CF MOTO CF500-5 User manual

WWW.CFMOTO.COM
CF500-5 SERVICE
CF500-5A MANUAL

All rights reserved
Zhejiang CFMOTO Power Co., Ltd.
April. 2009
WWW.CFMOTO.COM

FOREWORD
This manual contains an introductory descrip-
tion of procedures for inspection
maintenance,overhaul,disassembly &
assembly,removal and installation of compo-
nents and parts,troubleshooting and service
data together with illustrations of our All
Terrain Vehicle Model
CF500-5 and CF500-5A
Chapter 1 general service information, tools,
vehicle structure and technical data.
Chapter 2:key points for inspection and
adjusting,service guide.
Chapter 2 and after Chapter 3 disassembly
of parts and components,installation,overhaul
and
troubleshooting.
Zhejiang CFMOTO Power Co., Ltd.
April. 2009
The manufacturer reserves the right to
make improvements or modifications to
the products without prior notice. Over-
haul and maintenance should be done
according to the actual state and condi-
tion of the ATV.

Converion table
Item Example Conversion
Pressure 200 kPa(2.00kgf/cm2)1kgf/cm2=98.0665kPa 1kpa=1000Pa
33kPa (250mmHg) 1mmHg=133.322Pa=0.133322kPs
Torque 18N.m(1.8kgf-m) 1kgf.m=9.80665N.m
Volume 419ml 1ml=1cm3=1cc
1l=1000cm3
Force 12N(1.2kgf) 1kgf=9.80665N

1-1
1 Maintenance Information
11
11
1
Cautions
Safety Cautions
1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly venti-
lated place for long time.
2. Do not touch the engine or muffler with bare hands after the engine has just stopped to
avoid scalding. Wear long-sleeve work clothes and gloves for operation.
3.Battery liquid (dilute sulfuric acid) is highly caustic and may cause burns to skin and eyes.
Flush with water if splashed to skin and get immediate medical attention. Flush with water if
splashed to clothes to avoid burns. Keep battery and liquid away from reach of children
4.Coolant is poisonous. Do not drink or splash to skin, eyes or clothes. Flush with plenty of
soap water if splashed to skin. If splashed into eyes, flush with water and consult the doctor.
If drinking the coolant, induce vomit and consult the doctor. Keep coolant away from reach of
children.
5.Wearproperwork clothes,cap andboots. Ifnecessary, weredust-glass, glovesand mask.
6. Gasoline is highly flammable. No smoking or fire.Also keep against sparks. Vaporized
gasoline is also explosive. Operate in a well-ventilated place.
7.When charged, Battery may generate hydrogen which is explosive. Charge the battery in a
well-ventilatedplace.
8. Be careful not to get clamped by the turning parts like wheels and clutch.
9. When more than two people are operating, keep reminding each other for safety purpose.
Cautions for Disassembling and Assembling
1. Use genuine CFMOTO parts, lubricants and grease
2. Clean the mud, dust before overhauling
3. Store the disassembled parts separately in order for correct assemble.
4. Replace the disassembled washers, o-rings, piston pin retainer, cotter pin with new ones.
5.Elastic retainersmight getdistorted afterdisassembled.Do notuse theloosened retainers.
6. Clean and blow off the detergent after disassembling the parts.Apply lubricants on the
surface of moving parts. Measure the data during disassembly for correct assembling.
7.If you do not know the length of screws, install the screws one by one and make sure they
are screwed in with same depth.
Cautions……………………………1-1
VIN Number & Engine Number……1-3
Main Data Table……………………1-4
Overhaul Data Table………………1-6
Tightening Torque………………1-13
Lubricant, Sealing Agent…………1-18
Cable Routing……………………1-22

