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CF MOTO CF500-3/UTV Service Manual
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CF MOTO CF500-3/UTV Service Manual

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Summary of Contents for CF MOTO CF500-3/UTV

  • Page 1 All manuals and user guides at all-guides.com CF500-3/UTV WWW.CFMOTO.COM...
  • Page 2 All manuals and user guides at all-guides.com FOREWORD INDEX This manual contains an introductory description Vehicle of procedures for inspection maintenance, Service Information overhaul disassembly & assembly removal and Vehicle Body,Muffler installation components parts, Inspection & Adjustment troubleshooting and service data together with Cooling System illustrations of our UTV Model CF500-3.
  • Page 3 All manuals and user guides at all-guides.com Conversion Table Item Example Conversion Pressure 200Kpa (2.00kgf/cm 1kgf/cm =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=1cm =1cc 1l=1000cm Force 12N (1.2kgf) 1kgf=9.80665N...
  • Page 4 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Cautions……………………………1-1 Tightening Torque………………1-13 VIN Number & Engine Number……1-3 Lubricant, Sealing Agent…………1-18 Main Data Table……………………1-4 Cable Routing……………………1-19 Overhaul Data Table………………1-6 Cautions Safety Cautions 1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly venti- lated place for long time.
  • Page 5 All manuals and user guides at all-guides.com &)0272 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.
  • Page 6 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ 9,1 1XPEHU DQG (QJLQH 1XPEHU &) 9HKLFOH ,GHQWLILFDWLRQ 1XPEHU /&(/'7= ( Q J L Q H 1 X P E H U & )    $...
  • Page 7 All manuals and user guides at all-guides.com &)0272 Main Data Table Item Parameter Model CF500-3 Length 2880mm Width 1435mm Height 1900mm Wheel base 1790mm Engine type CF188-A Displacement 493Cm Fuel type Unleaded gasoline RQ-93or above Dry weight 554kg Number of Passengers 2 (including driver) 150kg Max.
  • Page 8 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ I t e m P a r a m e t e r A ir F ilter type Sponge elem ent filter Type Vacuum D iaphragm type F u e l M IK U N I B S R 36-89 D e v i c e C arburetor...
  • Page 9 All manuals and user guides at all-guides.com &)0272 Maintenance Data Table Lubrication System Item Standard Service Limit Engine Oil Volume when 2200mL Capacity replacing Volume when 2300mL replacing filter Specially Recommended Oil(See Original 4-stroke motorcycle SAE-15W-40 Substitutes must be used in the following range.
  • Page 10 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Cooling System Standard/ Service Item Remark Parameter Limit Full Capacity 2900ml Reservoir tank Coolant 300ml capacity Capacity Standard Density Opening pressure of radiator cap 108kpa(1.1kgf/ Initial Temperature 72±2 Full opening Temperature Thermostat 4.5mm/95 Full opening lift...
  • Page 11 All manuals and user guides at all-guides.com &)0272 Front Wheel O p e ra tio n Ite m Sta n d a rd L im it P la y w he e l Ve rtic a l 1 .0 m m 2 .0 m m H o rizo n ta l 1 .0 m m...
  • Page 12 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Battery, Charging Device, Pickup Coil Item Standard permanent magnet 3-phase Model alternator flywheel rotor Output 3-phase AC 0.2Ω-0.3Ω Charging Coil Resistance Pickup Coil Resistance 110Ω-140Ω Magneto Voltage of Magneto Motor 100V 5000r/min Motor engine is off...
  • Page 13 All manuals and user guides at all-guides.com &)0272 Valve System + Cylinder Head (mm) Item Standard Operation Limit Intake 30.6 Valve Diameter Exhaust 27.0 Intake 0.05-0.10 Valve Clearance( Idle Speed) Exhaust 0.17-0.22 Fit Clearance between Valve Intake 0.010-0.037 Guide and Valve Stem Exhaust 0.030-0.057 Internal dia.
  • Page 14 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Cylinder + Piston + Piston Ring+ Crankshaft (mm) Operation Item Standard Remark Limit Cylinder Pressure 1000kPa Fit Clearance between 0.030-0.051 0.15 Piston and Cylinder 87.460-87.480 Piston Skirt dia. Testing the point away skirt end 87.380 10mm Internal dia.
  • Page 15 All manuals and user guides at all-guides.com &)0272 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 Shifter and fit flute gap 0.10-0.40 0.50 Left Shifter Sliding Thickness...
  • Page 16 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Tightening Torque Item Torque N·m(kgf·m) Item Torque N·m(kgf·m) 5mm Bolt, nut 5(0.5) 5mm Screw 4(0.4) 6mm Bolt, nut 10(1.0) 6mm Screw 9(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...
  • Page 17 All manuals and user guides at all-guides.com &)0272 Engine Tightening Torque Table Screw dia. Torque Item Remark ntity Sensor, Reverse Gear M10×1.25 Spark Plug M12×1.25 Water Temperature Sensor Rc1/8 Apply screw thread sealant Valve Clearance Adjusting Nut Drive Disc Nut M20×1.5 Driven Disc Nut M20×1.5...
