500 - U5 (CF500-3) - Technical Service Manual.pdf - Mojo

CF500-3/UTV 

WWW.CFMOTO.COM

FOREWORD 

This manual contains an introductory description 

of procedures for inspection maintenance, 

overhauldisassembly & assemblyremoval and 

installation of components and parts, 

troubleshooting and service data together with 

illustrations of our UTV Model CF500-3. 

Chapter 1general service information, tools 

vehicle structure and technical data. 

Chapter3: key points for inspection and 

adjustingservice guide. 

Chapter 2 and after Chapter 3disassembly of 

parts and componentsinstallationoverhaul and 

troubleshooting. 

The manufacturer reserves the right to make 

improvements or modifications to the 

products without prior notice. Overhaul and 

maintenance should be done according to 

the actual state and condition of the UTV. 

INDEX 

Vehicle 

Service Information 1 

Vehicle Body,Muffler 2 

Inspection & Adjustment 3 

Cooling System 4 

Removal and Installation of Engine 5 

Removal, Inspection and Assemble of 6 

Engine 

Carburetor 7 

Front Wheel, Front Brake, Suspension, 8 

Steering 

Rear Wheel, Rear Brake, Suspension 9 

Front and Rear Axle 10 

Battery, Charging System 11 

Ignition System 12 

Lighting, Dashboard & Switches 13 

Circuit DiagramWiring Diagram 14 

Troubleshooting 15

Conversion Table 

Item Example Conversion 

Pressure 200Kpa (2.00kgf/cm 2 ) 

33kpa(250mmHg) 

1kgf/cm 2 =98.0665kpa 1kpa=1000pa 

1mmHg=133.322Pa=0.133322Kps 

Torque 18Nm(1.8kgf-m) 1kgf m=9.80665Nm 

Volume 419ml 1ml=1cm 3 =1cc 

1l=1000cm 3 

Force 12N (1.2kgf) 1kgf=9.80665N

Cautions 

Safety Cautions 

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Cautions……………………………1-1 

Tightening Torque………………1-13 

VIN Number & Engine Number……1-3 

Lubricant, Sealing Agent…………1-18 

Main Data Table……………………1-4 

Cable Routing……………………1-19 

Overhaul Data Table………………1-6 

1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated 

place for long time. 

 

2. Do not touch the engine or muffler with bare hands after the engine has just stopped to 

avoid scalding. Wear long-sleeve work clothes and gloves for operation. 

3.Battery liquid (dilute sulfuric acid) is highly caustic and may cause burns to skin and eyes. 

Flush with water if splashed to skin and get immediate medical attention. Flush with water if 

splashed to clothes to avoid burns. Keep battery and liquid away from reach of children 

4.Coolant is poisonous. Do not drink or splash to skin, eyes or clothes. Flush with plenty of 

soap water if splashed to skin. If splashed into eyes, flush with water and consult the doctor. 

If drinking the coolant, induce vomit and consult the doctor. Keep coolant away from reach of 

children. 

5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask. 

6. Gasoline is highly flammable. No smoking or fire. Also keep against sparks. Vaporized 

gasoline is also explosive. Operate in a well-ventilated place. 

7.When charged, Battery may generate hydrogen which is explosive. Charge the battery in a 

well-ventilated place. 

8. Be careful not to get clamped by the turning parts like wheels and clutch. 

9. When more than two people are operating, keep reminding each other for safety purpose. 

Cautions for Disassembling and Assembling 

1. Use genuine CFMOTO parts, lubricants and grease 

2. Clean the mud, dust before overhauling 

3. Store the disassembled parts separately in order for correct assemble. 

4. Replace the disassembled washers, o-rings, piston pin retainer, cotter pin with new ones. 

5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers. 

6. 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. 

7.If you do not know the length of screws, install the screws one by one and make sure they 

are screwed in with same depth.

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8.Check if the disassembled rubber parts are aged and replace if necessary. Keep the 

rubber parts away from grease. 

9.Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque, 

from big to small and from inner side to outer side. 

10.Replace aged latex parts before assembling. Do not mix volatile oil and grease on the 

surface,due to aggressivness of fuel and oil. 

11.Apply or inject recommended lubricant to the specified parts 

12.Use special tools wherever necessary. 

13.When ball bearing disassembled by pressing ball ring, it can not be reused. 

14.Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly. 

Replace if the axial or radial play is too big. 

If the surface is uneven, clean with oil and replace if the cleaning does not help.When 

pressing the bearing into the machine or to the shaft 

Replace the bearing if it could not be pressed tight. 

15.Install the one-side dust-proof bearing in the right direction. When assembling the open 

type or double-side dustproof bearing, install with manufacturermark outward. 

16.Keep the bearing block still when blowing dry the bearing after washing clean. Apply oil or 

lubricant before assembling. 

17.Install the elastic circlip properly. Turn the circlip after assembling to make sure is has 

been installed into the slot. 

18.After assembling, check if all the tightened parts are properly tightened and can move 

smoothly. 

19.Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these parts 

with water if splashed. 

21.When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if any, into the 

groove. Replace the pipes or hoses that cannot be tightened. 

22.Do not mix mud or dust into engine and/or the hydraulic brake system. 

23.Clean the gaskets and washers of the engine casing before assembling. Remove the 

scratches on the joint faces by polishing evenly with an oilstone. 

24.Do not twist or bend the cables too much. Distorted or damaged cables may cause poor 

operation. 

25.When assembling the parts of protection caps, insert the caps to the grooves, if any.

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Main Data Table 

Item 

Parameter 

Model 

CF500-3 

Length 

2880mm 

Width 

1435mm 

Height 

1900mm 

Wheel base 

1790mm 

Engine type 

CF188-A 

Displacement 493Cm 3 

Fuel type 

Unleaded gasoline RQ-93or above 

Dry weight 

554kg 

Number of Passengers 

2 (including driver) 

Max. Load 

150kg 

Tire 

Front 25×8 12 

Rear 25×10 12 

Min. Ground Clearance 

350mm 

Turning Diameter 

9m 

Starting 

Electrical starting 

Engine Type 

Single cylinder, 4-stroke, Liquid-cooled, 

4 valves, OHC 

Combustion Chamber Type Triangle 

Valve Driving Type 

SOHC /Chain Drive 

Bore ×Stroke 

87.5mm×82.0mm 

Engine Compression Ratio 10.2:1 

Lubrication Type 

Pressure & Splash 

Oil Pump Type 

Rotor 

Lubricant Filter Type 

Full flow filter screen 

Oil Type 

SAE15W-40/SF 

Cooling Type 

Closed coolant circulation 

Coolant Type -35 anti-rust coolant


Fuel 

Device 

Gearing 

Steering 

Device 

Brake Type 

Bumper 

Device 

Frame Type 

Item 

Parameter 

Air Filter type 

Sponge element filter 

Type 

Vacuum Diaphragm type 

Carburetor 

MIKUNI BSR36-89 

Diameter of mixing 36mm 

valve 

Clutch Wet, Auto-Centrifugal 

Operation 

Mode 

Automatic CVT +Parking & Gear Shifting 

Gears Shift Low Gear, High Gear & Reverse Gear 

Shift 

Mode/order 

Manual /L-H-N-R 

CVT 

Transmissi 2.3 0.90 

on Ratio 

Final 

Ratio 

1.333 24/18 Bevel Gear 

Secondar 

Gear y Ratio 

1.952 41/21 

Ratio 

Low Gear 2.25(36/16) High Gear 

Gears 

1.474(28/19)Reverse Gear1.471(25/17) 

Total 

Low Gear5.857High Low3.835Reverse 

Gear 3.828 

Engine Output 

Mode 

Front/Rear Shaft 

Direction of Output 

Rotation 

Clockwise on forward shift 

Steering Inner 31º 

Angle Outer 27º 

Front 

Hydraulic Disc 

Rear 

Hydraulic Disc 

Suspensio 

n 

Swing Arm 

Welded Steel Tube and Plate

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Maintenance Data Table 

Lubrication System 

Engine Oil 

Capacity 

Item Standard Service Limit 

Volume when 2200mL 

 

replacing 

Volume when 2300mL 

 

replacing filter 

Recommended Oil(See Original Specially for 4-stroke 

motorcycle 

SAE-15W-40 

Substitutes must be used in the 

following range. 

API type: SE or SF grade 

Oil Pump Rotor 

Gap between 

Inner and Outer 

Rotors 

Gap between 

Outer rotor and 

boday 

Oil pressure 

SAE type: Choose from the left 

chart according to the 

environmental temperature 

0.030.1mm 

0.030.1mm 

3000r / min/ 130-170KPa 

0.15mm 

0.12mm 

Fuel System 

Item 

Standard 

Fuel 

Capacity 

Carburetor 

Tank 

Full capacity 27.0L 

Type 

MIKUNI BSR36-89 

Jet Number 

07G0 

Mixing Valve Diameter 36mm 

mm 

Main Jet 

N102221-130# 

Main air Jet MD13/24 -35# 

Needle 

J8-5E26 

Main Nozzle 

785-401011-P-0M 

Idle Jet 

N224103-22.5# 

Idle Adjusting Screw 

604-16013-1A 

Idle Speed 

1300±100r / min


Cooling System 

Coolant 

Capacity 

Item 

Standard/ 

Parameter 

Full Capacity 

2900ml 

Reservoir tank 

capacity 

300ml 

Standard Density 50% 

Service 

Limit 

Remark 

 

Opening pressure of radiator cap 108kpa(1.1kgf/ 

cm 2 ) 

Initial Temperature 72±2 

Full opening 

88 

Thermostat 

Temperature 

Full opening lift 3.5 4.5mm/95 

range 

Temperature 

Resistance(Ω 

Temperature and 

Resistance of 

Water 

Temperature 

Sensor 

50 154±16 

80 52±4 

100 27±3 

120 16±2 

Temperature of 

Thermostat 

Close-Open 

Open-Close 

88 Round 

82 Round 

Coolant Type 

-35 anti-frozen, antisepsis, 

high-boil coolant

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Front Wheel 

Front 

Wheel 

Item 

Standard 

Operation 

Limit 

Play of wheel Vertical 1.0mm 2.0mm 

rim Horizontal 1.0mm 2.0mm 

Groove 3.0mm 

Tire 

70kPa 0.70kgf 

Pressure 

cm 2 

Rear Wheel 

Rear 

Wheel 

Item 

Play of wheel 

rim 

Tire 

Operatio 

Standard 

n Limit 

Vertical 1.0mm 2.0mm 

Horizont 

1.0mm 

2.0mm 

al 

Groove 3.0mm 

Pressure 84kPa 0.84kgf cm 2 

Brake System 

Item 

Standard 

Operation 

Limit 

Front 

Brake Brake Disc Thickness 4mm 3mm 

Rear 

Brake 

Brake Pedal Play 0mm 

Brake Disc Thickness 7.5mm 6.5mm

Battery, Charging Device, Pickup Coil 


AC 

Magneto 

Motor 

Rectifier 

Battery 

Ignition Device 

Item 

Standard 

Model 

permanent magnet 3-phase 

alternator flywheel rotor 

Output 

3-phase AC 

Charging Coil Resistance 20 0.2Ω-0.3Ω 

Pickup Coil Resistance 

110Ω-140Ω 

Voltage of Magneto Motor 

engine is off 

100V AC 5000r/min 

Max. Output Power 

300W 5000r/min 

Rated Voltage 

13.5V-15.0V, 5000r/min 

Peak Voltage of Pickup Coil 

120V 

Three-phase annular rectification, 

Silicon controlled parallel-connected 

regulated voltage 

Capacity 

12V 18Ah 

Fully 

12.8V 

Charged 

Terminal Point 

Insuffici 

Voltage 

ent

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Valve System + Cylinder Head 

(mm) 

Item Standard Operation Limit 

Valve Diameter 

Valve Clearance( Idle Speed) 

Fit Clearance between Valve 

Intake 30.6 

Exhaust 27.0 

Intake 0.05-0.10 

Exhaust 0.17-0.22 

Intake 0.010-0.037 

Guide and Valve Stem Exhaust 0.030-0.057 

Internal dia. of Valve Guide Intake & Exhaust 5.000-5.012 

Exterior dia. of Valve Stem 

Intake 4.975-4.990 

Exhaust 4.955-4.970 

Valve Stem Run-out Intake & Exhaust 0.05 

Length of Valve Stem End Intake & Exhaust 2.9-3.1 2.3 

Thickness of Valve Head Intake & Exhaust 0.5 

Valve Head Seal Run-out Intake & Exhaust 0.03 

Width of Valve Seats Seal Intake & Exhaust 0.9-1.1 

Length of Valve Spring Intake & Exhaust 40 38.8 

Valve Spring Tension 

Intake & Exhaust 

Tension182-210N 

/Length31.5mm 

Cam Height 

Fit Clearance between Camshaft 

Intake 33.430-33.490 33.130 

Exhaust 33.500-33.560 33.200 

22 0.032-0.066 0.150 

Exterior dia. &Bore. 17.5 0.028-0.059 0.150 

Camshaft Exterior dia. 

Camshaft Bore Internal dia. 

