CF MOTO ZFORCE 500 Owner's Manual
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CF MOTO ZFORCE 500 Owner's Manual

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All manuals and user guides at all-guides.com
READ THIS MANUAL CAREFULLY
It contains important safety information
CF500US (ZFORCE 500)
4X4
This ATV should not be ridden
by anyone under 16 years of age.

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Summary of Contents for CF MOTO ZFORCE 500

  • Page 1 All manuals and user guides at all-guides.com READ THIS MANUAL CAREFULLY It contains important safety information CF500US (ZFORCE 500) This ATV should not be ridden by anyone under 16 years of age.
  • Page 2 All manuals and user guides at all-guides.com WELCOME Thank you for purchasing a CFMOTO vehicle, and welcome to our world-wide family of CFMOTO enthu- siasts. Be sure to visit us online at www. CFMOTO. com for the latest news, new product introductions, upcoming events, career opportunities and more.
  • Page 3 All manuals and user guides at all-guides.com WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 4: Foreword Foreword

    All manuals and user guides at all-guides.com Rider Safety Signal words A word that calls attention to a safety message or messages, or a property damage message or messages, and designates a degree or level of hazard seriousness. The signal words in this stan- dard are DANGER, CAUTION and NOTICE.
  • Page 5 All manuals and user guides at all-guides.com WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could resullt in serious injury or death. WARNING Improper operation of this vehicle could result in serious injury or death.
  • Page 6 All manuals and user guides at all-guides.com ALWAYS USE AN APPROVED, SUITABLE HELMET AND PROTECTIVE GEAR FOR OP- ERATOR AND PASSENGER. NEVER USE DRUG OR ALCOHOL BEFORE OR WHEN RIDING.

  • Page 7: Introduction

    All manuals and user guides at all-guides.com Introduction Thank you for purchasing a CFMOTO vehicle. This Owner’s Manual is intended to acquaint the owner/operator with the various vehicle con- trols and safe operating instructions. It contains important safety information, driving skills, along with basic maintenance and inspection procedures.
  • Page 8 All manuals and user guides at all-guides.com Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only.

  • Page 9: Table Of Contents

    All manuals and user guides at all-guides.com Table of Contents FOREWORD FOREWORD ......................Rider safety......................Introduction......................SAFETY INFORMATION GENERAL PRECAUTIONS..................13 Avoid Carbon Monoxide Poisoning..............13 Avoid Gasoline Fires and Other Hazards............. 13 Avoid Burns from Hot Parts................. 14 Accessories and Modifications................14 SAFE OPERATION - RESPONSIBILITIES..............
  • Page 10 All manuals and user guides at all-guides.com PREPARE TO RIDE....................23 Before you Go....................23 Riding Gear......................23 AVOID ACCIDENTS....................24 Avoid Rollovers and Tipovers................24 Avoid Collisions....................26 RIDING YOUR VEHICLE..................26 Practice Exercises....................26 Off-Road Operation..................... 28 General Riding Techniques.................. 29 MOVING LOADS AND DOING WORK..............
  • Page 11 All manuals and user guides at all-guides.com Throttle Pedal...................... 43 Brake Pedal......................44 Shift Lever......................44 SECONDARY CONTROLS..................46 Ignition Switch....................46 Horn Switvh..................... 47 H/L Beam Switch....................48 2WD/4WD Switch.................... 49 Override Switch....................50 Front Hood..................... 50 Winch Switch..................51 Hazard Switch.....................
  • Page 12 All manuals and user guides at all-guides.com Tool Kit........................ 59 Glove Compartment................... 59 Passenger Handholds..................60 Driver Seat......................60 Passenger Seat....................60 Seat Belts......................61 Winch......................... 61 Fuel Cap......................61 Anchoring Hooks....................61 Hitch Support...................... 61 Cargo Box......................61 SUSPENSION......................61 Suspension Adjustment Guideline..............
  • Page 13 All manuals and user guides at all-guides.com Starting the Engine..................... 67 Shifting the Transmission..................67 SPECIAL PROCEDUES..................68 Cleaning the CVT Inlet..................68 What to do if Water Collects in CVT..............68 What to do if Vehicle is Submerged..............68 Transporting the Vehicle..................
  • Page 14 All manuals and user guides at all-guides.com Fuses........................86 Lights........................88 Drive Shaft Boots....................89 Wheel Bearing....................89 Wheel and Tires....................89 Suspension......................90 Brakes........................ 90 Throttle Body...................... 92 Valve Clearance Adjustment................92 VEHICLE IDENTIFICATIONS VEHICLE IDENTIFICATIONS.................. 93 Engine Identification Number................93 Vehicle Identification Number................
  • Page 15 All manuals and user guides at all-guides.com WIRING DIAGRAM...

