CF MOTO CF500 User manual

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1. Overhaul Information
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Cautions
Safety Cautions
1. Hazardouscomponentsin exhaust. Do not run the engine in aenclosed or poorly ventilated
place for long time.
2. Donot 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) ishighly caustic and may cause burns to skinand eyes.
Flush with water if splashed to skin and getimmediate medicalattention. Flush with water if
splashed to clothesto 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 consultthe doctor. Keep coolant awayfrom reach of
children.
5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and 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 whichis explosive. Charge the battery in a
well-ventilated place.
8. Be careful not to get clamped by the turning parts like wheels and clutch.
9. When more than twopeople are operating, keep reminding each other for safety
purpose.
Cautions for Disassembling and Assembling
1. Use genuine CFMOTOparts, lubricants and grease
2. Clean the mud, dustbefore overhauling
3. Store the disassembled partsseparately in order for correct assemble.
4.Replace the disassembled washers, o-rings, piston pin retainer, cotter pin with new ones.
5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers.
1-1

1. Overhaul Information
6. Clean and blow offthe detergent after disassembling the parts. Apply lubricants on the
surface ofmoving parts. Measure the dataduring disassembly for correct assembling.
7. If you do not know the length of screws, installthe screws one by one and make sure they
are screwed in with same depth.
8. Pre-tighten the bolts, nutsand screws, then tighten according to the specified torque,
from big to small and from inner side to outer side.
9. Check ifthe disassembled rubber parts are aged and replace if necessary. Keep the
rubber parts away from grease.
10. Applyor inject recommended lubricant to the specified parts.
11.Use special tools wherever necessary.
12.Replace the disassembled ballbearings with new ones.
13. Turn the inner and outer rings of ballbearing to make sure the bearing will turn smoothly.
Replace ifthe axialor radial play is too big. If the surface is uneven, clean with oil and
replace if the cleaning doesnot help.
When pressing the bearing into the machine or to the shaft, replace the bearing ifit could not
be pressed tight.
14.Install the one-side dust-proof bearing in the right direction. When assembling the open
type or double-side dustproof bearing, install with manufacturer s mark outward.
15. Keep the bearing blockstill when blowing drythe bearing after washing clean. Apply
oil or lubricant before assembling.
16. Install the elastic circlip properly. Turn the circlip after assembling to make sure ishas been
installed into the slot.
17. After assembling, check if allthe tightened parts are properly tightened and can move
smoothly.
18. Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these partswith
water if splashed.
19. Install oil seal with the side of manufacturer smark outward.
Do not fold or scratch the oil seal lip. Apply grease to the oil seal lip before
assembling
20. When installing pipes, insert the pipe till the end of joint. Fitthe pipe clip, if any, into
the groove. Replace the pipes or hoses that cannot be tightened.
21. Do not mix mud or dust into engine and/or the hydraulic brake system.
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1. Overhaul Information
22. Clean the gasketsand washers of the engine casing before assembling. Remove the
scratches on the joint faces by polishing evenly with an oilstone.
23. Do not twist or bend the cables too much. Distorted or damaged cables may cause poor
operation.
24. When assembling the partsof protection caps, insert the caps to the grooves, ifany.
1- 3

1. Overhaul Information
VIN Number and Engine Number
Vehicle Identification Number: LCELDTS~
Engine Number: CF188~
1- 4

1. Overhaul Information
Main DataTable
Item Parameter
Model CF500/CF500-A
Length 2120mm/2320mm
Width 1170mm
Height 1230mm
Wheel base 1290mm/1490mm
Engine type CF188
Displacement 493ml
Fuel type Unleaded gasoline 90 Octane or
above
Dry weight 337Kg/340Kg
Number of Passengers 1 for CF500, 2 for CF500-A
(including driver)
Max. Load 150kg/225Kg
Front 25x8-12
Tire Rear 25x10-12
Ground Clearance 275mm
Min. turning diameter 4.5m/4.8m
Starting Electrical starting/Recoilstarting
Engine type Single cylinder, 4-stroke,
Liquid-cooled, 4 valves, OHC
Combustion chamber type Triangle
Valve Driving type SOHC chain driving
Bore x stroke 87.5mm X 82.0mm
Compression Ratio 10.2:1
Max. power 24Kw/7000 rpm
Max. torque 36N.M/5500 rpm
Lubrication type Pressure & Splash
Oil pump type Rotor
Oil filter type Fullflow filter screen
Engine
Cooling type Closed coolant circulation
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1. Overhaul Information
1- 6
Item Parameter
Air Filter type Sponge element filter
Type Vacuum Diaphragm type
MIKUNI BSR36-89
Fuel
device Carburetor Diameter of mixing
valve 36mm
Type Wet, auto-centrifugal
Clutch Operation mode Automatic (CVT) + Parking &
Gear shifting
Gear type Bevel gear
Initial Transmission Reduction ratio 2.938
Gear type Bevel Gear
Secondary
transmission Reduction ratio 2.938
Type Automatic (CVT) + Parking &
Gear shifting
Function Auto-centrifugal
Transmission ratio 2.88~0.70
Final Ratio 1.333 (24/18, bevel gear)
Secondary
Ratio 1.952 (41/21)
Gears Low Gear: 2.25 (36/16), High
Gear: 1.35(27/20), Reverse
Gear: 3.828
Gearing
Gearbox
Gear
Ratio
Total Low Gear: 5.857, High Gear:
3.514, Reverse Gear: 3.828
Right 30Steering
device Steering angle Left 30
Front HydraulicDisc
Brake type Rear Hydraulic Disc
Bumper
Device Suspension Swing Arm
Frame
type Welded steeltube and plate

