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CFMoto CF500 - Service Manual

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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
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Summary

FOREWORD

1. Overhaul Information

Safety and Disassembly Cautions

General safety guidelines and precautions for disassembly and assembly.

Key Vehicle Specifications

VIN, engine number, and main data table for vehicle specifications.

Component Standards and Data

Datasheet with standards, service limits, and torque values for various components.

System Specifications

Specifications for front wheel, brake, battery, charging, and ignition systems.

Cable Routing and Lubrication

Cable routing diagrams and lubricant/sealing agent application guidelines.

2. Vehicle Body, Muffler

Troubleshooting Vehicle Body and Muffler

Troubleshooting for vehicle body and muffler issues.

Body Panel and Rack Removal

Procedures for removing front rack, seat, rear rack, and panels.

Side Panel and Footrest Board Removal

Steps for removing side panels and footrest boards.

Fender, Fuel Tank, and Muffler Service

Removal and installation of fenders, fuel tank, and muffler.

3. Checks & Adjustment

Periodic Maintenance and Valve Clearance

Periodic maintenance schedule and valve clearance adjustment procedures.

Steering, Brake, and Wheel Checks

Checking steering system operation, brake system components, and wheels.

Suspension, Gear Shifting, and Throttle Checks

Inspecting suspension, adjusting gear shifting, and checking throttle/speed limiter.

Cooling System and Pressure Checks

Checking coolant level, radiator, hoses, and performing pressure tests.

4. Cooling System

Engine Coolant Safety and Circuit Testing

Warnings for coolant handling and procedures for testing the cooling circuit.

Coolant Replacement and Air Discharge

Steps for replacing coolant and discharging air from the cooling system.

5. Engine Removal and Installation

Engine Removal Preparations and Steps

Cautions and detailed steps for engine removal.

Engine Installation and Axle Service

Procedures for engine installation and axle removal/installation.

6. Front Wheel, Front Brake, Suspension, Steering

Maintenance Standards and Troubleshooting

Standards for front wheel/brake and troubleshooting for steering/suspension.

Front Wheel and Hub Service

Procedures for front wheel and hub removal, assembly, and disassembly.

Brake System Service

Inspection and installation of front caliper, disc, and master cylinder.

Suspension and Drive Shaft Service

Removal and service of front suspension components and CV drive shafts.

Handlebar, Switches, and Mirrors Service

Disassembly and inspection of handlebar, switches, and mirrors.

Steering System Service

Procedures for removing and installing the steering stem and bearings.

7. Rear Wheel, Rear Brake, Suspension

Overhaul Standards and Troubleshooting

Standards for rear wheel/brake and troubleshooting for rear wheel/suspension.

Rear Wheel and Hub Service

Inspecting the rear wheel rim and disassembling the wheel hub.

Rear Brake and Parking Brake Service

Service procedures for rear brake caliper, disc, and parking brake.

8. Battery, Charging System

Charging System Overview and Generator Checks

Charging system layout, generator coil resistance, and performance checks.

Battery and Regulator;Rectifier Service

Battery removal/installation and regulator/rectifier inspection.

AC Magneto Inspection

Measuring AC magneto resistance and checking connections.

9. Ignition System

Ignition System Troubleshooting

Common ignition system problems and their remedies.

Spark Plug and Ignition Coil Checks

Inspecting spark plug, ignition coil, and CDI unit.

Pickup Coil and System Diagram

Measuring pickup coil voltage and reviewing the ignition system diagram.

10. Lighting, Instruments, Switches

Bulb, Fuse Standards and Headlight Troubleshooting

Standards for bulbs/fuses and troubleshooting headlight issues.

Bulb Replacement Procedures

Procedures for replacing headlight, brake, tail, and turning indicator bulbs.

Switch and Sensor Inspections

Inspecting ignition switch, handlebar switches, and fuel sensor.

11. Circuit Diagram, Wiring Diagram

12. Troubleshooting

Engine Starting and Running Problems

Diagnosing and resolving engine starting, running, and stalling issues.

Engine Performance and Overheating Issues

Addressing poor engine performance, overheating, and noises.

Gearshift and Carburetor Problems

Diagnosing and resolving gearshift and carburetor related issues.

13. Engine Overhaul Information

Conversion Table and General Precautions

Unit conversions and general safety precautions for engine overhaul.

Fuel, Oil, Coolant Recommendations

Recommendations for fluids and detailed engine technical specifications.

Overhaul Data and Tightening Torques

Specific data, service limits, and tightening torques for engine components.

Maintenance Tools for Engine Overhaul

List of tools required for engine maintenance and repair.

14. Checks & Adjustment

Periodic Maintenance and Valve Clearance

Periodic maintenance schedule and valve clearance adjustment procedures.