  • Page 16: General Precautions

    All manuals and user guides at all-guides.com General Precautions Avoid Gasoline Fires and Other Hazards Gasoline is extremely flammable and highly ex- Avoid Carbon Monoxide Poisoning plosive. Fuel vapors can spread and be ignited All engine exhaust contains carbon monoxide, by a spark or flame many feet away from the a deadly gas.

  • Page 17: Avoid Burns From Hot Parts

    All manuals and user guides at all-guides.com – water and change your clothes. and familiarize yourself with their function and effect on the vehicle. Avoid Burns from Hot Parts The exhaust system and engine become hot during operation. Avoid contact during and Safe Operation - Responsibilities shortly after operation to avoid burns.

  • Page 18: Operator - Be Qualified And Responsible

    All manuals and user guides at all-guides.com Operator - Be Qualified and Responsible Carrying Passenger Read this Owner’s Manual and the warning Only carry one passenger. The passenger must decals on this vehicle carefully. Take a safety be properly seated in the passenger seat. training on open areas if available.

  • Page 19: Riding Carefully

    All manuals and user guides at all-guides.com Riding Carefully der to reduce the chance of skidding out of – This vehicle is not a toy and can be hazard- control. ous to operate. This vehicle handles differ- – Always be sure there are no obstacles or ently from other vehicles, such as motor- people behind the vehicle when reversing.

  • Page 20: Occupant Restraint System

    All manuals and user guides at all-guides.com Do not put your hands and/or feet outside of – Never operate on excessively rough, slippery the vehicle when driving. The ROPS will not or loose terrain until you have learned and protect you from injury in all rollovers. practiced the skills necessary to control this Always have your authorized CFMOTO dealer vehicle on such terrain.
  • Page 21 All manuals and user guides at all-guides.com tion dry out the brakes. – Always ensure to properly park the vehicle on the flattest terrain section available. Put shift lever in PARK, stop engine, remove key before leaving the vehicle. – Never assume that the vehicle will go ev- erywhere safely.

  • Page 22: Pre-Ride Inspection Check List

    All manuals and user guides at all-guides.com...
  • Page 23 All manuals and user guides at all-guides.com ITEM INSPECTION TO PERFORM REMARKS Cargo Load: If you transport a cargo, respect the rear cargo box capacity of 100 kg(220.31 lb). Ensure cargo is properly secured to the rear cargo box. Vehicle Load: Ensure that total load on the vehicle (in- cluding operator, passenger, cargo and added cargo and load accessories) does not exceed 315 kg( 694lb ).
  • Page 24 All manuals and user guides at all-guides.com What to Do Before Starting the Engine (Key ON) ITEMS INSPECTION TO PERFORM REMARKS Check operation of indicator lights in dashboard. Dashboard Check for messages in dashboard. Check cleanliness of headlights, taillights, turn signals, posi- tion lights and reflectors.
  • Page 25 All manuals and user guides at all-guides.com What to Do After the Engine is Started ITEMS INSPECTION TO PERFORM REMARKS Check if steering operates freely by completely turning it Steering from side to side. Turn the ignition switch to OFF to verify if engine will Ignition switch shut down.

  • Page 26: Prepare To Ride

    All manuals and user guides at all-guides.com Prepare To Ride can shatter or fly off, and they allow wind and airborne objects to reach the eyes. A Before you Go helmet with face protection or a pair of Perform pre-ride inspection to confirm the safe goggles offer better eye protection.

  • Page 27: Avoid Accidents

    All manuals and user guides at all-guides.com 3. Gloves vehicles designed for use primarily on paved or smooth terrain may not. A pair of off-road gloves with knuckle pro- tection can protect your hands in the event A rollover or other accident can occur quickly of an accident or a rollover.
  • Page 28 All manuals and user guides at all-guides.com * Never attempt donuts, skids, slides, fishtails, steer downhill if possible. jumps, or other stunts. If vehicle starts to * Avoid steep hills and follow procedures in skid or slide, steer in the direction of the skid this manual for climbing and descending or slide.

