CFMoto UTV Terracross CF500-6 4x4. Service Manual - part 1

NEVER Operate：

●

Without first viewing owner

'

s manual and quick start guide.

●

With more than one passenger.

●

On hills steeper than 15 degrees

●

On public roads

●

On paved surfaces-pavement may seriously affect handling and control.

●

With Non-CFMOTO approved accessories. 

ALWAYS：

●

Keep hands and feet inside vehicle.

●

Reduce speed and use extra caution when carrying a passenger.

●

Operate slowly in reverse-avoid sharp turns or sudden braking.

●

Make sure passenger reads and understands all safety labels

●

Watch for branches or other hazards that could enter vehicle

.

Locate and Read Owner

'

s manual, Follow all INSTRUCTIONS and WARNINGS. If Owner

'

s manual is missing, contact a CFMOTO dealer for replacement.

G

Read,  understand,  and  follow  all  of the  instructions  and  safety  precautions  in 
this  manual  and  on all  product  labels.  Failure  to follow  the  safety  precautions 

could  resullt  in serious  injury  or death.

The engine exhaust gas from this product contains CO, which is deadly gas and
 could cause headache, giddy, disgusting or lose consciousness, even death.

Instructions

Thank you for purchasing a CFMOTO vehicle, and welcome to our worldwide family of CFMOTO owners. 

We proudly produce an exciting line of utility and recreational products.

●

All terrain vehilce (ATV)

●

Utility vehicle (patrol, forest protecting and hunting)

●

Motorcycles

      

CFMOTO, a company which is specialized in production of liquid-cooled engine, is the top-level supplier

 in China

. 

Compared

 

to

 

same

 

displacement

 

of

 

air

-

cooled

 

engine

, 

engine  cooling effect is better, oil

 temperature can be adjusted more freely, more powerful and lower fuel consumption, longer engine
 working life. 

      

For

 

safe

 

and

 

enjoyable

 

operation

 

of

 

your

 

vehcile

, 

be

 

sure

 

to

 

follow

 

the

 

instructions

 

and

 

recom-

mendations

 

in

 

this

 

owner

'

s manual. Your manual contains instructions for minor maintenance, but

 informations about major repairs is outlined in the CFMOTO service manual and should be performed
 only by CFMOTO service dealer and technician.

      

Your

 

CFMOTO

 

dealer

 

knows your vehicle best and is interested in your total satisfaction. Be sure to

 return to your dealerhship for all of your service.

Due  to constant  improvements  in the  design  and  quality  of  production  components, 
some  minor  discrepancies  may  result  between  the  actual  vehicle  and  the  information 

presented  in

 

this  publication

. 

Depictions  and/or  procedures  in  this  publication  are 

intended  for  reference  use  only.

-1-

Table of Contents

   

VIN  No.

…………………………………………………………………………………

2
3

   

Safety

……………………………………………………………………………………………  

   

Features

 

and

 

Controls

………………………………………………………………………… 

31

   

Operation

………………………………………………………………………………………   

51

   

Emission

 

control

 

systems

………………………………………………………………      

71

   

Maintenance

……………………………………………………………………………………  

72

   

Specification

…………………………………………………………………………………… 

120

Troubleshooting

…………………………………………………………………………………

123

   

Circuit  layout

…………………………………………………………………………………… 

128

…   

…

…

…
…

……

-2-

Vehicle Identification Number

        

Record your vehicle

'

s identification number and engine serial number in the spaces provided, remove

 

“

ignition

” 

key

 

and store it in a safe place for duplicating spare key if keys are lost, otherwise ignition

 key can only be replaced.

Vehicle Identification No.

：

Engine Serial No.

：

①
②

  SAFETY

Rider Safety

The following signals or symbols appear throughout this manual and on your vehicle. Your  safety is 
involved when words or symbols are used. Become familiar with these meanings  before reading the

 manual.

The safety alert warning indicates a potential hazard that may result in serious injury or death.

A

 

caution

 

indicates

 

a

 

situation

 

that

 

may

 

result

 

in

 

damage

 

to

 

your

 

vihicle

.

A note alert you to important informations or instructions.

CAUTION

NOTE

-3-

-4-

    Safety Decals and Locations

    

Warning decals have been placed

 

on

 

your

 

vehicle

 

for

 

your

 

protection

. 

