CFMoto ATV CF500/CF500-A. Service Manual

6. Front Wheel, Front Brake, Suspension, Steering

Steering System

1 Bolt 1

2 Rubber

、

Right Bracket

，

Dashboard

、

Left Bracket

，

Dashboard

、

Alum Cover

，

Handlebar

、

Bolt 2

、

Front Bracket

，

Dashboard

、

Bolt 3

、

Lock Pad

、

Adapter Plate

、

Bush

、

Bushing

，

Steering Stem

、

Seal Ring 25

、

Tie-Rod

、

Steering Lock 26

、

Nut 4

、

Screw 2 27

、

Steering Knuckle 2

、

Cotter Pin

、

Nut 1

、

Washer 1

、

Pitman Arm

、

Washer 2

、

Nut 2

、

Steering Knuckle 1

、

Nut 3

6-17

6. Front Wheel, Front Brake, Suspension,

Steering

Steering Stem

Remove:

--Dashboard front cover(

→

6-12)

--Front wheel (

→

6-2)

Disconnect handlebar switch connector

Hammer the lock pad flat with a flat screwdriver and
hammer

Remove:

-- Bolt 1 and Bolt 2
--Steering stem bushing, adapter plate


--Cotter pin
--Tie-rod nut and washer

Press down steering tie-rod and separate from steering
stem




Remove fixing bolt of steering stem

Lift steering stem with handlebar from vehicle.

Installation:

Reverse the removal procedure for installation

NOTE:
Check steering after installation (3-3)

Main cables and wires shall be routed properly
(chapter 1)

6-18

6. Front Wheel, Front Brake, Suspension,

Steering

Steering Bearing, Oil Seal

Remove:

--Front wheel (

→

6-2)

--Steering stem (

→

6-18)

Remove front left & right arms(upper & lower)(

→

6-9)

Remove steering bearing and oil seal from frame with
special tool

Special tools:
Bearing removal tool set
Rotor puller
Removal tool shaft
Removal tool hammer

Installation

Reverse the removal procedure for installation.

Special tools:
Tool A, Bearing Race
Tool shaft

Note:
Use special tools for installation of bearing.

Reverse the removal procedure for installation of
the steering system.

NOTE:
Check steering after installation.

6-19

7. Rear Wheel, Rear Brake, Suspension

Overhaul Info………………………………….. 7-1
Troubleshooting………………………………..7-2
Rear Wheel……………………………………..7-3

Rear Fork………. …………………7-4
Rear Shock A

bsorber…..…...….. 7-5

Overhaul information

Note

Securely support the vehicle when overhauling the rim and suspension system.

Use genuine parts of bolts and nuts for rear rim and suspension.

Do not overexert on the wheels to avoid possible damage to the wheels.

When removing tire from rim, use special tire lever and rim protector to avoid damage to the

rim.

Overhaul standard

Item Standard

Limit

Longitudinal

－

2.0mm

Rim Vibration

Horizontal

－

2.0mm

Remained Tire

Tread

－

1.6mm

Rear

Wheel

Tire

Tire Pressure

35kpa(0.35kgf/cm

)

－

Rear

Brake

Brake Lever Free Play

－

20mm

－

Tightening torque

Rear wheel axle nut 110-130N•m
Rim mounting bolt 50-60N•m
Upper mounting bolt, Shock absorber 40-50N•m
Lower mounting bolt, Shock absorber 40-50N•m

7-1

7. Rear Wheel, Rear Brake, Suspension

Troubleshooting

Rear Wheel Wobbles

Rim

warpage

Faulty

tire.

Tire pressure too low

Improper wheel balance

Improper tightening of wheel axle nut

Loosened wheel nut

Rear Shock Absorber Is Too Soft

Weak

spring.

Oil leakage from rear shock absorber

Rear Shock Absorber Is Too Hard.

Bent rear shock absorber

Tire pressure is too high

Poor Brake Efficiency

Improper brake adjustment

Stained brake pad or brake disk

Worn or damaged brake pad

7-2

7. Rear Wheel, Rear Brake, Suspension

Rear Wheel

Removal:

Refer to front wheel removal (

→

6-3)

Inspection:

Rim:

Damage, warpage, serious scrapes:

→

Replace

Slowly turn the wheel, measure the rim vibration with a
dial gauge.

Service limit: Axial: 2.0mm
Radial: 2.0mm

Installation:

Refer to front wheel installation (

→

6-3)

Wheel Hub

Remove:

--Rear wheel

（→

7-3

）

--Rim axle nut
--Wheel Hub

Installation:

Reverse the removal procedure for installation.

Tightening torque, Rim Axle Nut

：

110-130N.m

7-3

7. Rear Wheel, Rear Brake, Suspension

Rear Brake

Rear Brake Caliper
Remove:
--Rear left wheel

（→

7-3

）

--2 bolts from arm
--Brake caliper

Inspection:

Brake Caliper:

Cracks, Oil leakage:

→

Replace

Installation

Reverse the removal procedure for installation.

Note

：

Refer to Chapter 1 for brake hose routing.