1-2
CFMOTO
14.Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly.
zReplace if the axial or radial play is too big.
zIfthe surfaceis uneven,clean withoil andreplace ifthe cleaningdoes nothelp.When
pressing the bearing into the machine or to the shaft
15. Install the one-side dust-proof bearing in the right direction. When assembling
theopen typeor double-sidedustproofbearing, installwith manufacturer¡¯smark
outward.
16. Keep the bearing block still when blowing dry the bearing after washing clean.
Apply oil or lubricant before assembling.
17. Install the elastic circlip properly. Turn the circlip after assembling to make
sure is has been installed into the slot.
18.After assembling, check if all the tightened parts are properly tightened and
canmove smoothly.
19. Brake fluid and coolant may damage coating, plastic and rubber parts. Flush
these parts with water if splashed.
20. Install oil seal with the side of manufacturer¡¯s mark outward.
zDo not fold or scratch the oil seal lip.
zApply grease to the oil seal lip before assembling
21. When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if
any, into the groove. Replace the pipes or hoses that cannot be tightened.
22. Do not mix mud or dust into engine and/or the hydraulic brake system.
23. Clean the gaskets and washers of the engine casing before assembling. Re-
move the scratches on the joint faces by polishing evenly with an oilstone.
24. Do not twist or bend the cables too much. Distorted or damaged cables may
cause poor
25. When assembling the parts of protection caps, insert the caps to the grooves,
ifany.

1-3
1 Maintenance Information
11
11
1
VIN Number and Engine Number
CF500-5/CF500-5A
VIN Number: LCELDTZ~
Engine Number:CF188~

1-4
CFMOTO
Main Data TableItem Parameter
Model CF500-5/CF500-5A
Length CF500-5: 2100mm CF500-5A: 2300mm
Width 1180mm
Height 1230mm
Wheel base CF500-5: 1290mm CF500-5A: 1490mm
Engine type CF188
Dis
p
lacement 493Cm
3
Fueltype Unleaded gasoline RQ-90or above
Dry weight CF500-5: 344 kg CF500-5A: 358 kg
Number of Passengers CF500-5:2 （Include driver）
Max. Load 210kg
Tire
Front Tire 25×8-12 40J
185/80-12 40J
Rear Tire 25×10-12 47J
270/60-12 47J
Min. Ground Clearance Min. Ground Clearance
Turning Diameter Turning Diameter
Engine
Startin
g
Electrical startin
g
, Manual Startin
g
Engine Type Single cylinder, 4-stroke, Liquid-cooled, 4
valves, OHC
Combustion Chamber T
yp
e Trian
g
le
Valve Driving Type SOHC /Chain Drive
Bore ×Stroke 87.5mm×82.0mm
Com
p
ression Ratio 10.2:1
Lubrication Type Pressure & Splash
Oil Pump Type Rotor
Lubricant Filter T
yp
e Full flow filter screen
Oil Type SAE15W-40/SF
Coolin
g
T
yp
e Closed coolant circulation
Coolant Type -35℃anti-rust coolant

1-5
1 Maintenance Information
11
11
1
Item Parameter
Fuel
Device
Air Filter type Sponge element filter
Carburetor
Type Vacuum Diaphragm type
MIKUNI BSR36-89
Diameter of mixing
valve 36mm
Gearing
Clutch Wet, Auto-Centrifu
g
al
Operation
Mode Automatic（CVT）+Parking & Gear Shifting
Gears Shift Low Gear, Hi
g
h Gear & Reverse Gear
Shift
Mode/order Manual /L-H-N-R
（CVT ）
Transmissio
n Ratio 2.88～0.70
Gear
Ratio
Final Ratio 1.333（24/18，Bevel Gear）
Secondary
Ratio 1.952（41/21）
Gears Low Gear ：2.25(36/16)；High Gear：
1.350(27/20) ；Reverse Gear ：
1.471(25/17)
Total Low Gear5.857 ；High Gear ：3.514 ；
Reverse Gear：3.828
AxleRatio
Front
A
xle 33 / 9 = 3.667
Rear
Axle 33 / 9 = 3.667
Engine Output Mode Front/Rear Shaft
Direction of Output
Rotation Clockwise on forward shift
Steering
Device Steering Angle Inner 31º
Outer 31º
Brake Type Front Hydraulic Disc
Rear H
y
draulic Disc
Bumper
Device Suspension Swing Arm
Frame T
yp
e Welded Steel Tube and Plate

