust on the brake drum is carci- nogenic if breathed in. Do not clean off the dust with com- which is explosive.Charge the battery in a well-ventilated pressed air. Use cleaning detergent to avoid dust place. 1 Service information Cautions for Disassembling and Assembling ■ ■ Use genuine CFMOTO parts, lubricants and grease Clean the mud, dust before overhauling。 ■ Replace the disassembled washers, o-rings,piston pin circlip, cotter pin with new ones. ■ Place and store the disassembled parts separately in ■. ■ Apply or inject recommended lubricant to the speci- ■ Check if the disassembled rubber parts are aged and replace if necessary.
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Keep the rubber parts away from fied parts. ■ If the disassembling of pressed ball bearing is done by pressing the balls, the disassembled bearing should not be used again. 1 Service information ■ After assembling, check if all the tightened parts are properly tightened and can move smoothly. ■ Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these parts with water if splashed.
■ Install oil seal with the side of manufacturer’s mark outward. Number Engrave Place CF250T-5 F r a m e N u m b e r : L C E T D J P K ~ Engine Number: 172MM-A ~.
1 Service information Major Specifications Item Parameter Model CF250T-5 Length 2225mm Width 875mm Height 1110mm Wheel base 1490mm Engine type 172MM-A Displacement 244.3ml Fuel type Unleaded gasoline 90 Octane or above Dry weight 166kg Number of Passengers 2(including driver) 150kg Max. Ite m P a ra m e te r A ir F ilte r typ e U re th a n e fo a m filte r Va c u u m D ia p h ra g m F u e l Typ e typ e d e v ic e. 1 Overhaul Information Overhaul Datasheet Lubricating device Service Item Standard limit Volume when - 0.8L Engine Oil replacing Capacity - 1.0L Full capacity Special for 4-stroke motorcycle SAE-10W-40、 20W-50 Substitutes must be used in the following range. API type: SE or SF grade Recommended Oil (see original). Cooling Device Item Standard 11 0 0 m l Full Capacity Coolant capacity 3 4 0 m l Reservoir tank capacity 5 0% Standard density 1 0 8 k p a ( 1.
1 k g f / c m Opening pressure of radiator cap 7 2 ±. 1 Service information Gearbox Item Standard For replacing 0. 2 L G ear oil For disassem bling 0. 2 5 L R ecomm ended gearbox oil SA E15W-40/SF Starting motor Item Standard Service Limit Starting m otor Brush length 12.0-12.5mm 11.0 Crankshaft 、. Front wheel Item Standard Service Limit - Bending, front wheel axle 0.2mm Play of wheel Vertical 0.8mm 2.0mm Front wheel Horizontal 0.8mm 2.0mm - Tire Groove 1.6mm ) - Pressure 250kPa( 2.5kgf/ cm Rear wheel Item Standard Service Limit Play of wheel Vertical 0.8mm 2.0mm.
1 Service information Battery、 Charging system Item Standard M odel P erm anent m agnet A C type O utput 3- phase A C A C m agneto M otor C harging coil R esistance (20 ℃ ) 0.2-0.3Ω T hree-phase annular rectification R ectifier Silicon controlled parallel-connected regulated voltage. Tightening torque Item Torque Nm(kgfm) Item Torque Nm(kgfm) 5 ( 0. 4 ) Bolt, nut 5mm Screw 5mm Bolt, nut 6mm Screw 6mm 9 ( 0. 0 ) Bolt, nut 8mm Bolt with flange, 6mmSH 1 0 (. 1 Service information Frame No. Of Diameter Tighteningtorque Type Bolt & Remarks (mm) Nm(kgfm) Engine disassembly Engine suspension mounting bolt 55( 5.6) Engine suspension shaft nut 80( 8.1) Front wheel, Front suspension, Steering 68( 7.0) Handlebar locknut 55( 5.6) Handlebar mounting nut 100(.