1. Overhaul Information
Overhaul Datasheet
Lubricating device
Item Standard Service
limit
Volume when replacing 1900m´Engine Oil
Capacity Full capacity 12200 m´
Recommended Oil (see original) Specially for 4-stroke
motorcycle
SAE-10W-40 20W-50
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
Gap between inner
and outer rotors 0.07~0.15mm 0.20mm
Gap between outer
rotor and body 0.07 0.17mm 0.25mm
Oil pump
Rotor
End face gap 0.05 0.10mm 0.12mm
Fuel Device Item Standard
Fuel Tank Capacity Full capacity 19.0´
Type MIKUNI BSR36-89
Main jet N102221-130#
Idle jet N224103-22.5#
Carburetor Idle speed 1300 100r/min
CoolingDevice
Item Standard
Full Capacity 1140m´
Reservoir tank capacity340m´
ݱ±´¿²¬
½¿°¿½·¬§ Standard density 30%
Opening pressure ofradiator cap 108kpa(1.1kgf/cm2)
Temperature / valve open 72 2C
Temperature/valve full open 88 C
̸»®³±-¬¿¬
Overalllift 3.5-4.5mm
1-7

1. Overhaul Information
Front Wheel Item Standard Service Limit
Vertical 1.0mm 2.0mm
Play ofwheelrim Horizontal 1.0mm 2.0mm
Groove -- 3.0mm
Front
Wheel Tire Pressure 35kpa(0.35kgf/cm3)--
Rear Wheel Item Standard Service Limit
Vertical 1.0mm 2.0mm
Play ofwheelrim Horizontal 1.0mm 2.0mm
Groove -- 3.0mm
Rear
wheel Tire Pressure 35kpa(0.35kgf/cm3)--
Brake System Item Standard Service Limit
Brake lever play 0mm --
Front brake Brake disc thickness 3.5mm 4mm
Brake lever play 5-10mm --
Brake Pedal Play 0mm
Rear brake Brake disc thickness 7.5mm 6.5mm
Battery Charging System
Item Standard
Model Permanent magnetAC type
Output 3- phase AC
AC magneto Motor Charging coil Resistance (20 ) 0.2-0.3
Rectifier Three-phase annular rectification, Silicon controlled
parallel-connected regulated voltage
Capacity 12V18Ah
Fully charged 12.8VTerminal
point
voltage Insufficient charge <11.8V
Standard 0.9A/5~10H
Battery
Charging
current/time Quick 4A/1H
Ignition system Item Standard
Ignition CDI ignition
Type DPR7EA-9(NGK)
OptionalDR8EA, D7RTC
Spark Plug Spark plug gap 0.8-0.9mm
Ignition timing Max. advanced angle 32 CA
Ignition coil Above 200VPeak voltage Pulse generator 150V
1-8

1. Overhaul Information
Light Instrument Switch Pickup coil
Item Standard
Main 20AFuseAuxiliary 10A15Ax3
Head light Hi/Lo 12V-35W/35W
Brake light/tail light 12V-21W/5W
Turning light 12V-10Wx4
Dashboard indicator light 12V-1.7W
Light Bulb
Other indicators 12V -3.4W
1-9