  • Page 18 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Torque Item Quantity Diameter mm Remark Bolt,Crankcase Bolt, Driven Sector Gear Mounting Bolt, Oil Filter M20×1.5 3 / 4  Oil Filter 1 6 / i n Bolt, Starting Motor Bolt, Cylinder Head Bolt, Cylinder Head(2 sides) Upper Lower...
  • Page 19 All manuals and user guides at all-guides.com &)0272 Engine Tools Measuring Tools Name Type Function Remark Vernier Calipers 0-150mm measure length and thickness measure the outer diameters of swing Micrometers 0-25mm arm, valve rod and camshaft Dialgauge 25-50mm Measure max. lift range of camshaft Dialgauge 75-100mm Measure piston skirt...
  • Page 20 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Special Purpose Tools Name Type Function Remark Disassemble/ install spark Spark Plug Wrench 172MM-022400-922-004 plug CF188-051000-922-001 Disassemble/install CVT CVT Wrench CF188-052000-922-001 drive/driven disc nut Oil Filter Wrench CF188-011300-922-001 Disassemble/ install oil filter Piston Pin Remover CF188-040004-922-002 Disassemble piston pin...
  • Page 21 All manuals and user guides at all-guides.com &)0272 Lubriantion Grease, Sealant Coated Section Attention Grease Turning Bearings Throttle Cable Connecting Portion Throttle Pedal Movable Parts Brake Pedal Movable Parts Multi-purpose grease Swing Arm Movable Parts Steering Inner Circle Surface Seat Lock Movable Parts Transmission Movable Parts O p e r a t i o n M a t e r i a l a n d I n s t a l l m e n t S u p p l e m e n t a r y o f E n g i n e E n g i n e o p e r a t i o n m a t e r i a l s i n c l u d e l u b r i c a n t ( o i l) , g r e a s e ( l u b r i c a n t g r e a s e ) a n d c o o l a n t ,...
  • Page 22 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ Cables, Pipes, Cable Routing...
  • Page 23 All manuals and user guides at all-guides.com &)0272...
  • Page 24 All manuals and user guides at all-guides.com 0DLQWHQDQFH ,QIRUPDWLRQ...
  • Page 25 All manuals and user guides at all-guides.com &)0272...
  • Page 26 All manuals and user guides at all-guides.com Overhaul info R e a r f e n d e r ( R H & L H ) D u m p Troubleshooting 2-11 Front top cove Front side support(RH&LH)2-2 Side door(RH&LH) 2-12 Front vent cover F o o t r e s t b o a r d ( R H &...
  • Page 27 All manuals and user guides at all-guides.com &)0272 Front top cover Remove Remove 7 nuts 1 from front top cover. Push forward and then remove the front top cover. Installation Reverse the removal procedure for installation Front side support(LH) Remove Remove mount bolts 2;...
  • Page 28 All manuals and user guides at all-guides.com Front vent cover Remove Remove front top cover Remove front side support(RH&LH) Remove nuts 1 Remove nuts 2 Remove nuts 3 Remove front vent cover Installation Reverse the removal procedure for installation...
  • Page 29 All manuals and user guides at all-guides.com &)0272 Front fender Remove Loosen all electronic component and plugs on front fender; Remove battery; Remove three bolts 1 Remove one nut 1 Remove twelve nuts 2 Remove six nuts 3 Loose cables on the fender; Remove front fender Installation Reverse the removal procedure for...
  • Page 30 All manuals and user guides at all-guides.com Front cover,steering stem Remove Loose nut 1 Loose nut 2 Remove front cover,steering stem Installation Reverse the removal procedure for installation Rear cover,steering stem Remove Loose nut 3 Remove ignition switch cover Remove rear cover,steering stem Installation Reverse the removal procedure for installation...
  • Page 31 All manuals and user guides at all-guides.com &)0272 Center cover,steering wheel Remove Exert upward to seperate center cover, steering wheel; Installation Reverse the removal procedure for installation Steering wheel Remove Remove center cover,steering wheel Loosen nut 1 Remove steering wheel Installation Note Align the front wheel first, and then ad-...
  • Page 32 All manuals and user guides at all-guides.com Seat,driver Remove Use the key to unlock the seat lock Remove cotter pin 1 Remove cotter pin pivot 1 Remove seat,driver Installation Reverse the removal procedure for installation Seat,passenger Remove Use the key to unlock the seat lock; Remove cotter pin 2 Remove cotter pin pivot 2 Remove seat,passenger...
  • Page 33 All manuals and user guides at all-guides.com &)0272 Gearshift unit Remove Loosen nut 2 Remove gearshift unit Installation Reverse the removal procedure for installation Note Check the return flexibility of gear limit, and the flexibility of gear shifting. Engine hood Remove Remove gearshit unit Loosen bolt 1...
