CROSSFIRE CF110 USER MANUAL
CROSSFIRE CF110 USER MANUAL This manual should be considered a permanent part of the motorcycle and should remain if it is resold. This manual contains the latest product information available before printing. Crossfire Motorcycles reserves the right to make changes at any time without notice. No part of this publication may be reproduced without written permission.
IMPORTANT PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. Please write the serial numbers of your motorcycle in the boxes below Chassis (VIN) Number Engine Number Key Number (If Available) Dealer Stamp CONSUMER INFORMATION FOR UNITED STATES Tampering with noise & emissions control systems is prohibited Owners are warned that the law prohibits: A.
WARRANTY Thank you for purchasing the CF110. Your CF110 Dirt Bike is warranted against defects in material and workmanship for the period of six months (6 months) from the date of purchase. Full service has to be conducted after 1 month of invoice date or after 10 hours of riding, whichever comes first. This warranty is limited to the original purchaser of product. Product found to be defective during that period will be repaired or replaced by Crossfire Motorcycles. at no charge.
CONTENTS IMPORTANT WARRANTY INFORMATION 04 SUSPENSION SYSTEM INTRODUCTION 06 FRONT SUSPENSION INSPECTION IMPORTANT SAFETY INFORMATION FRONT SUSPENSION ADJUSTMENT 07 - 08 36 - 38 36 36 -37 SAFETY INFORMATION FOR PARENTS 09 REAR SUSPENSION INSPECTION 37 SAFETY LABEL INFORMATION 10 REAR SUSPENSION ADJUSTMENT 38 COMPONENT LOCATIONS RIMS, TIRES & SPOKES 11 - 12 39 - 41 39 SERIAL NUMBER LOCATIONS 13 WHEEL INSPECTION HANDLE BAR LEVER CONTROLS 13 TIRE AIR PRESSURE 40 TIRE INSPECTION 40
INTRODUCTION Congratulations on choosing your Crossfire motorcycle. Your Crossfire Motorcycle was designed as a recreational motorcycle for off-road use only by a single rider. Before riding, take plenty of time to get acquainted with your motorcycle and how it works. To protect your investment, we urge you to keep your motorcycle well maintained. In addition to regular maintenance, it is just as important to observe and perform all pre-ride and periodic checks detailed in this manual.
IMPORTANT SAFETY INFORMATION Your personal safety, and the safety of those around you, is extremely important. Operating this motorcycle safely is an important responsibility. Crossfire Motorcycles has provided operating procedures and other information on labels and in this manual to help you make informed decisions about safety. This information will alert you to potential hazards that could harm you or others.
IMPORTANT SAFETY INFORMATION A motorcycle can provide many years of service and pleasure, provided you take responsibility for safety, properly maintain your motorcycle and understand the challenges you may encounter while riding. Listed below are some of the most important safety measures one should take when riding. Never Ride Without a Helmet. Helmets significantly reduce the number and severity of head injuries. Never ride your motorcycle without a helmet.
IMPORTANT SAFETY INFORMATION FOR PARENTS As a parent, your child’s safety is your first priority. Riding an off-road motorcycle is very fun. However, just like riding a bicycle, bad decisions can result in injury. As a parent, you can greatly prevent accidents by making informed decisions about if, when and how your child will ride. Always supervise your child when he/she is riding. Please refer to the Motorcycle Safety Foundation at msf-usa.org for proper safety procedures.
SAFETY LABEL INFORMATION This page will show you where to find the safety labels on your motorcycle. You will find that some labels warn you of potential hazards. Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or becomes hard to read, contact your Crossfire dealer for a replacement.
COMPONENT LOCATIONS When you ride a motorcycle off-road, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle. This section of the manual will show the location and operation of all the basic controls of your motorcycle.
COMPONENT LOCATIONS Fuel Cap Brake Caliper Kick Starter Spark Plug Rear Brake Lever Brake Disc Fuel Valve Air Filter CDI Box Brake Disc Drive Chain Shift Lever Brake Caliper 12
SERIAL NUMBER LOCATIONS VIN – Chassis Number The VIN number is located in one of three places on the chassis. 1. Right side of frame. 2. Left side of frame. 3. Steering head tube. Write this number in the VIN box on page 3. Picture for Reference only Engine Model & Serial Number The engine model number and serial number is stamped on the left side of the engine under the countershaft sprocket. Write this number is the Engine Number box on page 3.