22 21.959-21.980 

17.5 17.466-17.484 

22 22.012-22.025 

17.5 17.512-17.525 

Camshaft Run-out 0.10 

Rocker Arm Internal dia. Intake & Exhaust 12.000-12.018 

Rocker Arm Shaft Exterior dia. Intake & Exhaust 11.973-11.984 

Plainness of Cylinder Head 

Adjoining Plant 

Plainness of Cylinder Head Cover 


 

0.03 0.05 

0.03 0.05


Cylinder + Piston + Piston Ring+ Crankshaft 

Item 

Standard 

Operation 

Limit 

Cylinder Pressure 

1000kPa 

Fit Clearance between 

Piston and Cylinder 

0.030-0.051 0.15 

87.460-87.480 

Piston Skirt dia. Testing the point away skirt end 87.380 

10mm 

Internal dia. of Cylinder 87.500-87.522 

Plainness of Cylinder 


0.015 0.05 

Piston Ring Free Gap 

Top Ring R 11.7 round 8.9 

2 nd Ring R 12 round 9.5 

Piston Ring Closed Gap 

Top Ring 0.15-0.30 0.60 

2 nd Ring 0.15-0.30 0.60 

Piston Annular Fit Top Ring 0.04-0.08 0.180 

Clearance 2 nd Ring 0.03-0.07 0.150 

Thickness Piston Ring 

Top Ring 0.97-0.99 

2 nd Ring 1.17-1.19 

Top Ring 1.03-1.05 

Piston Annular Width 2 nd Ring 1.22-1.24 

Oil Ring 2.51-2.53 

Internal dia. of Piston Pin 

Bore 

23.002-23.008 23.030 

Exterior dia. Piston Pin 22.995-23.000 22.980 

Rod Small End Inner dia. 23.006-23.014 23.040 

Rod Big End Gap 0.10-0.55 1.0 

Rod Big End Thickness 24.95-25.00 

Crankshaft Run-out 0.03 0.08 

(mm) 

Remark

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Clutch+Transmission 

(mm) 

Item Standard Limit Remark 

Clutch Friction plate inner dia. 140.00-140.15 140.50 

Clutch Joint Rotation 

Clutch lock-up Rotation 

1800-2400r/min 

3300-3900r/min 

Drive Belt Width 35.2 33.5 

Driven Disc Spring Free Length 168 160 

Shifter and fit flute gap 0.10-0.40 0.50 

Left Shifter Sliding Thickness 5.8-5.9 

Right Shifter Sliding Thickness 5.8-5.9 

Plunging Flute Width 6.0-6.2 

Driven Output Gear Sliding 

Width 

6.0-6.2


Tightening Torque 

Item Torque N·m(kgf·m) Item Torque 

N·m(kgf·m) 

5mm Bolt, nut 5(0.5) 5mm Screw 4(0.4) 

6mm Bolt, nut 10(1.0) 6mm Screw 9(0.9) 

8mm Bolt, nut 22(2.2) 6mmSH Bolt with flange, 10(1.0) 

10mm Bolt, nut 34(3.5) 6mm Bolt with flange, nut 12(1.2) 

12mm Bolt, nut 54(5.5) 8mm Bolt with flange, nut 26(2.7) 

10mm Bolt with flange, nut 39(4.0) 

For others not listed in the chart, refer to the standard tightening torque. 

Notes: Apply some engine oil on the part of screw thread and adjoining 

surface. 

Item 

Thread Dia. Quantity Torque 

(mm) 

N·m(kgf·m) 

Remark 

 

Bolt, Engine Assembling M12×1.25×140 2 5060 

Bolt, Swing Arm M10×1.25×70 16 4050 

Bolt, Rear Absorber M12×1.25×60 4 5060 

Bolt, Front Absorber M10×1.25×55 4 4050 

Bolt, Rear Wheel Shaft Holder M10×1.25×100 4 4050 

Mounting Nut, Rim 901-07.00.02 M20 16 7080 

Rim, Rim Shaft 903-07.00.03 M24 4 130150 

Nut, Parking Caliper M10×1.25 2 4050 

Bolt, Front Axle M10×1.25×90 1 4050 

Bolt, Front Axle M10×1.25×25 2 4050 

Bolt, Rear Brake Caliper M10×1.25×20 2 40~50 

Bolt, Front Brake Disc 901-08.00.03 8 2530 

Nut, Tie-Rod M10×1.25 4 4050 

Locknut, Steering Stem M12×1.25 1 4050 

Bolt, Muffler M8×30 1 3035 

Bolt, Exhaust Pipe M8×35 2 3035 

Mounting Bolt, Rear Axle M10×1.25×110 2 4050 

Bolt, Front Bracket Front Axle M8×14 2 3545 

Bolt, Rear Bracket Front Axle M8×14 2 3545 

Back End Bolt, Rear Trans. 

Shaft 901-30.00.01 6 4050 

Front End Bolt, Rear Trans. 

Shaft 901-29.00.01 4 3545 

Bolt, Front Trans. Shaft 901-29.00.01 8 3545 

Bolt, Front Brake Caliper M8×20 4 2030 

Nut, Tilt Support M8×1.25 4 3545 

Mounting Bolt, Steering M8×14 4 3545 

Locknut, Cross Axle Steering M8×25 2 3545 

Thermo Switch CF250T-420500 1 912

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Engine Tightening Torque Table 

Item 

Qua 

ntity 

Screw dia. 

mm 

Torque 

N.m 

Remark 

Sensor, Reverse Gear 1 M10×1.25 20 

Spark Plug 1 M12×1.25 18 

Water Temperature Sensor 1 Rc1/8 8 Apply screw thread sealant 

Valve Clearance Adjusting Nut 4 M5 10 

Drive Disc Nut 1 M20×1.5 115 

Driven Disc Nut 1 M20×1.5 115 

Circle Nut, Driving Disc 1 M30×1 100 

Nut, Front Output Shaft 1 M14×1.5 97 

Nut, Drive Bevel Gear 1 M22×1 145 

Nut, Driven Bevel Gear 1 M16×1.5 150 

Fixing Nut, Clutch 1 M18×1.5 70 Left handed 

Limiting Nut, Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant 

Limiting Nut, Front Output Shaft 1 M55 80 

Apply screw thread sealant, 

left handed 

Bolt, Swing Arm Shaft 2 M14×1.25 28 

Drain Bolt 1 M12×1.5 30 

Mounting Bolt, Overriding Clutch 6 M8 26 Apply screw thread sealant 

Mounting Bolt, Magneto Stator 3 M6 10 Apply screw thread sealant 

Bolt, CVT Windshield 3 M6 10 Apply screw thread sealant 

Link Bolt, Oil Pipe 2 M14×1.5 22 

Mounting, Oil Pump 3 M6 10 

Mounting Bolt, Pressure Limiting 

Valve 

2 M6 10 

Bolt, Drive Bevel Gear Cover 4 M8 32 

Bolt, Driven Bevel Gear Cover 4 M8 25 

Locating Bolt, Shift 1 M14×1.5 18 

Flange Bolt, Fan 1 M10×1.25 55


Torque 

Item Quantity Diametermm 

N.m 

14 M6 10 

Bolt,Crankcase 

3 M8 25 

Bolt, Driven Sector Gear 1 M6 12 

Mounting Bolt, Oil Filter 1 M20×1.5 63 

Oil Filter 1 3/416 /in 1820 

Bolt, Starting Motor 2 M6 10 

Bolt, Cylinder Head 4 M10 38 

Bolt, Cylinder Head(2 sides) 2 M6 10 

1 M8 25 

Remark 

 

Upper and Lower Bolt, 

Cylinder 

4 M6 10 

Bolt, Cylinder Head Cover 12 M6 10 

Bolt, Chain Tensioner 2 M6 10 

Nut, Chain Tensioner 1 M8 8 

Bolt, Radiator Fan 3 M6 10 

Thermostat Bolt 2 M6 10 

Bolt, Water Pump Cover 3 M6 6 

Mounting Bolt, Water Pump 2 M6 10 

Fixed Bolt, Timing Sprocket 

Bolt without remarks 

2 M6 15 

M5 4.5-6 

M6 8-12 

M8 18-25 

APPly 

threadsealant 

screw

&)0272 

Engine Tools 

Measuring Tools 

No Name Type Function Remark 

1 Vernier Calipers 0-150mm measure length and thickness 

2 Micrometers 0-25mm 

measure the outer diameters of swing 

arm, valve rod and camshaft 

3 Dialgauge 25-50mm Measure max. lift range of camshaft 

4 Dialgauge 75-100mm Measure piston skirt 

5 Inner dia. Gauge, Cylinder Measure inner dia. of cylinder head 

6 Inner dia. Gauge, 10-34mm 

Inner dia. of swing arm, piston pin hole, 

and rod head hole 

7 Dial Test Indicator 1/100 Run-out 

8 Knife Straight Edge plainness 

9 Feeler Gauge Plainness, adjusting valve clearance 

10 Fuel Level Gauge Fuel level length of carburetor 

11 Plasticgauge Fit clearance 

12 pull tension gauge Spring bounce 

13 Tachometer Engine rotation rate 

14 Cylinder Pressure Meter pressure in cyclinder 

15 Oil Pressure Gage Oil pressure 

16 Barometer Opening pressure of radiator cover 

17 Ohmmeter Resistance and voltage 

18 Amperemeter Opening of currency / switch 

19 Thermometer Liquid temperature 

20 Timing Lights Test spark timing 

21 Torque Tester One Set Tightening torque 

Auxiliary Measuring Instrument 

22 Alcohol Burner Warming up 

23 Magnet Stand Install dialgauge 

24 Slab Auxiliary measure supplementary 

25 V-Block Run-out supplementary 

26 Forcep Install valve clip 

27 Plier Disassemble and install circlip 

28 Joint Plier Disassemble and install flange 

29 Impact Driver Disassemble cross recessed bolt 

30 Slot Type Driver 

31 Cross Type Driver


Special Purpose Tools 

No Name Type Function Remark 

1 Spark Plug Wrench 172MM-022400-922-004 

Disassemble/ install spark 

plug 

 

2 CVT Wrench 

CF188-051000-922-001 

CF188-052000-922-001 

Disassemble/install CVT 

drive/driven disc nut 

3 Oil Filter Wrench CF188-011300-922-001 Disassemble/ install oil filter 

4 Piston Pin Remover CF188-040004-922-002 Disassemble piston pin 

5 

Magneto stator 

Remover 

CF188-031000-922-001 

Disassemble magneto 

stator 

6 Crankcase Dissociator Divide L/R crank case 

7 Crank Remover 

8 Crank Tool 

Disassemble crank shaft 

from left crankcase 

Install crank shaft on left 

crankcase 

9 

Valve Spring 

Compressor 

CF188-022006-922-001 

Disassemble/ install valve 

spring 

10 Valve Former CF188-022004-922-001 Grind valve 

11 Circle Nut Wrench CF188-052000-922-003 

12 Driven Disc Clamp CF188-052000-922-004 

13 Driven Disc Former CF188-052000-922-002 

14 Limiting nut Wrench CF188-062204-922-001 

Disassemble CVT driven 

disc 


disc 


disc 

Disassemble driven bevel 

gear bearing limiting nut 

15 Bearing Tool One full set Install bearing and oil ring 

16 Bearing Remover One full set Disassemble bearing 

17 Oil Ring Remover Disassemble bearing 

18 Limiting Nut Wrench CF188-060008-922-001 

Disassemble front output 

shaft bearing limiting nut 

Disassemble fan connector 

19 Fixing Wrench CF188-A-180003-922-003 

flange, adjust valve 

clearance

&)0272 

Lubriantion Grease, Sealant 

Coated Section Attention Grease 

Turning Bearings 

Throttle Cable Connecting Portion 

Throttle Pedal Movable Parts 

Brake Pedal Movable Parts 

Swing Arm Movable Parts 

Steering Inner Circle Surface 

Seat Lock Movable Parts 

Transmission Movable Parts 

Multi-purpose grease 

Operation M aterial and Installm ent Supplem entary of Engine 

Engine operation m aterials include lubricant (oil), grease (lubricant grease) and coolant, 

installm ent supplem entary includes plane sealant and screw 

thread sealant. 

Nam e Type Parts Rem ark 

lubricant 

/o il 

Specially for 4-stroke 

motorcycle 

SAE-15W -40 

S u bstitu te s m u st b e 

used in the following 

range. 

API type: SE or SG 

grade 

Replacem ent see 

1-3 

Rotating section and carriage in 

cylinder, 


crankcase 


cylinder head 

See Lubrication System s Diagram 

5-14 

capacity 

2200m L replace oil 

2300 m L replace oil 

filte r 

2600 m L engine 

overhaul 

Lubricant 

w ith 

Piston pin, valve rod part, valve 

m olybdenu 

m 

ring, cam 

shaft 

Grease/lubri 

cant grease 

# 3 M oS 2 l ith ium 

based grease 

Oil seal lip, O ring and other latex 

sealing, bearing with seals, and 

CVT bearing/housing 

Coolant -35? anti-frozen, 

anti-rust, high – boiled 

coolant 

Plane 

sealant 

Screw 

thread 

sealant 

Cooling system , water seals 

Coupling surfaces of cases, cases 

and cylinder, cylinder head and 

cylinder head cover 

Som e screw thread 

Capacity based on 

radiator pipe system

Cables, Pipes, Cable Routing 


&)0272


&)0272

Overhaul info2-1 Rear fender(RH&LH) Dump 

Troubleshooting2-1 

Front top coveFront side support(RH&LH)2-2 

box2-11 

Side door(RH&LH)2-12 

Front vent cover2-4 Footrest board(RH&LH)2-13 

Front&Rear cover,Steering stem2-5 Dashboard panel,Bumper2-14 

Center cover, steering wheel, Monut Fuel tank,Headrest,driver&passenger2-15 

seat,steering wheel, Combination Safety belt,driver&passenger, 

switch2-6 

Seat,Driver&Passenger2-7 

Gearshift unit, engine hood2-8 

Belt fastener2-16 

Roll-over bar, Rear mirror(RH&LH)2-17 

Bumper protector,Cabel and motor2-18 

Link plate (RH&LH),Skid plate(Center)2-9 Rear side support(RH&LH) 

Skid plate(RH&LH) 2-10 Protector(RH&LH),dump box,Bracket dump 

box2-19 

Overhaul Information 

Operation Cautions 

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 explosive 

when it is vaporized, so operation should be done in a well-ventilated place. 

Remove and Install muffler after it is fully cold. 

This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe, 

muffler and fuel tank. 

Hoses, cables and wiring should be routed properly. 

Replace the gasket with a new one after muffler is removed. 

After muffler is installed, check if there is any exhaust leakage. 

