CFMoto ATV CF500/CF500-A. Service Manual - part 3

 

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CFMoto ATV CF500/CF500-A. Service Manual - part 3

 

 

                                                                                                                          2. Vehicle Body, Muffler 

Front Vent Grille 

Remove:

 

--Front fender (

2-8)    

--Bumper (

2-13) 

--Bolt 1, Bolt 2, Bolt 3, Bolt 4 
--Front vent grille 
 

Note: For removal of front vent grille only,   

Just remove 2 fixing bolts   

of bumper and 2 center fixing bolts,   

then pull bumper down 

 

Installation:                                     

Reverse the removal procedure for installation 
 
 

Fuel Tank 

 

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: 

 
--Left and right side panel (

2-6) 

--Front fender (

2-8) 

--Fuel tank top cover (

2-8)                             

--Bolt 1, Bolt 2 
                                               
Disconnect 3P connectors of fuel sensor 
                                                     
 
 
 

 

 

                                                                                                                                   
 
 

 

                                     
                                                 

   2-15 

                                                                                                                          2. Vehicle Body, Muffler 

Remove Bolt 3, Bolt 4 
 
 
 
 
 
Remove: 
--Fuel hose I and Clamp       
--Fuel tank 
 

Installation: 

Reverse the removal procedure for installation. 
 

Note: 

Be careful not to damage main cable,   

pipes and hoses. Main cable, cables,   

pipes and hoses should be routed properly   

according to the routing drawing. 

Take precaution against fuel leakage   

when removing fuel Fuel Hose I

 

 

 

 

 

 

 

 

 

Fuel Tank Bottom Plate,   

 

Remove: 

--Fuel tank (

2-15) 

--Bolt 1 
--Bolt 2 
--Fuel tank top cover 
 
 

Installation: 

Reverse the removal procedure for installation. 

Note: 

Be careful not to damage main cable, pipes and hoses. 

Main cable, cables, pipes should be routed properly 

according to the routing drawing 

                                                                                                                                 

 

 

 
 
 
                                                       

2-16 

                                                                                                                          2. Vehicle Body, Muffler 

Muffler 

Caution: Perform disassembly only   

after the muffler is cooled down. 

 

Remove: 

 
--Seat (2-3) 
--Right side panel (2-7) 
--Nut1, Nut 2 for exhaust pipe elbow 
 
 
           
 
 
 
Remove Bolt 1               
 
 
 
 
 
                                         
 
Remove Bolt 2, Bolt 3 
Remove muffler   
 

 

 

Installation:

 

Reverse the removal procedure for installation. 
 

Note: 

Replace sealing gasket when installing the muffler. 
 
 

 
 
 
 
 
 
                                                                                                                                   

 

 
 
 
                                             

            2-17 

                                                                                                                          2. Vehicle Body, Muffler 

 
 

Visible Parts 

                     

 
 

 

 
 
 
 
 
 
 
 
 
 
 
                                                                                                                         

              2-18 

                                                            3. Checks & Adjustment 

Overhaul Info……………………………..3-1   
Inspection & Maintenance………………3-2 
Steering Stem, Brake System…………..3-5 
Wheels…………………………………….3-7 

Suspension System…………………..3-9 
Gear Shifting, Fuel Device…………...3-10 
Cooling System..………………………3-12 
Lighting System...……………………...3-14 

Overhaul info 
Operation Cautions 
Note 

z

  DO NOT keep the engine running for long time in a poorly ventilated or enclosed place 

because of the harmful components like CO, etc, in the exhaust gas. 

z

  The muffler and engine are still very hot when the engine is just stopped. Careless contact 

may cause serious burn. Be sure to wear fatigue dress with long sleeves and gloves if the 
work has to be done after the engine is just stopped. 

z

  Gasoline is highly flammable, smoking is strictly forbidden in the work place. Keep alert on 

the electrical sparks. Besides, vaporized gasoline is highly explosive, so work should be 
done in a well-ventilated place. 

z

  Be careful that your hands or clothes not get nipped by the turning or movable parts of the 

driving system. 

Note 
The vehicle should be parked on hard and level ground

 

Periodic Maintenance Table 

The table below lists the recommended intervals for all the required periodic maintenance work 
necessary to keep the vehicle at its best performance and economy. Maintenance intervals are 
expressed in terms of kilometer, miles and hours, whichever occurs first. 
Note: More frequent maintenance may be required on vehicles that are used in severe 
conditions. 