Read and follow the instructions of the decals on the vehicle very 
carefully. If any of the decals depicted on the vehicle in this manual 
differ from the decals on your vehicle, always read and follow

 

the

 

instrctions

 

of

 

decals

 

on

 

your

 

vehicle

.

①

Cargo box warning

②

Towing load waring

Warning

●

Passengers can be thrown off. This can cause 

serious injury or death.

●

Never carry passengers in cargo box.

●

Max. load of cargo box

：

100kg

●

Towing bracket veritcal load

：

50kg

，

Towing load

：

125kg

(

including cargo

)

③

Tire pressure and overload warning

Improper tire, tire pressure or overloading can 
cause loss of control resulting in SEVERE INJURY OR DEATH.

Tire pressure

：

PSI

（

kpa

）

Front tire

：

10

（

70

）

Rear tire

:   （

84

）

Maximum weight capacity

:

Including driver, passenger, cargo and accessories

：

250kg

Reduce speed and allow greater distance for braking when 
Carrying cargo. Overloading or carrying tall, off-center or 
Unsecured loads will increase your risk to control. Loads should be 
centered and carried as low as possible in box. For stability

 

on

 

rough

or hill terrain, reduce speed and cargo. Be careful if load extends over
the side of box.

12

Safety Decals & Locations

Cab frame

①

Warning

●

ALWAYS WEAR YOUR SEAT BELT 

and make sure passenger wears seat belt.

●

VEHICLE OVERTURN can cause severe injury or death. 

The cab frame is not designed or intended to rollover protection.

Shift caution

warning

Caution

To avoid transmission damage, Shift only when vehicle is stationary or at idle. 
When vehicle is stopped, place shift in the parked position.

Age warning
Warning

Operating this vehicle if you

'

re under age of 16 increase your chance of 

Severe injury or death. Never operating this vehicle under age 16 or without 
valid driver

'

s licence.

Overturn warning
Warning

Improper operation can cause this vehicle to overturn and lead to serious injury or death.
This vehicle handles differently than cars, trucks or other off-road vehicles. In order to avoid 
oveturns

●

Avoid sharp overturns

●

Never turn when applying heavy throttle.

●

Never make abrupt steering maneuvers.

●

Operate at speeds appropriate for your skills, the conditions

And the terrain.

●

DO NOT do power slides, 

“

donuts

”, 

jumps

 

or

 

other

Jumping stunts.

-5-

Safety Decals and Locations

Passenger safety warning

①

Warning

Never carry passenger under age 12
Never carry more than one passenger
Never ride after using drugs or alcohol
To reduce the risk of SEVERE INJURY or DEATH, 
Never carry a passenger under age 12 or too small to

 

Firmly plant feet on the floor and securely grasp hand holds.

The passenger must always

●

Wear seat belt.

●

Use an approved helmet and protective gear.

●

Securely grasp hand holds and plant feet firmly on the floor.

●

Tell operator to slow down or stop if uncomfortable get-off 

and walk if conditions require.

●

Keep hands and feet inside vehicle at all times.

●

Watch for branches, brush, and other hazards that could enter vehicle.

-6-

Operation warning

②

 

Safety decals and Locations
Pre-ride warning

①

Always use approved helmet and protective gear for operator and passenger.
Never use with drugs or alcohol.
Improper vehicle use can result in SEVERE INJURY or DEATH.

Never operate

：

●

Without first reading and understanding of safety guide.

●

With more than one passenger.

●

On hilles steeper than 15 degrees.

●

On paved surfaces-pavement may seriously affect handling 

Or control.

●

With Non-CFMOTO genuine parts or accessories. They may 

seriously affect stability.

Always

：

   Keep hands and feet inside vehicle.

●

Reduce  speed  and  use  extra  caution  when  carrying  passenger

●

Operate slowly in reverse- avoid sharp turns or sudden braking.

●

Make sure passenger reads and understands all safety labels.

●

Watch for branches or other hazards that could enter vehicle.

Locate and read owner

'

s manual, follow all instructions and warnings. If owner

'

s 

Maunal is missing, contact CFMOTO dealer for detailed information.

Driving warning

●

-7-

Safety Warning and Locations

Pre-ride warning

①

4WD operation warning

Must stop or at idle when changing
2WD and 4WD switch to avoid damage 
of transmission parts
When Diff-lock is locked, it will enhance vehicle

'

s

 

maneuverability

, 

please

 

keep

 

low

 

speed

 

and

 

enough braking distance to avoid out of control.