Tightening torque 

Muffler Rear Fixing Bolt: 35-45N.m 

Muffler Exhaust Pipe Bolt: 35-45N.m 

Muffler Body Fixing Bolt: 35-45N.m 

Troubleshooting 

Loud exhaust noise 

Broken muffler 

Exhaust leakage 

Insufficient power 

Distorted muffler 

Exhaust leakage 

Muffler clogged 

MufflerGearshift unit2-20 

Description of visible parts2-21

&)0272 

Front top cover 

Remove 

Remove 7 nuts 1 from front top cover. 

Push forward and then remove the front 

top cover. 

Installation 

Reverse the removal procedure for 

installation 

Front side support(LH) 

Remove 

Remove mount bolts 2; 

Remove front side support(LH); 

Installation 


installation 

Front side support(RH) 

Remove 

Remove mount bolts 3; 

Remove front side support(RH); 

Installation 


installation

Front vent cover 

Remove 

Remove front top cover 

Remove front side support(RH&LH) 

 

 

Remove nuts 1 

Remove nuts 2 

Remove nuts 3 

Remove front vent cover 

Installation 

Reverse the removal procedure for installation

&)0272 

Front fender 

Remove 

Loosen all electronic component and plugs 

on front fender; 

Remove battery; 

Remove three bolts 1 

Remove one nut 1 

Remove twelve nuts 2 

Remove six nuts 3 

Loose cables on the fender; 

Remove front fender 

Installation 


installation

Front cover,steering stem 

Remove 

Loose nut 1 

Loose nut 2 

Remove front cover,steering stem 

Installation 


installation 

 

Rear cover,steering stem 

Remove 

Loose nut 3 

Remove ignition switch cover 

Remove rear cover,steering stem 

Installation 


installation

&)0272 

Center cover,steering wheel 

Remove 

Exert upward to seperate center cover, 

steering wheel; 

Installation 


installation 

Steering wheel 

Remove 

Remove center cover,steering wheel 

 

Loosen nut 1 

Remove steering wheel 

Installation 

Note 

Align the front wheel first, and then adjust 

steering wheel; 


installation 

Mount seat,steering wheel 

Remove 

Remove steering wheel 

Loosen nut 1 

Remove mount sear,steering wheel 

Installation 


installation 

Nut 1 torque 

Remove mount seat,steering wheel 

Loosen nuts 2 

Remove cable and plugs 

Remove combination switch 

Installation 


installation

Seat,driver 

Remove 

Use the key to unlock the seat lock 

Remove cotter pin 1 

Remove cotter pin pivot 1 

Remove seat,driver 

Installation 


installation 

 

Seat,passenger 

Remove 

Use the key to unlock the seat lock; 

Remove cotter pin 2 


Remove seat,passenger 

Installation 


installation

&)0272 

Gearshift unit 

Remove 

Loosen nut 2 

Remove gearshift unit 

Installation 


installation 

Note 

Check the return flexibility of gear limit, and 

the flexibility of gear shifting. 

Engine hood 

Remove 

Remove gearshit unit 

Loosen bolt 1 

Loosen nut 1 

Lift engine hood 

Installation 


installation

Link plate(LH) 

Remove 

Remove nut 1 

Remove link plate(LH) 

Installation 


installation 

 

Link plate(RH) 

Remove 

Remove nut 2 

Remove link plate(RH) 

Installation 


installation 

Skid plate(Center) 

Remove 

Remove nut 3 

Remove skid plate(center) 

Installation 


installation

&)0272 

Skid plate(LH) 

Remove 

Loosen nut 1 

Loosen bolt 1 

Loosen bolt 2 

Remove skid plate(LH) 

Installation 


installation 

Skid plate(RH) 

Remove 

Loosen nut 2 

Loosen bolt 3 

Loosen bolt 4 

Remove skid plate(RH) 

Installation 


installation

Rear fender(LH) 

Remove 

Remove bolt 1 

Remove rear fender(LH) 

Installation 


installation 

 

Rear fender(RH) 

Remove 

Remove bolt 2 

Remove rear fender(RH) 

Installation 


installation 

Dump box 

Remove 

Remove nut 1 

Take out cotter pin 1 


Loosen dump box hook 

Lift dump box 

Installation 


installation

&)0272 

Side door(LH) 

Remove 

Remove bolt 1 

Remove side door(LH) 

Installation 


installation 

Side door (RH) 

Remove 

Remove bolt 2 

Remove side door(RH) 

Installation 


installation

Footrest board(LH) 

Remove side door(LH) 

Remove link plate(LH) 

Remove skid plate(center) 

Remove skid plate(LH) 

Remove bolt 1 

Remove nut 1 

Remove footrest board(LH) 

Installation 


installation 

 

Footrest board(RH) 

Remove side door(RH) 

Remove link plate(RH) 

Remove skid plate(center) 

Remove skid plate(RH) 

Remove bolt 2 

Remove nut 2 

Remove bolt 3 

Remove footrest board(RH) 

Installation 


installation

&)0272 

Dashboard panel 

Remove 

Remove front side support(RH&LH) 

 

Remove front fender 

Remove footrest board(RH&LH) 

Loosen cable and plug on dashboard panel 

Remove bolt 1 

Remove bolt 2 

Remove dashboard panel 

Installation 


installation 

Bumper 

Remove 

Remove bolt 3 

Remove bumper 

Installation 


installation

Fuel tank 

Remove 

Remove rear wheel(RH) 

Loosen high-pressure fuel pipe 

Loosen fuel sensor connector 

Remove bolt 1 

Remove fuel tank 

Installation 


installation 

 

Headrest,driver 

Remove 

Remove nut 1 

Remove headrest,driver 

Installation 


installation 

Headrest,passenger 

Remove 

Remove nut 2 

Remove headrest,passenger 

Installation 


installation

&)0272 

Safety belt,driver 

Remove 

Remove bolt 1 

Remove bolt 2 

Remove safety belt,driver 

Installation 


installation 

Safety belt,passenger 

Remove 

Remove bolt 3 

Remove bolt 4 

Remove safety belt,passenger 

Installation 


installation 

Safety belt fastener 

Remove 

Remove bolt 5 

Remove safety belt fastener 

Installation 


installation

Roll-over bar 

Remove 

Remove nut 

Remove bolt 

Remove nut 

Remove bolt 

Remove roll-over bar 

 

Installation 


installation 

Rear mirror(LH) 

Remove 

Remove rear mirror(LH)27 

Rear mirror(RH) 

Remove 

Remove rear mirror(RH)25

&)0272 

Bumper protector 

Remove 

Remove nut 9 

Remove bumper protector 1 

Installation 


installation 

Cable and motor 

Remove 

Remove nut 16and bolt 4 

Remove bolt 2 

Remove cable and motor 15 

Installation 


installation

Rear side support(LH) 

Remove 

Remove nut 1 

Remove side support(LH)26 

Installation 


installation 

 

Rear side support(RH) 

Remove 

Remove nut 1 

Remove rear side support 27 

Installation 


installation 

Protector(LH),dump box 

Remove 

Remove nut 1 

Remove protector(LH),dump box 25 

Installation 


installation 

Protector(RH),dump box 

Remove 

Remove nut 1 

Remove protector(RH),dump box 6 

Installation 


installation 

Bracket,dump box 

Remove 

Remove bolt 17 

Remove bracket,dump box19 

Installation 


installation

&)0272 

Muffler 

Caution: Perform disassembly only 

after the muffler is cooled down. 

Remove 

Remove connect nut 1 on muffler pipe 

elbow 

Remove spring 

Remove bolt 1 

Remove bolt 4 

Remove muffler 

Caution: Perform disassembly only 

after the muffler is cooled down. 

Note: 

Replace sealing gasket when installing 

the muffler. 

Gearshift unit 

Remove 

Remove bolt 2 

Remove bolt 3 

Loosen nut 2 

Remove gearshift unit 

Note: 

Replace sealing gasket when installing 

the muffler.

Description of visible parts

&KHFNV $GMXVWPHQW 

Overhaul Info3-1 

Valve Clearance3-13 

Maintenance Time3-2 

Inspection & Maintenance3-3 

Steering Stem, Brake System3-6 

Wheels3-8 

Suspension System3-10 

Gear Shifting, Fuel Device3-11 

Accelerator Pedal3-12 

 

 

 

Engine Idle&Spark plug3-14 

Air Filter3-15 

Carburator hose&Driving Belt3-16 

Water-Cooling system3-18 

Oil-cooling&Lubrication system3-21 

Clutch checklocked speed check3-24 

Water temperature&Lighting device 

check3-25 

 

 

Overhaul Info 


Note 

 

 

 

 

 

 

DO NOT keep the engine running for long time in a poorly ventilated or enclosed 

 

place because of the harmful components like CO, etc, in the exhaust gas. 

The muffler and engine are still very hot when the engine is just stopped. Careless 

contact may cause serious burn. Be sure to wear fatigue dress with long sleeves 

and gloves if the work has to be done after the engine is just stopped 

Gasoline is highly flammable, smoking is strictly forbidden in the work place. Keep 

alert on the electrical sparks. Besides, vaporized gasoline is highly explosive, so 

work should be done in a well-ventilated place. 

Be careful that your hands or clothes not get nipped by the turning or movable parts 

of the driving system 

 

 

 

 

 

 

Note 

The vehicle should be parked on hard and level ground 

Replace parts regularly 

Parts replacement time is subject to time or kilometers, whichever occurs first.

&)0272 

Regular 

Maintenance Table 

The table below lists the recommended intervals for all the required periodic maintenance 

work necessary to keep the vehicle at its best performance and economy. Maintenance 

intervals are expressed in terms of kilometer, miles and hours, whichever occurs first. 

Note: More frequent maintenance may be required on vehicles that are used in severe 

conditions. 

Inte 

Km 

Initial 

250km 

Every 

500 km 

Every 1000 km 

Item 

rval 

Hours 

Initial 20 

Hours 

Every 50 

hours 

Every100hours 

Remarks 

Valve clearance I I 

IN0.05~0.10 

EX0.17~0.22 

Idle Speed I I 1300100r/min 

Spark plug 

I I 

R( Every :6000km ) 

No carbon deposit 

Gap0.8~0.9mm 

Air Filter I C R(every :20000km) 

Fuel Hose, Carburetor I R(every: 4-year) 

Clutch I 

Drive Belt I R(Every :2000Km) 

Oil Filter R R 

Oil change R R 

Coolant Leve I I 

Water Hose & Pipes I I 

Coolant 

R( every: 2-year) 

ICheck and adjust, or replace if necessary RReplace CClean


Check & Maintenance 

Check Item 

Interval 

Part Item Daily 

Interval 

1/2 

Year 

Annual 

Standard 

Steering wheel 

Operation 

agility 

 

Steering 

System 

Steering 

System 

Damage 

Installation condition of 

steering system 

Sway of ball stud 

 

 

 

 

Brake pedal 

Free play 

Brake 

Efficiency 

 

Pedal rear 

0mm 

end 

Connecting rod, oil 

pipe & Hose 

Looseness, 

Slack and damage 

 

 

Brake 

System 

Front and rear brake fluid 

level 

 

Brake fluid should 

be above LOWER 

limit 

Hydraulic brake and 

brake disc 

Brake disc damage and 

wear 

 

Replace when the 

thickness of front 

brake disc is less 

than 3.0mm, rear 

brake less than 

6.5mm. 

Front 

tire 70kPa 

Tire pressure 

0.70kgf/cm 2 

Rear tire 84kPa 

0.84kgf/cm 2 

Chap and damage 

Driving 

System 

Wheel 

Groove depth and 

abnormal wear 

 

 

No wear indication 

on the surface of tire 

(the remained depth 

of groove should not 

be less than 1.6mm) 

Loosened wheel nut and 

axle 

 

Sway of front wheel 

bearing 

 

 

Sway of rear wheel 

bearing 

 

 

Buffer 

System 

Suspension arm 

Sway of Joint parts, 

rocker arm damage 

Shock absorber Oil leakage and damage 

 

 

Function 

 

Front axle Transmission, lubrication 

Drive- 

Train 

system 

Rear axle Transmission, lubrication 

Gear box Transmission, lubrication 

Remove filling bolt, 

add oil till oil level 

reaches edge of 

filling hole

&)0272 

Drive 

Train 

Electric 

al 

System 

Engine 

Check Item 

Intervals 

1/2 

Part Item Daily Annual 

year 

Final shaft Looseness of 

 

(Drive joint parts 

shaft) Sway of Spline 

Ignition Spark plug 

Device 

Ignition timing 

Battery Terminal Joint 

Wiring 

Looseness and 

damage of joints 

 

Fuel leakage 

Fuel 

device Throttle 

Cooling Coolant level 

system Coolant leakage 

Standard 

Spark plug 

gap0.8 

0.9mm 

Throttle 

grip 

clearance 

35mm


Check Item 

Intervals 

Part Item Daily 

1/2 Annua 

year l 

Lighting device 

and turning Function 

indictors 

Alarm and lock 

device 

Function 

 

Instruments Function 

Looseness or damage 

Exhaust pipe caused by improper 

 

and muffler installation 

Function of muffler 

 

Frame 

Looseness and/or 

damage 

 

Others 

Lubrication & grease of 

frame parts 

 

Abnormal parts 

which can be 

determined 

when driving 

Make sure if there is any 

abnormal with relative 

parts. 

 

Standar 

d

&)0272 

Steering Stem 

Park the vehicle on level place, hold steering 

wheel, and shake in the direction as illustrated 

on the right and see if there is any sway 

In case of any sway, check if it is the problem 

of the steering stem or other parts and then 

do the maintenance accordingly. 

In case of sway of the steering stem, tighten 

the locknut or disassemble the steering stem 

for further check. 

Park the vehicle on level place, slowly turn the 

steering wheel left and right to see if it can 

turn freely. 

In case there is any hindrance, check if there 

is any interference . If no, check the steering 

tie-rod end, and check if the steering stem 

bearing is damaged 

. 

Note: 

Make sure the steering can be operated 

freely. 