Steering, Brake, and Wheel Checks

Checking steering, brakes, wheels, and suspension systems.

Engine Oil, Cooling System, and Pressure Checks

Inspecting lubrication, cooling systems, cylinder, and oil pressure.

Clutch Inspection and Drive Belt Service

Checking clutch engagement and servicing the drive belt.

15. Engine Removal, Inspection & Installation

Engine Removal Procedures

Detailed steps for removing engine components and the engine.

Engine Installation Procedures

Procedures for installing the engine and its main assemblies.

Crankshaft and Connecting Rod Service

Inspection and service of crankshaft and connecting rod components.

Clutch, Sheave, and Belt Service

Inspection and service of clutch, sheaves, and drive belt.

16. Carburetor

Carburetor Removal and Disassembly

Steps for removing and disassembling the carburetor.

Carburetor Inspection and Cleaning

Inspecting carburetor components for damage or clogs.

Carburetor Measurement and Adjustment

Measuring float height, fuel level, and making adjustments.

17. Cooling and Lubrication System

Cooling System Components and Safety

Diagram of cooling system and safety precautions for coolant.

Cooling Circuit Testing and Coolant Replacement

Testing cooling circuit pressure and replacing coolant.

Radiator, Hoses, Fan Motor, and Thermoswitch Service

Inspecting and servicing radiator, hoses, fan motor, and thermoswitch.

Water Temperature Sensor, Thermostat, and Water Pump Service

Inspecting sensor, thermostat, and servicing the water pump.

18. Electrical System

Charging System Overview and Generator Checks

Charging system layout, generator coil resistance, and performance checks.

Battery Service

Procedures for battery removal, installation, and inspection.

Starting Motor Service

Inspection of starter motor components like brushes and commutator.

Ignition System Components and Tests

Checking ignition coil voltage, resistance, and pickup coil performance.

19. Troubleshooting

Engine Starting and Running Problems

Diagnosing and resolving engine starting, running, and stalling issues.

Engine Performance, Overheating, and Noises

Addressing poor engine performance, overheating, and noises.

Gearshift and Carburetor Problems

Diagnosing and resolving gearshift and carburetor related issues.

Cooling System and Ignition System Issues

Troubleshooting cooling and ignition system faults.

Summary

FOREWORD

1. Overhaul Information

Safety and Disassembly Cautions

General safety guidelines and precautions for disassembly and assembly.

Key Vehicle Specifications

VIN, engine number, and main data table for vehicle specifications.

Component Standards and Data

Datasheet with standards, service limits, and torque values for various components.

System Specifications

Specifications for front wheel, brake, battery, charging, and ignition systems.

Cable Routing and Lubrication

Cable routing diagrams and lubricant/sealing agent application guidelines.

2. Vehicle Body, Muffler

Troubleshooting Vehicle Body and Muffler

Troubleshooting for vehicle body and muffler issues.

Body Panel and Rack Removal

Procedures for removing front rack, seat, rear rack, and panels.

Side Panel and Footrest Board Removal

Steps for removing side panels and footrest boards.

Fender, Fuel Tank, and Muffler Service

Removal and installation of fenders, fuel tank, and muffler.

3. Checks & Adjustment

Periodic Maintenance and Valve Clearance

Periodic maintenance schedule and valve clearance adjustment procedures.

Steering, Brake, and Wheel Checks

Checking steering system operation, brake system components, and wheels.

Suspension, Gear Shifting, and Throttle Checks

Inspecting suspension, adjusting gear shifting, and checking throttle/speed limiter.

Cooling System and Pressure Checks

Checking coolant level, radiator, hoses, and performing pressure tests.

4. Cooling System

Engine Coolant Safety and Circuit Testing

Warnings for coolant handling and procedures for testing the cooling circuit.

Coolant Replacement and Air Discharge

Steps for replacing coolant and discharging air from the cooling system.

5. Engine Removal and Installation

Engine Removal Preparations and Steps

Cautions and detailed steps for engine removal.

Engine Installation and Axle Service

Procedures for engine installation and axle removal/installation.

6. Front Wheel, Front Brake, Suspension, Steering

Maintenance Standards and Troubleshooting

Standards for front wheel/brake and troubleshooting for steering/suspension.

Front Wheel and Hub Service

Procedures for front wheel and hub removal, assembly, and disassembly.

Brake System Service

Inspection and installation of front caliper, disc, and master cylinder.

Suspension and Drive Shaft Service

Removal and service of front suspension components and CV drive shafts.

Handlebar, Switches, and Mirrors Service

Disassembly and inspection of handlebar, switches, and mirrors.

