CFMoto ATV CF500/CF500-A. Service Manual - part 2

1. Overhaul Information

1-14

1. Overhaul Information

1-15

2. Vehicle Body, Muffler

Overhaul Info…………………… ….………….2-1
Troubleshooting……….….……….……………..2-1
Front Rack, Bolt Cap………………………….…2-2
Seat, Seat Support & Rear Rack……………….2-3
Front & Rear Rack Panels, Front Top Cover….2-4
Rear Top Cover……………………..…………....2-5
Left Side Panel…………………………………...2-6
Right Side Panel……………………………….…2-7
Fuel Tank Top Cover, Front Fender…………....2-8
Footrest Board (LH, RH)………………………...2-9

Rear Fender, Engine Skid Plate (Front, Center, Rear),
Double Seat, Protection Plate……………………………..2-10
Front Inner Fender (RH,LH), Front Protector (RH, LH)…2-12
Rear Protector (RH,LH), Bumper, Bumper Protector……2-13
Bumper Cap…………………………………..……………..2-14
Front Vent Grille, Fuel Tank…………………….………….2-15
Bottom Plate, Fuel Tank…………………………………….2-16
Muffler……………………………………….………………..2-17
Description of Visible Parts………….…………………..…2-18

Overhaul Information

Operation Cautions

Warning

Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.
Special attention should also be paid to sparks. Gasoline may also be explosive when it is
vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.

This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe, muffler and fuel

tank.

Hoses, cables and wiring should be routed properly.

Replace the gasket with a new one after muffler is removed.

After muffler is installed, check if there is any exhaust leakage.

Tightening torque

Muffler Rear Fixing Bolt: 35-45N.m
Muffler Exhaust Pipe Bolt: 35-45N.m
Muffler Body Fixing Bolt: 35-45N.m

Troubleshooting

Loud exhaust noise

Broken

muffler

Exhaust

leakage

Insufficient power

Distorted

muffler

Exhaust

leakage

Muffler

clogged

2-1

2. Vehicle Body, Muffler

Front Rack, Bolt Cap

Remove:

Remove 2 nuts from the bottom of front fender

Exert upward and remove bolt cap

Remove:

--Fixing Bolt 1 , Bolt 2

--Fixing Bolt 3, Bolt 4
--Front rack

Installation:

Reverse the removal procedure for installation

Tightening Torque:      Fixing Bolt 1, Bolt 2
                                        35 N.m -45N.m
                                        Fixing Bolt 3, Bolt 4

25 N.m -30N.m

2-2

2. Vehicle Body, Muffler

Seat

Remove:

Pull upward seat buckle
Lift and push seat backward

Installation:

Press upward seat buckle
Press seat forward and down

Note:

Make sure that the seat is firmly installed.

Seat Support, Rear Rack

Remove:

--Seat (

→

2-3)

--Bolt 1, bolt 2
Remove seat support

Remove the 2 nuts for rear rack and rear fender
from rear fender bottom


Disconnect connectors of rear turning indicator

2-3

2. Vehicle Body, Muffler

Remove Bolt 1, Bolt 2
Remove rear rack

Installation

Reverse the removal procedure for installation

Tightening Torque: Fixing Bolt, Rear Rack
35 N.m -45N.m

Ornament Panel, Front Rack

Remove:

Remove four tapping screw from front rack

Installation:

Reverse the removal procedure for installation.

Ornament Panel, Rear Rack

Repeat above procedure for removal and installation
of ornament panel, rear rack.

Front Top Cover

Remove:

Remove front rack (

→

2-2)

Push upward plastic screw from front fender
bottom with a flat screwdriver;
Remove plastic screw and plastic screw seat



Separate clasps of top cover from fuel tank
and front fender as illustrated on the right;
Push forward and remove front top cover.

2-4

2. Vehicle Body, Muffler

Installation:

Reverse the removal procedure of installation.

Rear Top Cover

Remove:

--Rear rack (

→

2-3)

Separate clasps of rear top cover from rear fender
Remove rear top cover

Installation:

Reverse the removal procedure and
direction for installation.

2-5

2. Vehicle Body, Muffler

Left Side Panel

Remove

--Seat (

→

2-3)

Remove Bolt 1 for left side panel and fuel tank top cover

Remove Bolt 2 for left side panel and front fender

Remove screw for left side panel and footrest board



Remove left side panel in the direction as illustrated on the
right

Installation:

Reverse the removal procedure of installation.

2-6

2. Vehicle Body, Muffler

Right Side Panel

Remove:

--Seat (

→

2-3)

Remove Bolt 1 for right side panel and fuel tank top cover

Remove Bolt 2 for right side panel and front fender

Remove screw for right side panel and right footrest board




Remove right side panel in the direction as illustrated on
the right

Installation:

Reverse the removal procedure of installation.