An accident may occur 

if the handlebar is out of control.


Master Cylinder 

Fluid level 

Check the brake fluid level 

When the brake fluid level is near to the lower 

limit line, check master cylinder, brake hoses 

and joints for leakage. 

Remove fluid reservoir cap. 

add DOT3 or DOT4 brake liquid till the upper 

limit line. 

 

Do not mix with dust or water when adding 

brake fluid. 

Use only the recommended of brake fluid 

to avoid chemical reaction. 

Brake fluid may cause damages to the 

surface of the plastic and rubber parts. 

Keep the fluid away from these parts. 

Slightly turn the steering wheel left and right 

till the master cylinder is in horizontal, then 

remove the fluid reservoir cap. 

Brake Disc, Brake Pad 

< Wear of brake pad> 

Check the brake pad wears from the mark 

as indicated. 

Replace the brake pad if the wear has 

reached position of wear limit trough. 

Note 

The brake pad must be replaced with a 

whole set. 

Checking and replacing the brake disc 

Front brake disc thickness: 

 

Rear brake disc: 

Min. limited thickness of the front brake disc: 

2.5mm 

Min. limited thickness of the rear brake disc: 

6.5mm 

Change the Brake Fluid 

< Changing Brake Fluid> 

Change the brake fluid once every year.

&)0272 

Wheels 

Lift front wheel on level place, and make sure 

there is no loading on the wheels. 

Shake the front wheel left and right to check 

whether the joint of front wheel is tightened 

and check whether it sways. 

Not tighten enough ? Tighten it 

Sway: Replace the rocker arm 

Front Toe-in size 

Park the vehicle on level place, measure the 

front toe-in 

Toe-in: B-A=0-10mm 

Toe-in out of the range ? 

Adjust the locknut of tie-rod 

Note: 

After the toe-in has been adjusted, slowly run 

the vehicle to check whether the direction of 

vehicle can be controlled by steering wheel.


Tire pressure 

Check the pressure of the tires with a pressure 

gauge. 

Note 

Check the tire pressure after tires are 

cooled. Driving under improper tire pressure 

will reduce the comfort of operation and riding, 

and may cause deflected wear of the tires. 

 

Specified pressure /tire 

Front wheel Rear wheel 

Pressure 70kPa 

0.70kgf/cm 2 

84kPa 

0.84kgf/cm 2 

Tires 25812 

251012 

sizes 205/80-12 255/65-12 

Tire Tread 

Check the tire tread. 

Tread Height: if < 3mm, then Replace with 

new tires 

Note: 

When the tread height is less than 3mm, 

the tire should be replaced immediately.

&)0272 

Wheel Nut and Wheel Axle 

Check front and rear wheel axle nuts for 

looseness 

Loosened axle nuts 

Tighten 

Tightening Torque: 

Front wheel axle nut: 

110-130N.m(11.2kgf.m-13.3kgf.m) 

Rear wheel axle nut: 

110-130N.m(11.2kgf.m-13.3kgf.m) 

Sway of Wheel Bearing 

Lift the front wheel 

Make sure there is loading on the vehicle 

Shake the wheel in axial direction for any 

sway In case of any sway, 

disassemble the front wheel and check 

the bearing 

Suspension System 

Park the vehicle on lever place, press the 

vehicle Several times up and down as 

illustrated on the right. 

In case of any rocking or abnormal noise, 

check whether there is any oil leakage 

from absorbers, or any damage or 

looseness of tightening parts.


Adjusting the Absorber 

Use special tools to adjust the length of 

absorber according to loading requirement 

Turnclockwisetoadjustfromhightolow 

 

Gear Shifting 

Shift the gear to check for flexibility and gear 

engagement Adjust the gearshift rod if necessary 

Release the locknut to adjust the length 

of gearshift rod 

Fuel Device 

Status of the fuel system 

Remove the seat (2-3) 

Check the fuel hose for any aging or damage. 

Aged or damaged fuel hose: Replace 

Check if there is cracks or bending with the 

vacuum tube. 

Cracked or bended vacuum tube: Replace

&)0272 

Throttle Lever Check 

Check the free play of throttle lever 

Free play: 3-5mm 

If out of range, then adjust 

Loosen locknut of throttle cable 

turn the regulator and adjust free play of 

throttle lever 

After adjusting, tighten locknuts and install 

throttle cable sleeve, 

Replace with a new throttle cable if the 

specified free play could not be acquired 

by adjusting the regulator or if there is still 

stickiness with the throttle.


Valve clearance 

The first check is necessary after 20 hours 

run-in, then have a check every 100-hour or 

1000 km; If cylinder head cover disassembled, 

check must be needed 

If clearance is too big, then noise will be 

too big; 

If clearance is too small, then damage valve 

and reduce power. 

Please check valve clearance based on standard 

intervals, If necessary, make adjustment as 

follows. 

Disassemble outside fan cover 

Remove coverof left crankcase cover 

Disassemble adjustment cover of inlet& 

outlet valve 

Turn crankshaft,make top dead line of 

flywheel designate triangle signal 

Insert guage to check clearance between 

valve end and bolt 

Valve clearance 

Inlet:0.05-0.10 

In cold condition, Outlet:0.17-0.22 

 

Check and adjustment must be done 

in cold condition 

Check and adjustment must be done 

when piston is at top dead position 

If valve clearance is over standard value, 

special tools must be used to adjust to 

permissible value. 

Methods as follows: 

Loosen valve bolt and nut, insert guage 

between top of valve and valve bolt(inlet 

valve: guage thickness 0.1mm;outlet valve: 

guage thickness 0.2mm), then 

tighten valve bolt to make it touch slightly 

with guage, finally tighten bolt and nut

&)0272 

Take away guage and double check 

clearance, it should be within standard 

value. Otherwsie one more adjustment is 

needed as before till clearance is within 

standard scope.Tighten torque of 

adjustment nut:10N.m 

Note: 

Tighten adjustment-nut only after 

clearance adjustment is made completely 

Cover iniet&outlet valve and hole, 

Assemble mannual starter and left plastic 

decoration cover.Some screw thread 

sealant used when nut of mannual starter 

is tightened 

Tool: Valve adjustment tools guage 

Material: Screw thread sealant 

Engine Idle 

First check after 20-hour run-in, then have a 

check 

every 50-hour or every 500km 

Start engine, after fully warm-up, measure 

with speedometer through turn soft shaft of 

carburator 

to make idle speed within1200~1400r/min 

Idle speed: 1300r/min+/-100r/min 

Note: Idle speed adjustment must be in warm 

condition. 

Tool: Speedometer 

Spark plug 

First check after 20-hour run-in,then have a 

check 

every 100-hour or every 1000km and replace 

every 6000km 

Use special tool to disassemble spark plug 

Type:DER7EA-9 (NGK) 

Spark plug check 

If electrode is over-burnt, insulator or 

thread damage, please replace with new 

spark plug


Check carbon deposit on spark plug and 

clean with proper toolSpark plug gap: Check 

with guage, If out of range, make adjustment 

Standard gap: 0.8~ 0.9mm 

Warning 

When change spark plug, need to check 

screw thread specification and its length inside 

combustion chamber, if it’s too short, 

carbon deposit will be caused and will damage 

engine. 

Installation of spark plug 

Warning 

In order to avoid damage of cylinder screw 

thread, use hand to tighten first, then use special 

wrench to tighten with stated below 

torque.Tighten torque:18N.m 

Tool: Special wrench for spark plug guage 

Air filter 

Check every 50 hours or 500km 

If necessary, wash and clean it 

If jammed by dirty dust or other particualrs, 

intake air flow will decrease, then cause engine 

output power reduce and oil consumption 

increaseCheck methods and clean 

Loosen fixing clip remove air filter 

cover 

Note: Before close air box, DO NOT drop 

O-ring into air box 

Loosen screw remove element kit 

 

divide air box supporter element 

press plate 

Put element into A basin with cleaning liquidtowash 

Squeeze element by hand and dry it, but 

DO NOT distort or damage element 

Put element into motorcycle oil B, properly 

squeeze excessive oil

&)0272 

Cleaning fluid 

OilSAE30 or SAE15W/40for motorcycles 

WarningDO NOT use gasoline or lowflash 

solvant to clean air filter element. 

Check if air filter damage or not, If yes, 

please replace with new one 

Note 

Make sure filter element is clean during 

working, 

Engine will be getting more worn if no air 

filter element or dirty and damaged element 

inside air box 

When engine works in a dirty conditon, 

air filter should be washed more frequently 

Remove water outlet plug 8 under air box and 

drain 

all water inside air box out 

Carburator fuel hose 

Check intervals: every100 hours or 

1000km, change every 4-year. If any damage 

or leakage, then replace with new one immediately 

Drive belt 

Disassemble 

 

pully, then loosen nut of primary pully 

Tool: CVT torque wrench 

Remove primary pully 1 

Use special tool to fix secondary pully, 

then loosen nut of secondary pully, finally 

remove secondary pully with belt. 

Tool: CVT torque wrench 

Remove belt from secondary 

pully


Check 

Check driving belt condition. If some crack 

or damage, replace with new driving belt 

Check width of driving belt. If >limit value, replace 

with new driving belt 

Width limit value :33.5mm 

Tool:vernier caliper 

 

Installation 

Installation process is opposite to disassembling 

process 

Note: 

Put driving belt and use plastic hammer to 

knock slightly on driving belt to make it lowest 

position between secondary tight pully and 

secondary loosen pully 

Use special tool to fix secondary pully and 

tighten nut with below torque 

Secondary pully nut torque: 115N.m 

Primary pully nut torque: 115N.m 

Turn primary pully and return belt to 

original position. Make belt turn with primary 

and 

secondary pully smoothly 

Install primary pully, and use torque 

wrench to tighten nut when use special tool to 

fix primary pully. 

Warning 

When installation of driving belt, 

arrow of belt should be clsockwise 

Interface of driving belt should be very 

clean, without dust and other particulars. 

Install CVT cover

&)0272 

Cooling System 

Note 

Check coolant level from reservoir tank, Do not 

check from 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. 

DO NOT open the radiator cap until the coolant 

temperature drops down. 

Coolant is poisonous, DO NOT drink or splash 

it to skin, eyes, and clothes. 

In case the coolant gets to the skin and 

clothes, wash with soap immediately. 

In case the coolant gets into eyes, rinse with 

plenty of water and go to consult the doctor 

In case of swallowing the coolant, induce vomit 

and consult the doctor. 

Keep the coolant in a safe place and away from 

reach of children. 

Coolant level 

Coolant might reduce due to natural evaporation. 

Check the coolant level regularly. 

Check every 50 hours or every 500km and replace 

coolant every 2 years 

Note 

Coolant can prevent rust and resist freeze. Ordi - 

nary water may cause engine rust or cracks in 

winter due to freezing. Coolant should be used. 

Park the vehicle on level ground for checking of 

the coolant. Inclined vehicle body will cause incorrect 

judging of the coolant level. 

Check the coolant after the engine is warmed up 

Start and warm up engine Stop the engine 

Check if the coolant level is between the upper 

and lower limit. 

When the coolant level is below the LOWER limit, remove reservoir tank cap and add coolant till upper limit. 

(Add coolant or diluted original liquid). 

Recommended coolant: CFMOTO coolant 

Standard density:50% 

( 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.) 

If the coolant reduces very fast, check if there is any 

leakage.The cooling system may be mixed with air 

when there is no coolant in the reservoir tank and the 

air should be dischargedbefore adding coolant.


Coolant replacement 

Remove radiator cover and reservoir cover 

Put laver under water pump, then loosen bolt 3 

Disassemble connecting hose 

Take coolant away from reservoir 

Note 

When engine is hot, DO NOT open radiator cover, 

otherwise steam gas or hot coolant will cause hurt 

Coolant is poisonous, DO NOT drink or splash it 

to skin, eyes, and clothes. 

Keep the coolant in a safe place and away from 

reach of children. 

When necessary, use clean water to wash radiator 

Assemble water hose tighten nut 

Fill new engine coolant into radiator 

Loosen bolt when coolant flow out from 

bolt holetighten boltWhen coolant reach full, then 

close and tighten radiator cover. 

Start engine and run few minutes 

then stop engine, reopen radiator cvoer to check if 

full or not. 

In case of not full, then inject some more coolant 

till full 

 

Warning: 

Repeat above procedure several times. 

Make sure no air remaining in the radiator.

&)0272 

Pour coolant into reservoir and keep upper line and 

lower line , tighten reservoir cover. 

WarningDO NOT mix other brand coolant into 

reservoir tank 

Radiator pipe check 

Check every 100 hours or every 1000Km 

Check radiator pipe, clamps and coolant leakage 

In case of damage or leakage, replace with new one 

Cylinder pressure check 

Cylinder pressure is very important signal for engine 

working condition, When necessary, need to check it. 

Cylinder pressure: 1000kPa 

If pressure is too low, it’ll cause: 

Cylinder will be over-worn 

Piston or piston ring will be worn 

Piston ring blocked into groove 

Valve seat closing improperly 

Cylinder gasket damage or other defectives 

Note In case of too low cylinder pressure, please 

check above situation. 

Cylinder pressure measurement 

Note Before measurement, cylinder head cover bolt 

is tighten under required torque and valve clearance is 

adjusted properly 

Engine warm-up before measurement 

Fully chargeable battery 

Disassemble spark plug 1 

Install cylinder compression gauge 2 on spark 

plug hole and tighten bolt 

Fully open choke 

Start engine to run few seconds, read and write 

highest cylinder pressure value 

ToolCylinder compression gauge 

Adaptor


Oil cool&Lubrication system 

Note 

After initial 20 hours or 250km run-in, oil and element 

should be replaced; 

Every100 hours or 1000Km, change oil and replace with 

element 

Every 10 hours check oil level during oil&element 

life-cycle 

Do oil level check after engine warm up and use oil 

guage 

Oil coolant&lubricant level check 

Due to evaporation or combustion, coolant or lubricant 

will be decreased, regular check is necessary. 