1-6
CFMOTO
Maintenance Data Table
Lubrication System
Item Standard ServiceLimit
Engine Oil
Capacity Volume when replacing 1900mL －
Volume when
re
p
lacin
g
filter 2200mL －
Recommended Oil（See Original）·Specially for 4-stroke motorcycle
SAE-15W-40
Substitutes must be used in the
following range.
API type: SE or SF grade
SAE type: Choose from the left
chart according to the
environmental temperature
Oil Pump Rotor
Gap between
Inner and Outer
Rotors
0.03～0.1mm 0.15mm
Gap between
Outer rotor and
boday
0.03～0.1mm 0.12mm
Oil pressure 130-170KPa at 3000r / min
Item Standard
Fuel Tank Ca
p
acit
y
Full ca
p
acit
y
19L
Carburetor
Type MIKUNI BSR36-89
JetNumber 07G0
Mixing Valve Diameter（mm）36mm
Main Jet N102221-130#
Main air Jet MD13/24 -35#
Needle J8-5E26
Main Nozzle 785-401011-P-0M
Idle Jet N224103-22.5#
Idle Ad
j
ustin
g
Screw 604-16013-1
A
Idle Speed 1300±100r / min
Fuel SystemFuel System
Fuel SystemFuel System
Fuel System

1-7
1 Maintenance Information
11
11
1
Cooling System
Item Standard/
Parameter Service Limit Remark
Coolant
Capacity
Full Capacity 2000ml
Reservoir tank
ca
p
acit
y
300ml
Standard Density 50%
Opening pressure of radiator cap
Thermostat
Initial
Temperature 72±2℃
Full opening
Tem
p
erature 88℃
Full opening lift
range 3.5～4.5mm/95?
Temperature and
Resistance of
Water
Temperature
Sensor
Temperature（℃） Resistance（Ω）
50 154±16
80 52±4
100 27±3
120 16±2
Temperature of
Thermostat
Close-Open 88℃Round
Open-Close 82℃Round
Coolant Type -35℃anti-frozen, antisepsis, high-boil
coolant

1-8
CFMOTO
Front Wheel
Brake System
Item Standard Operation
Limit
Front Wheel
Play of wheel
rim Vertical 1.0mm 2.0mm
Horizontal 1.0mm 2.0mm
Tire Groove －3.0mm
Pressure 35kPa （0.35kgf ／
cm2）
－
Item Standard Operation
Limit
Rear Wheel
Play of wheel
rim
Vertical 1.0mm 2.0mm
Horizonta
l 1.0mm 2.0mm
Tire Groove －3.0mm
Pressure 30kPa（0.30kgf／cm
2
）－
Item Standard Operation
Limit
Front Brake Brake End Play 0mm －
Brake Disc Thickness 3.5mm 2.5mm
Rear Brake Brake End Play 5-10 mm － Brake Pedal Play 0mm －
Brake Disc Thickness 7.5mm 6.5mm
Rear Wheel

1-9
1 Maintenance Information
11
11
1
Battery, Charging Device, Pickup Coil
Ignition Device
Item Standard
Ignition CDI ignition
Spark Plug
Type Resistance Spark plug
Standard DPR7E
A
-
9(NGK)
Optional DR8EA 、D7RTC
Spark plug gap 0.8-0.9mm
Spark
Characteristic ＞8mm，1mpa
Ignition Timing BTDC10ºCA1500r/min
Ignition Coil
Resistance Initial 0.1Ω-0.5Ω
Secondar
y
12KΩ-22KΩ
Peak Voltage
Ignition Coil ＞150V
Pulse
Generator 2V
Starter Rela
y
Coil Resistance 3Ω-5Ω
Secondary Starter Relay Coil
Resistance 90Ω-100Ω
Item Standard
Fuse Main 20A
Auxiliar
y
10A×2 15A×2
Light, Bulb
Fuse
Head Light（Hi／Lo）12V—35W/35W×2
Brake Light/ Tail Light 12V—5W×2
Turnin
g
Li
g
ht 12V—21W/5W
Dashboard Indicator Light 12V—10W×4
Indicators φ5 LED
Main LCD
Item Standard
AC
Magneto
Motor
Model P e rm a n e n t m a g n e
t
A C Typ e
Out
p
ut 3-
p
hase AC
Charging Coil Resistance（20?）0.2Ω-0.3Ω
Pickup Coil Resistance 110Ω-140Ω
Magneto without Load Voltage/(Idle
Speed) ＞100V（AC）， 5000r/min
Max. Output Power 300W，5000r/min
Rated Volta
g
e 13.5V-15.0V, 5000r/min
Peak Voltage of Pickup Coil ＞120V
Rectifier Three-phase annular rectification, Silicon controlled parallel-connected
regulated voltage
Battery
Ca
p
acit
y
Ca
p
acit
y
Terminal Point
Volta ge
Fully
Charged 12.8V
Insufficient
Charged <11.8V
Charging
Current/time Standard 0.9A／5～10H
Quick 4A／1H
Lights Dashboard, Switch