2-7

2. Vehicle Body, Muffler

Top Cover, Fuel Tank

Remove:

--Seat (

→

2-3)

--Front rack (

→

2-2)

--Front top cover (

→

2-4)

--Left side panel (

→

2-6)

--Right side panel (

→

2-7)

--Bolt 1, Bolt 2

--Bolt 3, Bolt 4
--Top cover, fuel tank

Installation:

Reverse the removal procedure of installation.

Front Fender

Remove:
--Front rack (

→

2-2)

--Front top cover (

→

2-4)

--Left side panel (

→

2-6)

--Right side panel (

→

2-7)

--Top cover, fuel tank (

→

2-8)

Disconnect wiring connectors from front fender;
Remove electrical components from front fender;
Remove 3 bolts from frame

Remove 6 screws and nuts from left and right
footrest board

Remove front fender

2-8

2. Vehicle Body, Muffler

Left Footrest Board

Remove:

--Left Side panel (

→

2-6)

--3 screws & nuts for front fender

--3 screws & nuts for rear fender



--Bolt 1
--Bolt 2
--Bolt 3
--Bolt 4
--Left footrest board

Installation:

Reverse the removal procedure for installation.

Right Footrest Board

Refer to Left Footrest Board for removal and installation

2-9

2. Vehicle Body, Muffler

Rear Fender

Remove:

--Seat (

→

2-3)

--Rear rack(

→

2-3)

--Rear top cover (

→

2-5)

--Left & right side panel (

→

2-6) (

→

2-7)

--Battery fixing plate, battery cover (

→

8-4)

Remove battery

Remove electrical components from rear fender
(Chapter 8)

Disconnect wiring connectors from rear fender
(Chapter 8)
Lift upward and remove rear fender

Engine Skid Plate(Front), Engine Skid Plate (Center),

Double Seat Protection Plate, & Engine Skid Plate

( Rear)

(1) Bolt 1

(2) Bolt 2

(3) Engine Skid Plate( Front)

(4) Bolt 3

(5) Bolt 4

(6) Engine Skid Plate (Center)

(7) Bolt 5

(8) Bolt 6

(9) Bolt 7

(10) Bolt8

(11) Double Seat Protection Plate

(12) Engine Skid Plate (Rear)

(13, 14) Bolt 9

(15) Bolt 10

2-10

2. Vehicle Body, Muffler

Disassembly
Note: Side skid plate (front), side skid plate (center),
side skid plate (rear) and double seat protection plate are
located at the bottom of vehicle.
The maintenance person should have to work under the
vehicle bottom when disassembling the above parts. For
safety purpose, make sure that the vehicle should be firmly
parked.

Engine Skid Plate (Front)

Remove:

--Bolt 1
--Bolt 2
--Bolt 3
--Bolt 4
--Engine skid plate (Front)

Installation:

Reverse the removal procedure for installation.

Engine Skid Plate (Center)

Remove:

--Bolt 5
--Bolt 6
Engine skid plate (center)

Installation:

Reverse the removal procedure of installation.

Double Seat Protection Plate

Remove:

--Bolt 7
--Bolt 8
--Double seat protection plate

Note: This part is not available for single seat vehicle.

Installation:

Reverse the removal procedure of installation.

Engine Skid Plate (Rear)

Remove:
--Bolt 9
--Bolt 10
Engine skid plate (rear)

Installation:

Reverse the removal procedure for installation.

2-11

2. Vehicle Body, Muffler

Front Right Inner Fender

Remove:

--Bolt 1
--Bolt 2
--Front right inner fender

Installation:

Reverse the removal procedure for installation.

Note: The clasp of front right inner fender

should hook water pipe when it is assembled.

Front Left Inner Fender

Remove:

--Bolt 1
--Bolt 2
--Front left inner fender

Installation:

Reverse the removal procedure for installation.

Front Left Protector

Remove:

Bolt 1
Pull backward and remove front left protector

Installation:

Reverse the removal procedure for installation.

Front Right Protector

Repeat the above procedure of removal and
installation for front right protector.

2-12

2. Vehicle Body, Muffler

Rear Left Protector

Remove:

--Bolt 1
--Bolt 2
--Rear left protector

Installation:

Reverse the removal procedure for installation.

Rear Right Protector

Repeat the above procedure of removal and
installation for rear right protector.

Bumper, Bumper Protector,

Remove:

--2 bolts from engine skid plate (front)

--Bolt 1
--Bolt 2
--Bolt 3
--Bolt 4
Remove bumper with bumper protector

Remove Bolt 5 and Bolt 6 for bumper and front rack

2-13

2. Vehicle Body, Muffler

Bumper Protector

Remove:

Remove bumper with bumper protector (

→

2-13),

Remove tapping screw of protector from bumper

Installation:

Reverse the removal procedure for installation

Bumper Cap

Remove:

There are four pieces of bumper caps, each
at the end of bumper pipe.
Pull bumper cap out from the end of bumper.

Installation:

Press bumper cap into bumper pipe.

2-14

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