Check level if between guage upper and lower line 

Recommended coolant&lubricant: SAE15W/ 

40SF 

Oil coolant leakage check 

Check oil radiator pipe,oil pump, oil hose, connecting 

place leakage 

In case of leakage, disassemble and repair(refer to 

chapter 4) 

Check oil hose aging, damage or crack 

Rubber hose will be aging due to hot condition or 

long-time use, cooling system heated will cause hose 

crack. Check if small crack by hand. 

In case of bad condition, replace with new one 

Check hose clamps or clips, if loosen happens , 

please tighten. 

Check if dustor mud blocked or damaged for oil radiator 

element 

Improve or repair radiator elements and use water or 

compress air to keep clean 

If damaged area of radiator element is over 20%, please 

replace with new one

&)0272 

Engine oil change 

Pull out oil guage 1, oil bolt 2 and gasket 3; 

Before engine is cooled down completely, 

release oil very fast till no oil remaining. 

Use solvent to clean guage, bolt and gasket. 

Install gasket and bolt 

Bolt torque: 30N.m 

Add new oil 

Put oil guage into crankcase,start engine, and 

run several minutes at idle speed, then stop engine 

3 mintues later, use oil guage to check if oil level is 

between upper limit line and lower limit line 

Note: 

Oil change must be in hot engine condition. 

When oil filter element changed, oil must be also changed. 

Oil filter element replacement 

Disassemble related partsSee oil change chapter 

Use special tool to disassemble oil filter element 

Install gasket and bolt 

Use special tool to install new element 

Filling oil and check 

See oil change chapter 

Toolspecial wrench for oil element 

Oil change volume 

Only oil change: 2200mL 

If also replace element:2300mL 

Engine overhaul: 2600mL 

Outside oil hose check 

Check outside oil hose 

In case of oil leakage or damage, 

replace with new oil hose


Oil pressure check 

Oil pressure is very important signal to reflect engine 

working condition 

Oil pressure:130~170kpa when RPM=3000r/min 

Pressure too high or too low will cause: 

 

If pressure is too low 

Oil element jammed 

Oil leakage 

O-ring damage 

Oil pump failure 

Combination of above 

If pressure is too high 

Oil viscosity too high 

Oil passage jammed 

Combination of above 

Oil pressure measurement 

Remove bolt plug of main oil passage 

Connect tachometer with high-tension cable 

Install oil pressure guage 

and adaptor in main oil passage 

Enigne warm-up 

Summer: run 10 minutes at 2000r/min 

Winter: run 20 minutes at 2000r/min 

After warm-up,increase engine speed to 3000r/min, 

then read and write valueshownby oil 

pressure guage 

After measurement, tighten bolt coated anaerobic 

adhesive with below-stated torque 

Torque: 23N.m 

Tool: Oil pressure guage 

Tachometer

&)0272 

Clutch engagement speed and locked speed check 

Engine equiped with centrifugal type automatic clutch 

Install engine on vehicle to check engagement 

speed and locked speed. Before check, need to 

check drive train system and warm up engine. 

Clutch engagement speed check 

Connecting tachometer with high-tension cables 

Start engine 

Shift to high-speed gear 

Open throttle slowly to check engine speed when vehicle moves forward 

Engagement speed1800r/min~2400r/min 

In case of out of this range, please check below. 

Clutch shoe 

Clutch housing 

Primary pully and secondary pully 

For more detailes, please see chapter 3 Clutch check 

Clutch locked speed check 

Connecting tachometer with high-tension cables 

Start engine 

Shift to high-speed gear 

Try to use front and rear brakes simultaneously 

Instantly open throttle fully to check engine highest speed during test 

locked speed3300r/min~3900r/min 

Warning: 

DO NOT maintain over 5 seconds when engine is fully loaded 

otherwise cause clutch or engine damage 

In case of out of this range, please check below. 

Clutch shoe 

Clutch housing 

Primary pully and secondary pully 

For more detailes, please see chapter 6 Clutch check


Check Water Temperature Gauge 

When engine is not working, the water temperature 

should be in the “0” position. Start the engine 

to check if the indicator works. If the indicator 

is not working, do the maintenance in time. 

 

Lighting System 

Adjusting headlight light beam 

Turn the headlight beam adjusting screw with 

a cross screwdriver and adjust the high/low 

beam to meet the requirement.



 

 

 

 

 

 

 

 

 

Notes 

f the radiator cap is opened when the coolant temperature is abovethe pressure 

of coolant will drop and get boiled rapidly. The steam jet may cause danger and injury. Cover 

the cap with a piece of rag after the coolant temperature goes down and open the cap slowly. 

Inspection of coolant should be done after the coolant is fully cooled. 

Coolant is toxic. Do not drink or splash it to skin, eyes or cloth. 

If coolant splashes in your eyes, thoroughly wash your eyes with water and consult a doctor. 

If coolant splashes on your clothes, quickly wash it away with water and then with soap and 

water. 

If coolant is swallowed, induce vomit immediately and see a physician. 

Store the coolant properly and keep it away from reach of children. 

Check radiator fins for mud block and/or damage. Correct the bent fins. Clean off the mud 

with water and compressed air. Replace with a new one if the damaged fin area reached 

20%. 

The overhauling of the water pump can be done without removing the engine. 

Add coolant through reservoir tank. Do not open the radiator cap except when disassembling 

the cooling system for adding or drainage of coolant. 

Do not stain the plastic parts with coolant. In case of any coolant stains, flush with water 

immediately. 

After disassembly of the cooling system, check the joints for leakage with a radiator cap 

tester (available in the market). 

Refer to Chapter 10 for overhauling of temperature transducer. 

Inspection standard 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tightening torque

&)0272 

Trouble Shooting 

Sharp rise of water temperature 

Faulty radiator cap 

Air in cooling system 

Faulty water pump 

Faulty thermostat (thermostat is not open) 

Clogged radiator pipe or cooling pipes 

Damage or clogged radiator fin 

Coolant is not enough 

Faulty or malfunction of fan motor 

No rise or slow rise of water temperature. 

Faulty thermostat (thermostat is not closed) 

Faulty circuit of water temperature display 

Coolant leakage 

Faulty water seal 

O-rings are aged, damaged or improperly sealed. 

Washers are aged, damaged or improperly sealed. 

Improper installation of pipes or hoses 

Pipes and/or hoses are aged, damaged or improperly sealed 

Sharp rise of engine oil temperature 

Air in cooling system 

Faulty engine oil pump 

Clogged radiator pipe or cooling pipes 

Damage or clogged radiator fin 

Engine oil is not enough 

Faulty or malfunction of fan motor 

No rise or slow rise of water temperature. 

Engine oil leakage 

Faulty water seal 

O-rings are aged, damaged or improperly sealed. 

Washers are aged, damaged or improperly sealed. 

Improper installation of pipes or hoses 

Pipes and/or hoses are aged, damaged or improperly sealed

Performance Check 

Checking coolant density 

Note: 

Open the radiator cap after coolant is fully 

cooled. 

Remove: 


Radiator cap (counter clockwise) 

 

Check with a densimeter if the coolant density 

adapts to the local temperature. 

Check coolant for stains or impurities. 

Inspection of radiator cap 

Note 

Open the radiator cap after the coolant is fully 

cooled. 

Remove: 

Front top cover 

Radiator cap 

Note 

Apply coolant on the sealing surface of radiator 

cap before attaching the tester to the radiator 

cap. 

Install the radiator cap tester to the radiator 

cap; 

Apply the specified pressure (radiator cap 

opening pressure) for 6 seconds and make 

sure that there is drop in pressure. 

Opening pressure of radiator cap: 

108k3D1.1 kgf/cm

&)0272 

Pressure testing of 

cooling system 

Install the radiator cap tester to the radiator 

cap;Apply the specified pressure (radiator 

cap opening pressure) for 6 seconds. 

Note 

Do not apply pressure over the specified pr 

essure [108kpa(1.1kgf/cm2)], or the coo 

ling system may be damaged.In case there 

is any pressure leakage, check the pipe, 

joint parts, joints of waterpump and drain 

age Replacing Coolant, Air Discharge 

Preparation of coolant 

Coolant is toxic, DO NOT drink or splash it 

to skin, eyes, and clothes. 

If coolant splashes in your eyes, thoroughly 

wash your eyes with water and consult 

a doctor. 

If coolant splashes on your clothes, 

quickly wash it away with water and then 

with soap and water. 

If coolant is swallowed, induce vomit immediately 

and see a physician. 

Store the coolant properly and keep it 

away from reach of children. 

Note 

Mix the coolant (undiluted) with soft water 

according to the temperature 5 

ę lower 

than the actual lowest local temperature. 

Coolant should be made from undiluted 

coolant with soft water. 

Standard density of coolant: 

Recommended coolant: CFMOTO coolant 

(Direct application without having to be 

diluted) Drainage of coolant 

Remove radiator cap cover 

Note :Open the radiator cap after the coolant 

is fully cooled. Remove: 


Radiator cap. (

Remove drain bolt 

Remove drain bolt, seal gasket from 

water pump, and drain coolant. 

After drainage, assemble with a new seal 

gasket, drain bolt and tighten 

 

 

Reservoir Tank 

Remove two mounting bolts and water pipe 

on reservoir tank; 

Remove reservoir tank; discharge coolant; 

Flush reservoir tank. 

Install reservoir tank; 

Install water pipe.

&)0272 

Adding Coolant 

Add coolant through radiator cap. 

Start the engine and discharge air from 

cooling system. 

Check from filling port that air is fully 

discharged from cooling system and install 

the radiator cap. 

Remove reservoir tank cap and add coolant 

till the upper limit. 

Note: 

Check coolant level when the vehicle is on 

an even ground. 

Air Discharge 

Discharge the air from cooling system 

according to the following steps: 

1. Remove drain bolt 

discharge air and install it. 

2. Start the engine and run it several 

minutes at idle speed; 

3. Quickly increase throttle 3~4 times to 

discharge air from cooling system; 

4. Add coolant till filling port; 

5. Repeat step 2 & 3 till no more coolant 

can be refilled; 

6. Check coolant level in reservoir tank 

and refill till upper limit,and install 

reservoir tank cap.

Engine Coolant 

The coolant used in cooling system is a mixture of 50% 

distilled water and 50% ethylene glycol antifreeze. This 

mixture provides the optimized corrosion resistance 

and fine heat protection. The coolant will protect 

the cooling system from freezing at temperature 

above If the vehicle will be operated at the 

environmental temperature below the mixing 

ratio of coolant should be increased to 55% 

 

or 60% according to the figure on the right. 

Warning: 

Use high quality ethylene glycol base antifreeze and 

mixed with distilled water. Never mix an alcohol base 

antifreeze and different brands of antifreeze; 

The ratio of antifreeze should not be more than 60% or 

less than 50%;Do not use anti-leak additive; 

Warning 

DO NOT open radiator cap when the 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 accidental 

swallow or stains, flush with plenty of water and consult 

the doctor immediately. 

Keep coolant away from reach of children. 

Inspection of Cooling Circuit 

Remove radiator cap and connect testerto 

filler.Warning! 

Do not open the radiator cap when the engine is still 

hot. 

Give a pressure of 120 kPa and check if the cooling 

system can hold this pressure for 10 seconds. 

If the pressure drops during this 10 seconds, it indicates 

that the there is leakage with the cooling system. 

In this case, check the complete system and replace 

the leaking parts or components. 

Warning!When removing the radiator cap tester, put a 

rag on the filler to prevent splash of coolant. 

 

Do not allow a pressure to exceed the radiator cap 

release pressure.

&)0272 

CheckandCleanofradiator 

and Hose Radiator cap Check 

Remove radiator cap 

Install radiator cap to cap tester 

Slowly increase pressure to 

93.3-122.7 kPa and check if the cap 

can hold the pressure for at least 10 seconds. 

If the cap cannot meet the pressure 

requirement, replace it. 

Radiator Cap Valve Opening Pressure: 

Standard: 93.9-122.9 kPa 

Tool: Radiator Cap Tester 

Radiator Inspection and Cleaning 

Remove dirt or trash from radiator 

with compressed air; 

Correct the radiator fins with a 

small screwdriver; 

Radiator Hose Inspection 

Check radiator hoses for leakage or 

damage. 

Leakage or DamageReplace 

Check tightening of clamps. Replace the 

clamps if necessary; 

After inspection and cleaning of radiator and 

hoses, check coolant level. Fill coolant if 

necessary.

Fan Inspect 

Remove fan motor from radiator 

Turn the vanes and check if they can turn 

smoothly; 

Check fan motor: Make sure that the battery 

applies 12 volts to the motor and the motor 

will run at full speed while the ammeter shall 

indicate the ampere not more than 5A. 

If the motor does not run or 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 Bolt Tightening Torque: 10N.m 

 

Inspection of Thermoswitch 

Check the thermoswitch for closing or opening 

by testing it at the bench as illustrated. 

Connect the thermoswitch to the circuit 

tester, place it in a vessel with engine oil. Place 

the vessel above a stove. 

Heat the oil to raise the temperature slowly 

and take the reading from thermometer 

when the thermoswitch closes and opens. 

Tool: ammeterThermoswitch Operating Temperature 

Standard: (OFF-ON): Approx. 

(ON-OFF): Approx. 

Warning: 

Avoid sharp impact on thermoswitch. 

Avoid contact of thermoswitch with thermometer 

or vessel 

Installation: Use a new O-ring and tighten 

the thermoswitch to the specified torque: 

Thermoswitch Tightening Torque: 17N.m 

Check coolant level after installation of 

thermoswitch. Fill coolant if necessary.

&)0272 

Water Temperature Sensor Inspect 

Place a rag under water temperature sensor 

and remove it from cylinder head. 

Check the resistance of water temperature 

sensor as illustrated on the right. Connect the 

temperature sensorto the circuit tester, 

place it in a vessel with engine oil. Place 

the vessel above a stove. 