OPERATING CONTROLS Stop Switch The stop switch turns off the engine. When this button is pressed, the ignition circuit is turned off. Fuel Fill To Open: Turn the cap counter-clockwise. To Close: Turn the cap clockwise, make sure the breather tube is installed. Fuel Tap OFF OFF - In this position, the fuel tap is closed. No fuel can flow to the carburetor. ON - In this position, the fuel tap is open. This means fuel can flow to the carburetor. With the lever in this position, the tank will be emptied.
OPERATING CONTROLS Shift Lever A The shift lever is on the left side of the engine. The gear positions are shown in the illustration on page 21. Foot Brake Lever The brake lever is located on the right side of the engine. Its basic operation is to apply the rear brake to slow or stop the motorcycle. Kick Start Lever The kick start lever is mounted on the right side of the engine. It is used to start the engine in case the electrical starter system is non-functional.
BEFORE RIDING Before you ride, you must be absolutely sure that you and your motorcycle are ready to ride. To help you get prepared, this section of the manual will discuss how to evaluate your riding readiness and how to perform our recommended pre-ride inspection of your motorcycle. If you are a parent, please be sure you have read the section “Important Safety Information for Parents” (Pg. 9).
IS THE MOTORCYCLE READY TO RIDE? Before each and every ride you take, it is extremely important that you inspect the motorcycle and make sure any problems you find are corrected. A pre-ride inspection is a must because off-road riding can be very tough on a motorcycle and you do not want to have a breakdown far from help.
BASIC OPERATION & RIDING This section of the manual gives basic information on how to begin riding your motorcycle. In this section we will cover how to start and stop the engine, how to use the throttle and brakes, how to use the clutch and shift gears, and things you need to do when you are finished riding. Break-In Period The first 80 km (50 miles) is the most important in the life of your motorcycle.
BASIC OPERATION & RIDING STARTING & STOPPING THE ENGINE Always follow the proper starting procedure as described below. STARTING PROCEDURE (KICK START) Starting When the Engine Is Cold 1. Turn the key switch to the “ON” position. 2. Make sure the transmission is in the neutral position. 3. Turn the fuel tap to the “ON” position. 4. Lift the choke lever up. 5. Press and hold the brake lever on the right side of the handle bar. 6. Open the throttle no more than 1/4 of the way. 7.
BASIC OPERATION & RIDING FLOODED ENGINE If the engine fails to start after repeated attempts, it may be flooded with excess fuel. Follow the steps below to clear a flooded engine. 1. 2. 3. 4. 5. Press the engine stop switch and hold it. Open the throttle completely. Kick start the engine several time. If necessary remove the spark plug and let it dry. Once the engine starts, rev the throttle ¼ turn, 2 or 3 times.
SHIFTING GEARS This motorcycle has four (4) forward gears. 4 To start riding, after the engine has been warmed up and the 3 side stand raised: 1. Close the throttle and squeeze the clutch lever all the way in. 2. Depress the shift lever from neutral down to first gear. Once 2 125cc – 140cc the transmission clicks into gear, the shift lever will return back N to the neutral “N” position once you remove your foot. 3.
BRAKING TECHNIQUE This section will cover basic braking technique for your motorcycle. To slow or stop the motorcycle, squeeze and hold the clutch lever and apply the front brake lever and rear brake pedal firmly and smoothly. If your speed is reduced a significant amount, you may need to downshift to a lower gear. Gradually increase your braking pressure as you feel it is needed. When you come to a stop, put your left foot down first, then the right foot.
MAINTAINING YOUR CROSSFIRE MOTORCYCLE Keeping your motorcycle in perfect operating condition is absolutely essential to your safety. It is also the best way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your motorcycle well maintained, this section includes a maintenance schedule for required servicing and step-by-step instructions on how to perform specific maintenance tasks.
MAINTENANCE SCHEDULE To keep your motorcycle safe and reliable when you ride, regular inspections and service is required. Below you will find a maintenance schedule that describes when components need to be inspected or serviced. The maintenance schedule lists item that can be performed with basic mechanical skills and hand tools. In addition, the maintenance schedule will list items that involve more extensive procedures and could require special training, tools and/or equipment.
