CFMoto ATV CF500/CF500-A. Service Manual

15. Engine Removal, Inspection & Installation

Oil strainer

Check oil strainer and

①

O-ring

for

damage

②

Damaged oil strainer:

→

Replace

Clean the surface of oil strainer with engine oil

Relief Valve

Check the valve body

①

、

valve and spring O

②

③

ring for damage or wear

④

Damage or wear:

→

Replace

Drive Bevel Gear

Use a clean rag to protect the drive bevel gear shaft,

clamp it to the pliers.

Loosen drive bevel gear nut 3, remove the drive

bevel gear 4 and adjust washer 5

Check the drive bevel gear 4 and output driven gear

2 for rust, scratch, wear or damage. Replace if any.

Check if the bearing 8 turns smoothly, replace with a

new bearing if necessary.

Adjust Washer 5 if any of right crankcase, drive

bevel gear 4, or drive bevel gear cover 1 is replaced.
Refer to bevel gear adjustment for details.

Apply engine oil to bearing 8 when assembling and

tighten nut 3 to the specified torque.

Drive bevel gear nut
Tightening torque: 145N.m

1. Drive bevel gear cover 5. Adjust washer
2. Output driven gear 6. Drive bevel

gear shaft

3. Drive bevel gear nut      7. Bearing press
4. Drive bevel gear     8. Bearing

15-42

15. Engine Removal, Inspection & Installation

Front Output Shaft

Check bearing 7 for smooth turning and abnormal

wear. Check oil seal 5 for damage.

Wear or damage:

→

Replace

Apply lubrication oil to bearing 7 and oil seal 5 lip

before assembly.

Apply thread locker to bearing limit nut 6 (left thread)

and tighten to the specified torque.

Bearing limit nut Tightening torque: 80N.m

Tighten Nut 1 to the specified torque
Front output shaft nut tightening torque: 97N.m

Driven Bevel Gear

Remove nut 19, washer 18, coupler 17 and oil seal 16.

Protect end thread of driven bevel gear with proper

device

②

. Fix bevel gear cover 14 and press out

driven bevel gear.

Place a clean rag

①

under bevel gear cover.

Remove bearing limit nut 10 with special tool

②

and

remove bearing.

Check driven bevel gear 8 surface for scratches,

wear. Scratch or wear:

→

Replace

Check free turning of bearing 9 and 11. Replace

with a new one if any abnormal is found.

Use new oil seal 16 and O-ring 12 when

assembling.

Adjust washer 13 if any of right crankcase, driven

bevel gear 8 or driven bevel gear cover 14 is
replaced. Refer to bevel gear adjustment for
details.

Apply lubrication oil to bearing 9 and 11 and oil seal

16, O-ring. Apply thread locker to nut 10 and tighten
to the specified torque.

Tightening torque :110N.m
Tool: driven bevel gear nut wrench
Driven bevel gear nut tightening torque:150N.m

Bevel Gear Washer Adjustment

Adjust

washer

①

and

②

when replacing crankcase

and/or bevel gear and/or bevel gear cover,

15-43

15. Engine Removal, Inspection & Installation

Bevel Gear

Note:

Proper bevel gear engagement depends

on that the gear backlash and tooth contact are
within the proper range.

Bevel Gear Backlash

Install drive and driven gears to the

crankcase. Wrap a (--) screwdriver

③

with a

rag

②

and insert it into the speed sensor

hole

①

of left crankcase to fix the drive

bevel gear.

Install special tool

③

and micrometer

④

Tool: Bevel gear side clearance dial gauge
Micrometer
a=46mm

Turn the driven bevel gear in each direction

and measure the backlash.

If the backlash is not within the

specification, adjust the thickness of the
driven bevel gear adjust washer. Re-check
the backlash until the backlash is correct.

Bevel Gear Backlash: 0.1-0.2mm

Adjustment

NOTE:

Measure four points in the mutual

vertical direction

Measured Backlash

Washer Thickness

Adjustment

＜

0.1mm

Decrease washer thickness

0.1~0.2m

Correct

＞

0.2mm

Increase washer thickness

15-44

15. Engine Removal, Inspection & Installation

Tooth Contact

After adjusting the backlash, check the tooth contact

according to the following procedures:

Remove drive and driven bevel gear shafts from

crankcase;

Clean and degrease every tooh of drive and driven

bevel gear;

Coat the driven bevel gear with machinist’s layout

dye or paste;

Install drive and driven bevel gear;

Rotate the driven bevel gear several turns in both

directions;

Remove drive and driven bevel gear shafts and

check the coated teeth of the drive bevel gear;

Refer to the illustration on the right for tooth contact

pattern

①

②

and

③

①

Incorrect (contact at tooth top)

②

Correct

③

Incorrect (contact at tooth bottom)

If tooth contact is correct (Contact

②),

continue the

next procedure.

If tooth contact is not correct (

②

and

③)

, adjust the

thickness of the washer of drive bevel gear. Repeat
above steps to check tooth contact until it is correct.