Heat the oil to raise the temperature slowly 

and take the reading from thermometer and 

ohmmeter 

Tool: Ohmmeter,Thermometer 

Temperature/Resistancetable 

Temperature 

 

Resistance 

 

50 80 100 120 

15416 524 273 162 

Installation: Apply a little thread locker and install 

it to the cylinder head by tightening to the 

specified torque. 

Water Temperature Sensor Tightening 

Torque: 10N.m 

Warn: 

Avoid sharp impact on temperature sensor 

void contact of temperature sensor with 

thermometer or vessel 

After installation, check the coolant level. 

Fill coolant if necessary. 

Inspection of Thermostat 

Remove thermostat case 

Remove thermostat

Check thermostat pellet for cracks, 

if damaged,replace it. 

Test the thermostat in the following steps: 

Pass a string between thermostat flange as illustrated 

on the right; 

Immerse the thermostat in a beaker with water. 

Make 

sure that the thermostat is in the suspended position 

without contact to the vessel. Heat the water 

by placing the beaker above a stove and observe 

the temperature rise on a thermometer; 

Take the temperature reading from thermometer 

when the thermostat valve opens. 

Thermostat Opening Temperature: 68-74 

Tool:thermometer 

Keep heating the water to raise the water 

temperature. Just when the water temperature 

reaches the specified value, the thermostat valve 

should have been lifted by 3.5-4.5mm 

Thermostat Valve Lift Standard: 

Water temperature: 

Valve lift: 3.5-4.5mm 

Either thermostat opening temperature or 

thermostat valve lift not conformed to the standard, 

replace it. 

Installation:Reverse the removal procedure for 

installation. 

Apply coolant to the rubber seal of thermostat. 

Install thermostat case. Tighten to the specified 

torque: 

Tightening Torque: 10N.m 

Water Pump 

Removal and Disassembly 

Drain coolant 

Note: Before draining coolant, check water pump 

for oil or coolant leakage. In case of oil leakage, 

check the water pump oil seal, O-ring. In case of 

coolant leakage, check the water seal.

&)0272 

Release clamps and remove water hoses 

Release bolts and remove water pump 

Remove O-ring 

Warning: Do not reuse the O-ring 

Remove the overflow tube 

Release water pump cover screws, water 

pump cover and gasket 

Remove E-ring and impeller 

Remove seal ring and rubber seal

Remove mechanical seal with special tool 

Note: The mechanical seal does not need to 

be removed if there is no abnormal condition. 

Warning: Do not reuse a removed mechanical seal 

 

 

Put a rag on the water pump body 

Remove oil seal. 

Note: The oil seal does not need to be removed if 

there is no abnormal condition 

Warning: Do not reuse a removed oil seal 

Remove bearing with special tool. 

Note: The bearing does not need to be removed if 

there is no abnormal noise. 

Warning: Do not reuse a removed bearing. 

Inspection of Water Pump 

 

Check the play of bearing 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 the bearing if there is abnormal condition; 

Mechanical Seal 

heck mechanical seal for damage, pay special 

attention to the seal face; 

In case of leakage or damage, replace the mechanical 

seal. If necessary, also replace the seal ring

&)0272 

Oil Seal 

Check oil seal for damage. Pay special attention 

to 

the oil seal lip; 

In case of damage or leakage, replace the 

oil seal; 

Water Pump Body 

Check the mating mace of water pump body 

with bearing and mechanical seal 

Damage: Replace 

Impeller 

Check the impeller and shaft for damage. 

Damage: Replace 

Assembly and Installation of Water Pump 

Install oil seal with special tool; 

Tool: Oil Seal Installer 

Note: The stamped mark on the oil seal 

faces outside 

Apply a little grease to the oil seal lip.

Install mechanical seal with a suitable socket wrench 

Note: Apply sealant to side of mechanical 

seal 

 

 

Install bearing with special tool 

Tool: Bearing Installer 

Note: The stamped mark on the bearing faces outside. 

Install seal ring to impeller 

Clean off the oil and grease from mechanical 

seal and install it into the impeller. 

Note: side of mechanical seal faces impeller 

Apply grease to impeller shaft 

Install impeller shaft to water pump body.

&)0272 

Install E-ring to water pump shaft; 

Install new gasket to water pump body; 

Install water pump cover and tighten the bolts and 

bleed bolt. 

Water Pump Cover Bolts Tightening Torque: 

6N.m 

Check impeller for smooth turning. 

Install the new O-ring 

Note: 

Use the new O-ring to prevent oil leakage; 

Apply grease to O-ring 

Install overflaw pipe.

Install water pump and tighten the bolts to 

the specified torque; 

Water pump bolts tightening torque: 10N. 

m 

 

 

ote: Set the water pump shaft slot 

end to oil pump shaft flat 

side 

Connect water hoses 

Add coolant

&)0272 

Coolant System Chart

Engine Oil Cooling and Lubricating System Illustration 

Engine parts (such as piston, cylinder,camshaft) in high-speed running should be lubricated. 

Use special engine oil for engine lubrication as lubrication function, as well as functions like 

cleaning, anti-rust,sealing and cooling. 

Oil drain bolt Clutch 

Washer,Oil drain boltCrankshaft 

Oil Pump Cylinder body 

Oil bypass valvePiston 

Oil inlet,Oil RadiatorCamshaft 

Oil outlet,Oil RadiatorOne-way clutch 

Oil FilterEngine dip rod 

Oil radiator

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Inspection Information 

Engine Removal and Installation5-2 

Romoval and Installation of Gearshift5-7 

Removal and Installation of Front and Rear 

axle5-5 

Inspection Information 

Note: 

When removalEngine,pls use jack to support the bodywork.Don’t damnify the frame,body 

of engine,bolt and cable etc. 

Please blind up the frame when removalthe engine. 

Dont removalengine from the bodywork when operateing as follows: 

OIL PUMP 

CARBURETOR,AIR FILTER. 

COVER,CYLINDER HEAD,CYLINDER HEAD,CYLINDER,CAMSHAFT 

CVTSYSTEM,LEFT SIDE COVER 

DECELERATE BOX 

RIGHT SIDE COVER,AC MAGNETO,WATE PUMP 

PISTONPISTON RING,PISTON PIN 

Separately the engine from the bodywork when operating as follows: 

CRANKCASE 

 

TIGHTEN TORQUE INSTALL BOLT UNDER ENGINE 

JOINT NUT OF CUSHION MAT

&)0272 

Disassembly Engine 

Romove plastic parts Chapter two 

Romove air filter 

Romove carburetor 

Romove hoop 

Romove water inlet hose of engine 

Romove inlet and outlet oil hose of engine 

Remove bolt 

Romove shift of Gearshift 

Remove hoop 

Romove water outlet hose of engine 

Separate bush.Remove magneto 

connectorspeed sensor connector,trigger 

connectorwater temperature sensor 

connector,gear position sensor.


Remove spark plug 

eparatejacket of starter relay,remove nut, 

romove anode cable of starter relay. 

 

Remove bolt and cathode cable of starter rely 

Remove fixing bolt of engine

&)0272 

Remove hoop of air inlet and outlet duct for 

CVT 

Remove carburetor 

Remove air filter 

Remove muffler 

Remove gearshift


Installation of engine 

Put engine on the bodywork. first,install two 

bolt and nut,then,install upper bracke and rear 

bracket. 

Tighten moment£ŗ 

upper bracke of engine: 

Adown fixing bolt of engine: 

Install water inlet and out let hose in the engine 

by hoop 

Install anode and cathode cable of starting 

Joint the connector of electrical cable. 

Install cap of spark plug 

Install shift of gearshift 

Install air filter,carburetor and other parts after 

remove. 

Removal and Installation of Frant and 

Rear axle 

Disassembly 

Hang the bodywork in the air by jack,keep it 

doesnt falling. 

Remove cover parts Chapter two 

Remove front and rear wheels and rocker 

Chapter 9 

Remove air filter 

Remove carburetor 

Remove engine 

Remove rear brake caliper Chapter 

nine

&)0272 

Remove bolt and nut fixed in the frame of Front 

axle. 

Remove bolt and nut fixed in the frame of Rear 

axle.


Remove joint bolt(18 unit)in drive shaft, Front 

and Rear axle 

Remove Front and Rear axle,Drive shaft and 

Rear brake disc 

Installation 

Installation as contradictorily process of 

romove 

Bolt torque of Front axle1P 

Bolt torque of Rear axle:1P 

Bolt torque of Front and Rear drive shaft: 

1P 

 

Gearshift 

Disassembly 

Romove lef and right side cover 

Romove Top cover,Fuel tank 

Remove Front Fender 

Romove Bolt 

Romove shift of Gearshift fixed in engine. 

Romove Bolt(2 units) of Gearshift by fixed in 

bodyworkRomove Gearshift. 

Installation 

Installation as contradictorily process of 

romove 

Need to inspect agility of Gearshift,if not,adjust 

the shift of Gearshift.in order to keep 

nicety for Gearshift.

Engine Removal/Installation Orders and the Relative Page Numbers 

Item 

Description 

Disasse Inspection/ Assembl 

mbly Maintenance y 

Remarks 

Engine Water Hose/Pipe 6-2 6-68 

Periphery Left Side Cover 6-2 6-68 

Recoil Starter 6-2 6-49 6-68 

Spark Plug 6-2 6-67 

Cylinder head Cover 6-3 6-14 6-66 

Engine Tensioner 6-3 6-24 6-66 

Front Side Camshaft 6-3 6-21 6-64 

Cylinder/Tensioner Plate 6-4 6-15/6-23 6-64 

Cylinder/Timing Chain Guide 6-4 6-24/6-23 6-64 

Piston 6-5 6-25 6-61 

Starting Motor 6-5 6-3 6-61 

Oil Filter 6-6 6-61 

Sector Gear 6-6 6-60 

Water Pump 6-7 6-60 

Engine Sheave Drum 6-7 6-48 6-59 

Left Side Left Crankcase Cover/Magneto 

Stator 

6-7 6-48 6-59 

Magneto Rotor 6-7 6-47 6-59 

Starting Driven Gear 6-8 6-47 6-58 

Starting Dual Gear/Idle Gear 6-8 6-48 6-58 

Oil Pump Sprocket and Chain 6-8 6-58 

CVT Cover 6-9 6-50 6-57 

Drive Belt 6-9 6-36 6-56 

Primary Sheave/Secondary 

Engine Sheave 

6-9 6-30 6-56 

Right Side CVT Housing/Clutch Outer Face 6-10 6-51 6-56 

Clutch 6-10 6-28 6-55 

Timing Chain 6-10 6-23 6-55 

Gear Position Bolt 6-11 6-55 

Right Crankcase 6-11 6-52 6-54 

Front Output Shaft Components 6-11 6-43 6-54 

Driven Bevel Gear Components 6-11 6-43 6-54 

Shift Cam 6-12 6-40 6-54 

Guide BarFork 6-12 6-39 6-54 

Engine 

Drive Bevel Gear Components 6-12 6-38 6-53 

Center 

Main Transmission Shaft 6-12 6-38 6-53 

Transmission Counter Shaft 6-12 6-42 6-54 

Balancer Shaft 6-12 6-46 6-53 

Crankshaft 6-13 6-27 6-53 

Oil PumpPressure-limiting Valve 6-13 6-41 6-52 

Left Crankcase 6-52 

NotesArrowhead direction is for engine removal ordersReverse the direction for 

assembly and installation

&)0272 

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Remove rotor and woodruff key 

Tool: Rotor Remover

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Battery, Charging System

&)0272 

2YHUKDXO 

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1RWH 

Usually no hydrogen will be generated during charging except when overcharged. Keep away from fires 

when charging. 

Electrolyte is highly corrosive, splash to clothes, skin or eyes will cause burn or loss of sight. Wash with 

plenty of water if splashed. In case of splash into eyes, wash with plenty of water and consult the doctor. 

The electrolyte on the clothes may contact the skin as well, it will cause damage to the clothes 

if stained for a long time. Change a clothes and wash away the electrolyte. 

1RWH 

Spark arc may be generated when removing or joining the electrical parts with switch on and will damage 

the electrical parts such as rectifier. Operation should be done with ignition switch OFF. 

Remove battery from vehicle for charging and do not open the electrolyte cover. 

1RWH 

Replace if the battery service life expired. 

Keep the ignition switch OFF when removing electrical parts. 

Disconnect the negative (-) connection of battery if it is stored on the vehicle 

Fast charging is not recommended as it may reduce the battery life 

If battery is repeatedly charged and discharged fully (fully-charged and fully-discharged), it may cause 

damage to the battery or shorten the service life or lower the capacity of battery. In addition, the capacity 

of battery will also lower in 2~3 years even under normal use. So the battery should also be replaced. 

If the open voltage is less than 12.4V, charge the battery normally to raise the open voltage up to 12.4V. 

Refer to troubleshooting table (11-3) for inspection of charging system 

Refer to Page No.4 for the parts of charging system. 

Refer to Engine Maintenance for removal and installation of AC magneto. 

Inspection of battery should be done following the owner’s manual of battery tester.

Battery, Charging System 

Overhaul standard 

Item 

Standard 

AC magneto Model 

Permanent magnet alternator 

Output 

3-phase AC 

Resistance of charging coil (20? ) 0.2 0.3Ω 

Rectifier Type 3-phase loop rectification, 

controllable parallel connection, 

regulated voltage 

Battery 

Capacity 

12V18Ah 

Current Leakage 

Less than1mA 

Voltage between terminals Fully-charged 12.8V 

Insufficient Less than 11.8V 

charge 

Charging current/time Standard 0.9A/5~10hours 

Fast charge 4A/60minutes 


Battery overflow 

Check battery with recommended test meter: 

YUASA ‘ BM310 or equivalent 

Correct 

Measure the current leakage of battery. (11 -5) 

Current: below 1mA 

Incorrect 

Incorrect 

Faulty Battery 

Disconnect rectifier, and 

measure current leakage 

again. 

Current: less than 1mA 

Correct 

Correct Incorrect 

Inspect the charging coil of AC magneto. 