Km 

Initial 200 

Every 1000 

Every 2000 

Miles 

Initial 100 

Every 600 

Every 1200 

Interval 
 

Item 

Hours 

Initial 20   

Every 40 

Every 80 

Remark 

Valve Clearance 

I --  I 

IN: 0.05~0.10 
EX:0.17~0.22 

Idle Speed 

1300±100r/Min 

-- --  I 

Spark Plug 

Replace every 6000Km 

No carbon deposit 
Gap: 0.8~0.9mm 

Air Filter 

-- 

Replace every 2000Km 

Fuel Hose, Carburetor 

-- 

-- 

Replace every 4 years 

Clutch -- 

-- 

 

Drive Belt 

-- 

 

Oil Filter 

-- 

 

Coolant Level 

 

Water Hose & Pipes 

 

Coolant 

Replace every 2 years 

I=Inpection and adjust, or replace if necessary 
R=Replace 
C=Clean                                                                                                                                      3-1 

                                                            3. Checks & Adjustment 

Inspection & Maintenance           

: Interval 

 

Item Intervals 

Part Item 

Daily 1/2 

Year 

A n n u a l

 

Standard 

Handlebar 

Operation 
agility 

 

 

 

 

Damage 

 

 

 

 

Installation 

condition of 

steering 

system 

 

 

 

 

Steering 

System 

Steering system

Sway of ball 

stud 

 

 

 

 

Free play 

 

 

 

 

Front: lever end 0mm 
Rear : lever end 0mm 

Brake lever 

Brake 

Efficiency 

 

 

 

 

Connecting rod, 

oil pipe & Hose 

Looseness, 

Slack and 

damage 

 

 

 

 

Front and rear 

brake fluid 

level 

 

 

 

Brake fluid should be 
above LOWER limit 

Brake 

System 

Hydraulic brake 

and brake disc 

Brake disc 

damage and 

wear 

 

 

 

Replace when the 
thickness of front 
brake disc is less than 
2.5mm, rear brake 
less than 6.5mm. 

Tire pressure 

 

 

 

Front tire: 35kPa 
(0.350kgf/

2

Rear tire: 
35kPa 
(0.35kgf/

2

Chap and 
damage  

 

 

 

 

Groove depth 
and abnormal 
wear 

 

 

 

No wear indication on 
the surface of tire (the 
remained depth of 
groove should not be 
less than 1.6mm) 

Loosened 
wheel nut and 
axle 

 

 

 

 

Sway of front 
wheel bearing 

 

 

 

 

Driving 

 

System 

Wheel 

Sway of rear 
wheel bearing 

 

 

 

 

 
                                                                                                                                               

        3-2 

                                                            3. Checks & Adjustment 

 
 
 
 
   

Suspension 

arm 

Sway of 

Joint parts, 

rocker arm 

damage 

 

 

 

 

Shock 

absorber 

Oil leakage 

and damage

 

 

 

 

Buffer 

System 

 Function 

 

 

 

 

Front axle 

Transmissio

n, lubrication

 

 

 

 

Rear axle 

Transmissio

n, lubrication

 

 

 

 

Gear box 

Transmissio

n, lubrication

 

 

 

Remove filling bolt, 

add oil till oil level 

reaches edge of 

filling hole. 

Looseness 

of joint parts

 

 

 

 

Drive 

Train 

Final shaft 

 

(Drive shaft) 

Sway of 

Spline 

 

 

 

 

Spark plug 

 

 

 

Spark plug gap: 

0.8-0.9mm 

Ignition 

Device 

Ignition 

timing 

 

 

 

 

Battery 

Terminal 

Joint 

 

 

 

 

Electrical 

System 

Wiring 

Looseness 

and damage 

of joints 

 

 

 

 

Fuel leakage

 

 

 

 

Fuel device 

 
 

Throttle   

 

Throttle grip 

clearance: 3~5mm

Coolant level

 

 

 

 

Engine 

Cooling 

system 

Coolant 

leakage 

 

 

 

 

 
 
 
                                                                                                                                                        3-3 

                                                            3. Checks & Adjustment 

Lighting 

device and 

turning 

indictors 

Function 

 

 

 

 

Alarm and 

lock device 

Function  

 

 

 

Instruments Function 

 

 

 

 

Looseness or damage 

caused by improper 

installation 

 
 

 
 

 

Exhaust pipe 

and muffler 

Function of muffler 

 

 

 

 

Frame 

Looseness and/or 

damage 

 

 

 

 

Others 

Lubrication & grease of 

frame parts 

 

 

 

 

Abnormal 

parts which 

can be 

determined 

when driving 

Make sure if there is any 

abnormal with relative 

parts. 