Adjustment

Tooth Contact

Washer Adjustment

Contact at tooth top

①

Increase

Thickness

Contact at tooth
bottom

③

Decrease Thickness

Note:

After adjusting the tooth contact, the backlash must

be checked again;

If the backlash is adjusted but tooth contact is still

out of specification, replace the drive and driven
bevel gears;

Both tooth contact and backlash should be within

the required specification.

15-45

15. Engine Removal, Inspection & Installation

Balancer Shaft

Remove the parts as illustrated on the right. Check

each part for abnormal wear or damage.

Wear or damage:

→

Replace

①

Balancer shaft gear

②

Woodruff key

③

Balancer shaft

④

Balancer shaft sprocket

⑤

Washer

⑥

Bolt

Magneto Rotor

Remove starter clutch nut;

15-46

15. Engine Removal, Inspection & Installation

Check starter clutch roller and holder for abnormal

wear or damage.

Wear or damage:

→

Replace

Install the starter clutch in the correct direction.

Note:

When install the starter clutch to the magneto rotor,
make sure side “A” is in the right direction.

Face arrow mark “B” to the engine side;

Apply engine oil to starter clutch.

Apply thread locker to bolt and tighten to the

specified torque:

Tightening torque of starter clutch bolt: 26N.m
Material: Thread Locker

Install the starter driven gear

Make that the starter driven gear turns in the

opposite direction of the arrow mark “B”. The gear
cannot turn in the direction of the arrow.

Check starter driven gear bearing. In case of

anything unusual, replace the bearing.

Remove starter driven gear bearing with special tool

Install starter driven gear bearing with special tool.

Tool: Bearing Installer/Remover

15-47

15. Engine Removal, Inspection & Installation

Electric Starter Gear

Check the gear surface for scrap or damage.

Scrape or Damage:

→

Replace

LEFT CRANKCASE COVER

Check magneto stator coil 2, pickup coil 3 for

damage,

burn or short circuit, if any , replace with new one;

Check bearing 4 for smooth turning. If it is stuck,

replace with a new one;

Check oil seal 5 for damage. Replace it if it’s

damaged;

Apply thread locker to the bolt when assembling.

Tightening torque for magneto coil bolt: 10N.m

Apply lubrication oil to bearing 4 and lubricant

grease to lip of oil seal 5 when assembling.

Recoil Starter

Disassembly

1— Recoil starter
2— Bolt
3— Washer
4— Starter pully

Inspection

Check sheave drum for burrs, cracks or rust. In case of
any abnormal, replace.

15-48

15. Engine Removal, Inspection & Installation

Recoil Starter

If the recoil starter works normally, it’s not necessary to disassemble it.

DISASSEMBLY

Remove nut 10,

Remove the parts from the starter housing.

WARNING !

The coil spring may quickly unwind and cause injury when the
sheave drum is opened. Wear proper hand and eye protection
beforehand.

Inspection

Check all the parts for damage.

Damage:

→

Replace

15-49

15. Engine Removal, Inspection & Installation

Assembly

Reverse the removal procedure for installation and

pay attention to the following:

Install sheave drum

①

, rope

②

, coil spring

③

damper

④

Wind the rope clockwise around the sheave drum

three times and hook the rope at “a” of sheave
drum.

WARNING !:

The coil spring may quickly unwind and cause injury
when the sheave drum is opened. Wear proper hand
and eye protection beforehand.

Install coil spring

①

and sheave drum

②

Apply lubricant grease to spring

Hook coil spring end

③

to the starter housing, wind

the coil spring clockwise.

Hook the other end

⑤

of coil spring to hook part

④

of sheave drum.

Install spring clamp

①

, friction plate

②

and bolt.

Turn sheave drum three times for pretension of coil

spring.

Install

handle

①

and handle cap

②

Tie a knot

④

on handle and release knot

③

Lead the rope through the hole of the starter

housing and tie a knot

③

so that the rope would not

be drawn back.

15-50

15. Engine Removal, Inspection & Installation

CVT Cover

Remove screw 5, oil seal limitator 4. Remove oil

seal 3 with special tool;

Check bearing 2 for free turning. In case of any

abnormal, remove with special tool and replace with
a new bearing;

Apply lubrication oil to outer ring of bearing and

install bearing with special tool. Check bearing for
smooth turning.

Apply grease to bearing inner side;

Apply grease to oil seal lip and install oil seal with

special tool.

Note:

Use a new oil seal.

Install oil seal limitator and tighten screw after

applying thread locker.

Tool: Bearing Remover
Oil Seal Remover
Bearing Installer

CVT Case

Check bearing 5 for smooth turning. In case of any

abnormal, remove screw 3 and bearing retainer 4
and replace with a new bearing.

Check oil seal 7. In case of any damage, replace it;

Apply grease to oil seal lip and install with special

tool.

Apply lubrication oil to bearing 5 and install with

special tool; Check bearing for smooth turning. The
seal side of bearing 5 should face bearing retainer
4.

Install bearing retainer 4 and screw 3.

Install oil seal 1 into clutch housing 2 with special

tool.

