春风CF8002ServiceManual

FOREWORDINDEXThismanualintroducesCF800-2maintenanceinformation,removal&installationprocedure,check&adjustmentmethods,troubleshootingandtechnicalspecificationsindetail.Thereareillustrationstoguideyouroperations.Chapter1mainlyintroducesgeneraloperationinformation,servicetools,vehiclestructureandbasicspecifications.Chapter2mainlyintroducescheck&adjustmentmethodsandhowtodovehiclemaintenance.Chapter3andfurtherchaptersmainlyintroduceremoval,installation,adjustment,maintenanceandtroubleshootinginformation.GeneralInformation1BodyandMuffler2InspectionandAdjustment3CoolingSystem4EngineRemovalandInstallation5AirIntakeSystem6IntakeManifold,CylinderHeadandCylinder7Crankcase,Crankshaft,Gearbox8CVTandClutch9EngineLubricationSystem10MagnetoSystem11FrontWheels,Brake,Suspension,Steering12RearWheels,Brake,Suspension13FrontDifferential,RearGearcase14ElectricalSystem15Lights,Instrument,Switches16Troubleshooting17CFMOTOreservesrighttomakeimprovementsandmodificationstotheproductswithoutpriornotice.Overhaulandmaintenanceshouldbedoneaccordingtoactualconditionofvehicle.AllrightsreservedZhejiangCFMOTOPowerCo.,Ltd.June.2011UnitConversionTableItemExampleConversionPressure200kPa(2.00kgf/cm²)33kPa(250mmHg)1kgf/cm2=98.0665kPa1kPa=1000Pa1mmHg=133.322Pa=0.133322kPsTorque18N·m(1.8kgf·m)1kgf·m=9.80665N·mVolume419ml(419cm3,419cc)419ml(0.419l)1ml=1cm3=1cc1l=1000cm3Force12N(1.2kgf)1kgf=9.80665N1-11GENERALINFORMATIONMAINTENANCEINFORMATIONOperationcautions1.Engineexhaustfumesarepoisonousandcanresultinlossofconsciousnessordeath.Donotruntheengineinanenclosedorpoorlyventilatedarea.2.Donottouchtheengineormufflerwithbarehandsaftertheenginehasbeenjuststoppedtoavoidburns.Wearlong-sleeveworkclothesandglovesforoperation.3.Batteryelectrolyte(dilutesulfuricacid)ishighlycausticandcanresultinburnsfromcontactwithskinandeyes.Ifyouspillelectrolyteonskin,flushwithwaterandseekformedicalattentionimmediately.Ifyouspillelectrolyteonclothes,flushwithwateriftoavoidburns.Keepbatteryandelectrolyteoutofreachofchildren.4.Coolantispoisonous.Donotdrinkorspillitonskin,eyesorclothes.Ifyouspillcoolantonskin,immediatelywashwithsoapandwater.Ifyouspillcoolantoneyes,flushwithwaterandseekpromptmediacalattention.Ifyouswallowcoolant,inducevomitandseethedoctor.Keepcoolantoutofreachofchildren.5.Wearproperworkclothes,capandboots.Ifnecessary,weredust-glass,glovesandmask.6.Gasolineishighlyflammable.Nosmokingorfire.Alsokeepgasolineawayfromsparks.Vaporizedgasolineisalsoexplosive.Operateinawell-ventilatedarea.7.Whenthebatteryisbeingcharged,itproducesexplosivegases.Chargethebatteryinawell-ventilatedarea.8.Becarefulnottogetpinchedbytheturningpartslikewheelsandclutch.9.Whenmorethantwopeopleareoperating,keepremindingeachotherforsafetypurpose.Cautionsforremovalandinstallation1.UsegenuineCFMOTOparts,lubricantsandserviceproducts.3.Cleanmud,dustbeforeservicing.2.Storetheremovedcomponentsseparatelyinorderforcorrectinstallation.4.Replacetheremovedwashers,o-rings,pistonpinretainers,cotterpinswithnewones.5.Elasticretainersmightgetdistortedafterdisassembled.Donotusetheloosenedretainers.6.Cleanandblowoffthedetergentafterremoval.Applylubricantsonthesurfaceofmovingparts.Measurethedataduringremovalforcorrectinstallation.7.Ifyoudonotknowthelengthofscrews,installthescrewsonebyoneandmakesuretheyarescrewedinwiththesamedepth.8.Checkiftheremovedrubberpartsareagedandreplaceifnecessary.Keeptherubberpartsawayfromgrease.9.Pre-tightenthebolts,nutsandscrews,thentorquetospecification.Thebasicsequenceisfrombigtosmall,frominnersidetooutersideandcriss-cross.10.Replaceagedrubberpartswhenassembling.Donotsplashgasoline,greaseontothesurface,asthiscouldcausedamage.Maintenanceinformation………….…1-1LocationofVIN/EIN…………………1-3Generalspecifications………………1-4Maintenancespecifications………1-6Tighteningtorquetable……………1-13Lubricantsandserviceproducts…1-19Wiring,pipes&cables………………1-20MIL/EVAPsystem…………………….2411-2ENGINEBREAK-INTherearemanymovablecomponentsinsidetheengine,suchaspiston,pistonring,cylinder,crankshaft,gearsandsoon.Duringinitialuseperiod,properrun-inforeverycriticalcomponentisnecessary.Break-incanhelpenginecomponentsmatcheachotherbetterandadjustworkingcondition.Carefultreatmentofanewenginewillresultinmoreefficientperformanceandalongerservicelife.Recommendedbreak-inperiod:First20hoursOperationguide:0~10HoursDonotoperatecontinouslyatmorethan50%throttleposition.Cooldowntheengineforevery5~10minutesafterevery1houroperation.Avoidsuddenacceleration.Varythethrottlepositionslowlyandsmoothly.Donotvarythethrottlepositionrapidly.10~20HoursAvoidlong-timerunatmorethan75%throttleposition.Donotopenthrottlecompletelyduringtheperiod.ATTENTION:1.Maintainandrepairasregularproceduresduringbreak-inperiod.2.Afterbreak-in,donotforgettocheckandmaintaintheenginebeforenormaluse.11.Applyorinjectrecommendedlubricanttothespecifiedlubricationpoints.12.Usespecialtoolswhennecessary.13.Whenballbearingisremovedbypressingsteelballs,itcannotbereused.14.Fingerturntheinnerandouterringsofballbearingtomakesurethebearingwillturnsmoothly.Replaceiftheaxialorradialplayistoobig