  • Page 29: Avoid Collisions

    All manuals and user guides at all-guides.com can be crushed between the cage and the is particularly important to fasten seat belts ground in a rollover. Keep hands on the and latch side doors and wear proper riding steering wheel or handholds. gear.
  • Page 30 All manuals and user guides at all-guides.com when turning. steering inputs and always at a very low speed. * Repeat turning exercise but this time main- tain the throttle at the same level while turn- * Repeat U turn exercise on the other side. ing.

  • Page 31: Off-Road Operation

    All manuals and user guides at all-guides.com role. * While running at low speed, simply turn the ignition key to the off position. Reverse Exercises This is to familiarize you with the vehicle’s The next step involves using the reverse. reaction when the engine is turned off while * Install 1 cone marker on both sides of the driving and to develop this reflex.

  • Page 32: General Riding Techniques

    All manuals and user guides at all-guides.com operated on steep or treacherous terrain. General Riding Techniques WARNING General Driving Tips Steering inputs in reverse operation in- Care, caution, experience and driving skill are crease the risk of rollover. the best precautions against the hazards of ve- hicle operation.
  • Page 33 All manuals and user guides at all-guides.com trails as they are designated specifically for Water will affect the braking ability of your ve- those uses. hicle. Make sure you dry the brakes by apply- ing them several times after the vehicle leaves the water.
  • Page 34 All manuals and user guides at all-guides.com Riding on Sand Riding on Gravel, Loose Stones or Other Slippery Surfaces Sand and riding on sand dunes is another unique experience but there are some basic Riding on loose stones or gravel is very similar precautions that should be observed.
  • Page 35 All manuals and user guides at all-guides.com sible at a right angle. Adjust speed without los- Uphill Driving ing momentum and do not accelerate abruptly. Use the low range (L) for uphill driving. Due Passenger must grasp handholds firmly and to its configuration, this vehicle has very good brace feet on the floor.
  • Page 36 All manuals and user guides at all-guides.com Downhill Driving This vehicle can climb steeper slopes than it can descend safely. Therefore, it is essential to assure that a safe route exists to descend a slope before you climb it. Decelerating while negotiating a slippery downhill slope could “to- boggan”...
  • Page 37 All manuals and user guides at all-guides.com Side Hilling WARNING Improper side hilling or turning on hills could cause the vehicle to be out of control or roll over and may result in serious injury or death. Whenever possible, side hilling (driving across a slope rather than up or down it) should be avoided.

  • Page 38: Moving Loads And Doing Work

    All manuals and user guides at all-guides.com Observe the rule... “what you take in, carry out” . Do not litter. Moving Loads and Doing Work Working with your Vehicle Your vehicle can help you perform a number of different light tasks ranging from snow removal to pulling wood or carrying cargo.
  • Page 39 All manuals and user guides at all-guides.com Vehicle Settings When Carrying Load Tilting the Cargo Box When the total load exceeds 315 kg, including The cargo box can be tilted to ease unloading. weight of operator, passenger, cargo, accesso- Use release handles on either side of cargo ries and trailer tongue weight, inflate the tires box.

  • Page 40: Hauling A Load

    All manuals and user guides at all-guides.com To lower the cargo box, simply push on the WARNING cargo box. Slack can cause the chain or cable to break WARNING and snap back. * Keep yourself and others clear of the When pulling another vehicle, be sure that cargo box and vehicle frame junction someone is controlling the pulled vehicle.

  • Page 41: Warning Decals And Location

    All manuals and user guides at all-guides.com hauling capacity and maximum tongue load. MAXIMUM HAULING CAPACITY Make sure there is at least some weight on Type of Trailer Tongue the tongue. Attach- Load Weight Note Always make sure load is evenly distributed ment Allowed Allowed...
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  • Page 46: Primary Controls

    All manuals and user guides at all-guides.com 2) Throttle pedal Primary Controls 1) Steering Wheel The throttle pedal is located on the right side of the brake pedal. The steering wheel is located in front of the The throttle pedal controls the engine speed. operator’s seat.

