CFMoto ATV CF500/CF500-A. Service Manual

10. Lighting, Instruments, Switches

Turning Light Switch

O Gr Sb

●

PUSH

●

Horn Switch

OFF

●

Br/L L

Overriding Switch

OFF

●

B/Br Gr/B

2 WD

、

4 WD

、

4WD Diff-Lock Switch

B
r
/
R

L
/
G

L
/
B

B
r
/
G

G
r
/
W

L
/
G

B
r
/
R

B
r
/
G

Lg
/B
r

2WD

●

4WD

●

LOC
K

●

Faulty handlebar switch:

→

Replace (

→

6-12).

Brake Light Switch

Disconnect brake light switch connector and check
terminators for continuity.

Hold the brake lever-----Continuity
Release the brake lever--- No continuity

No continuity:

→

Replace brake light switch

Horn

Inspection:

Remove front vent grille (

→

2-15)

Disconnect horn.
Connect with a fully charged 12V battery and check if
the horn sounds.

Faulty Horn:

→

Replace

10-8

10. Lighting, Instruments, Switches

Removal and Installation

Remove horn plug.

Remove fixing bolt and horn.

Reverse the removal procedure for installation.

Dashboard

Run the vehicle at low speed and check if the speed
indicator moves.

Faulty speedometer:

→

Replace

Removal and Installation

Remove front top cover (

→

2-4)

Remove front cover of dashboard (

→

3-12)

Disconnect dashboard wire connector.
Remove fixing nut and remove dashboard in the
direction as illustrated on the right

Reverse the removal procedure for installation.

Note:
Main cables and wires shall be routed properly.

10-9

10. Lighting, Instruments, Switches

Fuel Sensor

Remove:

--Fuel tank top cover (

→

2-8)

--4 fixing bolts

--Fuel sensor

Disconnect 2P connector

Inspection

Remove fuel sensor (refer to above steps)

Connect 2P connector

Turn ignition switch to ON

Shake fuel sensor float with hand, locate the float
position and check if it conforms to the fuel gauge
reading.

Non-conformity:

→

check main cable for damage or

short circuit

→

Check fuel sensor and fuel gauge

Remove fuel sensor 2P connector.

Connect multimeter between 3P connector terminals.

Shake float with hand and measure the resistance of
float at different positions.

Connection Terminal:
Upper: Blue/White-Green: 4-10

(20

℃

)

Lower: Blue /White-Green: 90-100

(20

℃

)

Faulty fuel sensor:

→

Replace

10-10

10. Lighting, Instruments, Switches

Water Temperature Transducer

Warning:
Be careful not to get scalded and do not place
flammables nearby.

Warning

Coolant must reach the switch thread, and the
depth from vessel bottom to sensor top should
be over 40mm.

Keep liquid temperature for three minutes
before measuring, and do not raise
temperature sharply.

The thermometer should not contact the vessel
bottom.

Disassembly:

Remove right side panel (

→

2-7)

Disconnect and remove transducer.
Put the transducer into a vessel with coolant, slowly
heat up the liquid and measure the transducer
resistance.

Temperature Resistance

℃

154

℃

100

℃

120

℃

Transducer out of range:

→

Replace

Install transducer

Connect water temperature transducer connector.
Fill coolant and discharge air
Reverse the removal procedure for installation of
plastic parts and seat.

10-12

12. Troubleshooting

Operation Notice……………………………………………………………………..12-1
Starting Failure/Hard Starting……………………………………………………….12-1
Unstable Engine Running or Engine Stops……………………………………..…12-2
Poor Engine Performance in High-speed Range or Slow Speed Rising………12-3
Unstable Idle Speed…………………………………………………………………12-4
Poor Engine Performance in Middle or High Range………..……………………12-5

Operating Notice

This chapter is a general explanation of major troubleshooting of the whole engine.
Refer to the relevant chapters for troubleshooting not listed in this chapter.

Starting Failure/Hard Starting

In case of starting failure or hard starting, refer to chapter of starting system (Engine maintenance
notebook) for troubleshooting and check the starting system whether have problems or not.