BASIC MAINTENANCE PROCEDURES FUEL (GASOLINE) Fuel Recommendation – Any unleaded gasoline with an octane rating of 90 or higher. The engine in your motorcycle has been designed to run on any gasoline with a pump octane rating of 86 or higher. Most service stations will display the octane rating above each pump. Although it is not required, Crossfire recommends use of gasoline with a 90 octane rating or higher to ensure maximum performance and reliability.
BASIC MAINTENANCE PROCEDURES ENGINE OIL Using proper oil, and regularly checking, adding and changing oil will help extend the service life of your engine. Even the best oil wears out and becomes thinner. Changing oil helps get rid of dirt and deposits in the engine. Operating the engine with old or dirty oil may damage your engine. Running the engine with not enough oil can cause serious damage to your engine. The chart below indicates oil for regular air temperatures.
BASIC MAINTENANCE PROCEDURES ENGINE OIL Cont. NOTICE NOTICE If the oil filter and cap are not installed correctly, it will cause serious engine damage. Allow the engine oil to circulate in the engine for 2 – 3 minutes before riding at start up. This will give enough time for the oil to lubricate all critical engine components. Failure to do so, will cause engine damage. NOTICE Do Not dispose of drained oil in an inappropriate manner. Most parts stores or auto shops do take used oil.
BASIC MAINTENANCE PROCEDURES AIR FILTER Proper air filter maintenance is extremely important for off-road vehicles. A dirty, water-soaked, worn-out air filter will allow dirt, dust, mud or other impurities to pass into the engine. If you are riding in wet and/ or muddy areas, you should service the air filter more often. Always replace the air filter with a genuine Crossfire filter specifically designed for your model or a filter of equal quality.
BASIC MAINTENANCE PROCEDURES THROTTLE THROTTLE FREEPLAY A. Throttle free-play should be 3 – 5 mm (0.10 – 0.20 in) B. If your throttle has more play than specified, adjustments need to be made. Follow the steps below: C. Minor adjustments are generally made with the upper adjuster. 1. Pull back the dust cover . 2. Loosen the lock nut 3. Turn the adjuster 4. Turning the adjuster in the direction will decrease freeplay. Turning the adjuster in the direction will increase freeplay. 5.
BASIC MAINTENANCE PROCEDURES ENGINE IDLE SPEED ENGINE IDLE SPEED ADJUSTMENT Remember, idle adjustment is not a real cure for other problems in your engines’ fuel delivery system. Adjusting the idle will not solve or compensate for a fault elsewhere in the engine. If you are having trouble, please contact your Crossfire dealer. The engine must be at normal operating temperature for an accurate adjustment. 1. If the engine is cold, start it up and let it warm up for 3-5 minutes then shut it off. 2.
BASIC MAINTENANCE PROCEDURES CLUTCH SYSTEM (if equipped) In order to ensure the best performance and durability from the clutch, always be sure you have proper clutch freeplay. Freeplay is needed to ensure that the clutch has room for wear. A clutch with no freeplay will begin to slip as the discs wear down. Failure to fix a slipping clutch can cause clutch damage. To check the freeplay, simply pull on the clutch lever.
BASIC MAINTENANCE PROCEDURES SPARK PLUG The recommended standard spark plug will work very well in most riding condition. However, if you plan on riding for extended periods of time at high speed or high engine rpm in hot climates, or plan extended riding in cold climates, a different plug may be recommended. A fouled (dirty) spark plug can cause your motorcycle to run poorly and lose performance. Follow the steps below to inspect, clean and/or replace the spark plug if needed. 1.
BASIC MAINTENANCE PROCEDURES BRAKING SYSTEM Your motorcycle is equipped with hydraulic disc brakes on both the front and rear wheels. Hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders. Follow the procedures below to adjust the brake levers to the specified ranges and check fluid levels. BRAKE LEVER ADJUSTMENT (REAR) 1. Remove the cotter pin . 2. Remove the pin . 3.
BASIC MAINTENANCE PROCEDURES BRAKING SYSTEM Cont. Hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders. Follow the procedures below to check and fill the cylinders with the specified brake fluid. RECOMMENDED BRAKE FLUID – DOT 4 ADDING BRAKE FLUID PROCEDURE (FRONT) NOTICE USE ONLY DOT 4 BRAKE FLUID. 1. Clean all dirt and dust from the master cylinder cap 2. Remove the cap screws with a Phillips head screwdriver. 3.
