CFMoto ATV CF500-A 4x4. Service Manual - part 6

 

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CFMoto ATV CF500-A 4x4. Service Manual - part 6

 

 

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on 
page 83.  Items not listed in the chart should be lubricated at the General Lubrication interval.

More often under severe use, such as wet or dusty conditions
All Season Grease
Use U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging

Engine

Brakes

Front Gear case

Rear Gear case

Ball Joint

SAE15W-40/SF

DOT3 or DOT4 fluid

SAE15W/40 SF or SAE80W/90 GL-4

SAE15W/40 SF or SAE80W/90 GL-4

Grease

Add to proper level on dip- stick.

Maintain level between fill lines. See page 42.

See Page 93.

See page 92.

Locate fitting on back side of struts and grease
with grease gun.

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Always check and change the engine oil at the intervals 
outlined in the Periodic Maintenance Chart beginning on 
page 83.  Always change the oil filter whenever changing oil.

1. Pull outward on the areas shown

.

2. Position the ATV on a level surface.
3. Start the engine and let it idle for 20-30 seconds. Stop the 

engine.

4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap

 and wipe off the 

dipstick

 with a clean rag.

6. Insert the dipstick in the oil filler hole and screwing it in, 

then remove it again to check the oil level.

The engine oil should be between the upper and 

lower limit marks.

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7. If the engine oil is at or below the lower limit mark, add 

sufficient oil of the recommended type to raise it to the 
correct level.

8. Insert the dipstick into the oil filler hole, and then tighten 

the oil filler cap.

9. Install the panel.

1. Start the engine, warm it up for several minutes, and then 

turn it off.

2. Place an oil pan under the engine to collect the used oil, 

and then remove the engine oil filler cap.

3. Remove the engine oil drain bolt

 to drain the oil from 

the crankcase.

6. Remove the oil filter cartridge with an oil filter wrench.

An oil filter wrench is available at a nearby dealer.

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7. Apply a light coat of engine oil to the O-ring

 of the new oil 

filter cartridge.

 Make sure the O-ring is seated properly.

8. Install the new oil filter cartridge with an oil filter wrench, and 

then tighten it to the specified torque with a torque wrench.

 Oil filter cartridge tightening torque: 17 N

m (1.7 

m

kgf, 12 ft

lbf)

10. Install the engine oil drain bolt, and then tighten it to the specified torque.

 Engine oil drain bolt tightening torque: 30 N

m (3.0 m

kgf, 22 ft

lbf)

11. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it.

Without oil filter cartridge replacement oil quantity: 1.8 L (1.58 Imp qt, 1.90 US qt)

With oil filter cartridge replacement oil quantity: 1.9 L (1.67 Imp qt, 2.01 US qt)

12. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage 

is found, turn the engine off immediately and check for the cause.

13. Turn the engine off, and then check the oil level and correct it if necessary.

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The rear gear case must be checked for oil leakage before 
each ride. If any leakage is found, have your dealer check 
and repair the ATV.

1. Place the machine on a level place.
2. Place a container under the rear gear case to collect the 

used oil.

3. Remove the oil filler bolt and the drain bolt to drain the oil.
4. Install the drain bolt and tighten it to the specified torque.

 Drain bolt (rear gear case) tightening torque: 23 

N

m (2.3 m

kgf, 16 ft

lbf)

5. Fill the rear gear case with oil.

 Periodic oil change oil quantity:

0.25 L (0.22 Imp qt, 0.26 US qt)
Total amount oil quantity:
0.30 L (0.26 Imp qt, 0.32 US qt)

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6. Install the filler bolt and tighten to the specified torque.

 Filler bolt (rear gear case) tightening torque: 23 N

m (2.3 m

kgf, 16 ft

lbf)

7. Check for oil leakage. If oil leakage is found, check for the cause.

 Be sure no foreign material enters the rear gear case.

1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil level. It should be 

up to the brim of the hole. If the level is low, add sufficient oil 
to raise it to the specified level.

3. Install the oil filler bolt and tighten it to the specified torque.

 Oil filler bolt tightening torque: 2

3 Nm (2.3 m

kgf, 16 ft

lbf)

1. Place the machine on a level place.
2. Place a container under the front gear case to catch the oil.
3. Remove the filler bolt and drain bolt to drain the oil.

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4. Install the drain bolt and tighten it to the specified torque.

Drain bolt tightening torque:

10 N

m (1.0 m

kgf, 7.2 ft

lbf)

5. Fill the front gear case with oil.

Periodic oil change oil quantity:

0.28 L (0.25 Imp qt, 0.3 US qt)
Total amount oil quantity:
0.33 L (0.29 Imp qt, 0.35 US qt)

6. Install the filler bolt and tighten it to the specified torque.
7. Check for oil leakage. If oil leakage is found, check for the cause.

 Be sure no foreign material enters the front gear case.

1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with 

engine temperature.

The coolant should be between the upper and lower limit marks.

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3. If the coolant is at or below the lower limit mark, remove 

the reservoir cap, add coolant to the upper limit mark, 
install the reservoir cap, and then install the panel.