 

 

 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 
 
                                                                                                                                                        3-4 

                                                            3. Checks & Adjustment 

Steering Stem 

Park the vehicle on level place, hold steering handlebar, 
and shake in the direction as illustrated on the right and see 
if there is any sway. 
 
In case of any sway, check if it is the problem of the steering 
stem or other parts and then do the maintenance 
accordingly. 
 
In case of sway of the steering stem, tighten the locknut or 
disassemble the steering stem for further check. 
 
Park the vehicle on level place, slowly turn the handlebar 
left and right to see if it can turn freely. 
 
In case there is any hindrance, check if it is from the main 
cable assembly or other cables.   
 
If no, check the steering tie-rod end, and check if the 
steering stem bearing is damaged.

   

 

Note: 

Make sure the steering can be operated freely.   

An accident may occur   

if the handlebar is out of control. 

 

Brake system 

Front brake lever free play 

Operate front brake lever and check brake efficiency and 

brake lever function. 

Check free play of front lever end. 

 

Free play: 0mm

 

 

 

 

 

 

 

 

 

 

 
 
 
 
 
 
                                                       

3-5 

                                                            3. Checks & Adjustment 

Master Cylinder 
 

<Fluid level> 
 

 

Check the brake fluid level 
 

 

When the brake fluid level is near to the lower limit line, check 
master cylinder, brake hoses and joints for leakage. Remove the 
two mounting screws on fluid reservoir cap. 
 
Remove the cap, add DOT3 or DOT4 brake liquid till the upper 
limit line. 
 

·

Do not mix with dust or water when adding brake fluid. 

·

Use only the recommended of brake fluid   
to avoid chemical reaction.   

·

Brake fluid may cause damages to the surface of the   
plastic and rubber parts.   
Keep the fluid away from these parts. 

·

Slightly turn the handlebar left and right till the master   
cylinder is in horizontal, then remove the fluid reservoir cap. 

 

Brake Disc, Brake Pad 

 

< Wear of brake pad> 
Check the brake pad wears from the mark as indicated. 
 
Replace the brake pad if the wear has reached position of wear 
limit trough. 
 

Note  
The brake pad must be replaced with a whole set. 
 

Checking and replacing the brake disc 
Front brake disc thickness: 

2.5 mm 

Replace 

Rear brake disc: 

6.5 mm 

Replace  

 
Min. limited thickness of the front brake disc: 2.5mm 
Min. limited thickness of the rear brake disc: 6.5mm 

 
 
Change the Brake Fluid 

< Changing Brake Fluid> 

Change the brake fluid once every year. 

 

 

 

 

 

 

                                                         

3-6

                                                            3. Checks & Adjustment 

Wheels 

 

Lift front wheel on level place, and make sure there is no loading 
on the wheels.   
 
Shake the front wheel left and right to check whether the joint of 
front wheel is tightened and check whether it sways. 
 
Not tighten enough: 

Tighten it 

Sway: 

Replace the rocker arm 

 

 

 

Front Toe-in size 

 

Park the vehicle on level place, measure the front toe-in   
Toe-in: B-A=0-10mm 
 
 
 
 
 
Toe-in out of the range: 

 Adjust the locknut of tie-rod     

 
   

 

 

Note:  

After the toe-in has been adjusted, slowly run the vehicle to 
check whether the direction of vehicle can be controlled by 
handlebar. 
 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
                       

                                  3-7

                                                            3. Checks & Adjustment 

Tire Pressure 

Check the pressure of the tires with a pressure gauge. 

Note  

Check the tire pressure after tires are cooled.   

 

Driving under improper tire pressure will reduce the comfort 

of operation and riding, and may cause deflected wear of the 

tires. 

Specified pressure /tire 

 

Front wheel    Rear wheel 

Press

ure 

35kPa(.035k

gf/cm

2

35kPa(0.50k

gf/cm

2

Tire 

Size 

25×8-12 25×10-12 

 

 

 

Tire Tread 

Check the tire tread. 