BASIC MAINTENANCE PROCEDURES BRAKING SYSTEM Cont. Hydraulic disc brake systems use a brake caliper to squeeze the rotors (brake disc) which causes the motorcycle to stop. Inside the brake caliper are brake pads. The brake pads are the part of the brake system that makes contact with the brake rotor. The pads must be checked in accordance with the maintenance schedule for the brake system as described on page(s) 31, 32, 33, 34. Follow the procedure below to check the brake pad wear. BRAKE PAD WEAR 1.
BASIC MAINTENANCE PROCEDURES FRONT SUSPENSION Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Crossfire dealer for service and/or inspection. Your Crossfire dealer is the most qualified to determine whether or not replacement parts or service is required. Your motorcycle is new. Break it in for about 2 hours with the original settings before attempting adjustments.
BASIC MAINTENANCE PROCEDURES FRONT SUSPENSION Cont. SUSPENSION ADJUSTMENT (FRONT) Cont. Over time, the forks suck in air, creating a build-up that will have a bad effect on the performance of the forks. 1. Put a support on the bottom of the bike so that the front tire is off the ground. 2. Turn the air bleeder screw on the top of the fork counter-clockwise to release the air. 3.
BASIC MAINTENANCE PROCEDURES REAR SUSPENSION Cont. The rear suspension of your motorcycle has an adjustment point at the bottom of the shock, it comes from the factory set to the softest setting. If you wish to make the rear suspension harder, follow the procedure below. Adjusting the rear shock is not hard, but like the front forks, changes should be made one at a time to gain an accurate understanding of how they affect the bike.
BASIC MAINTENANCE PROCEDURES RIMS, TIRES & SPOKES Maintenance of spoke tension and wheel trueness (roundness) is critical to safe motorcycle operation. During the first 100 miles of riding, spokes will loosen faster due to the initial seating of the parts. Excessively loose spokes will cause the motorcycle to become unstable at high speed and could cause you to lose control. Loose spokes can also cause rim and spoke damage (not covered in the warranty).
BASIC MAINTENANCE PROCEDURES TIRE INSPECTION A flat tire or tire blowout can be very inconvenient and can even cause you to have an accident. Take the time to inspect your tires and wheels before you ride. For more information about handling a flat tire, refer to the section of this manual titled, Resolving the Unexpected. Ø Inspect the tire carefully for bumps or bulges in the sidewall of the tire and inside of the treads. replace any tires that have bumps or bulges in them.
BASIC MAINTENANCE PROCEDURES NEW TIRE BREAK-IN PERIOD New tires need proper break-in to assure maximum performance, just as the engine does. Wear-in the tread surface by gradually increasing your cornering lean angles over the first 160 km (100 miles) before attempting maximum performance. Avoid hard acceleration, hard cornering, and hard braking for the first 160 km (100 miles). WARNING FAILURE TO PERFORM BREAK-IN OF NEW TIRES COULD CAUSE TIRE SLIP AND LOSS OF CONTROL.
BASIC MAINTENANCE PROCEDURES DRIVE CHAIN SYSTEM Cont. Use the diagram below to determine if the sprockets need to be replaced. Never use a new chain with a damaged or worn sprocket. NOTICE THE USE OF A NEW CHAIN ON A WORN SPROCKET WILL CAUSE RAPID CHAIN WEAR. CHAIN ROLLER CHAIN ROLLER INSPECTION 1. Check the lower roller for wear and damage. 2. If the roller is worn or damaged, it must be replaced before your next ride. 3. If the roller has been worn down, then the roller must be replaced. 4.
BASIC MAINTENANCE PROCEDURES CHAIN SLIDERS CHAIN SLIDER INSPECTION 1. Check the slider 2. If the wear limit replaced. for wear. has been reached Fig. 3, it must be 1. Check the guide slider for wear Fig. 2 2. Replace the guide slider if it is worn to the bottom of the wear limit. Fig. 3 Fig. 2 Fig. 3 NOTICE THE SLIDERS MUST BE REPLACED IF WORN DOWN TOO FAR.
