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

1-7
1 OverhaulInformation
1
MainTechnical Parameter
Item Parameters
Models VR150T
Length 2034mm
Width 700mm
Height 1186mm
Wheel Base 1353mm
Engine Model 1P58MJ
Displacement 152.7ml
Fuel 90 Octane or above
Dry Weight 126kg
Number ofPassengers 2 人(Inl. Driver)
Max. Load 150kg
Front 100/80－16
Tyre Rear 110/80－16
Min. Ground Clearance 140mm
Turning Radius 4.0m
Starting Electric Start
Engine Type 4 Stroke Gasoline Engine
Cylinder Arrangement Single Cylinder,Horizontal
Combustion Chamber Semi-spherical
Valve Drive OHC Chain Drive
Bore×Stroke 58×57.8mm
Compression Ration 10.3∶1
Max. Power 7.0kw/7500r/min
Max. Torque 9N·m/6000r/min
Open 0°(1mm)BTDC
Inlet Close
30°ABDC
Open 35°BTDC
Valve Train
Outlet
Close 5°TDC
Lubrication Type Pressure & Splash
Oil PumpType Rotor type
Oil Filter Type Full flowfilter
Engine
Cooling Type Forced Water Cooling

1-8
Item Parameter
Air Filter type Paperfilter element
Type VacuumDiaphragm
Fuel device
Carburetor Diameter of valve
26mm
Type Dry, auto-centrifugal
Clutch Startingmode Auto-centrifugal
Gear type Bevel
InitialTransmission Reduction ratio 3.7700/3.13
Gear type Vertical
Secondary
transmission Reduction ratio 3.21
Type Vtypeteethbelt
Startingmode AutoCVT
Gearing
Gearbox Transmission
ratio
2.500~0.800
Right 38? Steering
device Steeringangle Left 38?
Front Disk
Braketype Rear Drum Disk
Frontwheel Cylinder
Buffer gear Suspension Rear wheel Swingarm
Frametype Weldedsteeltubeand
plate

1-9
1 OverhaulInformation
1
Troubleshooting Datasheet
Lubricating device
Item Standard Service
Limit
Replacing 0.8l－OilCapacity
FullCapacity 1.0 l －
·Specialfor4-stroke
Motorcycle
SAE-10W-40、20W-50
Use substituteoil only withinthe
followingcategory。
·APICategory ：SEorSF
Engineoile
·SAECategory：Select fromthe
lefttableaccordingtothe
temperature
Clearanceof
Inner&Outer
rotor
0.15mm 0.20mm
BodyClearance 0.15～0.23mm 0.25mm
OilPump
Rotor
Surface
Clearance
0.05～0.10mm 0.12mm
Item Standard
FuelTank
Capacity
Full Capacity 7.0l
Mark BS26
MainJet #97.5
Low Speed jet #15
Float Chamber level 30±0.5mm
Carburetor
Idle Speed 1600±150r/min

1-10
Cooling Device
Cylinder head、valve
Auto CVT
Item Standard
Fullvolume 0.88l
Volumeofsecondarywater
tank
0.11l
Coolant
capacity Standarddensity 30%(ratewhenusingoriginal
solution)
Openingpressureofwaterinletcap 108kPa(1.1kgf/cm 2)
Thermostat Temperature/ valveopen 72±2C?
Temperature/valvefullopen 88C ?
Overallopendisplacement 3.5 -4.5mm
Item Standard Servicelimit
Compression pressureof cylinder 700kpa(7.0kgf/
cm2 )-260r/min
—
IN 0.05mm — Valveclearance
EX 0.20mm —
Deflection degreeofcylinderhead —0.05mm
IN 30.74-30.86mm 30.69mm
Camshaft Heightofcamtip
EX 30.33-30.45mm 30.28mm
Innerdiameterofrocker IN/EX 10.000-10.015mm 10.10mm
Valverocker
Outer diameterofrocker IN/EX 9.978-9.987mm 9.91mm
IN 4.975-4.99mm 4.965mmExternaldiameterofvalve
rod EX 4.955-4.97mm 4.945mm
IN 5-5.012mm 5.04mmInnerdiameterofvalve
guide EX 5.012mm 5.04mm
IN 0.01-0.037mm 0.075mmClearancebetween valve rod
andguide EX 0.03-0.057mm 0.095mm
Thrownheightof guide IN/EX 11.9-12.1mm —
Valve
Valveguide
cover
Contactwidthofvalve seat IN/EX 0.9-1.1mm 1.8mm
Valvespring Deadlength(external/inner)
IN/EX 35.0/32.3mm 33.5/30.8mm
Item Standard Servicelimit
Movabledrivenfacecomp. 24.007-24.028mm 24.07mm
Outer diameterofdriving facecomp. 23.959-23.98mm 23.92mm
Transmission
DrivingWheel
Weight roller comp. 19.95-20.05mm 19.45mm
Beltwidth 21.7-23.3mm 20.7mm
Thickness of frictiondisc —2.75mm
Inner diameter ofclutch outer comp. 124.5-124.2mm 125mm
Deadlengthof clutch spring 144-146mm 140mm
Outer diameterofdrivenface 33.95-33.975 33.92mm
Clutchdriven
face
Innerdiameterofmovabledriven
face
34.000-34.025mm 34.06mm

