CFMoto ATV CF500/CF500-A. Service Manual - part 10

14. Checks & Adjustment

Inspection:

Inspect drive belt for wear and damage. If any cracks or
damages are found, replace drive belt with a new one.

Inspect drive belt for width, if width is out of

service limit,

replace drive belt with a new one.

Service Limit: 33.5mm

Tool: Vernier Caliper

Installation

Reverse the removal procedure for installation. Pay
attention to the following:
Insert drive belt, as low as possible, between secondary
sliding sheave and primary fixed sheave.
Hold secondary sheave with a special tool and tighten
the nut to the specified torque.

Nut, Secondary Sheave: 115 N.m

Install primary sheave and nut. Hold the primary sheave
with a special tool and tighten the nut to the specified
torque.

Nut, Primary Sheave:115N.m

Turn primary sheave, until the drive belt is properly
seated and both the primary and secondary sheaves
rotate together smoothly and without slipping.

Caution:

Fit the drive belt with the arrow on the drive belt

points toward normal turning direction.

The drive belt contact surface of the driven face

should be thoroughly cleaned.

Install CVT cover

14-7

14. Checks & Adjustment

Inspection of Lubrication System

Check Engine Oil Level

Keep the engine in a plan position.

Remove the fixture A, fixture B, then remove the left

side cover 1.

Remove oil dip rod 2

Clean oil dip rod, insert oil dip rod but do not tighten

it.

Take out oil dip rod and check if oil is between upper

and lower limit.

If the engine oil is insufficient, fill more oil until the

sufficient oil is obtained.

Engine Oil: SAE10W/40 classification SF or SG

Replacing Engine Oil

Remove left side cover 1, oil dip rod 2, drain bolt 3

and washer 4.

Drain out the engine oil while the engine is still

warm.

Clean oil dip rod, drain bolt and washer with solvent.

Install washer and drain bolt.

Drain Bolt: 30 N.m

Fill engine oil. ( about 1900ml)

14-8

Replace engine oil and oil filter initially at 20

hours or 200km and every 80 hours or 2000km

thereafter.

Note:

Keep the engine in a plan position

Do not tighten oil dip rod when measuring oil

level

14. Checks & Adjustment

Install oil dip rod, start the engine and allow it to run

for several minutes at idling speed.

Turn off the engine and wait for about 3 minutes,

and then check the oil level on the dipstick.

Replacing Oil Filter

Remove relative parts ( see Replacing Engine Oil)

Remove oil filter

①

with the special tool

Install washer and drain bolt

Install new oil filter with the special tool

Fill engine oil (about 2000ml) and check (see

Replacing Engine Oil)

Tool: Oil Filter Wrench

Inspection of External Oil Pipe

Check external oil pipe for leakage or damage.

Leakage or Damage:

→

Replace

14-9

Caution:

The engine oil should be changed when the engine is
warm. If the oil filter should be replaced, replace engine
oil at the same time.

Engine Oil Capacity
When replacing oil: 1.9L
When replacing oil filer: 2.0 L
Engine overhaul:2.2 L

14. Checks & Adjustment

Inspection of Cooling System

Check radiator, reservoir tank and water hoses.
Leakage or Damage:

→

Replace

Check coolant level by observing the upper and the
lower limit on the reservoir tank.
If the level is below lower limit, fill coolant until the level
reaches the upper limit.

Replacing Coolant

Remove radiator cap and re

①

servoir tank cap .

②

Place a pan below water pump, and drain coolant by

removing drain plug and water hose .

③

④

Drain coolant from reservoir tank.

Clean radiator with fresh water, if necessary.

Connect water hose and tighten drain

④

bolt

③

securely.

Fill the specified coolant into the radiator.

Loosen bleed bolt on water pump, when coolant

⑤

flow from bleed bolt, tighten the bolt. Install radiator
cap

①

securely after filling coolant.

Start the engine and keep it running for several

minutes. After warm up and cooling down the
engine, open radiator cap and check coolant. Fill the
specified coolant until the level is between the upper
and lower lines on the reservoir tank.

Caution:

Repeat the above procedures several times and make
sure the radiator is filled with coolant and air is
discharged.

14-10

Check initially at 40 hours or 1000km, replace
coolant every 2 years.

Warning !

Do not open radiator cap when engine is hot,

you may be injured by escaping hot liquid or
vapor.

Engine coolant is harmful. If coolant splashes in

your eyes or clothes, thoroughly wash it away
with water and consult a doctor. If coolant is
swallowed, induce vomiting and get immediate
medical attention.

Keep coolant away from reach of children

14. Checks & Adjustment

Fill coolant into the reservoir tank till between upper and
lower limit.
Install reservoir tank cap.

Inspection of Radiator Hose

Check radiator hose and clamp.
Leakage or Damage:

→

Replace

Inspection of cylinder pressure

Check cylinder pressure is necessary.

Cylinder Pressure: 1000kpa

A lower cylinder pressure may be caused by:

Excessive wear of cylinder;

Wear of piston or piston ring;

Piston ring jam in groove;

Poor closure of valve seat;

Damaged cylinder gasket or other defects

Note:

When cylinder pressure too low, check the above

items.

