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(CF625-B/CF625-C)maintenanceinformation,disassemblyprocedure,check&adjustmentmethods,trouble-shootingandtechnicalspecifications.Thereareillustrations,drawingtoguideyouroperations.Chapter1mainlyintroducesgeneraloperationinformation,tools,vehiclestructureandbasicspecifications.Chapter2mainlyintroducescheck&adjustmentmethodsandhowtodovehiclemaintenance.Chapter3mainlyintroducesdisassembly,installation,adjustment,maintenanceandtrouble-shootinginformation.CFMOTOreservesrighttomakeimprove-mentsandmodificationstotheproductswithoutpriornotice.Overhaulandmainte-nanceshouldbedoneaccordingtoactualconditionofvehicle.ZhejiangCFMOTOPowerCo.,Ltd.Aug.2009CONTENTSMaintenanceInformation1VehicleBody,Muffler2Checking&Adjustment3Cooling&LubricatingSystem4EngineDisassembly&Assembly5EngineDisassembly,Check&Assembly6789FuelSupply&AirIntakeSystemFrontWheel,Brake,Suspension,SteeringSystemRearWheel,Brake,SuspensionSystemFront&Rearaxle10ElectricSystem1112Lighting,Odometer,SwitchTroubleshooting13ConversionTableItemExampleConversionPressure200kPa(2.00kgf/cm2)1kgf/cm2=98.0665kPa1kpa=1000Pa33kPa(250mmHg)1mmHg=133.322Pa=0.133322kPsTorque18Nm(1.8kgfm)1kgfm=9.80665NmVolume419ml1ml=1cm3=1cc1l=1000cm3Force12N(1.2kgf)1kgf=9.80665N1.MaintenanceInformationCautionsSafetyCautions1.Hazardouscomponentsinexhaust.Donotruntheengineinaenclosedorpoorlyventilatedplaceforlongtime.2.Donottouchtheengineormufflerwithbarehandsaftertheenginehasjuststoppedtoavoidburns.Wearlong-sleeveworkclothesandglovesforoperation.3.Batteryacid(dilutesulfuricacid)ishighlycausticandmaycauseburnstoskinandeyes.Flushwithwaterifsplashedtoskinandgetimmediatemedicalattention.Flushwithwaterifsplashedtoclothestoavoidburns.Keepbatteryandliquidawayfromreachofchildren4.Anti-freezeispoisonous.Donotdrinkorsplashtoskin,eyesorclothes.Flushwithplentyofsoapwaterifsplashedtoskin.Ifsplashedintoeyes,flushwithwaterandconsultthedoctor.Ifdrinkingthecoolant,inducevomitandconsultthedoctor.Keepcoolantawayfromreachofchildren.5.Wearproperworkclothes,capandboots.Ifnecessary,weredust-glass,glovesandsafetyglasses.6.Gasolineishighlyflammable.Nosmokingorfire.Alsokeepagainstsparks.Vaporizedgasolineisalsoexplosive.Operateinawell-ventilatedplace.7.Whencharging,Batterymaygeneratehydrogenwhichisexplosive.Chargethebatteryinawell-ventilatedplace.8.Becarefulnottogetpinchedbytheturningpartslikewheelsandclutch.9.Whenmorethantwopeopleareoperating,keepremindingeachotherforsafetypurpose.CautionsforDisassemblingandAssembling1.UsegenuineCFMOTOparts,lubricantsandgrease3.Cleanthemud,dustbeforeoverhauling2.Storethedisassembledpartsseparatelyinorderforcorrectassemble.4.Replacethedisassembledwashers,o-rings,pistonpinretainer,cotterpinwithnewones.5.Elasticretainersmightgetdistortedafterdisassembled.Donotusetheloosenedretainers.6.Cleanandblowoffthedetergentafterdisassemblingtheparts.Applylubricantsonthesurfaceofmovingparts.Measurethedataduringdisassemblyforcorrectassembling.7.Ifyoudonotknowthelengthofscrews,installthescrewsonebyoneandmakesuretheyarescrewedinwithsamedepth.8.Checkifthedisassembledrubberpartsareagedandreplaceifnecessary.Keeptherubberpartsawayfromgrease.9.Pre-tightenthebolts,nutsandscrews,thentightenaccordingtothespecifiedtorque,frombigtosmallandfrominnersidetoouterside.10.Replaceagedrubberpartsbeforeassembling.Donotmixvolatileoilandgreaseonthesurface,duetoaggressivnessoffuelandoil.11.Applyorinjectrecommendedlubricanttothespecifiedparts12.Usespecialtoolswherevernecessary.13.Whenballbearingdisassembledbypressingballring,itcannotbereused.Caution………………………………1-1NumbersMarkingLocations……….1-3MainParametersTable……………1-4MaintenanceParametersTable…...1-6TighteningTorque…………………1-13Grease&Sealant…………………1-18Wiring,Pipe&CablesLayout……1-19FailureIndicator…………………….1-2314.Turntheinnerandouterringsofballbearingtomakesurethebearingwillturnsmoothly.Replaceifanyaxialorradialplayisfound.Ifthesurfaceisuneven,cleanwithoilandreplaceifthecleaningdoesnothelp.Whenpressingthebearingintothemachineortotheshaft.15.Installtheone-sidedust-proofbearingintherightdirection.Whenassemblingtheopentypeordouble-sidedustproofbearing,installwithmanufacturer’smarkoutward.16.Keepthebearingblockstillwhenblowingdrythebearingafterwashingclean.Applyoilorlubricantbeforeassembling.17.Installtheelasticcirclipproperly.Turnthecirclipafterassemblingtomakesureithasbeenseatedintotheslot.18.Afterassembling,checkifallthetightenedpartsareproperlytightenedandcanmovesmoothly.19.Brakefluidandcoolantmaydamagecoating,plasticandrubberparts.Flushthesepartswithwaterifsplashed.20.Installoilsealwiththesideofmanufacturer’smarkoutward.Donotfoldorscratchtheoilseallip.Applygreasetotheoilseallipbeforeassembling21.Wheninstallingpipes,insertthepipetilltheendofjoint.Fitthepipeclip,ifany,intothegroove.Replacethepipesorhosesthatcannotbetightened.22.Donotmixmudordustintoengineand/orthehydraulicbrakesystem.23.Cleanthegasketsandwashersoftheenginecasingbeforeassembling.Remo