CFMoto ATV CF500/CF500-A. Service Manual

12. Engine Removal, Inspection and Installation

Install secondary sheave;

Install primary sliding sheave

Tighten primary sheave nut with special tool to the

specified torque;

Primary sheave nut tightening torque: 115 N·m

Tool: Rotor Holder

Tighten secondary sheave nut with special tool to

the specified torque;

Secondary sheave tightening torque: 115 N·m

Tool: Rotor Holder

Note:

Turn the primary fixed sheave until the belt is seated in
and both primary and secondary sheaves move together
smoothly without slip.

CVT Case Cover

Install the new gasket and dowel pins.

15-58

12. Engine Removal, Inspection and Installation

Install CVT case cover bolts and tighten diagonally

in several steps.

Engine Left

Oil Pump Sprocket and Chain

Install oil pump drive sprocket;

Install oil pump driven sprocket;

Install oil pump drive chain;

Install oil pump sprocket bolt;

Install sprocket retainer with a long nose pliers

Tool: Long Nose Pliers

Dual Gear, Idle Gear

Install dual gear shaft and

①

dual gear

②

Install dual gear

③

, dual gear

④

and bush

⑤

Starting Driven Gear

Install starting driven gear

⑥

15-59

12. Engine Removal, Inspection and Installation

Install starting driven gear;

Magneto Rotor

Install woodruff key into crankshaft groove;

Install magneto rotor 1;

Note:

Degrease the tapered part of rotor and crankshaft.

Use nonflammable solvent to clean off the oily or greasy
matter and fully dry the surfaces.

Left Crankcase Cover

Install dowel pin2 and gasket 3

Note:

Use a new gasket

Apply Lubricant grease to oil sea lip;

Install left crankcase cover;

Install

bolts;

Recoil Starter

Install recoil starter 1

Install O-ring 2

Note:

Use a new O-ring and apply lubricant grease to

the O-ring

Install washer 3 and bolt 4, tighten to the specified

torque:

Recoil starter bolt tightening torque: 55N.m

15-60

12. Engine Removal, Inspection and Installation

Water Pump

Install water pump;

Install water pump fixing bolts;

Note:

Before tightening the bolts, be sure to insert oil

pump shaft into groove of water pump shaft.

Sector Gear

Install the parts as illustrated on the right.

1- sector gear cover and gasket
2-dowel pin
3-drive sector gear
4-driven sector gear
5-driven sector gear bolt

Note:

When the shift cam is in the neutral position, the

mark of drive sector gear should be between the two
marks of the driven sector gear.

Driven sector gear tightening torque: 14N.m

Install gearshift rocker arm

Install rocker arm bolt 7and washer 8

15-61

12. Engine Removal, Inspection and Installation

Oil Filter

Install oil filter bolt and tighten to the specified

torque;

Oil filter bolt tightening torque: 63 N·m

Apply engine oil to O-ring;

Install oil filter, turn it by hand until the filter gasket

contacts the mating surface. Tighten the bolts to the
specified torque.

Tool: Oil Filter Wrench

Starting Motor

Apply engine oil to new O-ring;

Install starting motor;

Install bolt and tighten to the specified torque

Tightening torque: 10N·m

Engine Top Side

Piston

Install the piston rings in the order of oil ring, ring

②

and ring.;

①

The first member to go into the oil ring groove is

spacer , after placing the spacer, fit the two side

①

rails .

②

Warning:

when installing the spacer ,

①

do not overlap its

two ends in the groove.

Install the second ring A and first ring B

Note:

1st ring and 2nd ring differ in shape

15-62

12. Engine Removal, Inspection and Installation

1st and 2nd rings have letter “R” marked on the side.

Be sure to bring the marked side to the top when
fitting them to the piston.

Position the gaps of the three rings as illustrated on

the right. Before installing the piston into the cylinder,
check that the gaps are so located.

Apply a light coat of moly oil to the piston pin;

Install piston pin into holes of piston and conrod

small end.

Note:

When installing the piston, the “IN” mark on piston

top is located to the intake side.

Place a clean rag beneath piston and install piston

pin circlip

①

Note:

while rotating crankshaft, pull the cam chain

upward, or the chain will be caught between sprocket
and crankcase.

Install the dowel pins and the new cylinder gasket;

Note:

Use a new cylinder gasket to prevent oil leakage

15-63

12. Engine Removal, Inspection and Installation

Cylinder

Apply engine oil to piston skirt and cylinder wall;

Hold each piston ring with proper position, insert

piston into the cylinder;

Tighten the cylinder base bolts temporarily;

Note:

When installing the cylinder and cylinder head,

pull the cam chain upward, or the chain will be caught
between sprocket and crankcase.

Install

chain

guide ;

①

Fit the dowel pin and new cylinder cover gasket;

Note:

Use a new cylinder cover gasket to prevent oil

leakage

Cylinder Head

Install the cylinder cover, tighten the cylinder head

bolts diagonally to the specified torque.

Cylinder head bolt tightening torque: Initial: 25 N·m

Final: 38 N·m

Tighten the cylinder head nuts to the specified

torque;

Cylinder head nuts tightening torque:

M6: 10 N·m
M8: Initial 10 N·m

Final 25 N·m

Tighten the cylinder top nuts and cylinder base to

the specified torque;

Tightening torque: 10 N·m

15-64

12. Engine Removal, Inspection and Installation

Install chain tensioner;

Camshaft

Align mark “A” on magneto rotor with

mark “B” on

crankcase;

Note:

while rotating crankshaft, pull the cam chain

upward, or the chain will be caught between
sprocket and crankcase.