  • Page 34 All manuals and user guides at all-guides.com Link plate(LH) Remove Remove nut 1 Remove link plate(LH) Installation Reverse the removal procedure for installation Link plate(RH) Remove Remove nut 2 Remove link plate(RH) Installation Reverse the removal procedure for installation Skid plate(Center) Remove Remove nut 3 Remove skid plate(center)
  • Page 35 All manuals and user guides at all-guides.com &)0272 Skid plate(LH) Remove Loosen nut 1 Loosen bolt 1 Loosen bolt 2 Remove skid plate(LH) Installation Reverse the removal procedure for installation Skid plate(RH) Remove Loosen nut 2 Loosen bolt 3 Loosen bolt 4 Remove skid plate(RH) Installation Reverse the removal procedure for...
  • Page 36 All manuals and user guides at all-guides.com Rear fender(LH) Remove Remove bolt 1 Remove rear fender(LH) Installation Reverse the removal procedure for installation Rear fender(RH) Remove Remove bolt 2 Remove rear fender(RH) Installation Reverse the removal procedure for installation Dump box Remove Remove nut 1 Take out cotter pin 1...
  • Page 37 All manuals and user guides at all-guides.com &)0272 Side door(LH) Remove Remove bolt 1 Remove side door(LH) Installation Reverse the removal procedure for installation Side door (RH) Remove Remove bolt 2 Remove side door(RH) Installation Reverse the removal procedure for installation...
  • Page 38 All manuals and user guides at all-guides.com Footrest board(LH) Remove side door(LH) Remove link plate(LH) Remove skid plate(center) Remove skid plate(LH) Remove bolt 1 Remove nut 1 Remove footrest board(LH) Installation Reverse the removal procedure for installation Footrest board(RH) Remove side door(RH) Remove link plate(RH) Remove skid plate(center) Remove skid plate(RH)
  • Page 39 All manuals and user guides at all-guides.com &)0272 Dashboard panel Remove Remove front side support(RH&LH) Remove front fender Remove footrest board(RH&LH) Loosen cable and plug on dashboard panel Remove bolt 1 Remove bolt 2 Remove dashboard panel Installation Reverse the removal procedure for installation Bumper Remove...
  • Page 40 All manuals and user guides at all-guides.com Fuel tank Remove Remove rear wheel(RH) Loosen high-pressure fuel pipe Loosen fuel sensor connector Remove bolt 1 Remove fuel tank Installation Reverse the removal procedure for installation Headrest,driver Remove Remove nut 1 Remove headrest,driver Installation Reverse the removal procedure for installation...
  • Page 41 All manuals and user guides at all-guides.com &)0272 Safety belt,driver Remove Remove bolt 1 Remove bolt 2 Remove safety belt,driver Installation Reverse the removal procedure for installation Safety belt,passenger Remove Remove bolt 3 Remove bolt 4 Remove safety belt,passenger Installation Reverse the removal procedure for installation Safety belt fastener...
  • Page 42 All manuals and user guides at all-guides.com Roll-over bar Remove Remove nut Remove bolt Remove nut Remove bolt Remove roll-over bar Installation Reverse the removal procedure for installation Rear mirror(LH) Remove Remove rear mirror(LH)27 Rear mirror(RH) Remove Remove rear mirror(RH)25...
  • Page 43 All manuals and user guides at all-guides.com &)0272 Bumper protector Remove Remove nut 9 Remove bumper protector 1 Installation Reverse the removal procedure for installation Cable and motor Remove Remove nut 16and bolt 4 Remove bolt 2 Remove cable and motor 15 Installation Reverse the removal procedure for installation...
  • Page 44 All manuals and user guides at all-guides.com Rear side support(LH) Remove Remove nut 1 Remove side support(LH)26 Installation Reverse the removal procedure for installation Rear side support(RH) Protector(RH),dump box Remove Remove Remove nut 1 Remove nut 1 Remove rear side support 27 Remove protector(RH),dump box 6 Installation Installation...
  • Page 45 All manuals and user guides at all-guides.com &)0272 Muffler Caution: Perform disassembly only after the muffler is cooled down. Remove Remove connect nut 1 on muffler pipe elbow Remove spring Remove bolt 1 Remove bolt 4 Remove muffler Caution: Perform disassembly only after the muffler is cooled down.
  • Page 46 All manuals and user guides at all-guides.com Description of visible parts...
  • Page 47 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Va l v e C l e a r a n c e      3 - 1 3 Overhaul Info3-1 Maintenance Time3-2 Engine Idle&Spark plug3-14 Inspection & Maintenance3-3 Air Filter3-15 Steering Stem, Brake System3-6 Carburator hose&Driving Belt3-16...
  • Page 48 All manuals and user guides at all-guides.com &)0272 Regular Maintenance Table The table below lists the recomm ended intervals for all the required periodic m aintenance work necessary to keep the vehicle at its best perform ance and econom y. Maintenance intervals are expressed in term s of kilom eter, m iles and hours, whichever occurs first.