Lubricant, Sealant A p p licatio n A reas N o tes G rease typ e In n er su rface, cylin d er sleeve C o n ical su rface, A C m ag n eto ro to r B earin g /flan k, co n n ectin g rod b ig en d In n er side, co n n ectin g ro d sm all en d C ran k shaft m ain b earin g su rface. 1 Service information Application areas Notes Types Bearing race, head pipe Lip,front wheel dust-proof seal Joint, meter flexible shaftJoint, throttle cable Throttle grip part Pivot, rear Multi-purpose lubrication oil pedal(L) Pivot, rear pedal( R ) Pivot, side stand Oil seal lip, rear fork Tooth flank, counter gear/small gear Axle part, main stand. Wiring, Piping and Cable Routing 1-18. 1 Service information Figure 1 1-19. 1 Service information 1-21. 2 Vehicle Body,Muffler 2-1 2-8 Overhaul Info Rear Bracket 2-2.
Main Stand Caution Make sure there is no deviation of the seat by shaking it up and down, back and forth after installation. Installation Install the left and right bush to the main stand. Note: Apply grease to the outer surface of bush. Install main stand to the vehicle with mounting bolt.
2 Vehicle Body,Muffler Seat Removal Unlock the passenger seat with ignition Push backward and lift passenger seat. Installation Reverse the removal procedure for installation.
Note: Make sure that the seats are firmly installed. Backrest Removal: — Three hex bolts — Backrest Installation Reverse the removal procedure for installation. Rear Right Panel Removal: — Seat — Bolt — Screw Separate Rear Left Panel from frame.
Remove rear left panel Installation Reverse the removal procedure for installation. Front Vent Panel Removal — Six Tapping Screws — Front Vent Panel Installation Reverse the removal procedure for installation. 2 Vehicle Body,Muffler Left Ornament Panel Removal — Tapping Screw 1 — Tapping Screw 2 — Left Ornament Panel Installation Reverse the removal procedure for installation. Right Black Panel, Right Ornament Panel Removal — Front Vent Panel — Rear Right Panel —. Right Panel Removal — Ignition key — Seat — Fuel tank — Front vent panel — Bolt, Tapping Screw — Separate front right and left panels by acting on the front of front right panel. — Separate front left panel from front left upper panel and remove front right panel. 2 Vehicle Body,Muffler Front Right Panel, Right Speaker Cover & Grille Removal — Seat — Fuel Tank — Front vent panel — Rear panel (L&R) — Black panel (L&R) — Protection panel (L&R) — Bolt 1, Bolt 2, Bolt 3 —.
— Screw 3, Screw 4 — Seat Lock Plate Remove Seat lock cable from seat lock Remove seat lock cable from gap and remove seat lock, Separate seat lock plate and seat lock from the vehicle Installation Allow seat lock cable through rear fender from gap, install seat lock cable on seat lock as illustrated. 2 Vehicle Body,Muffler — Bolt 3 — Rear bracket Installation Reverse the removal procedure for installation Rear Part of Rear Fender, Tool Box Removal — Remove driver seat — Seat lock plate — Tapping screw1, 2,3,4,5 — Tapping screw 6 and tapping screw 7 —. Tool box Removal — Turn over rear fender, remove tapping screw 1, tapping screw 2, tapping screw 3,remove tool box Installation Reverse the removal procedure for installation Rear License Plate Removal — Bolt 1, Bolt 2, Nut 1, Nut 2, —.
2 Vehicle Body,Muffler Fender Removal — Seat — Seat lock plate — Rear fender — Bolt 1, Bolt 2, Bolt 3 — Splash fender comp. Installation Reverse the removal procedure for installation Rear Fender (Center) Removal — Seat — Rear part, rear fender —. Right Cover Removal — 3 Screws — Right side cover Installation Reverse the removal procedure for installation 2-12. 2 Vehicle Body,Muffler Fuel Tank Disassembly Warning Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention should also be paid to sparks.
Gasoline may also be explo- sive when it is vaporized, so operation should be done in a well-ventilated place. Muffler Caution: Perform disassembly only after the muffler is cooled down. Remove: — Seat — Bolt 1, Bolt 2, ornament Plate — Muffler elbow joint nut Remove Bolt 1,2,3 Remove muffler.
