CMSI Inc. VR150T User manual

CMSI
SERVICE MANUAL
VR150T
VERSION A

Servicing information 1
Vehicle body、muffler 2
Inspection & Adjustment 3
Lubricating system 4
Carburetor 、air filter 5
Cooling system 6
Disassemblyof engine 7
Cylinder head cover、cylinder head、
cylinder body、valve
8
CVTsystem 9
Gearbox 10
Right side cover、magneto、water pump 11
Crankcase body、crankshaft、piston set 12
Front wheel、front brake、front suspension、
steering system
13
Rear wheel、rear brake、rear suspension
system
14
Battery、charging system 15
Ignition system 16
Electric starting system、overriding clutch
17
Lighting、instruments & meters、switch 18
Circuit diagram、wiring diagram 19
Troubleshooting
FOREWORD
This manual contains an introductory descrip-
tion of procedures for inspection，maintenance,
overhaul，disassembly & assembly，removal
and installation of components and parts, trouble-
shooting and service data together with illustra-
tionsofourscooters
Chapter 1：general service information, tools，
vehicle structure and technical data.
C h a p te r 2：i n s p e c t io n a n d a d j u s t in g k e y
points，service guideline。
Chapter 3: and later：disassembly of parts and
c o m p o n e n t s ，i n s t a l l a t i o n ，o v e r h a u l a n d
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 cooters.
INDEX

ConversionTable
Item Example Conversion
Pressure 200Kpa
(2.00lgf/cm2)
33kpa(250mmHg)
1kgf/cm2=98.0665kpa 1kpa=1000pa
1mmHg=133.322Pa=0.133322Kps
Torque 18 ·N(1.8kgf-m) 1kgf·m=9.80665N ·m
Volume 419ml 1ml=1cm3=1cc
1l=1000cm3
Force 12N(1.2kgf) 1kgf=9.80665N

1-1
1 OverhaulInformation
1
Cautions 1-1 Special Tools ...1-16
Cautions for Disassembling andAssembling..1-3 Lubricant, SealingAgent . 1-18
VIN Number & Engine Number.. 1-6 Cable Routing ...1-20
Main Data Table .....1-7 Protecting Device for Hazardous
Overhaul Data Table.. ...1-9 Gas Proliferation .1-27
Tightening Torque .1-14 SecondaryAir Intake Device .1-28
Cautions for Operation
Safety Cautions
Warning: Hazardous components in exhaust. Warning: Do not touch the engine
Do not run the engine in a enclosed or or muffler with bare hands after the engine
poorly ventilated place for long time. has just stopped to avoid scalding. Wear
long-sleeve work clothes and gloves for operation.
Caution: Battery liquid(dilute sulfuric acid) Warning: Coolant is poisonous. Do not
is highly causitic and may cause burns to drink or splash to skin, eyes or clothes.
skin and eyes. Flush with water if splashed Flush with plenty of soap water if splashed to
to skin and get immediate medical skin. Flush with water and consult the doctor.
attention. Flush with water if splashed to If drinking the coolant, induce vomiting and
clothes to avoid burns. Keep battery and consult doctor. Keep coolant away from reach
liquid away from reach of children of children.
Caution: Wear proper work clothes, Warning: Gasoline is highly flammable. No
cap and boots. If necessary, were dust- smoking or fire. Also keep against sparks.
glass,gloves and mask if necessary. Vaporized gasoline is also explosive. Operate
in a well-ventilated place.

1-2
Caution: When charged, Battery may Warning: The asbestos dust on the brake
generate hydrogen which is explosive. drum is carcinogenic is breathed in.
Charge the battery in a well-ventilated Do not clean off the dust with compressed air.
place. Use cleaning detergent to avoid dust
proliferation.
Warning: Be careful not to get clamped Warning: When more than two people are
by the turning parts like wheels and operating, keep reminding each other for
clutch. safety purpose.

1-3
1 OverhaulInformation
1
Cautions for Disassembling and Assembling
■UsegenuineCMSI parts,■Cleanthemud,dustbeforeoverhauling
lubricants and grease
■Place and store the disassembled parts ■Replace the disassembled washers, o-rings,
Separately in order for correct assemble. ■Piston pin circlip, cotter pin with new ones.
Elastic circlips might get distorted after
Disassembled. Do not use the loosed circlips.
■Clean and blow off the detergent ■Measure the data during disassembly for
after disassembling the parts. Apply correct assembling.
lubricants on the surface of
movingparts.
■If not knowing the length of screws, ■Pre-tighten the bolts, nuts and screws, then
install the screws one by one and tighten tighten according to the specified torque,
withsametorque.Frombigtosmallandfrominnersidetoouterside.

1-4
■Check if the disassembled rubber parts ■Apply or inject recommended lubricant to
are aged and replace if necessary. Keep the the specified parts.
rubber parts away from grease.
■Use special tools wherever necessary ■If the disassembling of pressed ball bearing
is done by pressing the balls, do not use the
disassembled bearing.
■Turn the ball bearing with hands to ■Install the one-side dust-proof bearing in
make sure the bearing will turn smoothly. The right direction. When assembling the
.Replace if the axial or radial play is too big. open type or double-side dustproof bearing,
.If the surface is uneven, clean with oil install with manufacturer’s mark outward.
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.
■Keep the bearing block still when blowing ■Install the elastic circlip properly.
dry the bearing after washing clean. Apply Turn the circlip after assembling to make
oil or lubricant before assembling. Sure is has been installed into the slot.

1-5
1 OverhaulInformation
1
■After assembling, check if all the tightened ■Br ake f l u id and c o olan t may d a mage
parts a r e properly ti ghtened an d can move coati n g, plast i c and r u b b e r parts. F l u s h
s m oo th l y. t h es e p a rt s w i th w a te r i f s p l a s he d.
■In st al l o i l s eal w ith t h e s i d e of ■W h en i n s tall i n g pi p e s , i n s ert t h e pi p e t i l l
manufacturer’s m ark out w ard. the e n d . F i t t he pip e clip , i f an y, i n t o t h e
.do not f o l d o r s c r at c h t h e o i l s e a l l i p gro ove . R e p l a c e t h e p i p e s t h a t c a n n ot be
. ap p l y g r e as e t o t h e o i l s e a l l i p t i gh t e n ed .
b ef ore ass embling
■Do n o t mix m u d o r dust i n t o e n g i n e ■Cl ean th e ga s k e t s a n d washers of th e e n gi n e
or t h e h yd raulic brake sys t e m . cas es b e f o r e as s e m b l in g . Rem o v e t h e scrat ch es
o n t h e c o n t ac t s u rfa c e s b y p o l i s hi n g e v e nl y w i t h
a n o i l s t o n e .
■D o n o t t w i st o r b e n d t h e c ab l e s t o o ■W h e n a s s e mb l i n g t h e p a r ts o f c a p s, i n s er t t h e
m uc h. D i s to r t ed o r d a m ag ed c ab l es c ap s t o t h e g ro o v es , i f a n y.
may ca u s e p o o r o p eration.

1-6
Locationofserial No