  • Page 49 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Check & Maintenance Interval Check Item Interval Standard Part Item Daily A n n u a l Year Operation Steering wheel agility Steering Damage System Installation condition of Steering System steering system Sway of ball stud Pedal...
  • Page 50 All manuals and user guides at all-guides.com &)0272 Check Item Intervals Standard Part Item Daily Annual year Looseness Final shaft Drive joint parts (Drive Train shaft) Sway of Spline Spark plug Spark plug Ignition Device 0.9mm Electric Ignition timing System Battery Terminal Joint Looseness and...
  • Page 51 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Check Item Intervals Standar Annua Part Item Daily year Lighting device turning Function indictors Alarm and lock Function device Instruments Function Looseness damage caused improper Exhaust pipe installation and muffler Function of muffler Looseness and/or...
  • Page 52 All manuals and user guides at all-guides.com &)0272 Steering Stem Park the vehicle on level place, hold steering wheel, and shake in the direction as illustrated on the right and see if there is any sway In case of any sway, check if it is the problem of the steering stem or other parts and then do the maintenance accordingly.
  • Page 53 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Master Cylinder Fluid level Check the brake fluid level When the brake fluid level is near to the lower limit line, check master cylinder, brake hoses and joints for leakage. Remove fluid reservoir cap.
  • Page 54 All manuals and user guides at all-guides.com &)0272 Wheels Lift front wheel on level place, and make sure there is no loading on the wheels. Shake the front wheel left and right to check whether the joint of front wheel is tightened and check whether it sways.
  • Page 55 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Tire pressure Check the pressure of the tires with a pressure gauge. Note Check the tire pressure after tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause deflected wear of the tires.
  • Page 56 All manuals and user guides at all-guides.com &)0272 Wheel Nut and Wheel Axle Check front and rear wheel axle nuts for looseness Loosened axle nuts Tighten Tightening Torque: Front wheel axle nut: 110-130N.m(11.2kgf.m-13.3kgf.m) Rear wheel axle nut: 110-130N.m(11.2kgf.m-13.3kgf.m) Sway of Wheel Bearing Lift the front wheel Make sure there is loading on the vehicle Shake the wheel in axial direction for any...
  • Page 57 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Adjusting the Absorber Use special tools to adjust the length of absorber according to loading requirement Turn clockwise to adjust from high to low Gear Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if nec- essary Release the locknut to adjust the length of gearshift rod...
  • Page 58 All manuals and user guides at all-guides.com &)0272 Throttle Lever Check Check the free play of throttle lever Free play: 3-5mm If out of range, then adjust Loosen locknut of throttle cable turn the regulator and adjust free play of throttle lever After adjusting, tighten locknuts and install throttle cable sleeve,...
  • Page 59 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Valve clearance The first check is necessary after 20 hours run-in, then have a check every 100-hour or 1000 km; If cylinder head cover disassembled, check must be needed If clearance is too big, then noise will be too big;...
  • Page 60 All manuals and user guides at all-guides.com &)0272 Take away guage and double check clearance, it should be within standard value. Otherwsie one more adjustment is needed as before till clearance is within standard scope.Tighten torque of adjustment nut:10N.m Note: Tighten adjustment-nut only after clearance adjustment is made completely Cover iniet&outlet valve and hole,...
  • Page 61 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Check carbon deposit on spark plug and clean with proper tool Spark plug gap: Check with guage, If out of range, make adjustment Standard gap: 0.8~ 0.9mm Warning When change spark plug, need to check screw thread specification and its length in- side combustion chamber, if it’s too short, carbon deposit will be caused and will dam-...
  • Page 62 All manuals and user guides at all-guides.com &)0272 Cleaning fluid Oil SAE30 or SAE15W/40 for motor- cycles Warning DO NOT use gasoline or low- flash solvant to clean air filter element. Check if air filter damage or not, If yes, please replace with new one Note Make sure filter element is clean during...
  • Page 63 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Check Check driving belt condition. If some crack or damage, replace with new driving belt Check width of driving belt. If >limit value, re- place with new driving belt Width limit value :33.5mm Tool:vernier caliper Installation Installation process is opposite to disassem-...
  • Page 64 All manuals and user guides at all-guides.com &)0272 Cooling System Note Check coolant level from reservoir tank, Do not check from radiator. If the radiator cap is opened while the engine is hot (over 100 ), the pres- sure of the cooling system will drop down and the coolant will get boiled rapidly.
  • Page 65 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Coolant replacement Remove radiator cover and reservoir cover Put laver under water pump, then loosen bolt 3 Disassemble connecting hose Take coolant away from reservoir Note When engine is hot, DO NOT open radiator cover, otherwise steam gas or hot coolant will cause hurt Coolant is poisonous, DO NOT drink or splash it to skin, eyes, and clothes.
  • Page 66 All manuals and user guides at all-guides.com &)0272 Pour coolant into reservoir and keep upper line and lower line , tighten reservoir cover. Warning DO NOT mix other brand coolant into reservoir tank Radiator pipe check Check every 100 hours or every 1000Km Check radiator pipe, clamps and coolant leakage In case of damage or leakage, replace with new one Cylinder pressure check...