Incorrect 

Resistance: 0.2-0.3 

•Faulty rectifier •Short circuit with 

• AC magneto has short main cable 

Correct or open circuit. •Faulty ignition switch 

Inspect monomer voltage of battery and 

record it. (11-4) 

Start engine, turn on headlight with high 

beam. 

Inspect battery’s voltage between 

terminals at the engine speed of 

5000rpm. (11-5) 

Correct 

Charging system is correct. 

 

Incorrect 

Inspect rectifier system (11-6) 

Incorrect 

•Main cable has short/open circuit. 

•Faulty contact of connectors 

Correct

&)0272 

Battery 

Removal 

Note: 

Keep the ignition switch at OFF before operation. 

Remove: 

Open the FRONT TOP COVER 

Remove the rubber tie of battery. 

Loosen negative pole screw and disconnect 

negative lead. 

Remove positive pole cap and screw. 

Disconnect positive lead 

Remove battery. 

Installation: 

Reverse the removal procedure for installation. 

Note: 

Apply clean lubricant grease to the pole after 

installation. 

Install cap firmly on the positive pole after installation. 

Inspection: 

Measure voltage between battery terminals, and 

check test status. 

Complete test: 12.8V 

Insufficient test:

Connect charger’spositivewiretobattery’s positive pole. 

Connect charger’s negative wire to battery’s negative 

pole. 

Charging current/time: 

Standard: 0.9A/5~10hours 

Fast charge: 4.0A/60mins 


Note: 

Keep the electrolyte temperature under 45. 

Reduce current to adjust the temperature if it is too high. 

Fast charge will reduce battery’s life or cause damage 

to battery. Do not use fast charge unless in emergency 

case. 

Inspection of Charging System 

Inspect charging status 

Remove battery (11-4) and install a fully charged 

battery. 

Keep ignition switch at “OFF” position. 

Connect voltmeter between battery’s terminals after 

engine is started and warmed up. 

Note: 

Avoid short circuit when measuring 

Overvoltage may be generated when removing or joining 

thebatteryterminalswithswitchONandwilldamage 

the multimeter and the electrical parts. 

Operation should be done with ignition switch OFF. 

Use a fully charged battery for inspection. 

 

Start engine and turn on high beam. 

Increase engine speed slowly. Check voltage between 

battery terminals. 

Voltage between terminals at engine speed of 

(5000r/min): 13.5-15V 

Standard: 

Battery’s monomer voltage

&)0272 

Remove fuse box from inside of front fender. 

Connect amperemeter between battery negative pole 

and negative lead 

Measure current leakage with ignition switch at the 

“OFF” position. 

Note: 

If the measured current is higher than the maximum 

limit, the multimeter will be burnt. Therefore, measure 

the current by shifting from the high to the low range. 

Do not turn on the ignition switch when measuring 

the current. 

Current Leakage: less than 1mA 

When current leakage is higher than specified limit, 

there is fault with the return circuit. 

Disconnect terminals and connectors while 

measuring current to check out the faults. 

Rectifier/Regulator 

System inspection 

Note: 

Inspection can be done without removing the AC 

magneto from engine. 

Open the seat by key 

Remove Front fender 

Remove the rubber tie of battery and remove the 

battery 

Disconnect the 2 connectors of rectifier/Regulator

Check the connector terminals for loosening, bending, 

rust or come-off. 


Check the following items of the main cable terminals 

of the two rectifier connectors: 

Installation: 


Note: 

Wires, hoses and cables should be routed properly. 

(Charpter1) 

Regulator/Rectifier 

Measure the resistance between the 

terminals using a multimeter. 

If any of the resistance is not within the specified 

value, replace the regulator/rectifier. 

 

NOTE: 

If the multimeter reads under 1.4V when the 

probes are not connected, replace the multimeter 

battery.

&)0272 

AC Magneto inspection 

Remove engine cover 

Remove AC Magneto(yellow,yellow,yellow),pickup coil 

(black/white,green)connecter. 

Resistance of Generator Coil 

Measure resistance between the three lead wires; 

Replace a new stator coil if resistance not within 

specified value, 

Check that the generator core is insulated. 

Set multimeter at 1×10Ω 

Generator Coil Resistance : 0.1-0.4Ω(Yellow-Yellow) 

Insulate Resistance: 12-22KΩ(Yellow-Earthing wire) 

Generator Non-load Performance 

Start engine run it at 5000r/min 

Measure AC voltage between three lead wires of 

generator with multimeter. 

Replace the generator if the voltage is lower than 

the specified value. 

Set Multimeter to AC Position 

Generator Non-load Performance: 

200V (AC) at 5000r/min

Layout for All Electricity Equipment in Vechile 

Battery, Charging System

Ignition System 

Overhaul InfoIgnition coil 

Troubleshooting Starting Motor 

Inspection of Ignition System Starter, auxiliary relay 

Pickup CoilCircuit diagram of the ignition system 

Overhaul information 

Note: 

Exhaust gas contains toxicant, DO NOT keep the engine run for a long time in a 

closed or poorly ventilated place. 

nspect ignition system in the order of the content in troubleshooting table 

Refer to (12-10) for ignition system diagram 

Ignition advancer is integrated in the CDI, so the ignition system will automatically adjust ignition time. 

Be careful with CDI overhaul. Dropping or strong impact may cause damage to CDI. In addition, over 

voltage may be generated on CDI and cause damage to return circuit when removing or joining the connectors 

and terminals with switch ON .Always shut the ignition switch when overhauling. 

Most of the failures of ignition system are caused by faulty contacts between connectors and terminals. 

Check all the connections for any faults before overhauling. 

Select spark plug of proper heat value. Improper spark plug may cause malfunction or damage of engine. 

Refer to Chapter 13 for inspection of switches

&)0272 

Overhaul standard 

Item 

Standard 

Ignition 

CDI, battery DC digital ignition 

Spark Plug 

Standard 

DPR7EA-9(NGK) 

Optional 

DR8EA, D7RTC 

Spark plug gap 

0.8-0.9mm 

Ignition timing Maximum advance 

34° CA 

angle 

Peak voltage 

Ignition coil >200V 

Impulse generator 

4V 

Special tool 

Peak voltage oscillograph 07HGJ-0020100 

(Use together with digital muitimeter available in the market with input resistance over 10MΩ/DCV)



Engine cannot be started. 

Check fuel and air channels for any faults; If the fuel and air channels are normal, check the ignition 

system. 

Inspect ignition system for the following items: 

1. Spark inspection: 

Check in the following steps: 

Remove spark plug 

Remove spark plug cap 

Set high tension flexible cable end to earth 

Check spark arc 

It is normal if spark arc is more than 8mmwhile it is weak if it is less than 5 mm. 

If the spark is normal, check the spark plug. 

A faulty spark plug may be caused by the following reasons: 

(1) Spark plug is too wet and drowned. This is because the gas mixture is too thick. Cut the fuel and 

start the engine several times.. 

(2) Carbon deposit on spark plug—Mixture too thick or oil combustion in the combustion chamber. 

Clean and burnish the spark plug. 

(3) Cracks with spark plug insulator. 

(4) Spark plug electrodes have short circuit or it is obstructed between negative pole and thread or 

positive pole and input end. 

2. Faulty spark includes: no spark and weak spark. 

Inspect the following aspects if there is no spark. 

(1). Inspect ignition coil with multimeter or measurement in the following steps: 

1) Measure primary bobbin resistance, usually it is about 1Ω. 

2) Measure secondary bobbin resistance, usually it is about 4.2K. 

3) Measure damp resistance, usually it is about 5K. 

(2). Check CDI if it is out of service. 

(3). Check ignition circuit. Usually the voltage between black wire and earth wire (green) should be 12V. If 

there is no voltage, check from the battery positive terminal to the end of black wire. 

(4). Check the cable: check if there are any faults from the input of trigger signal (output of magneto pickup) 

to output (CDI terminal) and ignition output wire (black/yellow). 

(5). Check stop switch. When switch is at the ignition position, black/white wire should be cut with green 

wire. 

In case of weak spark, check the following: 

(1). Check CDI . 

(2). Check ignition coil and secondary coil whether there is short circuit, or fault with the damp resistance. 

 

Inspection the input pickup signal whether in right direction.

&)0272 

Note: 

If the spark plug generates no spark, check first if 

there is come-off, loosening or poor contact with the 

wiring, then measure the peak voltage. 

Different multimeter has different input resistance 

and shows different readings. Measure with digital 

multimeter with input impedance over10MΩ/DCV ). 

Connect peak voltage oscillograph with digital 

multimeter. 

Special tools 

Peak voltage oscillograph 519-922-150000 

(Use together with digital multimeter available from 

the market with input impedance over 10MΩ•DCV) 

Ignition Coil Primary Voltage 

Note: 

Measure after all the wires are correctly connected. 

Inspection should be done when the spark plug 

and spark plug cap are properly installed. If the spark 

plug is removed, the peak voltage will rise. 

Remove left side panel. (2-8) 

Keep spark plug in the cylinder head, install qualified 

spark plug on the spark plug cap and earth 

the engine. 

Open rubber cover of ignition coil, keep the ignition 

wire connected, and connect peak voltage oscillograph 

between primary wire terminal and frame body earth 

wire. 

Special tool 

Peak voltage oscillograph 

(Use together with digital multimeter available from the 

market with input impedance over 10M/DCV) 

Connecting terminals: black/yellow (+) –frame earth 

wire (-) 

Turn ignition switch to the ON position, and start 

engine. 

Peak voltage: above 150V


Primary voltage of the ignition coil 

Note 

Make sure that the battery voltage 12V, and the 

ignition coil lead is not disconnected. 

Refer to relevant manuals while using the multi-meter 

and the peak voltage adapter. 

Ignition Coil resistance 

Caution: Do not touch the tester probes or the 

spark plug to avoid electric shock.

&)0272 

Pickup Coil 

Note 

Measure after all the wires are correctly connected. 

Any wires disconnected can not make the correctly 

test. 

Inspect with compression pressure in the cylinder, 

spark plug and spark plug cap are properly installed. 

If the spark plug is removed and then do the 

measurement, the peak voltage will rise 

Removeengine panel 

Remove front top cover 

Disconnect CDI unit connector 

Connect peak voltage oscillograph terminal with the 

following terminal of main cable. 

Special tools 

Peak voltage oscillograph 07HGJ-0020100 

(Use together with digital multimeter available from the 

market with input impedance over 10M/DCV) 

Connecting terminal: blue/yellow (+) –green (-) 

Turn ignition switch to the ON position, and start 

engine. 

Peak voltage: over 2.0V 

Note: 

When measuring the voltage, do not touch the terminal 

with finger to avoid electric shock. 

If peak voltage obtained from CDI unit connector is 

improper, measure again the peak voltage on the AC 

magneto 2P connector. 

Ignition coil resistance: 

Digital multimeter in 

Ignition coil resistance 

Change a new ignition coil if the resistance isn’t in 

this range.


Pickup 

Remove: 

— AC magneto connector 

—Water pump inlet hose and outlet hose, and 

drain coolant. (Chapter 4) 

—Crankcase breather hose. (Engine Service) 

—Muffler. (Chapter 2) 

— Engine right side cover. (Engine Service) 

Note: 

Stator is installed on the right side cover and is 

attached by the magnet of rotor. Be careful not to 

hurt the fingers when removing. 

Loosen bolt, remove AC magneto stator and pickup. 

pickup resistance 

Installation 


Ignition Coil 

Remove left side panel (2-8) 

Remove spark plug cap from spark plug 

(Engine Service) 

Loosen bolt, and remove ignition coil. 

Installation 

 


Note: 

Wires, cables and hoses should be routed 

properly (Chapter 1)

&)0272 

Starting Motor


Brushes 

Check brushes for abnormal wear, cracks 

or moothness in the brush holder. 

Wear, cracks or non-smoothness: Replace 

Commutator 

Check Commutator for discoloration, 

abnormal wear or undercut. 

Abnormal wear or Damage: Replace 

If the commutator is discolored, polish with 

a sand paper and clean with a clean and 

dry cloth. 

If there is undercut, scrape out insulator B 

and make its distance between A as d 

d 1.5mm 

Armature Coil 

Check for continuity between each segment 

and between each segment and 

armature shaft using a multimeter. 

If there is no continuity between the segments 

or there is continuity between 

segments and shaft, replace the armature 

with a new one. 

Oil Seal 

Check Oil Seal Lip for damage or leakage. 

Damage or leakage: 

Replace with a new starting motor

&)0272 

Starter Relay 

Apply 12V to the terminals and check for 

continuity between the positive and negative 

terminals using a multimeter. 

If the starter relay clicks and continuity is found, 

the starter relay is OK. 

If there is no continuity when without the 12V, 

the relay is OK. 

Note: Do not apply the battery voltage to the starter 

relay for more than 2 seconds. This may cause 

overheat and damage the relay coil. 

Measure the coil resistance between the terminals 

using a multimeter. If the resistance is out of the 

specified value, replace the starter relay with a new 

one. 

Set multimeter to 1x10Ω position 

Starter relay coil resistance: 3-5Ω 

Auxiliary Starter Relay 

Apply 12V to starter relay positive and negative 

terminals and check for continuity between A 

and B using a multimeter. 

If the starter relay clicks and continuity is found, 

the starter relay is OK. 

If there is no continuity when without the 12V, 

the relay is OK. 

Set multimeter to 1x100Ω position 

Auxiliary starter relay coil resistance: 90-100Ω


Ignition System Diagram


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. 

Inspection of water temperature alarm may use fire source and liquid of high temperature. Do not put 

flammable matters nearby and take care not to get burnt. 

The temperature of headlight is quite high when turned on. Replacing with bare hand or stained glove will 

cause 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. 