②

Air filter ventilator warning

●

DO NOT cover air filter ventilator to avoid

damage of engine.

●

Keep air entering through ventilator smoothly.

-8-

Rider  safety

Failure to follow the warning contained in this manual can result in severe injury or death.
Your CFMOTO vehicle is not a toy and can be hazardous to operate. This vehicle handles 
differently than cars, trucks or other off-road vehicles.A collision or rollover can occur quickly
 even during routine maneuvers like turning, or driving on hilles or over obstacles if you take
 improper precautions. 

Read and understand your owner

'

s manual and all warning before operating the vehicle.

 Always heed the following instructions and procedures which are outlined further detailes
 within your owner

'

s manual.

●

Read this manual and all labels carefully, following the operating procedures described.

●

Never carry a passenger until you have operated this vehicle at least 2 hours and have completed the New

 Operator Driving procedures outlined on pages 57-58. 

●

Operation is prohibited for anyone under 16 years of age or anyone without valid driving licence.

●

Never carry a passenger under age 12. Make sure any passenger is tall enough to comfortably and safely

 reach the hand holds and place both feet on

 

the

 

floor

. 

●

Riders should wear seat belts at all times. Seat belts reduce the severity of injury in the event of sudden 

stop or accident. 

●

Helmet and eye protection are required for both operator and passenger at all times.

●

Always keep hands and feet inside vehicle.

●

Never allow a passenger to ride in the cargo box. Never carry more than one passenger.

●

Never permit a guest to operate this vehicle unless the guest has read this manual and all products label 

and has completed the New Operator Driving procedures outlined on pages 58-59. 

●

To reduce tipover risk, be especially careful when encounting obstacles and slopes and braking on hills or

 during turns.

●

Never operate with Non-CFMOTO genuine accessries which may seriously affect vehicle

'

s stability and

 could cause the vhicle to overturn. 

-9-

Rider  safety

●

This vehicle handles differently than cars, trucks or other off-road vehicles. Turning improperly can result in

 an overturn. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering mane-

uvers. 

 

Operate at speeds appropriate for your skills, the conditions and terrain.Do not do power slides, 

“

donuts

”, 

jumps

 

or

 

other

 

driving

 

stunts

. 

●

Never operate at excessive speeds. Always travel at speed appropriate for your skills

, 

your passenger

'

s

 skills and operation conditions.

●

This vehicle is for off-road only. Never operate on public roads and always avoid paved surfaces.

●

Never use drugs or alcohol before or during driving.

●

Always inpsect your vehicle before driving each time to make sure it

'

s in safe operating condition. Always

 follow the inspection and maintenance procesures and schedules described in this manual.

●

Always keep both hands on the steering wheel during operation. A passenger should always be seated in 

the passenger seat with both feet on the floor and both hands firmly grasping securely the hand holds. 

●

Always travel slowly and pay extra attention when driving on unfamiliar terrain. Be alert to changing terrain.

●

Never operate on excessively rough, slippery and loose terrain.

●

Always follow properly turning procedures described in this manual. Practice turning at low speeds before

 attempt to faster turn at higher speeds.

●

Always have this vehicle checked by authorized  CFMOTO dealer if it has been involved in an accident

.

●

Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully

 before attempt to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open
 throttle suddenly or make sudden gear changes. Never go over the top of hill at high speeds.

 

-10-

Rider Safety

 

Always

 

follow

 

the

 

proper

 

procedures

 

outlined

 

in

 

this

 

manual

 

for

 

traveling

 

downhill and for braking on

 hills. Check the terrain carefully

 

before descending a hill. Never travel downhill at high speed. Avoid

 

going 

downhill at an angle,

 

which

 

would

 

cause

 

the

 

vehicle

 

to

 

lean

 

sharply to one side. Travel straight down the

 hill where possible.

 

Avoid

 

crossing

 

the

 

side

 

of

 

a

 

hill

.

 

Always

 

check

 

for

 

obstacles

 

before

 

operating

 

in

 

a

 

new

 

area

. 

Never

 

attempt to operate over large obsta-

cles such as rocks or fallen trees.

 

Always follow the proper procedures outlined in this manual when

 

operating

 over obstacles.

 

Always

 

be

 

careful

 

of

 

skidding

 

or

 

sliding

. 

On

 

slippery

 

surfaces

 

such

 

as

 

ice, travel slowly and exercise

 caution to reduce the chance of skidding

 

or sliding out of control.