Installation Reverse the removal procedure for installation Install muffler ornament Plate Note: Replace sealing gasket when installing the muffler. 2 Vehicle Body,Muffler Description of Visible Parts 2-15. 3 Inspection & Adjustment Overhaul info 3-1 Ignition 3-9 Replacement of parts 3-1 Lubrication 3-11. Check & M aintenance ○ : Interval Check & m aintenance item Intervals Standard Part Item ○ Handlebar O peration agility ○ D am age Steering ○ Steering colum n device Front fork Bearing, Steering ○ C olum n Front wheel: lever end 10-30m m ○.
3 Inspection & Adjustment Check & Maintenance item Intervals Standard Part Item Looseness of joint ○ ○ Final Transmis- parts sion device Shaft ○ Sway of spline Spark plug ○ ○ Status of spark plug gap:0.8-0.9mm Ignition ○ ○ Ignition timing Electrical ○. Check & maintenance item Intervals Standard Part Item ○ ○ ○ Lighting and turning indictors Function ○ Alarm and lock Function ○ Instruments Function Looseness or damage ○ caused by installation Exhaust pipe and m uffler ○ Function of m uffler ○. 3 Inspection & Adjustment Steering Column Park the scooter with main stand, lift front tire, hold the lower part of shock-absorber and shake back and forth to see if there is any sway. In case of any sway, check if it is the problem of the steer- ing column or other parts and then do the maintenance accordingly. Master Cylinder Check the brake fluid level When the brake fluid level is near to the lower limit, check master Cylinder, brake hoses and joints for oil leakage. Remove the two mounting screws on oil cup cap, remove cap, add DOT3 or DOT4 brake fluid till the upper limit.
3 Inspection & Adjustment Wheel & Tire Tire Pressure Check the tire pressure with a pressure gauge. Note Check tire pressure when tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause deflected wear of the tires.
Tire pressure parameter: Specified pressure/tire Front. Looseness of Wheel Nuts and Wheel Axle Nuts Check front and rear wheel axle nuts for looseness. Tighten in case of any looseness according to the specified torque: Tightening torque: Front wheel axle nut: 80N m(8.2kgf m) Rear wheel axle nut: 140N m(14.3kgf m) Sway of wheel bearing Park the scooter with the main stand, and lift the front wheel. 3 Inspection & Adjustment Rear suspension Press the rear suspension up and down several times. In case of any rocking or abnormal noise, check the rear shock absorbers and the hanging pivot part. Check rear shock absorbers for oil leakage, damage or looseness of the tightening parts.
Remove the spark plug Check the central and side electrodes of the spark plug for any erosion, burning or damage of the insulate electromagnet. Burning → Replace Recommended spark plug: Standard DPR7EA-9 Optional Electrode gap 0.80.9mm Install the spark plug. Note To avoid damage to the thread of spark plug hole, when installing the spark plug, screw in with hand and then.
3 Inspection & Adjustment Lubrication Inspection of engine oil Warm up the engine. Stop the engine and remove the oil dip rod and clean it. Park the scooter on level ground.Insert the oil dip rod (DO NOT screw in) and check engine oil level 23 minutes after the engine stopped. Install the cleaned drain bolt and new sealing gasket, and tighten it according to the specified torque.
Torque: 2 5 N m ( 2. 5 k g f m ) Add the recommended engine oil. Engine oil capacity: 0.8L(for replacing) 1.0L(for disassembling) Check the oil level with the dip rod while adding till the oil level reaches upper limit. 3 Inspection & Adjustment Replacing Air Filter Element Remove: — Seat — Rear left panel — Left black Panel — Left Panel — Front left Panel — Screw 1,2,3,4,5and Air filter cover Remove filter element and replace it. Reverse the removal order for installation. Idle Speed Note Check and adjust the following items before.
Throttle Grip Check agility of throttle grip In case of any stiffness, check the throttle cable for damage or rust. Check free play of throttle grip.