Tool: Oil Seal Installer

Bearing Installer

15-51

15. Engine Removal, Inspection & Installation

Crankcase

1. Right Crankcase
2. Bearing
3. Oil Seal
4. Bearing
5. Bearing
6. Bearing
7. Oil Seal
8. Washer, Reverse Gear Sensor
9. Reverse Gear Sensor

10. O-ring
11. Gear Sensor
12. Left Crankcase
13. Screw
14. Oil Pipe
15. Link Bolt
16. Washer
17. Bearing
18. Bearing

19. Bearing
20. Bearing
21. Bearing
22. Oil Dip Rod
23. O-ring
24. Speed sensor
25. Bolt
26. Washer
27. Oil Drainage Bolt

Clean and grease the bearings, turn the inner race

of bearing and check the play, noise and smooth
turning. In case of any abnormal, remove bearing
with special tool and replace;

Check all the oil seals for over wear or damage. In

case of any over wear or damage, remove with
special tool and replace with a new oil seal;

Remove gear sensor 11 and check for continuity

with reverse gear sensor 9 with a multimeter.

Remove link bolt and oil pipe 14 and check oil pipe

for crack or clog. Replace with a new one if any;

Remove oil drainage bolt 27 and clean it.

Note:

Check bearing for smooth turning after installation.

15-52

15. Engine Removal, Inspection & Installation

Install new O-ring and apply grease;

Install gear sensor;

Install reverse gear sensor 9 and tighten to the

specified torque.

Reverse gear sensor tightening torque: 20N.m

Install speed sensor 24

Install oil pipe and tighten the link bolt to the

specified torque;

Link bolt tightening torque: 18M.m

Install washer 26 and oil drainage bolt 27 and

tighten to the specified torque;

Drain bolt tightening torque: 30N.m

Tool: Bearing Remover

Bearing Installer
Multimeter

III Engine Assembly

Reverse the engine removal procedure for installation.

Caution:

Clean all the parts before assembly;

Make sure that the parts are in good condition

without any damage;

Apply engine oil to the moving parts before

assembly;

Apply grease to oil seal lip and O-ring

Caution:

Make sure that drive belt, primary and secondary
sheaves are not stained with grease.

Engine Center

Oil Pump and Relief Valve

Install oil pump and relief valve to left crankcase, as

illustrated on the right. Tighten to the specified
torque:

Oil pump bolt: 10N.m
Relief valve bolt: 10N.m

15-53

15. Engine Removal, Inspection & Installation

Connecting Rod

Install connecting rod to left crankcase with special

tool;

Note:

Do not hammer the conrod into crankcase with

plastic mallet;

Use special tool to avoid affect of conrod precision

Tool: Conrod Installer

Balancer Shaft

Install balancer shaft

Caution:

Balancer shaft driven gear should be aligned to

the mark as illustrated.

Main Shaft, Counter Shaft

Install main shaft and counter shaft.

15-54

15. Engine Removal, Inspection & Installation

Shift Cam, Shift For

Install shift can

①

and shift fork

②

Check each part for smooth turning

Install low range driven gear to counter shaft

③

Spray adequate engine oil to each part.

Drive Bevel Gear

Install drive bevel gear and tighten to the specified

torque.

Drive bevel gear tightening torque: 32N. m

Right Crankcase

Driven Bevel Gear

Install driven bevel gear and tighten to the specified

torque.

Driven bevel gear tightening torque: 25N. m

Check bevel gear backlash (Refer to 12-44)

Front Output Shaft

Install front output shaft to right crankcase

15-55

15. Engine Removal, Inspection & Installation

Apply sealant

①

to the mating face of right

crankcase.

Note:

Apply sealant evenly in an uninterrupted thin line.

Install 2 dowel pins

②

Assemble crankcase and tap slightly with a rubber

hammer so that the crankcase is properly fitted.

Install bolt and tighten to the specified torque.

Crankcase bolt tightening torque: M6: 10N.m
M8: 25N.M

Note:

Crankcase bolts should be tightened diagonally in

several steps.

Place the steel ball and install gear positioning bolt

and tighten the bolt to the specified torque.

Gear positioning bolt tightening torque: 18M.m

Engine Right

Timing Chain

Put on timing chain 2

Clutch

Install clutch 1 and nut 2. Tighten the nut to the

specified torque (left thread).

Clutch nut tightening torque: 70N.m

15-56

12. Engine Removal, Inspection and Installation

Install new o-ring in spacer

⑥

⑧

Install spacer onto the clutch housing shaft, then

install into CVT case

Note:

align oil nick on spacer with oil hole on the shaft

CVT Case

Install dowel pin ,

④

gasket and gasket

②

⑤

to the

right crankcase. Install CVT case assembly to right
crankcase.

Install bolt and nut

⑿

③

Note:

Tighten bolt/nut diagonally

Use a new gasket

Install air guide plate and scre

⑩

⑾

Primary Sheave, Secondary Sheave, Drive Belt

Install primary fixed sheave

①

as illustrated on the

right;

Install drive belt between secondary sliding/fixed

sheave and tap with a plastic hammer to keep the
belt as low as possible.

Note:

Install the drive belt with the arrow on the belt turn in

the clockwise direction

Drive belt contact surface should be free from any

stains.

15-57

CFMoto ATV CF500/CF500-A. Service Manual - part 13