1-11
1 OverhaulInformation
1
Deceleration Device
Item Standard
Replacement 0.15LEngine oil
Disassembly 0.15L
Recommended deceleration engine oil SAE15W-40/SF
Starting motor
Item Standard Limit
Starting motor Brushlength 10mm 7mm
C r a n k s h a f t 、P i s t o n 、C y l i n d e r
Standard （mm）
Item
VR150
Limit （mm）
Axial clearance 0.16-0.304 0.5Shaft big
endside
Radial clearance 0.005-0.017 0.05
Crankshaft
Playof crankshaft -- 0.10
Piston installing direction The seal “in”toward
inlet side
--
Outer diameter of Piston 57.97-57.99
57.92
Piston pin inner diameter 15.002-15.008 15.04
Piston pin outer diameter 14.994-15.000 14.98
Shaft small endside inner diameter 15.016-15.034 15.05
Clearance of cylinder& piston 0.02-0.04 0.08
Clearance of piston &pin 0.002-0.014 0.04
Clearance of pin &shaft 0.016-0.040 0.06
Piston ring（一）
0.02-0.044 0.07Clearance
tetween
Pistonring &
groove
Piston ring（二）
0.02-0.044 0.07
Piston ring（一）
0.15-0.30 0.45
Piston ring（二）
0.10-0.25 0.45
Piston ring
end gap
Oil ring 0.2-0.7 0.9
Piston
Installingdirection，piston ring Upper seal --
Inner diameter 58-58.019
58.049
Upper distortion -- 0.05
Roundness -- --
Cylinder
Column -- 0.05

1-12
Front wheel
Item Standard Limit
Bending,front wheel shaft -- 0.2mm
Vertical 0.8mm 2.0mmPlay ofwheelrim
Horizontal 0.8mm 2.0mm
Groove -- 1.6mm
Frontwheel
Tire
Air pressure 250kpa(2.5kgf/cm3)
--
Rear wheel
Item Standard Limit
Vertical 0.8mm 2.0mmPlay of wheel rim
Horizontal 0.8mm 2.0mm
Groove -- 1.6mm
Rear wheel
Tire
Air pressure 300kpa(3.0kgf/cm3) --
Brake system
Item Standard Limit
Brake handlefree travel 10-30mm --Front brake
Brake disc thickness 4mm 3mm
Brake handlefree travel 10-30mm --Rear brake
Brake disc thickness 4mm 3mm

1-13
1 OverhaulInformation
1
Battery、Charging system
Item Standard
Model P ermanent magnet
AC type
Output 3- phaseAC
AC magneto Motor
ChargingcoilResistance (20℃) 0.2 -0.3 Ω
Rectifier Three-phase annular
rectification
Silicon controlled
parallel-connection
regulatedvoltage
Capacity 12V8Ah
Fullycharged 12.8VTerminal
point
voltage
Insufficient charge <11.8V
Standard 0.9A/5~10H
Battery
Charging
current/time Quick 4A/1H
Ignitionsystem
Light 、Panel 、Switch、Pickup coil
Item Standard
Main 20AFuse
Auxiliary 10Ax2 5Ax2
Headlight （Hi/Lo）12V-35/35W
Brakelight/tail light 12V-21/5W
Turninglight 12V-10Wx4
Odometer indicator light 12V-1.7W
Fuel levelillumination light 12V-1.7W
Turning indicator light 3.4W-12Vx2
Light，Bulb
High beamindicator light 3.4W-12Vx1
Item Standard
Ignition CDIignition
Type NGK
Standard DPR7EA-9
Option
Spark plug
Spark plug clearance 0.7-0.8mm
Ignition timing Max. advanced angle 33°BTDC
Ignition coil 150VPeak voltage
Pulse generator 0.8V
≥
≥