1-10
CFMOTO
Valve System + Cylinder Head (mm)
Item Standard OperationLimit
Valve Diameter Intake 30.6
Exhaust 27.0
Valve Clearance( Idle Speed) Intake 0.05-0.10
Exhaust 0.17-0.22
FitClearancebetween Valve
Guide and Valve Stem
Intake 0.010-0.037
Exhaust 0.030-0.057
Internal dia. of Valve Guide Intake & Exhaust 5.000-5.012
Exterior dia. of Valve Stem Intake 4.975-4.990
Exhaust 4.955-4.970
Valve Stem Run-out Intake & Exhaust 0.05
Length of Valve Stem End Intake & Exhaust 2.9-3.1 2.3
Thickness of Valve Head Intake & Exhaust 0.5
Valve Head Seal Run-out Intake & Exhaust 0.03
Width of ValveSeats Seal Intake & Exhaust 0.9-1.1
Length of Valve Spring Intake & Exhaust 40 38.8
Valve Spring Tension Intake & Exhaust Tension182-210N
/Length31.5mm
Cam Height Intake 33.430-33.490 33.130
Exhaust 33.500-33.560 33.200
FitClearance between
Camshaft Exterior dia. &Bore.
φ22 0.032-0.066 0.150
φ17.5 0.028-0.059 0.150
Camshaft Exterior dia. φ22 21.959-21.980
φ17.5 17.466-17.484
Camshaft Bore Internal dia. φ22 22.012-22.025
φ17.5 17.512-17.525
Camshaft Run-out 0.10
Rocker Arm Internal dia. Intake & Exhaust 12.000-12.018
Rocker Arm Shaft Exterior dia. Intake & Exhaust 11.973-11.984
Plainness of Cylinder Head
Adjoining Plant 0.03 0.05
Plainness of Cylinder Head
CoverAdjoining Plant 0.03 0.05

1-11
1 Maintenance Information
11
11
1
Cylinder+Piston+Piston Ring+Crankshaft (mm)
Item Standard
Operation
Limit Remark
Cylinder Pressure 1000kPa
Fit Clearance between
Piston and Cylinder 0.030-0.051 0.15
Piston Skirtdia.
87.460-87.480
Testing the pointaway skirt end
10mm
87.380
Internal dia. of Cylinder 87.500-87.522
Plainness of Cylinder
Adjoining Plant 0.015 0.05
Top Ring R 11.7 round 8.9
Piston Ring Free Gap 2nd Ring R 12 round 9.5
Top Ring 0.15-0.30 0.60
Piston Ring Closed Gap 2nd Ring 0.15-0.30 0.60
Top Ring 0.04-0.08 0.180Piston Annular Fit
Clearance 2nd Ring 0.03-0.07 0.150
Top Ring 0.97-0.99
Thickness Piston Ring 2nd Ring 1.17-1.19
Top Ring 1.03-1.05
2nd Ring 1.22-1.24
Piston Annular Width
Oil Ring 2.51-2.53
Internal dia.of Piston Pin
Bore 23.002-23.008 23.030
Exterior dia. Piston Pin 22.995-23.000 22.980
Rod Small End Inner dia. 23.006-23.014 23.040
Rod Big End Gap 0.10-0.55 1.0
Rod Big End Thickness 24.95-25.00
Crankshaft Run-out 0.03 0.08