Free play: 2-6mm Out of above range → Adjust Remove adjustable throttle cable sleeve Remove locknut, turn adjuster and adjust free play. 3 Inspection & Adjustment Cooling Caution Check of coolant level should be done on the reservoir tank instead of the radiator. If the radiator cap is opened while the engine is hot (over 100℃ ), the pressure of the cooling system will drop down and the coolant will get boiled rapidly. When the coolant level is below the lower limit, remove reservoir tank cap and fill coolant till upper limit.
(coolant or diluted original liquid). Recommended coolant: CFMOTO coolant Standard density:30%( Freezing temperature of coolant varies according to the different mixture ratio.
Adjust the mixture ratio according to the lowest temperature in the place where the vehicle is used.). 3 Inspection & Adjustment Lighting Adjusting headlight beam Turn screw with a cross driver to adjust the headlight beam. 4 Lubrication system Overhaul info 4-1 Troubleshooting 4-1 Oil pump 4-2 Overhaul info Caution The maintenance of the oil pump should be done after disassembling the right side cover.
(→ 11) When the measured values exceed the service limit, replace the oil pump. Oil pump Remove bolt and partition plate Remove retaining ring. Remove sprocket and chain. Remove 2 bolts, partition plate A, oil pump Disassembly Remove screw and disassembly oil pump.
4 Lubrication system Inspection Check clearance between pump body and outer rotor. Service Limit: 0.25mm→ Replace Check clearance between teeth top of inner rotor and teeth end of outer rotor. → Replace Service Limit: 0.20mm Check clearance between pump body and end face of in- ner and outer rotors. Tighten shaft with screw Make sure shaft can rotate freely. Installation Install oil pump and Partition Plate A to right crankcase.
Tighten with 2 bolts. Make sure shaft can rotate freely. Install chain, driven sprocket and fix with retaining ring.
Polymerize hole of partition plate B with claw of partition plate A. 5 Carburetor、 Air Filter Chapter 5 Carburetor、 Air Filter Overhaul info 5-1 Carburetor installation 5-9 Troubleshooting 5-2 Mixture Adjust Screw. Troubleshooting Starting Failure Engine Stop when Throttle is full open ◆ Damaged diaphragm No fuel in fuel tank; ◆ Clogged vacuum tube Fuel supply failure ◆ Faulty fuel pump Too much fuel in cylinder Clogged air filter u Dirty fuel Faulty fuel pump Unsteady Engine Idle Speed Thinner Gas Mixture. 5 Carburetor、 Air Filter Carburetor Removal Remove seat, rear left and right panels(→ 2-3→ 2-4,) Release clamp for carburetor and air filter. Release screw and remove carburetor joint. Note: Do not drop the screw.
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Loosen throttle cable adjusting nut and lock nut, remove throttle cable from carburetor. Remove 2 screws from enriching device adjusting plate. Remove enriching device.
Note: Disconnect top box cover after removing rear right panel. Be careful not to damage the valve after removing enrich- ing device. Inspection of enriching device Check the conduction of wires of enriching device. Resistance: 27.06mm → Replace Check primary fixed sheave collar for wearing or damage.
Measure outer diameter of primary fixed sheave collar. Service limit: 153.8mm → Replace Check clutch carrier for wearing or damage. Measure thickness of clutch shoe. Service limit: 40.06mm → Replace Check if there is any stepped wearing in the guide groove. Replace the bearing on the secondary sheave. Drive out the needle bearing with oil seal.
The needle bearing must be replaced with a new one. 9 Primary Sheave, Clutch, Secondary Sheave Apply lube to roller bearing.
Special Tool: Driving tool handle General purpose tool: Bearing Remover 32 × 35mm Driving Tool Guide 22mm Install split washer. Apply lube from the inner side of driven face. Note: Apply evenly 1113g of lube. Install rubber blocks onto driving plate wrists. Install clutch carrier to driving plate and clutch return spring onto clutch carrier. Install pressure plate and fix with split washer. Keep the opening of split washer inward.