BASIC MAINTENANCE PROCEDURES DRIVE CHAIN ADJUSTMENT Follow the procedure below to adjust the drive chain slack. Be sure that you are parked on a level surface and the engine is turned OFF. CHAIN ADJUSTMENT 1. Loosen the rear axle nut . 2. Loosen the lock nut on both right and left side. 3. Turn the adjusting bolts counter-clockwise to decrease slack in the chain, or clockwise to increase slack. 4. Make sure the gap between the adjusting plate and swing arm are the same on both left and right sides. 5.
BASIC MAINTENANCE PROCEDURES DRIVE CHAIN ADJUSTMENT Cont. If you have been riding in extremely muddy or dusty conditions, the drive chain should be removed and cleaned before you apply lubricant. Follow the procedure below to remove and clean or replace the drive chain with a new one. CHAIN REMOVAL, CLEANING & REPLACEMENT 1. Remove the master link retaining clip with needle nose pliers. Do not bend or twist the clip. Remove the master link and remove the drive chain. 2.
TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1. Examine the Carburetor - Be sure there is fuel flowing into the carburetor. Is there fuel flowing into the carburetor? No - Clogged fuel hose/line or clogged fuel filter - Clogged fuel valve - Clogged fuel tank breather hose - Sticking or stuck carburetor float Yes - SEE STEP 2 2. Examine the Spark Plug - Remove the spark plug and inspect.
TROUBLESHOOTING ENGINE LACKS POWER 1. Examine the Drive-train - Raise the wheel off the ground and spin by hand. Does the wheel spin freely? No - Brake dragging, improperly mounted brake pads - Worn or damaged wheel bearings - Bent axle Yes - SEE STEP 2 2. Check the Tire Pressure - Use a tire pressure gauge to check the tire pressure of each tire Is the tire pressure correct? No - Faulty tire valve - Punctured tire and/or inner tube Yes - SEE STEP 3 3.
TROUBLESHOOTING ENGINE LACKS POWER Cont. 8. Carburetor Inspection - Disassemble the carburetor and check for clogs Was the carburetor clogged and dirty? No - SEE STEP 9 Yes - Carburetor is not serviced frequently enough - Contaminated fuel 9.
TROUBLESHOOTING POOR PERFORMANCE AT IDLE & LOW SPEED Cont. 2. Spark Test - Test for ignition spark by removing the spark plug and inserting it into the spark plug cap. Place the open end of the spark plug on a metal part of the engine and kick start the engine. You should see a nice blue spark on the end of the spark plug. A faint spark will not start the engine.
TROUBLESHOOTING POOR HANDLING Steering is heavy - Steering stem nut too tight - Damaged steering head bearings - Check tire pressure Either wheel has a Wobble - Excessive wheel bearing play - Bent Rim - Improperly installed wheel hub - Damaged swing-arm - Bent frame - Loose or broken spokes - Old tires with “dry-rot” The motorcycle pulls to one side - Front and rear wheels out of alignment - Faulty shock absorber - Damaged fork(s) - Bent Swing-arm - Damaged axel - Damaged frame - Damaged upper or lower trip
RESOLVING THE UNEXPECTED GENERAL GUIDELINES If you encounter trouble during a ride, the first thing you should do is stop as soon as it is safely possible. Do not continue to ride if you have a flat tire, if you hear an unusual noise, or if your motorcycle just does not feel right. If you continue to ride, you will cause more damage the motorcycle and endanger your own safety. After you stop, take time to carefully look over your motorcycle and identify the problem.
RESOLVING THE UNEXPECTED IF YOU HAVE A FLAT TIRE How you handle a flat tire on the trail will depend on the severity of the damage to the tire and/or the inner tube and what tools and supplies you keep with you. If you have a slow leak or a minor puncture, there are two ways you can try to make a temporary repair: 1. Use an aerosol tire sealer to seal the puncture and inflate the tube. You can do this without removing the wheel. 2. Use a tube repair kit to patch the hole in the inner tube.
MAINTENANCE SCHEDULE RECORD Odometer or Hour Reading 00,000 Odometer or Hour Reading Odometer or Hour Reading Km. hrs. Km. hrs. Km. hrs. Dealer Stamp Dealer Stamp Dealer Stamp Date Date Date Signature Signature Signature Odometer or Hour Reading Odometer or Hour Reading Odometer or Hour Reading Km. hrs. Km. hrs. Km. hrs.
NOTES 54
NOTES 55
Crossfire Motorcycles Book #: Y870501d VER.