1. Overhaul Information
Tightening torque
Item Torque N·m(kgf·m) Item Torque N·m(kgf·m)
5mm Bolt, nut 5(0.5) 5mm Screw4(0.4)
6mm Bolt, nut 10(1.0) 6mm Screw9(0.9)
8mm Bolt, nut 22(2.2) 6mmSH Bolt with flange, 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 flange, nut 26(2.7)
10mm Bolt with flange, nut39(4.0)
For others not listed in the chart, refer to the standard tightening torque.
Notes: 1.Apply some engine oil on the part of screw thread and contact surface.
Item Thread Dia.
(mm)
Quantity Torque
N·m(kgf·m)
Front Upper Bolt, Engine M8x60 135~45
Rear Upper Bolt, Engine M10x1.25x110140~50
Front Upper Bolt, Engine Bracket M8x14 135~45
Rear Upper Bolt, Engine Bracket M8x14135~45
Lower Mounting Bold, EngineM12x1.25x140250~60
Bolt, SwingArm M10x1.25x7016 40~50
Bolt, Rear Absorber M10x1.25x50440~50
Bolt, Front Absorber M10x1.25x50 440~50
Bolt, Rear Wheel Support M10x1.25x100440~50
Mounting Nut, Rim 901-07.00.02 M20 16 50~60
Nut, Rim Shaft 901-07.00.03 M10 4110~130
Mounting Screw, Rear Brake Pump M6x25 218~22
Bolt, Rear Brake Caliper M10x1.25x20240~50
Bolt, Front Brake Disc 901-08.00.03 M8 825~30
Bolt, Front Brake Caliper M8x14 435~45
Bolt, Handlebar M8x55 420~30
Nut, Tie-rodM10x1.25 440~50
Locknut, Steering Stem M14x1.5 1100~120
Rear Mounting Bolt, Muffler M8x30130~50
Bolt, Exhaust Pipe M8x14130~35
Mounting Bolt, Muffler M8x40 130~35
Mounting Bolt, Rear Axle M10x1.25x110240~50
Mounting Bolt, Front Axle M10x1.25x90140~50
Mounting Bolt, Front Axle M10x1.25x25240~50
Bolt, Front AxleSupport M8x14 235~45
Bolt, Rear Transmission Shaft Rear End 901-30.00.01640~50
Bolt, Rear Transmission Shaft Front End 901-29.00.01435~45
Bolt, Front Transmission Shaft 901-29.00.01835~45
ThermoswitchCF250T-420500128~30
Bolt 1, Front Rack M8x14235~45
Bolt 2, Front Rack M6x12225~30
Bolt, Rear RackM8x14 435x45
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1. Overhaul Information
Lubricant, Sealing Agent
Application AreasCautions Lubricants & Grease
Oil SealLip, Steering Stem
Pivot, Rear Brake Pedal
Joints, Throttle Cable
Throttle Lever
Multi-purpose Lubricating
Grease
Dust-proofSeal Lip, Front
Shock absorber #5 Absorber Oil
Inner surface, Handlebar Engine Oil
1-11

1. Overhaul Information
Cable Routing
1. Connector, Fan Motor 2. Connector, CDI 1.Ignition Coil 2. Water Temperature Sensor
3. CDI 4. Wire Clip 3. Cable, Parking 4. Breather Hose, Reservoir Tank
5. Connector, Starting Switch5. Vacuum Tube 6. Wire Clip
6. Connector, Dashboard 7. Connector for Magneto, Gear Sensor and Pickup Coil
7. Connector, Handlebar Switch (L&H) 8. Fuel Pipe, Carburetor
8. Connector, Ignition Switch 9. Wire, Starting Motor
9. Wire Clip 10. Steel Wire Clip
1-12

1. Overhaul Information
1-13

1. Overhaul Information
1-14

1. Overhaul Information
1-15

2. Vehicle Body, Muffler
Overhaul Info . .2-1
Troubleshooting . . . ..2-1
Front Rack, Bolt Cap . 2-2
Seat, Seat Support & Rear Rack .2-3
Front & Rear RackPanels, Front Top Cover .2-4
Rear Top Cover .. ....2-5
Left Side Panel ...2-6
Right Side Panel . 2-7
Fuel Tank Top Cover, Front Fender ....2-8
Footrest Board (LH, RH) ...2-9
Rear Fender, Engine Skid Plate (Front, Center, Rear),
Double Seat, Protection Plate ..2-10
Front Inner Fender (RH,LH), Front Protector (RH, LH) 2-12
Rear Protector (RH,LH), Bumper, Bumper Protector 2-13
Bumper Cap .. ..2-14
Front Vent Grille, Fuel Tank . .2-15
Bottom Plate, Fuel Tank .2-16
Muffler . ..2-17
Description of Visible Parts . .. 2-18
Overhaul Information
Operation Cautions
É¿®²·²¹
Gasoline is highly flammable, therefore smoke and fire are strictlyforbidden in the work place.
Specialattention shouldalsobe paid to sparks. Gasoline may alsobe explosive when it is
vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.
This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe, muffler and fuel
tank.
Hoses, cables and wiring should be routed properly.
Replace the gasket with a new one after muffler is removed.
After muffler is installed, check if there is any exhaustleakage.
Ì·¹¸¬»²·²¹ ¬±®¯«»
Muffler Rear Fixing Bolt: 35-45N.m
Muffler Exhaust Pipe Bolt: 35-45N.m
Muffler Body Fixing Bolt: 35-45N.m
Ì®±«¾´»-¸±±¬·²¹
Loud exhaust noise
Broken muffler
Exhaust leakage
ײ-«ºº·½·»²¬ °±©»®
Distorted muffler
Exhaust leakage
Muffler clogged
2-1

2. Vehicle Body, Muffler
Ú®±²¬ ο½µô Þ±´¬ Ý¿°
λ³±ª»æ
Remove 2 nuts from the bottom of front fender
Exert upward and remove bolt cap
λ³±ª»æ
--Fixing Bolt 1 , Bolt 2
--Fixing Bolt 3, Bolt 4
--Front rack
ײ-¬¿´´¿¬·±²æ
Reverse the removal procedure for installation
Tightening Torque: Fixing Bolt 1, Bolt 2
35 N.m -45N.m
Fixing Bolt 3, Bolt 4
25 N.m -30N.m
2-2