Rear Brake Disc

Remove:
--Rear left wheel

（→

7-3

）

--Rear drive shaft
--Rear brake caliper (

→

7-4)

--6 shear bolts
--Parking brake

（→

7-4

）

--Rear brake disc

（→

6-3

）

Inspection

Brake Disc:

Thickness< 6.5mm:

→

Replace

Installation

Reverse the steps of removal for installation.

Note

：

Refer to Chapter 1 for brake hose routing.

Parking Brake

Remove:
--Rear left wheel

（→

7-3

）

--Rear drive shaft
--Rear brake caliper (

→

7-4)

--6 shear bolts
--Parking brake

7-4

7. Rear Wheel, Rear Brake, Suspension

Rear Suspension System

Rear Right Suspension
NOTE
DO NOT remove both left and right suspension at the same time to avoid fall down of the vehicle.

(1) Left Ball Pin
(2) Nut 1
(3) Stabilizer Bar
(4)

Rubber Support, Right Rear Arm

(5) Bracket
(6) Bolt 1
(7) Bolt 2
(8) Bracket
(9) Rubber Support
(10) Bolt 3

(11) Bolt 4
(12) Nut 2
(13) Bolt5
(14) Right Ball Pin
(15) Nut 3
(16) Bolt 6
(17) Rear Right Upper Arm
(18) Rear Right Lower Arm
(19) Bolt 7
(20) Bolt 8

(21) Nut 4
(22) Bolt 9
(23) Nut 5
(24) Nut 6
(25)Bolt10
(26) Rear Right Absorber
(27) Nut 7
(28) Nut 8

Disassembly

Stabilizer Bar

Remove:

Bolt 1(6), Bolt 2 (7), Bolt 3 (10), Bolt 4 (11), Bracket (8)and(5),
Rubber Support (4) and (9), Nut 2 (2), Nut 10 (12), Left Ball Pin (1), Right Ball Pin (14)

Remove:

Stabilizer Bar (3)

Installation:

Reverse the removal procedure for installation

7-5

7. Rear Wheel, Rear Brake, Suspension

Right Rear Absorber

Removal

Note:

Securely support the vehicle when removing rear left and right absorbers.

Suspend wheels from ground.

Maintenance of rear absorbers only does not require removal of rear suspension.

Remove the following parts for rear right shock absorber

(25) Bolt 10
(27) Nut 7
(19) Bolt 7
(28) Nut 8

Remove rear right shock absorber

Installation:

Reverse the removal procedure for installation.

Rear Right Arm

Refer to

Front Left Upper Arm

in Chapter 13 for the removal, inspection and installation of

Rear Right Arm

Rear Left Suspension

Refer to

Rear Right Suspension

for the removal, inspection and installation of

Rear Left Suspension.

7-6

8. Battery, Charging System

Overhaul information

Note

Usually no hydrogen will be generated during charging except when overcharged. Keep

away from fires when charging.

Electrolyte is highly corrosive, splash to clothes, skin or eyes will cause burn or loss of sight.

Wash with plenty of water if splashed. In case of splash into eyes, wash with plenty of water
and consult the doctor. The electrolyte on the clothes may contact the skin as well, it will
cause damage to the clothes if stained for a long time. Change a clothes and wash away the
electrolyte.

Note

Spark arc may be generated when removing or joining the electrical parts with switch on and

will damage the electrical parts such as rectifier. Operation should be done with ignition
switch OFF.

Remove battery from vehicle for charging and do not open the electrolyte cover.

Note

Replace if the battery service life expired.

Keep the ignition switch OFF when removing electrical parts.

Disconnect the negative connection of battery if it is stored on the vehicle

Fast charging is not recommended as it may reduce the battery life.

If battery is repeatedly charged and discharged fully (fully-charged and fully-discharged), it

may cause damage to the battery or shorten the service life or lower the capacity of battery.
In addition, the capacity of battery will also lower in 2~3 years even under normal use. So the
battery should also be replaced.

If the open voltage is less than 12.4V, charge the battery normally to raise the open voltage

up to 12.4V.

Refer to troubleshooting table (

→

8-3) for inspection of charging system

Refer to Engine Maintenance for removal and installation of AC magneto

Inspection of battery should be done following the owner’s manual of battery tester.

8-2

8. Battery, Charging System

Overhaul standard

Item Standard

Model Permanent

magnet

alternator

Output 3-phase

AC magneto

Resistance of charging coil (20

℃

)

0.2-0.3

Ω

Rectifier Type

3-phase loop rectification,

controllable parallel

connection, regulated

voltage

Capacity 12V10Ah

Current Leakage

Less than1mA

Fully-charged 12.8V

Voltage between

terminals

Insufficient charge

Less than 11.8V

Standard 0.9A/5~10hours

Battery

Charging current/time

Fast charge

4A/60minutes

Troubleshooting

Battery overflow

Incorrect Faulty Battery

Correct

Incorrect

Correct

Correct Incorrect

→

Incorrect

•Faulty rectifier •Short circuit with

• AC magneto has short

main cable

or open circuit.