9 Primary Sheave, Clutch, Secondary Sheave Secondary Sheave Assembly Clean sheave face Install oil seal to secondary sliding sheave. Apply lube to O seal and install it to secondary sliding sheave.
Apply lube to inner side of secondary sheave and guide pin. Install seal collar Clean the overflow lube.
Note: In case there is any lube or grease on the secondary sheave. Make sure to clean it Install clutch spring and clutch to secondary sheave and adjust with clutch spring compressor. Compress clutch spring with clutch spring compressor. 9 Primary Sheave, Clutch, Secondary Sheave Primary Sheave, Clutch, Secondary Sheave 9-17. 10 Gearbox Chapter 10 Gearbox Overhaul Information.10-1 Inspection.10-2 Trouble Shooting.10-1 Assembly 10-4 Disassembly.10-2 Overhaul Information Overhaul Standard Recommended Oil: SAE15W-40 or SAE20W-50 for 4-stroke motorcycle. Disassembly Remove: — CVT cover (→ 9-3) — Primary sheave, clutch, secondary sheave (→ 9-1,9-8) — Oil drainage bolt and drain gearbox oil — Rear wheel (→ 14-2) — Bolt and gearbox — Gearbox washer, dowel pin Remove adjust washer. Remove countershaft gear, countershaft.
10 Gearbox Check final shaft gear and final shaft for ablation, wearing or damage. Check gearbox bearing and oil seal for wearing or damage.
Use bearing remover for replacement of gearbox counter- shaft bearing and drive shaft bearing. Special Tool: Bearing Remover Set 12mm -Bearing remover 12mm -Bearing remover handle. Assembly Drive the new drive shaft bearing into left crankcase. General Purpose Tool: Driving Tool Guide 22mm Driving Tool Handle A Drive the new final shaft bearing into left crankcase.
General Purpose Tool: Driving Tool Guide 20mm Driving Tool Handle A Drive the new countershaft bearing into left crankcase. 10 Gearbox Insert drive shaft into gearbox drive shaft bearing. Special Tool: Drive Shaft Installation Tool Drive Shaft Installation Tool Sleeve (2 pcs) Install countershaft, countershaft gear, final shaft, final shaft gear, final shaft oil seal and thrust washer.
Install dowel pin and new gearbox washer. Install drive shaft oil seal. Gearbox 10-6. 11 Right Side Cover,Magneto, Water Pump Chapter 11 Right Side Cover,Magneto, Water Pump Overhaul Information 11-1 Water Pump Installation.11-4 Right Side Cover Removal 11-2 Flywheel Installation.
11-5 Stator, Pickup Coil Removal.11-3 Stator, Pickup Coil Installation. Right Side Cover Removal Remove right side cover (→ 2-3) Drain coolant (→ 6-4) Drain engine oil (→ 3-11) Remove 2 oil pipe tightening bolts, 2 pieces of 8mm oil pipe bolt,1 piece of 12mm oil pipe bolt. Remove oil pipe. Remove water hose from water pump and right side cover. 11 Right Side Cover,Magneto, Water Pump Stator, Pickup Coil Removal Remove: — 2 bolts; — Crankcase breather hose; — Pickup coil; — 3 fixing bolts for stator; — Stator from right side cover; — Wire protection sleeve from right side cover Flywheel Removal Remove oil channel joint from crankshaft. Water Pump Inspection of Water Seal When there is coolant leakage from inspection hole of lower part of right side cover, replace water seal by remov- ing right side cover.
Removal of Water Pump Impeller Drain coolant (→ 6-4) Drain engine oil (→ 3-11) Remove: —. 11 Right Side Cover,Magneto, Water Pump Check water seal and gasket for any damage or wearing. Note: Water seal and gasket should be replaced by set.
Removal of Water Pump Shaft Remove: — Right side cover (→ 11-2) — Elastic retainer from right side cover —. Drive the new oil seal into right side cover with its mark outward. Special Tool: Bearing Puller 28× 30mm General Purpose Tool: Removing &Installation Handle Drive the new water seal into right side cover.