Testing Cylinder Pressure

Note:

Before testing of cylinder pressure, make sure that

cylinder head bolts are tightened to the specified torque
and valve clearance has been properly adjusted.

Warm up the engine before testing;

Make sure battery is fully charged;

Remove spark plug 1;

Install cylinder pressure gauge 2 in spark plug

hole and tighten nut;

Keep throttle full open;

Press start button crank the engine a few

seconds. Record the maximum reading of
cylinder pressure.

Tools:

Cylinder Pressure Gauge

Adaptor

14-11

Warning:

Never mix with other brand

Perform inspection every 40 hours or

14. Checks & Adjustment

Inspection of Oil Pressure

Oil Pressure: 130

～

170kpa at 3000r/min

Lower or higher oil pressure may be caused by:

Oil pressure

Ⅰ

is too low

Clogged oil filter;

Leakage from oil passage;

Damaged

O-ring;

Oil pump failure;

Combination of above items;

Oil pressure

Ⅱ

is too high

Oil viscosity is too high;

Clogged oil passage;

Combination of above items;

Testing Oil Pressure

Remove

bolt

①

;

Connect tachometer with ignition coil

②

Install oil pressure gauge and joint seat to main oil

③

gallery.

Warm up engine as per following:

Summer: 10 minutes at 2000r/min
Winter: 20 minutes at 2000r/min

After warming up, increase engine speed to 3000r/min,
and record readings of oil pressure gauge.

After testing, apply thread locker to the thread in the

hole of main oil channel. Install bolt and tighten to
the specified torque.

Tighten torque

：

23N.m

Tools

：

Oil pressure gauge

Tachometer

14-12

14. Checks & Adjustment

Inspection of Clutch Engagement and Lock-up

CF188 engine is equipped with a centrifugal type
automatic clutch.
Before checking the initial engagement and clutch
lock-up two inspection checks must be performed to
thoroughly check the operation of the drive train.

I Initial Engagement Inspection

Connect tachometer to ignition coil

Start

engine

Shift gear lever to “High” position

Slowly increase throttle and note down the engine

speed (r/min) when the vehicle starts to move
forward.

Engagement speed:1800r/min

～

2400r/min

If the engagement speed is out of the above range,
check the following:

Clutch

shoes

Clutch shoe wheel

Primary and secondary sheave

Refer to Chapter 12 for inspection of clutch

II Clutch Lock-up Inspection

Connect the tachometer to ignition coil;

Start the engine;

Shift gear lever to “High” position;

Apply front and rear brakes as firmly as possible;

Fully open the throttle for a brief period and note the

maximum engine speed obtained during the test
cycle.

Lock-up Speed: 3300r/min

～

3900r/min

Warning:
Do not apply full power for more than 5 seconds or
damage to clutch or engine may occur.
If the lock-up speed is out of the above range, check the
following:

Clutch

shoes

Clutch

wheel

Primary and secondary sheave

Refer to Chapter 12 for inspection of clutch

Tool:

Tachometer

14-13

15. Engine Removal, Inspection & Installation

Engine Removal/Installation Orders and the Relative Page Numbers

Item

Description

Disassembly

Inspection

Maintenance

Assembly Remarks

Water Hose/Pipe

15-2

15-11

15-69

Left Side Cover

15-2

—

15-69

Engine

Periphery

Recoil Starter

15-2

15-49

15-68

Spark Plug

15-2

15-4

15-68

Cylinder Head Cover

15-3

15-14

15-66

Tensioner 15-3

15-24

15-67

Camshaft 15-3

15-21

15-65

Cylinder Head/Tensioner Plate

15-4

15-15/15-23

15-64

Cylinder/Timing Chain Guide

15-4

15-24/15-23

15-64

Engine

Front

Side

Piston 15-5

15-25

15-62

Starting Motor

15-5

15-3

15-62

Oil Filter

15-6

15-9

15-62

Sector Gear

15-6

—

15-62

Water Pump

15-7

15-61

Sheave Drum

15-7

15-48

15-60

Left Crankcase Cover/ Magneto Stator

15-7

15-48

15-60

Magneto Rotor

15-7

15-47

15-60

Starting Driven Gear

15-8

15-47

15-59

Starting Dual Gear/Idle Gear

15-8

15-48

15-59

Engine

Left Side

Oil Pump Sprocket and Chain

15-8

—

15-59

CVT Cover

15-9

15-51

15-58

Drive Belt

15-9

15-36

15-57

Primary Sheave/Secondary Sheave

15-9

15-30

15-57

CVT Housing/Clutch Outer Face

15-10

15-51

15-57

Clutch 15-10

15-28

15-56

Engine

Right

Side

Timing Chain

15-10

15-23

15-56

Gear Position Bolt

15-11

—

15-56

Right Crankcase

15-11

15-52

15-56

Front Output Shaft Components

15-11

15-43

15-55

Driven Bevel Gear Components

15-11

15-43

15-55

Shift Cam

15-12

15-40

15-55

Guide Bar, Fork

15-12

15-39

15-55

Drive Bevel Gear Components

15-12

15-42

15-55

Main Transmission Shaft

15-12

15-38

15-54

Transmission Counter Shaft

15-12

15-38

15-54

Balancer Shaft

15-12

15-46

15-54

Crankshaft 15-13

15-27

15-54

Oil Pump, Pressure-limiting Valve

15-13

15-41

15-53

Engine

Center

Left Crankcase

15-52

Notes:

Arrowhead direction is for engine removal orders. Reverse the direction for assembly and installation

15-1

15. Engine Removal, Inspection & Installation

Ⅰ

Engine Removal

Preparation before engine removal

Prepare a proper tray used for load of components

Prepare necessary removal and assembly tools

Drain up engine oil

（

→

11-8

）

Drain up coolant

（

→

11-10

）

△

Engine Periphery
Water Hose/Pipe

Remove water hose clamp and

①

②

;

Remove water hose

③

Remove

screw

④

and water hose

⑤

Left Side Cover

Remove 6 bolts(M6X20) of left side cover

⑥

Remove left side cover

⑥

Recoil Starter

Remove 4 bolts

（

M6X12

）

of recoil starter

Remove recoil starter

⑦

Inspection Plug

Remove inspection plug with screwdriver

⑧

Engine Front Side

Spark Plug

Remove spark plug with special wrench

⑨

Tool: Spark Plug Wrench

Turn crankshaft, align T.D.C. line A on magneto rotor

with mark B of left crankcase

15-2

15. Engine Removal, Inspection & Installation

Cylinder Head Cover

Remove valve adjusting cover

Remove12 bolts of cylinder head cover

Remove cylinder head cover

Timing Chain Tensioner

Remove screw plug , insert

①

a flat screwdriver into

slot of timing chain tensioner adjuster , turn it
clockwise to lock tensioner spring;

Remove tensioner fix bolt

Remove tensioner and gasket

Camshaft

Loosen timing sprocket bolt;

Remove timing sprocket bolt and lock;

15-3

15. Engine Removal, Inspection & Installation

Remove

C-ring

①

Remove timing sprocket from camshaft, remove

camshaft

Remove tensioner plate

Cylinder Head

Remove cylinder head bolt

Remove cylinder head bolts diagonally;

Remove cylinder head

Cylinder

Remove dowel pin and cylinder head gasket

Remove timing chain guide

①

15-4

Note:

Take care not to drop spacer, bolt, bolt lock

and C-ring into crankcase.

Note

Take care not to drop dowel pin into

crankcase

15. Engine Removal, Inspection & Installation

Remove cylinder bolt

Remove

cylinder

Remove dowel pin and cylinder gasket

Piston

Remove piston pin circlip with

①

long nosed pliers

Remove piston pin and

②

piston

③

Tool: Piston Pin Remover

Engine Left Side

Starting Motor

Remove 2 bolts of starting motor

Remove starting motor

15-5

Note

：

Take care not to drop dowel pin

into crankcase

Note

：

When performing above removal process,

be sure to hook up timing chain to
prevent it from falling into crankcase

Note:

Put a clean rag under piston so as not to

drop piston pin circlip into crankcase

Notes:

When installing piston, make sure its

identification conforms to that of cylinder;

When removing piston pin, clean off burrs of

piston pin hole and groove. If it’s difficult to
remove the piston, DO NOT hammer, use a
special remover

④

15. Engine Removal, Inspection & Installation

Oil Filter

emove oil filter with special tools

Tool: Oil filter Remover

Sector Gear

Remove bolt 1 of gearshift rocker arm

Remove gasket 2 and gearshift rocker arm 3

Remove bolt of sector gear housing cover

Remove wire clip and sector gear housing cover

Remove dowel pin and gasket

Remove drive sector gear 4

Remove bolt 5 of driven sector gear

Remove washer 6 and driven sector 7

15-6

15. Engine Removal, Inspection & Installation

Water Pump

Screw out bolt of water pump

Remove water pump

Sheave Drum

Remove the sheave drum by using a suitable bar;

Remove washer and sheave drum

Left Crankcase Cover

Remove

bolts;

Remove left crankcase cover

Remove dowel pin and gasket

Magneto Rotor

Install attachment 1 to crankshaft end

Install special tool to rotor thread;

Remove rotor and woodruff key

Tool:

Rotor Remover

15-7

15. Engine Removal, Inspection & Installation

Starting Motor Gear

Remove driven gear 1 and needle bearing

Remove spacer 2

·Remove dual gear and shaft 3

·Remove idle gear and shaft 4

Oil Pump Sprocket and Chain

Remove drive sprocket nut 5

Remove C-ring 6

Remove oil pump drive and driven sprockets and

chain

15-8

15. Engine Removal, Inspection & Installation

Engine Right Side

CVT Cover

Remove bolt of CVT cover

Remove CVT cover

Remove gasket and dowel pin

CVT(Continuously Variable Transmission)

Remove primary sheave nut with special tool

Remove primary sliding sheave

Remove secondary sheave nut with special tools

Remove secondary sheave

Remove drive belt

Tool:

Sheave Holder

Remove primary fixed sheave

①

Remove bolt for air guide plate.

Remove air guide plate

15-9

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