•Faulty ignition switch

Correct

Charging system is correct.

Incorrect

Incorrect l •Main cable has short/open circuit.

•Faulty contact of connectors

Correct

8-3

Check battery with recommended test meter:
YUASA ‘ BM310 or equivalent

Measure the current leakage of battery. (

→

8-5)

Current: below 1mA

Inspect the charging coil of AC magneto.
Resistance: 0.2-0.3

Ω

Inspect monomer voltage of battery and
record it. (

→

8-4)

Start engine, turn on headlight with high
beam.
Inspect battery’s voltage between
terminals at the engine speed of
5000rpm. (

→

8-5)

Standard: monomer voltage<charge
voltage<15V

Inspect rectifier system (

→

8-6)

Disconnect rectifier, and
measure current leakage
again.
Current: less than 1mA

8. Battery, Charging System

Battery

Note:

Keep the ignition switch at OFF before operation.

Remove:

--Seat (

→

2-3)

--Bolt1&Bolt2
--Battery fixing plate
--Battery cover

Loosen negative pole screw and disconnect negative
lead.
Remove positive pole cap and screw.
Disconnect positive lead.

Installation:

Reverse the removal procedure for installation.

Note:

Apply clean lubricant grease to the pole after

installation.

Install cap firmly on the positive pole after

installation.

Inspection:

Measure voltage between battery terminals, and check
test status.

Complete test: 12.8V
Insufficient test: <11.8V
Insufficient charge:

→

Recharge

Note:

When recharging after normal charging, measure

the voltage between terminals after 30 minutes.
Measuring immediately after recharging will not gain
the correct test due to the sharp voltage changes
between the terminals.

Battery

Note:

Usually no hydrogen will be generated during charging
except when overcharged. Keep away from fires when
charging.

Charge according to the current and time specified on
the label of battery.

Remove battery from vehicle. (Refer to above content)

8-4

8. Battery, Charging System

Connect charger’s positive wire to battery’s positive
pole.
Connect charger’s negative wire to battery’s negative
pole.

Charging current/time: Standard: 0.9A/5~10hours

Fast charge: 4.0A/60mins

Note:

Keep the electrolyte temperature under 45

℃

Reduce current to adjust the temperature if it is too
high.

Fast charge will reduce battery’s life or cause

damage to battery. Do not use fast charge unless
in emergency case.

Inspection of Charging System

Inspect charging status

Remove battery (

→

15-4) and install a fully charged

battery.

Keep ignition switch at “OFF” position.

Connect voltmeter between battery’s terminals

after engine is started and warmed up.

Note:

Avoid short circuit when measuring

Overvoltage may be generated when removing
or joining the battery terminals with switch ON
and will damage the multimeter and the
electrical parts. Operation should be done with
ignition switch OFF.

Use a fully charged battery for inspection.

Start engine and turn on high beam.

Increase engine speed slowly. Check voltage between
battery terminals.
Voltage between terminals at engine speed of
(5000r/min): 13.5-15V

Standard:
Battery’s monomer voltage<charging voltage<15V
(5000rpm

)

Electric Leakage Test

Remove seat (

→

2-3)

Remove battery fixing plate (

→

2-3)

Open battery cover

Keep ignition switch at the “OFF” position, and remove
negative wire from battery.

8-5

8. Battery, Charging System

Remove fuse box from inside of rear fender.



Connect amperemeter between battery negative pole
and negative lead

Measure current leakage with ignition switch at the
“OFF” position.

Note:

If the measured current is higher than the

maximum limit, the multimeter will be burnt.
Therefore, measure the current by shifting from the
high to the low range.

Do not turn on the ignition switch when measuring

the current.

Current Leakage: less than 1mA

When current leakage is higher than specified limit,
there is fault with the return circuit.

Disconnect terminals and connectors while measuring
current to check out the faults.

Rectifier/Regulator
System inspection

Note:

Inspection can be done without removing the AC
magneto from engine.

Remove:

--Seat (

→

2-3)

--Right & left side panels (

→

2-6)

--Rear top cover(

→

2-5)

--Battery cover and battery(

→

8-4)

--Rear fender(

→

2-10)

Disconnect the 2 connectors of rectifier/Regulator

8-6

8. Battery, Charging System

Check the connector terminals for loosening,
bending, rust or come-off.

Check the following items of the main cable terminals of
the two rectifier connectors:

Item Result

Battery wire

(red)

There should be voltage between

red terminal (+) and frame body

earth wire

Earth wire

(green)

Green terminal must be connected

with frame body earth wire

Charging coil

(yellow, yellow,

yellow)

Resistance between yellow

terminals is: 0.2-0.3

Ω

(at 20

℃

)

Ignition switch

lead wire

(black)

Black lead wire must be

connected with black terminal.

Installation:

Reverse the removal procedure for installation.

Note:

Wires, hoses and cables should be routed properly.

(

→

Charpter1)

8-7

CFMoto ATV CF500/CF500-A. Service Manual - part 6