  • Page 47: Brake Pedal

    All manuals and user guides at all-guides.com 3) Brake Pedal 4) Shift Lever The brake pedal is located on the left side of The shift lever is located on the right of the the throttle pedal. driver’s seat.The shift lever is used to change the gearbox position.
  • Page 48 All manuals and user guides at all-guides.com Shift Button High Range This position selects the high speed range Press shift button before shifting the gear. of the gearbox. It is the normal driving speed L Range range. It allows the vehicle to reach its maxi- This position selects the low speed range of mum speed.

  • Page 49: Secondary Controls

    All manuals and user guides at all-guides.com Park Ignition switch has 3 positions. Use a key to control the ignition switch and then start the The park position locks the gearbox to help engine. prevent vehicle movement. When the key is in the position of “OFF” , it can WARNING be removed from the ignition switch.

  • Page 50: Horn Switvh

    All manuals and user guides at all-guides.com Headlight, dashboard light, and position lights go on when light switch is in this position. Dashboard light, and position lights go on when light switch is in this position. Headlight, dashboard light, and position •...

  • Page 51: H/L Beam Switch

    All manuals and user guides at all-guides.com 1. High /low beam indicator 2. Light switch...

  • Page 52: 2Wd/4Wd Switch

    All manuals and user guides at all-guides.com 2WD/ 4WD Switch b CAUTION This switch selects 2 Wheel Drive or 4 Wheel The vehicle must be stopped to engage Drive mode when the vehicle is stopped and o r d i s e n g a g e b o t h 2 W D / 4 W D a n d the engine is running.

  • Page 53: Override Switch

    All manuals and user guides at all-guides.com The override switch main function is to – When 4WD/LOCK is set to LOCK, the indi- bypass the engine speed limiter in 4WD cator blinks constantly until 4WD LOCK is LOCK operation by allowing maximum engine engaged.

  • Page 54: Winch Switch

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  • Page 55: Dc Outlets

    All manuals and user guides at all-guides.com 12V DC Outlets 1. SET button 2. Clock button To reset the clock: 1. 12V DC outlet This vehicle has 1 DC outlet. 1. Press and release clock button once to ad- Output voltage:12 V vance the setting by one hour.

  • Page 56: Multifunction Meter

    All manuals and user guides at all-guides.com 1. Metric/Imperial Units Multifunction Meter To switch between metric and imperial General Description units, press the “SET“ button once in ODO Coolant temperature gauge mode. When coolant temperature gauge is in green 2. Trip Meter Mode zone or at the “C“...
  • Page 57 All manuals and user guides at all-guides.com Odometer Indicates the total milage the vehicle has traveled. Press mode button to toggle to TRIP meter, or tachometer, or imperial units mode. 4WD indicator : When 2WD/4WD switch is set to 4WD, this indicator will be on.
  • Page 58 All manuals and user guides at all-guides.com L range indicator Hi beam indicator 2 This indicator lights up when gearbox is in L This indicator lights up when high beam is range. selected. P indicator 3 H range indicator This indicator lights up when parking is engaged.
  • Page 59 All manuals and user guides at all-guides.com Oil pressure warning indicator NOTE If this indicator lights up when engine revs If indicator light goes on or speedometer over 1000 rpm, it indicates engine oil is not does not work, please have your dealer check enough or oil pressure is too low.

  • Page 60: Equipment

    All manuals and user guides at all-guides.com...
  • Page 61 All manuals and user guides at all-guides.com...

  • Page 62: Footrests

    All manuals and user guides at all-guides.com 1) Footrests The vehicle is equipped with driver and passenger footrests to allow firmly planting feet on vehicle floor, which helps to maintain proper body position while riding. The footrests help minimize the risk of leg or foot injury.

  • Page 63: Passenger Handholds

    All manuals and user guides at all-guides.com To adjust seat, move the seat lever to unlock 5) Winch Cable Control Connector This vehicle comes with a winch cable control, the seat. Release the lever to lock the seat which is designated to use when the winch into desired position.

  • Page 64: Winch

    All manuals and user guides at all-guides.com Seat belt indicator light will flash if seat belt is of the vehicle behind the passenger seat. not fastened during driving. Capacity: 27L 16) Cargo Box 12) Anchoring Hooks Refer to the safety decals on cargo box for To provide anchoring point in order to secure loads information.