No Fuel No fuel in fuel tank

Clogged fuel hose
Clogged float valve

Reached Clogged fuel filter
Clogged fuel tank cap breather hole

Weak spark or         Faulty spark plug
   No spark             Stained or damaged spark plug

Normal spark Faulty high tension coil or short circuit

Faulty Ignition coil or short circuit
Faulty ignition switch

Faulty CDI unit

Faulty pickup coil

Low or no            Faulty cylinder head (Engine Service)
Compression        Worn or damaged Cylinder and piston
                                          ring

Faulty cylinder gasket

Normal compression pressure

Nearly start, but Deteriorated fuel
starting failure Improper idle speed adjustment

Secondary air intake into air intake pipe

Engine cannot be started Improper ignition time
Clogged air filter

Wet spark plug           Carburetor overflow
                                                    Excessive opening of throttle
                          Clogged air filter

Dry spark plug

No Air current

Faulty fuel enrichment device

12-1

Loosen drain screw, check if fuel
has reached carburetor

Remove spark plug and mount it
to spark plug cap, get it earthed
and check spark

Measure compression pressure

Try starting as operation

Remove spark plug and check
again

Remove carburetor over 30
minutes, connect ethylene pipes
with fuel increment loop and blow

12. Troubleshooting

Unstable Engine Running or Engine Stops

No petrol in fuel tank

No fuel Clogged fuel hose
Clogged float valve

With Fuel Clogged fuel filter

Clogged fuel tank cap breather hole

Stained, damaged and color changed

Stained or damaged spark plug

Improper spark plug heat value

Normal Spark Plug

Weak spark or        Faulty spark plug or stained spark plug
   No spark            Faulty Ignition coil
                      Faulty high tension coil or short circuit

Faulty ignition switch

Normal Spark Faulty pickup coil

Faulty CDI unit

Low or no Worn Cylinder and piston ring

compression Faulty cylinder gasket
pressure

Normal

compression

pressure

Incorrect Faulty pickup coil

Faulty CDI unit

Correct

Improper adjustment Refer to Engine Service

Correct adjustment

Air intake Faulty tightening of carburetor joint

No secondary air

No continuity Broken cable of fuel enrichment device

Faulty fuel enrichment device

Normal Continuity

12-2

Loosen drain screw, and check
the if fuel has reached carburetor

Remove spark plug
and check it

Remove spark plug and mount it
to spark plug cap, get it earthed
and check spark

Measure compression pressure
with pressure meter

Check ignition timing

Check caburetor
mixture screw

Check if there is
secondary air into
carburetor joint

Remove fuel enrichment
device wire lead and
check continuity

12. Troubleshooting

With Air current

Faulty fuel enrichment device

No air current

Clogged carburetor

Poor Engine Performance in Hi-speed Range or Slow Speed Rising

No rise of Clogged air filter

Engine speed Clogged fuel hose and filter

Clogged fuel tank cap breather hole

Clogged muffler

Engine speed rises

Incorrect Faulty pickup coil

Faulty CDI unit

Correct

Low or no             Worn Cylinder and piston ring
Compression
Pressure                Faulty cylinder gasket

Normal compression pressure

Clogged
                            Clogged carburetor

Not clogged

Stained damage and color changed

Spark plug stained and damaged
Improper spark plug heat value

Normal Spark Plug

Overheated Faulty mixture gas

Faulty fuel
Carbon deposit in combustion Chamber

Too much advanced ignition timing

Overheated

Cylinder knock Carbon deposit in combustion chamber

No cylinder knock

Clutch slip

2-3

Connect fuel enrichment
device wire lead with
battery for 5 Minutes.
Connect ethylene pipe
with fuel increment loop
and blow.

Run vehicle at high engine speed
(on an flat asphalt road)

Check ignition timing

Measure compression pressure
with pressure meter

Check carburetor

Check spark plug

Check the engine for
overheating

Accelerate or continuous
high-speed operation

12. Troubleshooting

Unstable Idle Speed

Incorrect Faulty pulse generator
Faulty CDI unit

Correct

Incorrect

Refer to fuel system (Engine Service)

Correct

Air intake Faulty tightening of carburetor joint

Faulty reed valve seal washer

No Air intake

Weak spark or       Stained or damaged spark plug
   No spark           Faulty Ignition coil
                      Faulty high tension coil or short circuit

Faulty ignition switch

Normal spark Faulty CDI unit

No Continuity Broken cable of fuel enrichment device
Faulty fuel enrichment device

Normal Continuity

With Air current

Faulty fuel enrichment device

No air current

Clogged carburetor

12-4

check ignition Timing

check carburetor
mixture screw

Check if secondary air
intake into carburetor
joint

Remove spark plug and mount it
to spark plug cap, get it earthed
and check spark

Remove fuel enrichment device
wire lead and check continuity

Connect fuel enrichment
device wire lead with
battery for 5 Minutes.
Connect ethylene pipe
with fuel increment loop
and blow.

12. Troubleshooting

Poor Engine Performance in Middle or High Range

Correct Faulty pulse generator
Faulty CDI unit

Correct

Clogged
Clean

Normal

No continuity Broken starting enriching cable

Faulty fuel enrichment device

Normal continuity

With Air current
Faulty fuel enrichment device

Not air current

2-5

check ignition timing

check carburetor

Remove fuel enrichment device
wire lead and check continuity

Connect fuel enrichment
device wire lead with
battery for 5 Minutes.
Connect ethylene pipe
with fuel increment loop
and blow.