Align the mark “A” on the camshaft so that they are

parallel with the mating surface of the cylinder head.

Note:

Do not rotate the magneto rotor while doing this.

when the sprocket is not positioned correctly, turn
the sprocket;

Engage the chain on the sprocket with the locating

pin “B” as illustrated on the right;

Recheck if the position of mark “A” and “C” is correct.

If not, reassemble until it is correct.

15-65

12. Engine Removal, Inspection and Installation

Install crankshaft C-ring

①

Install lock washer so that it covers the locating pin;

Apply thread locker to the bolts before installing, and

tighten them to the specified torque;

Sprocket bolt tightening torque: 15 N·m

Bend up the lock washer to lock the bolts.

Cylinder Head Cover

Clean the mating surface of cylinder head and

cylinder head cover;

Install dowel pin to the cylinder head

Apply sealant to the mating surface of the cylinder

head cover;

Install cylinder head cover bolts, tighten diagonally

to the specified torque.

Cylinder head cover bolt tightening torque: 10 N·m

Note:

When tightening the cylinder head cover bolts,

the piston must be at top dead center on the

compression stroke.

15-66

12. Engine Removal, Inspection and Installation

Gasket Sealant Applying Place

Chain Tensioner

Insert (--) screwdriver into slotted end of chain

tension adjuster, turn it clockwise to lock the
tensioner spring;

Install the chain tensioner and the new washer 1;

Install the bolt 2, tighten it to the specified torque;

Chain tensioner bolt tightening torque: 10 N·m

After chain tensioner is installed, turn the (--)

screwdriver counter clockwise. The tensioner rod
will be advanced under spring force and push
tensioner against chain.

15-67

12. Engine Removal, Inspection and Installation

Install the new gasket 3;

Install chain tensioner screw, tighten it to the

specifiedTorque

Chain tensioner screw tightening torque: 8 N·m

Valve Adjuster Cover

Refer to 11-3 for valve clearance;

Use new rubber gasket and apply grease;

Install Valve Inspection Cap

Install valve inspection cap bolt;

Spark Plug

Install spark plug with special tool and tighten to the

specified torque;

Note:

To avoid damage to the cylinder head thread,

screw in the spark plug with hand first, then
tighten it to the specified torque with spark plug
wrench.

Spark plug tightening torque: 18N.m
Tool: Spark Plug Wrench

Engine Periphery

Recoil

Starter

Install

recoil

starter

Apply thread locker to the bolts and then tighten;

Valve Inspection Cap

Install valve inspection cap

15-68

12. Engine Removal, Inspection and Installation

Left Plastic Cover

Install left plastic cover 6

Water Pipe and Hose

Install water hose 5

Install bolt 4

Install water hose 3

Install clamp 1 and 2

15-69

16. Carburetor

1. Carburetor Removal

Disassemble the carburetor in the following serial number:

Serial No.

Description

Qty.

Serial No. Description

Qty.

1 Idle

Adjust

Shaft

1 10

Drain

Screw

Vacuum Chamber Cover

Float Chamber

3 Spring

1 12

Float

Jet Needle Holder

Needle Valve Set

Spring

Main Jet (MJ)

Jet Needle Set

Needle Jet (NJ)

Vacuum Diaphragm

Pilot Jet (PJ)

Piston Valve

Starter Jet (GS)

Enriching Diaphragm

Pilot Air Jet (PAJ)

16-2

16. Carburetor

2. Inspection

Check carburetor body for cracks or damage.

Cracks or damage:

→

Replace

Check carburetor float chamber, fuel passage for

dirt or clog. Clean these parts.

Check

float

①

, float tang

②

for damage.

Damage:

→

Replace

Check valve seat

①

, needle valve

②

, O-ring

③

for

damage, abnormal wear or dirt.

Damage or wear or dirty:

→

Replace

Note:

Valve set

①

, needle valve

②

should be replaced as

a set.

Check piston valve

①

for scratches, abnormal wear

or damage.

Scratches, wear or damage:

→

Replace

Check

diaphragm

②

for tears.

Tears:

→

Replace

Check vacuum chamber cover

①

, spring

②

for

damage or cracks.

Damage or cracks:

→

Replace

16-3

16. Carburetor

Check the diaphragm

for tears

①

;

Tears:

→

Replace

Check the spring

②

,cover

for damage and tears

③

;

Damage or tears:

→

Replace

Check the jet needle

, mail jet

, needle jet

, pilot

①

②

③

air jet

, pilot jet

, starter jet

and starter

④

⑤

⑥

plunger

⑦

for wear and bends;

Wear or bends:

→

Replace

Check above jets for clog. Blow out the jets with

compressed air.

Insert piston valve into carburetor body and check

the free movement;

Check free movement of throttle valve. Replace with
a new one if it’s stuck;

3. Measurement and Adjustment

Keep the carburetor in a upside down position.

Measure distance “a” from the mating surface of
float chamber (without gasket) to the top of float.

Note:

The float arm should rest on the needle valve. Do

not compress the needle valve.

Float Height: 10

1mm

16-4

CFMoto ATV CF500/CF500-A. Service Manual - part 14