Cfmoto CF500-3/UTV Service Repair Manual

CF500-3/UTV WWW.CFMOTO.COM

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 UTV Model CF500-3. 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 UTV. Vehicle Service Information 1 Vehicle Body,Muffler 2 Inspection & Adjustment 3 Cooling System 4 Removal and Installation of Engine 5 Removal, Inspection and Assemble of Engine 6 Carburetor 7 Front Wheel, Front Brake, Suspension, Steering 8 Rear Wheel, Rear Brake, Suspension 9 Front and Rear Axle 10 Battery, Charging System 11 Ignition System 12 Lighting, Dashboard & Switches 13 Circuit Diagram、 Wiring Diagram 14 Troubleshooting 15

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

1-1 1 Maintenance Information 1 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. 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… … … … … … … … 1-19

1-2 CFMOTO 8.Check if the disassembled rubber parts are aged and replace if necessary. Keep the rubber parts away from grease. 9.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. 10.Replace aged latex parts before assembling. Do not mix volatile oil and grease on the surface,due to aggressivness of fuel and oil. 11.Apply or inject recommended lubricant to the specified parts 12.Use special tools wherever necessary. 13.When ball bearing disassembled by pressing ball ring, it can not be reused. 14.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. 15.Install the one-side dust-proof bearing in the right direction. When assembling the open type or double-side dustproof bearing, install with manufacturer mark 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 can move smoothly. 19.Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these parts with water if splashed. 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. Remove 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 operation. 25.When assembling the parts of protection caps, insert the caps to the grooves, if any.

1-3 1 Maintenance Information 1 VIN Number and Engine Number CF500-3 Vehicle Identification Number: LCELDTZ ～ Engine Number ： CF188-A ～

1-4 CFMOTO Main Data Table Item Parameter Model CF500-3 Length 2880mm Width 1435mm Height 1900mm Wheel base 1790mm Engine type CF188-A Displacement 493Cm 3 Fuel type Unleaded gasoline RQ-93or above Dry weight 554kg Number of Passengers 2 (including driver) Max. Load 150kg Front 25 × 8 － 12 Tire Rear 25 × 10 － 12 Min. Ground Clearance 350mm Turning Diameter 9m Starting Electrical starting Engine Type Single cylinder, 4-stroke, Liquid-cooled, 4 valves, OHC Combustion Chamber Type Triangle Valve Driving Type SOHC /Chain Drive Bore × Stroke 87.5mm× 82.0mm Compression Ratio 10.2:1 Lubrication Type Pressure & Splash Oil Pump Type Rotor Lubricant Filter Type Full flow filter screen Oil Type SAE15W-40/SF Cooling Type Closed coolant circulation Engine Coolant Type -35 ℃ anti-rust coolant

1-5 1 Maintenance Information 1 Item Parameter Air Filter type Sponge element filter Type Vacuum Diaphragm type MIKUNI BSR36-89 Fuel Device Carburetor Diameter of mixing valve 36mm Clutch Wet, Auto-Centrifugal Operation Mode Automatic （ CVT ） +Parking & Gear Shifting Gears Shift Low Gear, High Gear & Reverse Gear Shift Mode/order Manual /L-H-N-R （ CVT ） Transmissi on Ratio 2.3 ～ 0.90 Final Ratio 1.333 （ 24/18 ， Bevel Gear ） Secondar y Ratio 1.952 （ 41/21 ） Gears Low Gear ： 2.25(36/16) ； High Gear ： 1.474(28/19) ； Reverse Gear ： 1.471(25/17) Gear Ratio Total Low Gear5.857 ； High Low ： 3.835 ； Reverse Gear ： 3.828 Engine Output Mode Front/Rear Shaft Gearing Direction of Output Rotation Clockwise on forward shift Inner 31 º Steering Device Steering Angle Outer 27 º Front Hydraulic Disc Brake Type Rear Hydraulic Disc Bumper Device Suspensio n Swing Arm Frame Type Welded Steel Tube and Plate

1-6 CFMOTO Maintenance Data Table Lubrication System Item Standard Service Limit Volume when replacing 2200mL － Engine Oil Capacity Volume when replacing filter 2300mL － 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 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 Pump Rotor Oil pressure 3000r / min/ 130-170KPa Item Standard Fuel Tank Capacity Full capacity 27.0L Type MIKUNI BSR36-89 Jet Number 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 Adjusting Screw 604-16013-1A Carburetor Idle Speed 1300±100r / min Fuel System

1-7 1 Maintenance Information 1 Cooling System Item Standard/ Parameter Service Limit Remark Full Capacity 2900ml Reservoir tank capacity 300ml Coolant Capacity Standard Density 50% Opening pressure of radiator cap 108kpa(1.1kgf/ cm 2 ) Initial Temperature 72 ± 2 ℃ Full opening Temperature 88 ℃ Thermostat Full opening lift range 3.5 ～ 4.5mm/95 ℃ Temperature （℃） Resistance( Ω ） 50 154 ± 16 80 52 ± 4 100 27 ± 3 Temperature and Resistance of Water Temperature Sensor 120 16 ± 2 Close-Open 88 ℃ Round Temperature of Thermostat Open-Close 82 ℃ Round Coolant Type -35 ℃ anti-frozen, antisepsis, high-boil coolant

Cfmoto CF500-3/UTV Service Repair Manual

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