1-14
Tightening torque
Item Torque N·m(kgf·m) Item Torque N·m(kgf·m)
Bolt,nut5mm 5(0.5) Screw 5mm 4(0.4)
Bolt,nut6mm 10(1.0) Screw 6mm 9(0.9)
Bolt,nut8mm 22(2.2) Boltwith flange, 6mmSH 10(1.0)
Bolt, nut10mm 34(3.5) Boltwithflange,nut
6mm
12(1.2)
Bolt, nut12mm 54(5.5) Boltwithflange,nut
8mm
26(2.7)
Boltwithflange,nut
10mm
39(4.0)
For others not listed in the chart, refer to the standard tightening torque.
Notes: 1.Apply some engine oil onthepart ofscrew thread and contact
surface.
2. Replace a new one when disassembling the locknut.
Type No. of Bolt
&Nut
Thread
diameter
Torque
N·m(kgf·m)
Remarks
Checking、adjusting
Check Gearboxoil /drainBolt
Engineoil filtercover
Drainoil,bolt
Spark plug
Lubricatingsystem
Oil plumpand mounting bolt
Screw,oil pumpplate
Coolantsystem
Waterdrainbolt
Watertemperatureindicator
Impeller,waterpump
Cylinder head/headcover
Cylinderheadcover bolt
Cylindercompoundbolt
Timing sprocketbolt
Tensionerspringholder bolt
Shaft，tensioner setthreadpin
Belt CVT system
Left sidecover bolt
Gearbox nut
Clutchspecialnut
Clutchnut
ACMagnetomotor
AC Magnetomotornut
Flange boltfor casing
Overriding clutchinner hex bolt
1
1
1
1
2
1
1
1
1
2
S2&L2
2
1
1
5
1
1
1
1
8
3
8
36
12
12
6
3
6
R1/8
7
6
8
5
8
8
6
14
28
12
14
6
6
22(2.2)
20(2.0)
25(2.5)
12(1.2)
10(1.0)
2(0.2)
8(0.8)
10(1.0)
10(1.0)
10(1.0)
30(3.0)&30(3.0)
9(0.9)
10(1.0)
13(1.3)
10(1.0)
59(6.0)
59(6.0)
53(5.3)
59(6.0)
12(1.2)
12(1.2)

1-15
1 OverhaulInformation
1
Frame body
Type No.of
Bolt&
Nut
Diameter
(mm)
Tightening torque
N·m(kgf·m)
Remarks
Engine disassembly
Enginesuspension mounting bolt
Enginesuspension shaftnut
Frontwheel,Frontsuspension, Steering
system
Handlebarlocknut
Steering handlemounting nut
Frontwheelaxlenut
Absorbermounting bolt(upper)
Rearwheel,Rearsuspension
Rear wheelaxlenut
Absorbermounting bolt(upper)
Absorbermounting bolt(lower)
Rear forkmountingbolt
Brakesystem
Frontbrakediscmounting bolt
Rear brakediscmounting screw
Frontbrake calipermounting bolt
Rear brakecaliper mountingbolt
2
1
1
1
1
4
1
2
2
2
5
3
2
2
10
10
25
10
12
8
16
10
8
10
6
8
8
8
55(5.6)
55(5.6)
68(7.0)
55(5.6)
80(8.1)
40(4.1)
140(14.3)
55(5.6)
30(3.1)
55(5.6)
12(1.2)
26(2.7)
30(3.1)
30(3.1)
Muffler
Mounting nut(Frontelbow)
Mounting bolt(Mufflerbarrel)
Other
Screw(Taillight/brake lightcomp.)
Screw(Rear turning indicatorlight
comp.)
2
2
6
2
8
10
4.2
4.2
26(2.7)
55(5.6)
1.8(0.18)
1.8(0.18)

1-16
Special tools
Toolname ToolNo. Usage
Fuelsystem
Adjusting toolfor mixed gas screw
Cylindercovercomp, Valve
Valve assemblyclipper
Valve guide reamer 5mm
Valve seat cutter
Valve lapper 27mm(45°IN)
Valve lapper 27mm(45°EX)
Belt CVT system
Multipurpose bracket
Clutch spring press tool
Decelerationsystem
Drive shaft press device
RollerBearing6202
RollerBearing6201
Bearing removingcombinationset
RollerBearing22x50x14
RollerBearing6301
RollerBearing6004
RollerBearing6205
Acgenerator/starting motor
Rotor puller
Front wheel, Front suspension
Steering system
Bearing remover shaft
Bearing remover head12mm
Press toolhandleA
Press toolsleeve28X32
Guide tool12mm
Locknut wrench
Handlebarbearingadjusting
wrench
Bearing removingcombinationset
Rotor puller
Remover shaft
Remover hammer
Handlebar bearingretainer installer
A27x40mm
Installing shaft
Handlebar bearing retainer installer
B30x50mm
Installingshaft
Frontfork cover, press tool
Charging, Ignitionsystem
Peak voltageregulator
Adjustingmixed gas screw
Disassemble valve system
Repair/clean the valve guide
Amend the valve seat
Disassemble nuts,
Drive face/clutch cover
Disassemblenut, driven face
Press thedrive shaft
Press drivenshaft bearing
Disassemblebearing
Install drive shaft bearing
Install finalshaft bearing
Disassemble stator
Disassemblewheelbearing
Install wheelbearing
Disassemblehandlebarlocknut
/bearing adjustingnut
Disassemblehandlebar bearing
outer ring
Install top ball retainer
Install bottom retainer
Install inner ring
Measure peakvoltage