—-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 with battery, 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 (?chapter 1) 

Refer to Chapter 2 for removal and installation of taillight and rear turning lights 

 

Fuse 

Light,bulb 

Item 

Standard 

Main 

20A 

Sub-fuse 15A3 

HeadlightHiLo 

12V-55/55W 

Brake lightTail light 

12V-21/5W 

Turning light 

12V-10W4 

Dashboard Indicator 

12V-1.7W 

Indicators 

12V-3.4W

&)0272 

TROUBLESHOOTING 

Head Light Cannot Turn On 

Broken fuse 

Open circuit with main cable 

Burnt Bulb 

Faulty Switch

Replacing Bulb 

Headlight Bulb 

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 13-5 

Disconnect headlight. 

Remove dust-proof cap, headlight connector, circlip 

andreplacewithanewbulb. 

Warning: 

Wear clean gloves when replacing bulb. 

Oil stains on the glass surface may cause 

break of bulb. Clean the stained surface with 

alcohol or isoamyl acetate. 

Make sure that the three pins of the bulb should 

be in line with the three positioning holes in the 

socket when replacing the bulb. 

Bulb specification: 12V-55/55W 

 

Reverse the removal procedure for installation 

After replacing the bulb, adjust headlight beam 

(chapter 3) 

Inspection of Headlight 

Turn the ignition switch to ON position, turn light 

switch to the illuminating position and check if the 

headlight is on. 

N: Normal 

till off: short circuit of main cable or broken main 

cable

&)0272 

Brake Light/Tail Light Bulb 

Remove 2 tapping screws, 

Remove tail light cover. 

Turn brake light/tail light bulb counter clockwise 

andremove it. 

Replace brake light/tail light bulb 

Bulb Specification: 12V-21/5W 


Front Turning Indicator Bulbs 

Remove headlight(13-5) 

Remove cover of front turning light 

Replace front turning light bulbs 

Bulb Specification: 12V-10W 

Rear Turning Indicator Bulbs 

Remove screw 

Remove rear turning indicator cover. 

Replace rear turning indicator bulbs. 

Bulb Specification: 12V-10W 

Reverse the removal procedure for installation.

Dashboard Lighter Bulb 

Remove dashboard (13-9) 

Remove bulb socket and replace with a new bulb. 

Bulb specification: 12V-1.7W 

Note: 

Main cable and wires should be routed properly 

(chapter 1) 


Dashboard Indicator Bulb 

Remove dashboard (13-9) 

Remove dashboard indicator socket. 

Remove indicating light bulb and replace with new 

one. 

Bulb specification: 12V-3.4W 


Headlight 

Remove: 

—Front fender(2-8) 

—3 fixing bolts of headlight cover. 

—Headlight cover 

—Fixing bolt of headlight, headlight connector, 

Headlight

&)0272 

Disconnect headlight connector. 


I‚‡r) 

Be careful not to damage main cable when 

assembling. 

After replacing, adjust the headlight beam. 

(chapter 3) 

Note 

Main cables and wires should be routed 

properly.( chapter 1) 

Ignition Switch 

Inspection 

Remove front & rear top cover(2-5) 

Disconnect 4P connector of ignition switch

Check according to the following table if the 

connector terminals are in continuity. 

 

 

 

Remove: 

Remove front cover of dashboard (2-5) 

Remove rear cover of dashboard (2-5) 

Disconnect 4P connector of ignition switch 

Remove bolt and ignition switch 


8‚€iv rq T v‡pu 

 

2-5 

2-6 

 

Check according to the following table if the 

connector terminals are in continuit.

&)0272 

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Brake Light Switch 

Disconnect brake light switch connector and check 

terminators for continuity. 

Hold the brake lever——Continuity 

Release the brake lever— No continuity 

No continuity: Replace brake light switch 

Horn 

Inspection: 

Remove front vent grille (2-3) 

Disconnect horn. 

Connect with a fully charged 12V battery and check 

if the horn sounds. 

Faulty Horn: Replace

Dashboard 

Run the vehicle at low speed and check if the speed 

indicator moves. 

Faulty speedometer:Replace 

Removal and Installation 

Remove front top cover (2-4) 

Remove front cover of dashboard 

Disconnect dashboard wire connector. 

Remove fixing nut and remove dashboard in the 

direction as illustrated on the right 


Note: 

Main cables and wires shall be routed properly.

&)0272 

Fuel Sensor 

Remove: 

—Fuel tank top cover with key 

—4fixingbolts 

—Fuel sensor 

Disconnect 2P connector 

Inspection 

Remove fuel sensor (refer to above steps) 

Connect 2P connector 

Turn ignition switch to ON 

Shake fuel sensor float with hand, locate the float position 

and check if it conforms to the fuel gauge reading. 

Non-conformity: -check main cable for damage or 

short circuit 

-Check fuel sensor and fuel gauge 

Remove fuel sensor 2P connector. 

Connect multimeter between 3P connector terminals. 

Shake float with hand and measure the resistance of 

float at different positions. 

Connection Terminal: 

Upper: Blue/White-Green: 4-10 (20) 

Lower: Blue /White-Green: 90-100 (20) 

Faulty fuel sensor:Replace

Put fuel sensor into installation hole of fuel tank. 

Fuel sensor should be fitted properly. 

No fuel leakage is allowed. 

Connect 2P connector 

Inspection of Fuel Gauge 

Switch on power supply and check if fuel level gauge 

functions normally. 

If fuel gauge works normally, 

Reverse the removal procedure for installation of plastic 

parts and seat.

&)0272 

Water Temperature Transducer 

Warning: 

Be careful not to get scalded and do not place 

flammables nearby. 

Warning 

Coolant must reach the switch thread, and 

the depth from vessel bottom to sensor top 

should be over 40mm. 

Keep liquid temperature for three minutes 

before measuring, and do not raise temperature 

sharply. 

The thermometer should not contact the 

vessel bottom. 

Disassembly: 

Remove right side panel (2-8) 

Disconnect and remove transducer. 

Put the transducer into a vessel with coolant, slowly 

heat up the liquid and measure the transducer 

resistance. 

Temperature Resistance 

50 154 16 

80 52 4 

100 27 4 

120 16 4 

Transducer out of range: Replace 

Install transducer 

Connect water temperature transducer connector. 

Fill coolant and discharge air 

Reverse the removal procedure for installation of 

plastic parts and seat.

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15-3


15-2 

joint the starting enriching to storage battery 

for 5 minutes, ethene pipe fuel return route 

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pressure 

 

 

carburetor stop up

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The engine cannot start or the 

starting difficulty 

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Symptom of failure Cause of Failure Solution measure 

The cylinder presses is too low 

Cylinder wear 

Replacement 

Piston curl attrition 

Replacement 

Air cylinder pad air leakage 

Replacement 

The air valve guide wears or the Repair or replacement 

valve seat is inappropriate 

Screwing tight 

The spark plug becomes less Inspection electricity 

crowded 

part 

The starting motor rotation is too Adjustment 

slow 

Adjustment 

The valve timing is not right 

8. The valve clearance is 

inappropriate 

The spark plug does not ignite 

Spark plug dirty 

The spark plug is moist 

The ignition coil has the breakdown 

Trigger winding abruption or short 

circuit 

Magneto breakdown 

CDI breakdown 

The carburetor lacks the fuel oil 

Clean or replacement 

Cleans dry or the 

replacement 

Replacement 

Replacement 

Replacement 

Replacement 



Replacement 

Replacement 


The engine does not have the 

idling regime or the idling 

regime is not steady 

Fuel tank air vent jamming 

Fuel tap jamming or breakdown 

Carburetor pin valve breakdown 

Fuel tank jamming 

5. Oil filter jamming 

The files position has not hung the 

neutral 

The valve clearance adjustment 

does not work as 

The valve seat is inappropriate 

The air valve guide has the flaw 

Rocking shaft or rocker arm shaft 

attrition 


Spark plug gap bad 

Ignition coil breakdown 

CDI breakdown 

9. Magneto breakdown 

10.The sub-room oil level is 

inappropriate 

11.Carburetor jet jamming 

12. Fuel tap breakdown 

13.The idling regime adjusting screw 

establishment is inappropriate 

Hangs the neutral 

Adjustment 

Replacement or 

conditioning 

Replacement 

Replacement 

Replacement 

Replacement or 

adjustment 

Replacement 

Replacement 

Replacement 

Adjusts the floating 

chamber altitude 

Clean 

Replacement 

Adjustment



In the engine high 

speed is not steady 

The engine exhaust 

has the blue smoke 

or the black smoke 

The engine power 

is insufficient 

Engine overheated 

The valve spring tension weakens 

Cam shaft attrition 


The spark plug gap is too small 

Matches was mad that the timing is not 

right 

Ignition coil breakdown 

The carburetor floating chamber is too low 

Spatial filter too dirty 

The fuel oil jamming causes the carburetor 

fuel oil feed insufficiency 

Fuel tap breakdown 

Lubricating oil excessive 


Air valve guide attrition 

The gas lacks the wall surface attrition or 

scratches 

Valve stem attrition 

Valve stem oil seal damage 

The valve clearance is inappropriate 

The valve spring tension weakens 

Matches was mad that the timing is not 

right 

Cylinder wear 


The valve seat is inappropriate 


The spark plug gap does not work as 

Carburetor jet jamming 

The carburetor floating chamber oil level 

does not work as 

Spatial filter too dirty 

Rocking shaft or cam shaft attrition 

Air feeder air leakage 

The lubricating oil are too many 

Piston top carbon deposit 

The lubricating oil are too few or are too 

many 

Oil pump breakdown 

Oil duct jamming 

The floating chamber oil level is too low 

Air feeder air leakage 

The lubricating oil is inappropriate 

Cooling system breakdown 

Replacement 

Replacement 

Cleaning up or replacement 

Adjustment or replacement 

Replacement 


chamber height 


Clean 

Replacement 

The inspection oil level 

leaves the excessive oil 

abreast in row 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Adjustment 

Replacement 

Replacement 

Replacement 

or 

conditioning 







Replacement 

Fastening or replacement 

The inspection oil level and 

trades the oil 

Cleaning up 

Inspects and increases or 

the reduction 

Replacement 

Cleaning up 



Fastening or replacement 

Trades the oil

&)0272 


Cylinder valves abnormal sound 

The valve clearance is too big 

The valve spring wears or breaks off 

Rocking shaft or cam shaft attrition 

Adjustment 

Replacement 

Replacement 

Piston abnormal sound 

Piston wear 

Cylinder wear 

Combustion chamber carbon deposition 

Piston pin or cotter hole attrition 

Piston curl or ring groove attrition 

Replacement 

Replacement 

Cleaning up 

Replacement 

Replacement 

Engine 

sound 

abnormal 

Timing chain link part abnormal sound 

The chain link elongates 

Chain wheel attrition 

The timing chain link tightener work is 

unusual 

Coupling abnormal sound 

The crank spline wears, damage 

The coupling internal spline wears, damage 

Crank abnormal sound 

Bearing abnormal sound 

The crankpin bearing wears or the 

agglutination 

The tolerance clearance is too big 

CVT abnormal sound 

Leather belt relaxation or attrition 

Driving disc roller attrition 

Replaces the chain link and 

the chain wheel 



Repair or replacement 

Replaces the crank 



Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

The coupling slips 

Changes the files 

not along or the 

deactivation 

Transmission system abnormal sound 

The gear wears or the damage 

Input or output shaft attrition 

Bearing attrition 

Bushing attrition 

Coupling hoof block attrition or damage 

The clutch spring tension weakens 

Outside coupling wheel disk attrition 

The leather belt wears or the relaxation 

The speed change operation gear breaks 

off 

The speed change pulls out the fork to 

twist 

Speed change drum attrition 

The selector rod adjustment is 

inappropriate 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement 

Replacement


Carburetor 


Torch-igniter assembly jamming 

Torch-igniter assembly channel jamming 

Cleaning up 

Cleaning up 

Starting difficulty Carburetor and actuating section Fastening, adjustment or 

attachment point air leakage 

The starting fills the work bad 

replacement seal 

Adjustment 

Idling regime or 

low speed bad 

High speed or 

medium speed bad 

Overflow or oil 

level fluctuation 

Cooling system / Radiator 

The deceleration valve jamming or 

becomes less crowded 

Deceleration valve channel jamming 

Air intake jamming 

Air admission bypass jamming 

The starting fills has not closed completely 

The idler screw is inappropriate 

The float is highly inappropriate 

Spray nozzle jamming 

Main air jet jamming 

Pin valve jamming 

Throttle valve work bad 

Oil filter jamming 

The floating chamber does not work as 

highly 

The starting fills has not closed completely 

The pin valve wears or the damage 

The pin valve spring breaks off 

Float work bad 

In the pin valve enters the dunghill or the 

boiler scale stops up 

Cleaning up or fastening 

Cleaning up 

Cleaning up 

Cleaning up 

Adjustment 

Adjustment 

Adjustment 

Cleaning up 

Cleaning up 

Cleaning up 

Adjustment 


Adjustment 

Adjustment 

Replacement 

Replacement 

Adjustment or replacement 

Cleaning up 


1 Canal jamming, radiator jamming 

2 The cooling system intake air, the 

coolant are few 

3 The water pump has the breakdown 

Engine overheated 4 Uses the inappropriate coolant 

5 The thermostat has the breakdown 

6 Cooling fan electrical machinery or hot 

sensitive switch out of control 

The engine coolant 

temperature is 

excessively low 

7 The cooling fan hot sensitive switch 

has the breakdown 

8 Very cold weather 

9 The thermostat has the problem 

Cleaning up 

Emits the air, to top up the 

refrigerant 

Inspection, replacement 

Replacement 

Replacement 


Replacement 

Covers the radiator 

Replacement 

Ignition system part 


Sparkless or the 

spark is too weak 

10 The igniter has the breakdown 

11 The spark plug has the breakdown 

12 The magneto has the breakdown 

13 Storage battery voltage insufficiency, 

expiration 

14 The ignition coil has the breakdown 

15 The trigger winding has the 

breakdown 






Inspection, replacement

500 - U5 (CF500-3) - Technical Service Manual.pdf - Mojo

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