  • Page 67 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Oil cool&Lubrication system Note After initial 20 hours or 250km run-in, oil and element should be replaced; Every100 hours or 1000Km, change oil and replace with element Every 10 hours check oil level during oil&element life-cycle Do oil level check after engine warm up and use oil guage...
  • Page 68 All manuals and user guides at all-guides.com &)0272 Engine oil change Pull out oil guage 1, oil bolt 2 and gasket 3; Before engine is cooled down completely, release oil very fast till no oil remaining. Use solvent to clean guage, bolt and gasket. Install gasket and bolt Bolt torque: 30N.m Add new oil...
  • Page 69 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Oil pressure check Oil pressure is very important signal to reflect engine working condition Oil pressure:130~170kpa when RPM=3000r/min Pressure too high or too low will cause: If pressure is too low Oil element jammed Oil leakage O-ring damage...
  • Page 70 All manuals and user guides at all-guides.com &)0272 Clutch engagement speed and locked speed check Engine equiped with centrifugal type automatic clutch Install engine on vehicle to check engagement speed and locked speed. Before check, need to check drive train system and warm up engine. Clutch engagement speed check Connecting tachometer with high-tension cables Start engine...
  • Page 71 All manuals and user guides at all-guides.com  &KHFNV $GMXVWPHQW Check Water Temperature Gauge When engine is not working, the water tempera- ture should be in the “0” position. Start the en- gine to check if the indicator works. If the indica- tor is not working, do the maintenance in time.
  • Page 72 All manuals and user guides at all-guides.com Overhaul Information Operation Cautions Notes f the radiator cap is opened when the coolant temperature is above the pressure of coolant will drop and get boiled rapidly. The steam jet may cause danger and injury. Cover the cap with a piece of rag after the coolant temperature goes down and open the cap slowly.
  • Page 73 All manuals and user guides at all-guides.com &)0272 Trouble Shooting Sharp rise of water temperature Faulty radiator cap Air in cooling system Faulty water pump Faulty thermostat (thermostat is not open) Clogged radiator pipe or cooling pipes Damage or clogged radiator fin Coolant is not enough Faulty or malfunction of fan motor No rise or slow rise of water temperature.
  • Page 74 All manuals and user guides at all-guides.com Performance Check Checking coolant density Note: Open the radiator cap after coolant is fully cooled. Remove: Front top cover Radiator cap (counter clockwise) Check with a densimeter if the coolant den- sity adapts to the local temperature. Check coolant for stains or impurities.
  • Page 75 All manuals and user guides at all-guides.com &)0272 Pressure testing of cooling system Install the radiator cap tester to the radiator cap;Apply the specified pressure (radiator cap opening pressure) for 6 seconds. Note Do not apply pressure over the specified pr essure [108kpa(1.1kgf/cm2)], or the coo ling system may be damaged.In case there is any pressure leakage, check the pipe,...
  • Page 76 All manuals and user guides at all-guides.com Remove drain bolt Remove drain bolt, seal gasket from water pump, and drain coolant. After drainage, assemble with a new seal gasket, drain bolt and tighten Reservoir Tank Remove two mounting bolts and water pipe on reservoir tank;...
  • Page 77 All manuals and user guides at all-guides.com &)0272 Adding Coolant Add coolant through radiator cap. Start the engine and discharge air from cooling system. Check from filling port that air is fully discharged from cooling system and install the radiator cap. Remove reservoir tank cap and add coolant till the upper limit.
  • Page 78 All manuals and user guides at all-guides.com Engine Coolant The coolant used in cooling system is a mixture of 50% distilled water and 50% ethylene glycol antifreeze. This mixture provides the optimized corrosion re- sistance and fine heat protection. The coolant will pro- tect the cooling system from freezing at temperature above  If the vehicle will be operated at the...
  • Page 79 All manuals and user guides at all-guides.com &)0272 Check and Clean of radiator and Hose Radiator cap Check Remove radiator cap  Install radiator cap to cap tester Slowly increase pressure to 93.3-122.7 kPa and check if the cap can hold the pressure for at least 10 seconds. If the cap cannot meet the pressure requirement, replace it.
  • Page 80 All manuals and user guides at all-guides.com Fan Inspect Remove fan motor from radiator Turn the vanes and check if they can turn smoothly;  Check fan motor: Make sure that the bat- tery applies 12 volts to the motor and the mo- tor will run at full speed while the ammeter shall indicate the ampere not more than 5A.
  • Page 81 All manuals and user guides at all-guides.com &)0272 Water Temperature Sensor In- spect Place a rag under water temperature sensor  and remove it from cylinder head. Check the resistance of water temperature sensor as illustrated on the right. Connect the temperature sensor to the circuit tester, place it in a vessel with engine oil.