Steering System Service

Procedures for removing and installing the steering stem and bearings.

7. Rear Wheel, Rear Brake, Suspension

Overhaul Standards and Troubleshooting

Standards for rear wheel/brake and troubleshooting for rear wheel/suspension.

Rear Wheel and Hub Service

Inspecting the rear wheel rim and disassembling the wheel hub.

Rear Brake and Parking Brake Service

Service procedures for rear brake caliper, disc, and parking brake.

8. Battery, Charging System

Charging System Overview and Generator Checks

Charging system layout, generator coil resistance, and performance checks.

Battery and Regulator;Rectifier Service

Battery removal/installation and regulator/rectifier inspection.

AC Magneto Inspection

Measuring AC magneto resistance and checking connections.

9. Ignition System

Ignition System Troubleshooting

Common ignition system problems and their remedies.

Spark Plug and Ignition Coil Checks

Inspecting spark plug, ignition coil, and CDI unit.

Pickup Coil and System Diagram

Measuring pickup coil voltage and reviewing the ignition system diagram.

10. Lighting, Instruments, Switches

Bulb, Fuse Standards and Headlight Troubleshooting

Standards for bulbs/fuses and troubleshooting headlight issues.

Bulb Replacement Procedures

Procedures for replacing headlight, brake, tail, and turning indicator bulbs.

Switch and Sensor Inspections

Inspecting ignition switch, handlebar switches, and fuel sensor.

11. Circuit Diagram, Wiring Diagram

12. Troubleshooting

Engine Starting and Running Problems

Diagnosing and resolving engine starting, running, and stalling issues.

Engine Performance and Overheating Issues

Addressing poor engine performance, overheating, and noises.

Gearshift and Carburetor Problems

Diagnosing and resolving gearshift and carburetor related issues.

13. Engine Overhaul Information

Conversion Table and General Precautions

Unit conversions and general safety precautions for engine overhaul.

Fuel, Oil, Coolant Recommendations

Recommendations for fluids and detailed engine technical specifications.

Overhaul Data and Tightening Torques

Specific data, service limits, and tightening torques for engine components.

Maintenance Tools for Engine Overhaul

List of tools required for engine maintenance and repair.

14. Checks & Adjustment

Periodic Maintenance and Valve Clearance

Periodic maintenance schedule and valve clearance adjustment procedures.

Steering, Brake, and Wheel Checks

Checking steering, brakes, wheels, and suspension systems.

Engine Oil, Cooling System, and Pressure Checks

Inspecting lubrication, cooling systems, cylinder, and oil pressure.

Clutch Inspection and Drive Belt Service

Checking clutch engagement and servicing the drive belt.

15. Engine Removal, Inspection & Installation

Engine Removal Procedures

Detailed steps for removing engine components and the engine.

Engine Installation Procedures

Procedures for installing the engine and its main assemblies.

Crankshaft and Connecting Rod Service

Inspection and service of crankshaft and connecting rod components.

Clutch, Sheave, and Belt Service

Inspection and service of clutch, sheaves, and drive belt.

16. Carburetor

Carburetor Removal and Disassembly

Steps for removing and disassembling the carburetor.

Carburetor Inspection and Cleaning

Inspecting carburetor components for damage or clogs.

Carburetor Measurement and Adjustment

Measuring float height, fuel level, and making adjustments.

17. Cooling and Lubrication System

Cooling System Components and Safety

Diagram of cooling system and safety precautions for coolant.

Cooling Circuit Testing and Coolant Replacement

Testing cooling circuit pressure and replacing coolant.

Radiator, Hoses, Fan Motor, and Thermoswitch Service

Inspecting and servicing radiator, hoses, fan motor, and thermoswitch.

Water Temperature Sensor, Thermostat, and Water Pump Service

Inspecting sensor, thermostat, and servicing the water pump.

18. Electrical System

Charging System Overview and Generator Checks

Charging system layout, generator coil resistance, and performance checks.

Battery Service

Procedures for battery removal, installation, and inspection.

Starting Motor Service

Inspection of starter motor components like brushes and commutator.

Ignition System Components and Tests

Checking ignition coil voltage, resistance, and pickup coil performance.

19. Troubleshooting

Engine Starting and Running Problems

Diagnosing and resolving engine starting, running, and stalling issues.

Engine Performance, Overheating, and Noises

Addressing poor engine performance, overheating, and noises.

Gearshift and Carburetor Problems

Diagnosing and resolving gearshift and carburetor related issues.

Cooling System and Ignition System Issues

Troubleshooting cooling and ignition system faults.

CFMoto CF500 Specifications

General IconGeneral
BrandCFMoto
ModelCF500
CategoryOffroad Vehicle
LanguageEnglish

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