1-12
CFMOTO
Clutch + Transmission (mm)
Item Standard Limit Remark
Clutch Friction plate inner dia. 140.00-140.15 140.50
Clutch Joint Rotation 1800-2400r/min
Clutch lock-up Rotation 3300-3900r/min
Drive Belt Width 35.2 33.5
Driven Disc Spring Free Length 168 160
Shifter and fit flute gap 0.10-0.40 0.50
Left Shifter Sliding Thickness 5.8-5.9
Right Shifter Sliding Thickness 5.8-5.9
Plunging Flute Width 6.0-6.2
Driven Output Gear Sliding Width 6.0-6.2

1-13
1 Maintenance Information
11
11
1
Tightening Torque
Item Torque N·m(kgf·m) Item Torque
N·m(kgf·m)
5mm Bolt, nut 5
(
0.5
)
5mmScrew 4
(
0.4
)
6mm Bolt, nut 10(1.0) 6mmScrew 9(0.9)
8mm Bolt, nut 22
(
2.2
)
6mmSH Bolt with flan
g
e, 10
(
1.0
)
10mm Bolt, nut 34(3.5) 6mm Bolt with flange,nut 12(1.2)
12mm Bolt, nut 54
(
5.5
)
8mm Bolt with flan
g
e, nut 26
(
2.7
)
10mm Bolt with flan
g
e, nut 39
(
4.0
)
For others not listed in the chart, refer to the standard tightening torque.
Notes: Apply some engine oil on the part of screw thread and adjoining surface.
Item Thread Dia.
(mm) Quantity Torque N·m(kgf·m) Remark
Upper FrontMountin
g
Bolt, En
g
ine M8×60 1 35～45
Upper Rear Mounting Bolt, Engine M10×1.25×110 1 40～50
Upper Rear Mounting Bracket Bolt,
Engine M8×14 1 35～45
Upper Front Mounting Bracket Bolt,
Engine M8×14 1
35～45
Low Mounting Bolt, Engine M12×1.25×140 2 50～60
Bolt, Swin
g
Arm M10×1.25×70 16 40～50
Bolt, RearAbsorbe
r
M10×1.25×50 4
40～50
Bolt, Front Absorber M10×1.25×50 4 40～50
Bolt, Rear Wheel Shaft Holder M10×1.25×100 4 40～50
Mountin
g
Nut, Rim 901-07.00.02 M20 16 50～60
Nut, Rim Shaft 901-07.00.03 M10 4 110～130
Mounting Screw, Rear Brake
Caliper M6×25 2 18～22
Bolt, Rear Brake Calipe
r
M10×1.25×20 2
40～50
Bolt, Front Brake Disc 901-08.00.03 M8× 8 25～30
Bolt, Front Brake Caliper M8×14 4 35～45
Locknut, Steering Stem M8×55 4 20～30
Nut, Steerin
g
Stem M10×1.25 4 40～50
Locknut, Steering Shaft M14×1.5 1 100～120
Rear Mounting Bolt, Muffler M8×30 1 30～35
Bolt, Exhaust Pipe M8×14 1 30～35
Mountin
g
Bolt, Exhaust Pipe M8×40 1 30～35
Mounting Bolt, Rear Axle M10×1.25×110 2 40～50
Mountin
g
Bolt, FrontAxle M10×1.25×90 1 40～50
Mounting Bolt, Front Axle M10×1.25×25 2 40～50
Back End Bolt, Rear Trans Shaft 901-30.00.01 6 40～50
Front End Bolt, Rear Trans Shaft 901-29.00.01 4 35～45
Bolt, Front Trans Shaft 901-29.00.01 8 35～45
Thermo Switch CF250T-420500 1 9～12
Mountin
g
Bolt 1, Front Rack M8×14 2 35～45
Mountin
g
Bolt 2, Front Rack M6×12 2 25～30
Mountin
g
Bolt , Rear Rack M8×14 4 35～45