  • Page 82 All manuals and user guides at all-guides.com Check thermostat pellet for cracks, if damaged,replace it. Test the thermostat in the following steps: Pass a string between thermostat flange as il- lustrated on the right; Immerse the thermostat in a beaker with water. Make sure that the thermostat is in the suspended posi- tion without contact to the vessel.
  • Page 83 All manuals and user guides at all-guides.com &)0272 Release clamps and remove water hoses Release bolts and remove water pump Remove O-ring Warning: Do not reuse the O-ring  Remove the overflow tube Release water pump cover screws, water pump cover and gasket Remove E-ring and impeller Remove seal ring and rubber seal...
  • Page 84 All manuals and user guides at all-guides.com Remove mechanical seal with special tool Note: The mechanical seal does not need to be removed if there is no abnormal condition. Warning: Do not reuse a removed mechanical seal Put a rag on the water pump body Remove oil seal.
  • Page 85 All manuals and user guides at all-guides.com &)0272 Oil Seal  Check oil seal for damage. Pay special at- tention to the oil seal lip;  In case of damage or leakage, replace the oil seal; Water Pump Body Check the mating mace of water pump body with bearing and mechanical seal Damage: Replace...
  • Page 86 All manuals and user guides at all-guides.com Install mechanical seal with a suitable socket wrench Note: Apply sealant to side   of mechanical seal Install bearing with special tool Tool: Bearing Installer Note: The stamped mark on the bearing faces outside. Install seal ring to impeller Clean off the oil and grease from mechanical seal and install it into the impeller.
  • Page 87 All manuals and user guides at all-guides.com &)0272 Install E-ring to water pump shaft; Install new gasket to water pump body; Install water pump cover and tighten the bolts and bleed bolt. Water Pump Cover Bolts Tightening Torque: 6N.m Check impeller for smooth turning. Install the new O-ring Note: Use the new O-ring to prevent oil leakage;...
  • Page 88 All manuals and user guides at all-guides.com Install water pump and tighten the bolts to the specified torque; Water pump bolts tightening torque: 10N. ote: Set the water pump shaft slot end   to oil pump shaft flat side Connect water hoses Add coolant...
  • Page 89 All manuals and user guides at all-guides.com &)0272 Coolant System Chart...
  • Page 90 All manuals and user guides at all-guides.com Engine Oil Cooling and Lubricating System Illustration Engine parts (such as piston, cylinder,camshaft) in high-speed running should be lubricated. Use special engine oil for engine lubrication as lubrication function, as well as functions like cleaning, anti-rust,sealing and cooling.
  • Page 91 All manuals and user guides at all-guides.com  5RPRYDO RI (QJLQH7UDQVPLVVLRQ 6\VWHP DQG *HDUVKLIW Inspection Information  Romoval and Installation of Gearshift Engine Removal and Installation5-2 Removal and Installation of Front and Rear  axle Inspection Information Note: When removalEngine,pls use jack to support the bodywork.Don’t damnify the frame,body of engine,bolt and cable etc.
  • Page 92 All manuals and user guides at all-guides.com &)0272 Disassembly Engine Romove plastic parts Chapter two Romove air filter Romove carburetor Romove hoop Romove water inlet hose of engine Romove inlet and outlet oil hose of engine Remove bolt Romove shift of Gearshift Remove hoop Romove water outlet hose of engine S e p a r a t e b u s h .
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  • Page 208 All manuals and user guides at all-guides.com Battery, Charging System ...
  • Page 209 All manuals and user guides at all-guides.com &)0272 2YHUKDXO LQIRUPDWLRQ 1RWH Usually no hydrogen will be generated during charging except when overcharged. Keep away from fires when charging. Electrolyte is highly corrosive, splash to clothes, skin or eyes will cause burn or loss of sight. Wash with plenty of water if splashed.
  • Page 210 All manuals and user guides at all-guides.com Battery, Charging System Overhaul standard Item Standard magneto Model Permanent magnet alternator Output 3-phase AC Resistance of charging coil (20? ) 0.3Ω Rectifier Type 3-phase loop rectification, controllable parallel connection, regulated voltage Capacity Battery 12V18Ah Current Leakage...
  • Page 211 All manuals and user guides at all-guides.com &)0272 Battery Removal Note: Keep the ignition switch at OFF before operation. Remove: Open the FRONT TOP COVER Remove the rubber tie of battery. Loosen negative pole screw and disconnect negative lead. Remove positive pole cap and screw. Disconnect positive lead Remove battery.
  • Page 212 All manuals and user guides at all-guides.com Battery, Charging System Connect charger’s positive wire to battery’s positive pole. Connect charger’s negative wire to battery’s negative pole. Charging current/time: Standard: 0.9A/5~10hours Fast charge: 4.0A/60mins Note: Keep the electrolyte temperature under 45 . Reduce current to adjust the temperature if it is too high.
  • Page 213 All manuals and user guides at all-guides.com &)0272 Remove fuse box from inside of front fender. Connect amperemeter between battery negative pole and negative lead Measure current leakage with ignition switch at the “OFF” position. Note: If the measured current is higher than the maximum limit, the multimeter will be burnt.