 

Never

 

operate

 

in

 

fast

-

flowing

 

water

 

or

 

in

 

water

 

that

 

exceeds

 

the

 

recommended

 

maximum depth. See

 page 65

. 

Wet

 

brakes

 

may

 

have

 

reduced stopping ability. To dry out the pads, apply the brakes lightly

 

sev-

eral times while driving slowly.

 

Always

 

be

 

sure

 

there

 

are

 

no

 

obstacles

 

or

 

people

 

behind

 

your

 

vehicle

 

when operating in reverse. When

 it's safe to proceed in reverse, move

 

slowly. Avoid making sharp turns in reverse.

 

Always

 

use

 

the

 

proper

 

size

 

and

 

type

 

of

 

tires

 

specified

 

for your vehicle.

 

Always maintain proper tire 

pressure.

 

Never

 

exceed

 

the

 

stated

 

load

 

capacity

 

for

 

this

 

vehicle

. 

Cargo

 

should

 

be properly distributed and securely

 attached. Reduce speed and follow

 

the instructions in this manual for hauling cargo or pulling

 

a

 

trailer. Allow 

a greater distance for braking.

 

Always

 

turn

 

off

 

the

 

engine

 

before

 

refueling

. 

Make

 

sure

 

the

 

refueling

 

area is well ventilated and free of

 any source of flame or sparks. Gasoline

 

is extremely flammable. See page 30 for fuel safety warnings.

 

Remove

 

flammable

 

material

 

containers

 

from

 

the

 

box

 

before

 

filling

.

 

Always

 

remove

 

the

 

ignition

 

key

 

when

 

the

 

vehicle

 

is

 

not

 

in

 

use

 

to

 

prevent

 

unauthorized use or accidental

 starting.

FOR MORE INFORMATION ABOUT SAFETY, please contact with your distributor.

-11-

Rider Safety

Modifications to your vehicle may negatively impact vehicle stability and

 

result in serious injury

 or death. Failure of critical machine components may

 

result from operation with any modifications

,

 

especially

 

those

 

that

 

increase

 

speed or power. This vehicle may become less stable at speeds

 higher than

 

those for which it is designed. Loss of control may occur at higher speeds.

Your vehicle

 

vehicle

 

is

 

designed

 

to

 

provide

 

safe

 

operation

 

when

 

used

 

as

 

directed.

 

Do

 

not

 

make

 

any

 

modifications

 

to

 

this

 

vehicle

.

 

Never

 

operate

 

with

 

accessories

 

not

 

approved

 

by

 

CFMOTO

 

for

 

use

 

on

 

this

 

vehicle.

 

The

 

operator

 

must

 

check

 

all

 

safety

 

components

 

before

 

each

 

ride

.

Make sure your vehicle is in excellent operating condition at all times.

Equipment Modifications

We are concerned for the safety of our customers and for the general

 

public. Therefore, we design accessories

 for your vehicle that take into

 

consideration safe vehicle handling and stability. Never operate with

 

acces-

sories not approved by CFMOTO

 

for

 

use

 

on

 

this

 

vehicle

. 

Non-approved

 

accessories may seriously affect

 vehicle stability and could

 

cause the vehicle to overturn.

Do not install on a CFMOTO

 

vehicle

 

any

 

equipment

 

that

 

may

 

increase

 

the

 

speed or power of the vehicle,

 or make any other modifications to the

 

vehicle for these purposes. Any modifications to the original equipment

 

of the vehicle create a substantial safety hazard and increase the risk of

 

bodily injury.

The warranty on your

 

vehicle

 

is

 

terminated if any equipment has

 

been added to the vehicle, or if any modif-

ications have been made to the

 

vehicle, that increases

 

its

 

speed

 

or

 

power

.

NOTE: 

The addition of certain accessories, including (but not limited to) mowers,

 

blades, tires, sprayers, or

 large

 

racks

, 

may

 

change

 

the

 

handling

 

characteristics of the vehicle. Use only CFMOTO

-

approved

 

acce-

ssories

, 

and familiarize yourself with their function and effect on the vehicle.

-12-

Safe Riding Gear

Always wear appropriate clothing when riding a CFMOTO

 

vehicle

. 

Wear

 

protective clothing for comfort and

 to reduce the chance of injury.

 

-13-

Stu rd y fo otw ear

Long Pants

Gloves

Long Sleeves

Eye Protection

Helmet