CFMOTO CF MOTO CF500 CF500-A ATV Workshop Service Manual

CF500/CF500-A 2006 By Chunfeng Holding Group Co. Ltd. First Edition, August 2006 All Rights Reserved Any reproduction or unauthorized use of this manual without written permission of CFMOTO is extremely prohibited

FOREWORD INDEX This manual contains an introductory description of procedures for inspection ， maintenance, overhaul， disassembly & assembly， removal and installation of components and parts, troubleshooting and service data together with illustrations of our All Terrain Vehicle Model CF500 and CF500-A Chapter 1：general service information, tools， vehicle structure and technical data. Chapter3: key points for inspection and adjusting，service guide. Chapter 2 and after Chapter 3：disassembly of parts and components， installation， overhaul and troubleshooting. The manufacturer reserves the right to make improvements or modifications to the products without prior notice. Overhaul and maintenance should be done according to the actual state and condition of the ATV. Vehicle Service Information 1 Vehicle Body、Muffler 2 Inspection & Adjustment 3 Cooling System 4 Removal and Installation of Engine, Drive Train and Gearshift Unit 5 Front Wheel, Front Brake, Suspension, Steering 6 Rear Wheel, Rear Brake, Suspension 7 Battery, Charging System 8 Ignition System 9 Lighting, Instruments & Switches 10 Circuit Diagram、Wiring Diagram 11 Troubleshooting 12 Engine Engine Overhaul Information 13 Checks & Maintenance 14 Engine Removal, Inspection and Installation 15 Carburetor 16 Cooling and Lubrication System 17 Electrical System 18 Troubleshooting 19

Conversion Table Item Example Conversion Pressure 200Kpa (2.00kgf/cm 2 ) 33kpa(250mmHg) 1kgf/cm 2 =98.0665kpa 1kpa=1000pa 1mmHg=133.322Pa=0.133322Kps Torque 18N·m(1.8kgf-m) 1kgf· m=9.80665N·m Volume 419ml 1ml=1cm 3 =1cc 1l=1000cm 3 Force 12N (1.2kgf) 1kgf=9.80665N

1. Overhaul Information Cautions…………………………………… 1-1 Tightening Torque……………….1-10 VIN Number & Engine Number………….…..1-4 Lubricant, Sealing Agent………..1-11 Main Data Table…………………..……… ..1-5 Cable Routing…………………...1-12 Overhaul Data Table………………………..…1-6 Cautions Safety Cautions 1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated 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. 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 which is 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 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 retainers might get distorted after disassembled. Do not use the loosened retainers. 1-1

1. Overhaul Information 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. 8. Pre-tighten the bolts, nuts and screws, then tighten according to the specified torque, from big to small and from inner side to outer side. 9. Check if the disassembled rubber parts are aged and replace if necessary. Keep the rubber parts away from grease. 10. Apply or inject recommended lubricant to the specified parts. 11. Use special tools wherever necessary. 12. Replace the disassembled ball bearings with new ones. 13. Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly. Replace if the axial or radial play is too big. If the surface is uneven, clean with oil and replace if the cleaning does not help. When pressing the bearing into the machine or to the shaft, replace the bearing if it 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 block still when blowing dry the bearing after washing clean. Apply oil or lubricant before assembling. 16. Install the elastic circlip properly. Turn the circlip after assembling to make sure is has been installed into the slot. 17. After assembling, check if all the tightened parts are properly tightened and can move smoothly. 18. Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these parts with water if splashed. 19. Install oil seal with the side of manufacturer’s mark 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. Fit the 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. 1-2

1. Overhaul Information 22. Clean the gaskets and 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 parts of protection caps, insert the caps to the grooves, if any. 1- 3

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

1. Overhaul Information Main Data Table 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/Recoil starting 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 Full flow filter screen Engine Cooling type Closed coolant circulation 1-5

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 30 ◦ Steering device Steering angle Left 30 ◦ Front Hydraulic Disc Brake type Rear Hydraulic Disc Bumper Device Suspension Swing Arm Frame type Welded steel tube and plate

1. Overhaul Information Overhaul Datasheet Lubricating device Item Standard Service limit Volume when replacing 1900ml — Engine Oil Capacity Full capacity 12200 ml — 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 19.0l Type MIKUNI BSR36-89 Main jet N102221-130# Idle jet N224103-22.5# Carburetor Idle speed 1300±100r/min Cooling Device Item Standard Full Capacity 1140ml Reservoir tank capacity 340ml Coolant capacity Standard density 30% Opening pressure of radiator cap 108kpa(1.1kgf/cm 2 ) Temperature / valve open 72±2C ◦ Temperature/valve full open 88 C ◦ Thermostat Overall lift 3.5-4.5mm 1-7

CFMOTO CF MOTO CF500 CF500-A ATV Workshop Service Manual

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