  • Page 214 All manuals and user guides at all-guides.com Battery, Charging System Check the connector terminals for loosening, bending, rust or come-off. Check the following items of the main cable terminals of the two rectifier connectors: Installation: Reverse the removal procedure for installation. Note: Wires, hoses and cables should be routed properly.
  • Page 215 All manuals and user guides at all-guides.com &)0272 AC Magneto inspection Remove engine cover  Remove AC Magneto(yellow,yellow,yellow),pickup coil (black/white,green)connecter. Resistance of Generator Coil Measure resistance between the three lead wires; Replace a new stator coil if resistance not within specified value, Check that the generator core is insulated.
  • Page 216 All manuals and user guides at all-guides.com Battery, Charging System Layout for All Electricity Equipment in Vechile...
  • Page 217 All manuals and user guides at all-guides.com Ignition System Overhaul Info Ignition coil Troubleshooting Starting Motor Inspection of Ignition System Starter, auxiliary relay Pickup Coil Circuit diagram of the ignition system Overhaul information Note: Exhaust gas contains toxicant, DO NOT keep the engine run for a long time in a closed or poorly ventilated place.
  • Page 218 All manuals and user guides at all-guides.com &)0272 Overhaul standard Item Standard Ignition CDI, battery DC digital ignition Spark Plug Standard DPR7EA-9(NG K) O ptional DR8EA, D7RTC Spark plug gap 0.8-0.9m m Ignition tim ing Maxim um advance 34° CA angle Peak voltage Ignition coil...
  • Page 219 All manuals and user guides at all-guides.com Ignition System Troubleshooting Engine cannot be started. Check fuel and air channels for any faults; If the fuel and air channels are normal, check the ignition system. Inspect ignition system for the following items: 1.
  • Page 220 All manuals and user guides at all-guides.com &)0272 Note: If the spark plug generates no spark, check first if there is come-off, loosening or poor contact with the wiring, then measure the peak voltage. Different multimeter has different input resistance and shows different readings.
  • Page 221 All manuals and user guides at all-guides.com Ignition System Primary voltage of the ignition coil Note Make sure that the battery voltage % 12V, and the ignition coil lead is not disconnected. Refer to relevant manuals while using the multi-meter and the peak voltage adapter.
  • Page 222 All manuals and user guides at all-guides.com &)0272 Pickup Coil Note Measure after all the wires are correctly connected. Any wires disconnected can not make the correctly test. Inspect with compression pressure in the cylinder, spark plug and spark plug cap are properly installed. If the spark plug is removed and then do the measurement, the peak voltage will rise Removeengine panel ...
  • Page 223 All manuals and user guides at all-guides.com Ignition System Pickup Remove: — AC magneto connector —Water pump inlet hose and outlet hose, and drain coolant. (Chapter 4) —Crankcase breather hose. (Engine Service) —Muffler. (Chapter 2) — Engine right side cover. (Engine Service) Note: Stator is installed on the right side cover and is attached by the magnet of rotor.
  • Page 224 All manuals and user guides at all-guides.com &)0272 Starting Motor...
  • Page 225 All manuals and user guides at all-guides.com Ignition System Brushes Check brushes for abnormal wear, cracks or moothness in the brush holder. Wear, cracks or non-smoothness: Re- place Commutator Check Commutator for discoloration, abnormal wear or undercut. Abnormal wear or Damage:  Replace If the commutator is discolored, polish with a sand paper and clean with a clean and dry cloth.
  • Page 226 All manuals and user guides at all-guides.com &)0272 Starter Relay Apply 12V to the terminals and check for continuity between the positive and negative terminals using a multimeter. If the starter relay clicks and continuity is found, the starter relay is OK. If there is no continuity when without the 12V, the relay is OK.
  • Page 227 All manuals and user guides at all-guides.com Ignition System Ignition System Diagram...
  • Page 228 All manuals and user guides at all-guides.com Overhaul Information Warning Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down. Inspection of water temperature alarm may use fire source and liquid of high temperature.
  • Page 229 All manuals and user guides at all-guides.com &)0272 TROUBLESHOOTING Head Light Cannot Turn On Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch...
  • Page 230 All manuals and user guides at all-guides.com Replacing Bulb Headlight Bulb Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down.
  • Page 231 All manuals and user guides at all-guides.com &)0272 Brake Light/Tail Light Bulb Remove 2 tapping screws, Remove tail light cover. Turn brake light/tail light bulb counter clockwise andremove it. Replace brake light/tail light bulb Bulb Specification: 12V-21/5W Reverse the removal procedure for installation Front Turning Indicator Bulbs Remove headlight(13-5) Remove cover of front turning light...
  • Page 232 All manuals and user guides at all-guides.com Dashboard Lighter Bulb Remove dashboard (13-9) Remove bulb socket and replace with a new bulb. Bulb specification: 12V-1.7W Note: Main cable and wires should be routed properly (chapter 1) Reverse the removal procedure for installation. Dashboard Indicator Bulb Remove dashboard (13-9) Remove dashboard indicator socket.