1-14
CFMOTO
Engine Tightening Torque Table
Item Q’ty Screw dia.（mm）Torque
（N.m）Remark
Sensor, Reverse Gear 1 M10×1.25 20
Spark Plug 1 M12×1.25 18
Water Temperature Sensor 1 Rc1/8 8 Apply screw thread sealant
Valve Clearance Adjusting Nut 4 M5 10
Drive Disc Nut 1 M20×1.5 115
Driven Disc Nut 1 M20×1.5 115
Circle Nut, Driving Disc 1 M30×1 100
Nut, Front Output Shaft 1 M14×1.5 97
Nut, Drive Bevel Gear 1 M22×1 145
Nut, Driven Bevel Gear 1 M16×1.5 150
Fixing Nut, Clutch 1 M18×1.5 70 Left handed
Limiting Nut, Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant
Limiting Nut, Front Output Shaft 1 M55 80 Apply screw thread
sealant, left handed
Bolt, Swing Arm Shaft 2 M14×1.25 28
Drain Bolt 1 M12×1.5 30
Mounting Bolt, Overriding Clutch 6 M8 26 Apply screwthread sealant
Mounting Bolt, Magneto Stator 3 M6 10 Apply screwthread sealant
Bolt, CVTWindshield 3 M6 10 Apply screwthread sealant
Link Bolt, Oil Pipe 2 M14×1.5 18
Mounting, Oil Pump 3 M6 10
Mounting Bolt, Pressure LimitingValve 2 M6 10
Bolt, DriveBevel Gear Cover 4 M8 32
Bolt, DrivenBevel GearCover 4 M8 25
Locating Bolt, Shift 1 M14×1.5 18
Flange Bolt, Fan 1 M10×1.25 55

1-15
1 Maintenance Information
11
11
1
Item Quantity Diameter（mm）Torque
（N.m）Remark
Bolt, Crankcase 14 M6 10
3 M8 25
Bolt, Driven Sector Gear 1 M6 12
Mounting Bolt, Oil Filter 1 M20×1.5 63
Oil Filter 1 3/4? （ 16 /in 18～20
Bolt, Starting Motor 2 M6 10
Bolt, Cylinder Head 4 M10 38
Bolt, Cylinder Head(2 sides) 2 M6 10
1 M8 25
Upper and Lower Bolt, Cylinder 4 M6 10
Bolt, Cylinder Head Cover 12 M6 10
Bolt, Chain Tensioner 2 M6 10
Nut, Chain Tensioner 1 M8 8
Bolt,Radiator Fan 3 M6 10
Thermostat Bolt 2 M6 10
Bolt, Water Pump Cover 3 M6 6
Mounting Bolt, Water Pump 2 M6 10
Fixed Bolt, Timing Sprocket 2 M6 15 Apply screw thread sealant
Bolt without remarks
M5 4.5-6
M6 8-12
M8 18-25

1-16
CFMOTO
Engine Tools
Measuring Tools
No Name Type Function Remark
1 Vernier Calipers 0-150mm measurelength and thickness
2 Micrometers 0-25mm measure the outer diameters of swing
arm, valve rod and camshaft
3 Dial gauge 25-50mm Measuremax. lift range of camshaft
4 Dial gauge 75-100mm Measurepistonskirt
5 Inner dia. Gauge, Cylinder Measureinner dia. of cylinder head
6 Inner dia. Gauge, 10-34mm Inner dia. of swing arm, piston pin hole,
and rod headhole
7 Dial Test Indicator 1/100 Run-out
8 Knife Straight Edge plainness
9 Feeler Gauge Plainness, adjusting valveclearance
10 Fuel Level Gauge Fuel level length of carburetor
11 Plastic gauge Fit clearance
12 pull tension gauge Spring bounce
13 Tachometer Enginerotation rate
14 Cylinder Pressure Meter pressure in cyclinder
15 Oil PressureGage Oil pressure
16 Barometer Opening pressure of radiator cover
17 Ohmmeter Resistance and voltage
18 Amperemeter Opening of currency / switch
19 Thermometer Liquid temperature
20 Timing Lights Testspark timing
21 Torque Tester One Set Tightening torque
Auxiliary Measuring Instrument
22 Alcohol Burner Warmingup
23 Magnet Stand Install dialgauge
24 Slab Auxiliary measure supplementary
25 V-Block Run-out supplementary
26 Forcep Install valve clip
27 Plier Disassemble and install circlip
28 Joint Plier Disassemble and install flange
29 Impact Driver Disassemble cross recessed bolt
30 Slot TypeDriver
31 Cross TypeDriver