．

Engine Overhaul Information

Conversion Table

Item Conversion
Press 1kgf/cm

=98.0665KPa 1KPa=1000Pa

1mmHg=133.322Pa=0.133322KPa

Torque 1kgf.m=9.08665N.m
Volume 1ml=1cm

=1cc

1l=1000 cm

Force 1kgf=9.80665N

Warning/Caution/Note

Please read this manual and follow is instructions carefully. To emphasize special information, the symbol and
the words WARNING,CAUTION and NOTE have special meanings. Pay attention to the messages highlighted
by these signal words.

Warning:

Indicates a potential hazard that could result in injury or death.

Caution:

indicates a potential hazard that could be result in vehicle damage.

Note:

provides key information to make procedures easier or instruction clearer.

Please note, however, that the warnings and cautions contained in this manual can’t possibly cover all the
potential dangerous information to the servicing, or lack of the vehicle. Except WARNINGS and CAUTIONS
stated in this manual, mechanic should have a basic understanding of the mechanical ideas and the procedure
of machine repair. If mechanic can’t master all the troubleshooting operation, please consult with qualified
mechanic for advice.

．

Engine Overhaul Information

General Precautions ………………………………..…………………………..10-2

Fuel, Oil and Coolant……………………………………………………………10-3

Brake-in …………………………………………………………………………..10-3

Engine Exterior and Engine No…………………………………………………10-4

Engine Specification………………………………………………..……………10-5

Overhaul Data…………………………………………………………………….10-6

Tightening Torque Table…………………………………………………………..10-10

Tools………………………………………………………………………………..10-12

Materials for Operation and Fixing ……………….……………………….…….10-14
.

13-1

．

Engine Overhaul Information

GENERAL PRECAUTIONS

When two or more persons work together, keep reminding each other for safety purpose.

When start the engine indoors, make sure that the exhaust gas is forced outdoors.

If use hazardous or flammable material, please strictly operate according to manufacturer’s operation

manual. Operate in a well- ventilated place.

Never use gasoline as a cleaning solvent.

Do not touch the engine oil, radiator or muffler with bare hands to avoid scalding before it is cooled.

Check all the lines, and fittings related to the system for leakages, after repairing fuel, cooling, lubricating

or exhaust system .

Do not dispose used oil, coolant or defective parts optionally for environmental purpose.

CAUTION:

Use genuine CFMOTO parts or their equivalent.

Place and store the disassembled parts separately in order for correct assemble.

Use special tools according to service manual.

Make sure that all parts used in reassembly are clean, lubricated them when specified.

Use the special lubricants, sealants and greases.

Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque, from big to small and

from inner side to outer side.

Fix torque screw with torque wrench, clean grease or oil from the screw thread before fixing.

Check the parts after disassembling, clean the parts before measuring.

Check parts for tightness and proper operation, after assembling.

Replace the disassembled washers, o-rings, seals, locknuts, lockwashers, cotter pins, circlips with new

ones.

13-2

Warning ! Proper service and repair procedures are important for the safety of

operator and the safety and reliability of the vehicle.

．

Engine Overhaul Information

FUEL, OIL, COOLANT

Fuel

Use unleaded gasoline with octane number over 90.

OIL

Use a premium quality 4-stroke motor oil to ensure
longer service life of your vehicle. Use only oils that
meet API service classifications SF or SG and that
have a viscosity rating of SAE10W/40. If oil with a
rating of SAE 10W/40 is not available, select an
alternative according to the chart.

ENGINE COOLANT

Since antifreeze also has corrosion and rust-inhibiting properties, always use coolant containing antifreeze,
even if the atmospheric temperature does not go below the freezing point.
It is suggested that the freezing point of antifreeze should be 5

℃

lower than the lowest ambient temperature

where the vehicle is used.

Recommended Coolant: -35

℃

antifreeze, corrosion-resistant, high boiling point coolant

Warning!

Coolant is poisonous. Never drink it. Store it properly.

Caution:

DO NOT mix coolant with that of other engines.

BREAK-IN PROCEDURES

During manufacturing only the best possible material are used and all machined parts are finished to a very
high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to
maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. Refer to the following break-in engine speed recommendations.
For better performance and durability, a new engine requires a run-in time of 20 hours as under:

0~10 Hours:

Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour
of operation. Vary the speed of vehicle from time to time. Do not operate it at one set throttle position.

10~20 Hours

Avoid prolonged operation above 3/4 throttles. Rev the vehicle freely but do not use full throttle at any time

Note:

Keep the daily maintenance during the run-in time and eliminate the troubles, if any. After 20h run-in time,

do the maintenance according to the owner’s manual for normal operation of the ATV.

13-3

CFMoto ATV CF500/CF500-A. Service Manual - part 8