  • Page 65: Fuel

    All manuals and user guides at all-guides.com To adjust suspension, observe the following rules: – Return to factory setting after loads are re- leased. – Ensure to adjust each shock spring on the same cam position. If the vehicle carrying loads are low, do not ad- just suspension to the highest position or the second highest position.

  • Page 66: Vehicle Fueling Procedure

    All manuals and user guides at all-guides.com Vehicle Fueling Procedure WARNING 1. Stop the engine. Fuel is flammable and explosive under certain 2. Have the driver and passenger get off the conditions. Be careful whenever using gaso- vehicle. line: 3. Unscrew slowly the fuel tank cap counter- –...

  • Page 67: Break-In Period

    All manuals and user guides at all-guides.com Break-In Period Preparations before driving: – Refuel if necessary. Operation During Break-In A break-in period of 20 operating hours or 750 – Place the vehicle on a level ground. Check km is required for this vehicle. the engine oil level.

  • Page 68: Pre-Ride Inspection

    All manuals and user guides at all-guides.com Pre-Ride Inspection WARNING Fuel is flammable and explosive under certain conditions. PRE-RIDE INSPECTION ITEMS INSPECTION TO PERFORM REMARKS Brake system/brake pedal Check the operation. Brake fluid Check the fluid level. Front suspension Check the operation. Lubricate if necessary. Rear suspension Check the operation.

  • Page 69: Basic Procedures

    All manuals and user guides at all-guides.com Indicators/switches Check the operation. Air filter element Inspect and clean. Air filter moisture catch tube Clean the liquids or sediment if visible. Headlights Check the operation. Brake/tail light Check the operation. Riding gear Wear helmet, gloves and protective clothes.

  • Page 70: Starting The Engine

    All manuals and user guides at all-guides.com Cold starting: CAUTION 1. Press down the brake pedal. – If engine does not start after a few sec- 2. Turn the ignition switch to “ “ . onds, do not keep the ignition switch in “ 3.

  • Page 71: Special Procedues

    All manuals and user guides at all-guides.com WARNING Stopping the Engine and Parking the Ve- Always put the vehicle in PARK when stopped hicle or parked to prevent rolling. WARNING Avoid parking on steep slope as the vehicle Special Procedures may roll away.

  • Page 72: What To Do If Vehicle Is Submerged

    All manuals and user guides at all-guides.com Transporting the Vehicle CAUTION CAUTION Have your dealer check this vehicle after you drain the water, as the residual water Do not transport the vehicle with it erected. could damage other engine components. If your vehicle needs to be transported, pro- ceed as follows: What to do if Vehicle is Submerged...

  • Page 73: Maintenance Schedule

    All manuals and user guides at all-guides.com Maintenance Schedule Maintenance is very important for keeping your vehicle in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual. Inspect, clean, lubricate, adjust and replace some components when necessary. Always use genuine spare parts.

  • Page 74: Maintenance Chart Key

    All manuals and user guides at all-guides.com Severe Use Definition – Frequent immersion in mud, water or sand – Racing or race-style high RPM use – Prolonged low speed, heavy load operation – Extended idle – Frequent short trip in wold weather Pay special attention to the oil level.

  • Page 75: Lubrication Recommendations

    All manuals and user guides at all-guides.com Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication intervals. Lubrication Chart ITEM LUBE...

  • Page 76: Maintenance Procedures

    All manuals and user guides at all-guides.com Maintenance Procedures Air Filter NOTE The air filter comes installed with a moisture catch tube. If dust or liquids collect in this tube, clean out this tube, air filter element and air filter housing. If a large amount of wa- ter is present in the air filter, have your dealer check for water entering crankcase.

  • Page 77: Spark Arrester

    All manuals and user guides at all-guides.com 6. Lightly clean out the dust collects on the CAUTION paper element. Do not start the engine without air filter. 7 . Replace the air filter as needed. Otherwise unfiltered air will enter the en- CAUTION gine and engine premature wear or even damage may occur.