  • Page 233 All manuals and user guides at all-guides.com &)0272 Disconnect headlight connector. Reverse the removal procedure for installation. 1 R W H  Be careful not to damage main cable when assembling. After replacing, adjust the headlight beam. chapter 3) Note Main cables and wires should be routed properly.( chapter 1)
  • Page 234 All manuals and user guides at all-guides.com Check according to the following table if the connector terminals are in continuity. Remove: Remove front cover of dashboard (2-5) Remove rear cover of dashboard (2-5) Disconnect 4P connector of ignition switch Remove bolt and ignition switch Reverse the removal procedure for installation &RPELQHG 6ZLWFK  2-5...
  • Page 235 All manuals and user guides at all-guides.com &)0272 +RUQ %XWWRQ 2YHUULGLQJ 6ZLWFK  : '  : '  : ' ' L I I  / R F N 6 Z L W F K Brake Light Switch Disconnect brake light switch connector and check terminators for continuity.
  • Page 236 All manuals and user guides at all-guides.com Dashboard Run the vehicle at low speed and check if the speed indicator moves. Faulty speedometer:Replace Removal and Installation Remove front top cover (2-4) Remove front cover of dashboard Disconnect dashboard wire connector. Remove fixing nut and remove dashboard in the direction as illustrated on the right Reverse the removal procedure for installation.
  • Page 237 All manuals and user guides at all-guides.com &)0272 Fuel Sensor Remove: —Fuel tank top cover with key —4 fixing bolts —Fuel sensor Disconnect 2P connector Inspection Remove fuel sensor (refer to above steps) Connect 2P connector Turn ignition switch to ON Shake fuel sensor float with hand, locate the float po- sition and check if it conforms to the fuel gauge reading.
  • Page 238 All manuals and user guides at all-guides.com Put fuel sensor into installation hole of fuel tank. Fuel sensor should be fitted properly. No fuel leakage is allowed. Connect 2P connector Inspection of Fuel Gauge Switch on power supply and check if fuel level gauge functions normally.
  • Page 239 All manuals and user guides at all-guides.com &)0272 Water Temperature Transducer Warning: Be careful not to get scalded and do not place flammables nearby. Warning Coolant must reach the switch thread, and the depth from vessel bottom to sensor top should be over 40mm.
  • Page 240 All manuals and user guides at all-guides.com &)0272...
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  • Page 242 All manuals and user guides at all-guides.com  )DLOXUH GLDJQRVLV 2 SH U DW L RQ DW W HQ W LR Q &DQQRW VWDUW RU WKH VWDUWLQJ GLIILFXOW\ Arrived...
  • Page 243 All manuals and user guides at all-guides.com &)0272 6WDUWV VHYHUDO PLQXWHV ODWHU HQJLQHV QRW WR EH VWHDG\ IODPHRXW Arrived 15-3...
  • Page 244 All manuals and user guides at all-guides.com  )DLOXUH GLDJQRVLV 15-2 joint the starting enriching to storage battery for 5 minutes, ethene pipe fuel return route blowing ,Q KLJK VSHHG DUHD SRZHU LQVXIILFLHQF\VSHHG FDQQRW JR XS pressure carburetor stop up...
  • Page 245 All manuals and user guides at all-guides.com &)0272 ,GOLQJORZ VSHHG 8QVPRRWK...
  • Page 246 All manuals and user guides at all-guides.com  )DLOXUH GLDJQRVLV ,Q PLGGOHKLJK VSHHG HQJLQH XQVWHDG\...
  • Page 247 All manuals and user guides at all-guides.com &)0272 (QJLQH FRPPRQ IDLOXUH GLDJQRVLV Symptom of failure Cause of Failure Solution measure The cylinder presses is too low Cylinder wear Replacement Piston curl attrition Replacement Air cylinder pad air leakage Replacement The air valve guide wears or the Repair or replacement valve seat is inappropriate Screwing tight...
  • Page 248 All manuals and user guides at all-guides.com  )DLOXUH GLDJQRVLV Symptom of failure Cause of Failure Solution measure The valve spring tension weakens Replacement Cam shaft attrition Replacement Spark plug dirty Cleaning up or replacement The spark plug gap is too small Adjustment or replacement Matches was mad that the timing is not Replacement...
  • Page 249 All manuals and user guides at all-guides.com &)0272 Symptom of failure Cause of Failure Solution measure Cylinder valves abnormal sound The valve clearance is too big Adjustment The valve spring wears or breaks off Replacement Rocking shaft or cam shaft attrition Replacement Piston abnormal sound Piston wear...
  • Page 250 All manuals and user guides at all-guides.com  )DLOXUH GLDJQRVLV Carburetor Symptom of failure Cause of Failure Solution measure Torch-igniter assembly jamming Cleaning up Torch-igniter assembly channel jamming Cleaning up Carburetor actuating section Fastening, adjustment Starting difficulty attachment point air leakage replacement seal The starting fills the work bad Adjustment...