 Coolant reservoir capacity(up to the upper limit 

mark):0.3 L (0.26 Imp qt, 0.32 US qt)

Hard water or salt water is harmful to the engine. You 
may use soft water if you can not get distilled water.

If water is added, have your dealer check the 

antifreeze content of the coolant as soon as possible. The radiator fan operation is completely 
automatic. It is switched on or off according to the coolant temperature in the radiator.

1. Place the ATV on a level surface.
2. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object 

as shown to prevent coolant from spilling on the footrest.)

3. Remove the radiator cap.
4. Remove the coolant reservoir cap.

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5. Disconnect the hose on the coolant reservoir side, and then 

drain the coolant from the coolant reservoir.

6. After draining the coolant, thoroughly flush the cooling 

system with clean tap water.

7. Replace the coolant drain bolt washer if it is damaged, and 

then tighten the coolant drain bolt to the specified torque.

 Coolant drain bolt tightening torque:

10 N

m (1.0 m

kgf, 7 ft

lbf)

10. Install the coolant reservoir hose.
11. Fill the recommended coolant into the radiator until it is 

full.

 Recommended antifreeze:

High quality ethylene glycol antifreeze containing 
corrosion inhibitors for aluminum engines.
Antifreeze and water mixing ratio:1:1
Total amount:1.9 L (1.67 Imp qt, 2.00 US qt)

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Coolant reservoir capacity
(up to the upper limit mark):
0.3 L (0.26 Imp qt, 0.32 US qt)

Hard water or salt water is harmful to the engine. You may 
use soft water if you can not get distilled water.

12. Install the radiator cap.
13. Start the engine and let it idle for several minutes. Stop the 

engine, and then check the coolant level in the radiator. If 
it is low, add more coolant until it reaches the top of the 
radiator.

14. Fill the coolant reservoir with coolant up to the upper limit.
15. Install the coolant reservoir cap and check for coolant 

leakage.

If any leakage is found, have your dealer check 

the cooling system.

16. Install the panels and the front rack.

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Check the protective boots for holes or tears.
If any damage is found, have them replaced by your dealer.

Removal
1. Remove panel.
2. Remove the spark plug cap.
3. Use the spark plug wrench in the tool kit to remove the 

spark plug as shown.

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The spark plug is an important engine component and is easy 
to inspect. The condition of the spark plug can indicate the 
condition of the engine. The ideal color on the white 
insulator around the center electrode is a medium-to-light tan 
color for a ATV that is being ridden normally. Do not 
attempt to diagnose such problems yourself. Instead, take the 
ATV to your dealer. You should periodically remove and 
inspect the spark plug because heat and deposits will cause 
the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other 
deposits are excessive, you should replace the spark plug with the specified plug.

Specified spark plug: DPR7EA-9 (NGK)

1. Measure the electrode gap with a wire thickness gauge and, if 

necessary, adjust the gap to specification.

Spark plug gap:0.8

0.9 mm (0.031

0.035 in)

2. Clean the gasket surface. Wipe off any grime from the threads.

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3. Install the spark plug and tighten it to the specified torque.

Spark plug tightening torque: 17.5 N

m (1.75 m

kgf, 12.5 ft

lbf)

If a torque wrench is not available when you are installing a spark plug, a good estimate of the 
correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified 
torque as soon as possible.

4. Install the spark plug cap.
5. Install the panel.

There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, 

empty the hose and clean the air filter element and air filter case.

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1. Remove the seat.
2. Remove the air filter case cover by unhooking the holders.
3. Remove the air filter element.
4. Remove the air filter element from its frame.
5. Wash the air filter element gently but thoroughly in solvent.
6. Squeeze the excess solvent out of the air filter element and 

let it dry.

Do not twist the air filter element when squeezing it.

7. Inspect the air filter element and replace it if damaged.
8. Apply foam air filter oil or other quality foam air filter oil to the air 

filter element. If foam air filter oil is not available, engine oil may 
be used.

The air filter element should be wet but not dripping.

9. Pull the air filter element over its frame.
10. Install the air filter element.
11. Install the air filter case cover and be sure to connect the hose.

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12. Install the seat.

 The air filter element should be cleaned every 20

40 hours. It should be cleaned and lubricated 

more often if the machine is operated in extremely dusty areas. Each time air filter element 
maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air 
filter element rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all 
fittings securely to avoid the possibility of unfiltered air entering the engine.

Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing 
rapid engine wear and possible engine damage. Additionally, operation without the air filter element will 
affect carburetor jetting with subsequent poor performance and possible engine overheating.

Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
1. Remove the bolts.
2. Remove the tailpipe by pulling it out of the muffler.
3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester 

portion of the tailpipe.

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4. Insert the tailpipe into the muffler and align the bolt holes.
5. Install and tighten the bolts.

When cleaning the spark arrester: Always let the exhaust 
system cool prior to touching exhaust components. Do 
not start the engine when cleaning the exhaust system.

If dust or water collects in the V-belt cooling duct check 
hose, remove the hose and clean it.

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