 

Tread Height: < 3mm

Replace with new tires 

Note: 

When the tread height is less than 3mm,   
the tire should be replaced immediately. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

                                     

                    3-8 

   

                                                            3. Checks & Adjustment 

Wheel Nut and Wheel Axle 

Check front and rear wheel axle nuts for looseness 

Loosened axle nuts: 

Tighten 

Tightening Torque: 

Front wheel axle nut:   

110-130N

·

m(11.2kgf

·

m-13.3kgf

·

m) 

Rear wheel axle nut:   

110-130N

·

m(11.2kgf

·

m-13.3kgf

·

m) 

 

 

Sway of Wheel Bearing 

Lift the front wheel   

Make sure there is loading on the vehicle 

Shake the wheel in axial direction for any sway 

 

In case of any sway,   

disassemble the front wheel and check the bearing 

 

Suspension System 

Park the vehicle on lever place, press the vehicle Several times up 
and down as illustrated on the right. 
 
In case of any rocking or abnormal noise, check whether there is 
any oil leakage from absorbers, or any damage or looseness of 
tightening parts. 
 
 
 
 
 
 
 
 
 
 
 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
                             

                          3-9 

                                                            3. Checks & Adjustment 

 

Adjusting the Absorber 

 
Use special tools to adjust the length of absorber   
according to loading requirement 
 
Turn clockwise to adjust from high to low             

 

 

 

 

 

Gear Shifting 

 
Shift the gear to check for flexibility and gear engagement 
 
Adjust the gearshift rod if necessary 
 
Release the locknut to adjust the length of gearshift rod 
 
 
 
 
 

 

Fuel Device 

 

Status of the fuel system 

Remove the seat (

2-3) 

Check the fuel hose for any aging or damage. 

Aged or damaged fuel hose: 

 Replace 

Check if there is cracks or bending with the vacuum tube.   

Cracked or bended vacuum tube: 

 Replace                                                                                             

 

 

 

 

 

 

 

 

 

 

                                     

                  3-10 

                                                            3. Checks & Adjustment 

Checking the Throttle Lever

   

 

 

 

 

 

Check the free play of throttle lever 

 

Free play: 3-5mm 

 

Out of range: 

Adjust 

 

Loosen locknut of throttle cable 
turn the regulator and adjust free play of throttle lever 
 

After adjusting, tighten locknuts and install throttle cable sleeve 

 

Replace with a new throttle cable if the specified free play could 
not be acquired by adjusting the regulator or if there is still 
stickiness with the throttle.   

 

 

Adjusting the Speed Limiter

 

The speed limiter is to limit the opening of throttle   

Check the maximum length of limiter screw thread 

Maximum screw thread: a=12mm 

Adjust with a cross driver. 

 

Note: 

For beginners, the speed limit should be fully tightened.   

Drivers with certain skills may adjust   
the throttle with speed limiter 
 

Maximum length of screw thread is 12mm.   

It is recommended to adjust the thread length to 3-5mm. 

 

 

 

 

 

                                                 

      3-11 

     

                                                            3. Checks & Adjustment 

Cooling System 

Note 

z

  Check coolant level from reservoir tank.   

Do not check from radiator.   
 
If the radiator cap is opened while the engine is hot (over 100

), the pressure of the cooling system will drop down and the 

coolant will get boiled rapidly.   
 
DO NOT open the radiator cap until the coolant temperature 
drops down. 

z

  Coolant is poisonous, DO NOT drink or splash it to skin, eyes, 

and clothes. 

In case the coolant gets to the skin and clothes, wash with 
soap immediately.   

In case the coolant gets into eyes, rinse with plenty of water 
and go to consult the doctor 

In case of swallowing the coolant, induce vomit and consult 
the doctor.   

z

  Keep the coolant in a safe place and away from reach of 

children. 

 

Coolant level 

Coolant might reduce due to natural evaporation.   
Check the coolant level regularly. 

Note 

z

  Coolant can prevent rust and resist freeze. Ordinary water 

may cause engine rust or cracks in winter due to freezing.   

z

  Park the vehicle on level ground for checking of the coolant.   

Inclined vehicle body will cause incorrect judging of the 
coolant level. 

z

  Check the coolant after the engine is warmed up. 

Start and warm up engine.            

     

Stop the engine.                   

 

Remove left side panel (

2-6)

 

Check if the coolant level is between the upper and lower 

limit. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

                                       

 3-12 

 

 

 

 

 

 

 

 

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