Note: Apply sealant to the contact part of water seal and right side cover before driving in the water seal. 11 Right Side Cover,Magneto, Water Pump Fix impeller to the water pump shaft. Tightening Torque: 1.01.4kgf m Note: Water seal and gasket should be replaced by set.
Install dowel pins and water pump cover gasket. Install water pump cover with 3 bolts. Connect oil pipe. Flywheel Installation Install driven gear to crankshaft. Install fixing plate and tighten bolt. Note: Make sure driven gear can turn smoothly.
Install dual gear to the shaft. Make sure there is no dust on the conical part of crankshaft.
Note: Make sure there is no oil stain on the conical part of crankshaft. 11 Right Side Cover,Magneto, Water Pump Apply moly grease to flywheel nut and screw part of crankshaft. Install flywheel nut to crankshaft. Hold flywheel with flywheel holder and tighten nut. Tightening Torque: 10.511.5kgf m General Purpose Tool: Flywheel Holder Install oil channel joint and spring to crankshaft. Keep water pump shaft groove in line with oil pump shaft.
Install right side cover. Install and tighten right side cover bolts. Connect crankcase breather hose to right side cover. Connect pickup coil and stator wire with couplers. Connect water hose with water pump and right side cover. 11 Right Side Cover,Magneto, Water Pump Make sure there is no impurity in the oil pipe. Install oil pipe with 2 pcs of 8mm bolts, 1 pcs of 12mm bolt and 2 pcs of cop- per washers.
Note: -Use black bolt on the cylinder head cover side. Use silver bolt on the right side cover. Right Side Cover, Magneto 11-12. 11 Right Side Cover,Magneto, Water Pump Water Pump 11-13. 12 Crankcase, Crankshaft, Piston Overhaul information 1 2-1 Crankshaft/piston12-4 Troubleshooting12-2 Crankcase assembly12-11 Disassembly of crankcase 12-3 Overhaul information Operation caution.
Inspection of crankshaft and crankcase must be done after the crankcase is disassembled. Inspection of these parts can only be done after removal of engine from vehicle.(→ Chapter 7). Tightening torque 0.8-1.2kgf m Crankcase bolt 0.7-1.1kgf m Cylinder Stud Troubleshooting Compression pressure is too low. Worn or damaged piston ring. Worn cylinder or piston. Poor sealing of cylinder cover and valve. (→ Chapter 8).
12 Crankcase, Crankshaft, Piston Disassembly of Crankcase Remove: — Bolt — Tenioner, timing chain — Timing Chain Remove crankcase bolts (9pcs) Put left crankcase downward and remove right crankcase. Note: Do not pry surface of crankcase gasket. Remove crankcase gasket and dowel pin. Remove crankshaft from left crankcase.
Remove bolt and remove oil pipe from right crankcase. Remove oil seal from left crankcase. The removed oil seal should be replaced with a new one when assembling.
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Crankshaft Measure axial gap of connecting rod big end. Service limit: 0.5mm → Replace Measure the gap in the X, Y directions at the end face of connecting rod big end. 12 Crankcase, Crankshaft, Piston Measure the vibration of crankshaft Service limit: 0.10mm → Replace Turn crankshaft and check for abnormal noise and gap. In case of abnormal noise, replace crankshaft in a whole set. Disassembly of Piston Remove piston pin retainer. Note: Take care not to drop piston pin retainer into crankcase. Take out piston pin and remove piston.
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Inspection of piston, piston pin and piston ring Measure inner diameter of piston-pin- bore Service Limit: 17.04mm → Replace Measure outer diameter of piston pin Service Limit: 0.09mm → Replace Ring 0.09mm → Replace Check piston for scraps, wearing of groove and side cracks. Measure inner diameter of connecting rod small end. Service Limit:. Measure piston outer diameter, at 14mm from piston skirt, in the direction 90° opposite to the piston pin. Service Limit: 22.10mm → Replace Outer Diameter.