  • Page 78: Engine Oil

    All manuals and user guides at all-guides.com the arrester screen. 1. Remove the passenger seat. 4. Insert the spark arrester into the muffler 2. Place the vehicle on the plain ground. and align the screw holes. 3. Start the engine and allow it to idle for 20 5.
  • Page 79 All manuals and user guides at all-guides.com NOTE Engine oil level should be between the upper and lower marks. 7 . If the engine level is below the lower mark, add oil to proper level. 8. Insert the oil dipstick and fully tighten it. 9.
  • Page 80 All manuals and user guides at all-guides.com 4. Use a new drain bolt washer and tighten it to specified torque. NOTE Drain bolt washer tightening torque: 30 N·m 5. Add recommended oil to specified level and then screw in the oil dipstick. NOTE –...

  • Page 81: Rear Gearcase Oil

    All manuals and user guides at all-guides.com Rear Gearcase Oil 7 . Check for oil leaks. If oil leakage is present, troubleshoot the failure. Check the rear gearcase for oil leaks prior to each use. If oil leakage is present, have your dealer determine the cause.

  • Page 82: Front Differential Oil

    All manuals and user guides at all-guides.com Front Differential Oil To Change the Front Differential Oil 1. Place the vehicle on a level surface. To Check the Front Differential Oil 2. Place an oil pan under the front differential 1. Place the vehicle on a level surface. to collect the used oil.

  • Page 83: Cooling System

    All manuals and user guides at all-guides.com Cooling System 3. If the coolant level in the coolant reservoir is below the lower mark, open the coolant To Check the Coolant Level reservoir cap and add coolant to the upper mark. Reinstall the coolant reservoir cap and other removed parts.
  • Page 84 All manuals and user guides at all-guides.com With vehicle on a level surface and engine To Change the Coolant cold, proceed as follows: 1. Place an container under the engine to col- lect the used oil. 2. Remove the coolant drain plug #1. 3.
  • Page 85 All manuals and user guides at all-guides.com NOTE CAUTION Remove the thermostat cover screw before Tap water or sea water is harmful for the en- filling the coolant. This would help to bleed gine. Always use recommended coolant. the air trapped in cooling system. Install the 9.

  • Page 86: Spark Plugs

    All manuals and user guides at all-guides.com Spark Plugs Access to Spark Plugs 1. Tilt the rear cargo box to access to spark plug of the first cylinder. 2. Remove air filter housing cover to access to spark plug of the second cylinder. Spark Plug Removal 1.
  • Page 87 All manuals and user guides at all-guides.com The ideal color of the porcelain insulator around the center electrode is a medium-to- light tan for a vehicle that is being ridden nor- mally. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 88: Battery

    All manuals and user guides at all-guides.com Battery Spark Plug Installation 1. Measure the spark plug gap with a feeler The battery is located under the front hood. gauge and, if necessary, adjust the gap to It is a maintenance-free type battery(AGM), specification.

  • Page 89: Fuses

    All manuals and user guides at all-guides.com milk. Follow with milk of magnesia, beaten 2. Ensure to the cables are properly routed egg, or vegetable oil. Seek prompt medical at- when installing the battery. tention. Fuses EYES: Flush with water for 15 minutes and get Fuse replacement prompt medical attention.
  • Page 90 All manuals and user guides at all-guides.com switch. Install the specified fuse and turn FUSE RATING on the ignition switch. If the fuse is blown Main fuse again, consult your dealer. Fuel pump/EFI/ignition power supply/auxiliary starter relay CAUTION Turn signal/position light/ Always use a fuse of the specified amper- dashboard/ horn/diff.

  • Page 91: Lights

    All manuals and user guides at all-guides.com Lights To adjust high beam, turn the screw #1. To adjust low beam, turn the screw #2. Always check light operation prior to each use. Replacing a headlight bulb If a headlight bulb burns out, replace it as fol- lows 1.

  • Page 92: Drive Shaft Boots

    All manuals and user guides at all-guides.com 1. Brake/tail light 1. Inner CV joint 2. Outer CV joint Drive Shaft Boots Wheel Bearing Drive Shaft Boot Inspection Wheel Bearing Inspection Check drive shaft boots for cracks, tears, Lift the vehicle and support it securely. leaking grease, etc.

  • Page 93: Wheel And Tires

    All manuals and user guides at all-guides.com Wheels and Tires Wheel Removal 1. Place the vehicle on a level surface. 2. Elevate the vehicle and place a suitable stand under the frame. 3. Remove the wheel nuts #1. 4. Remove the wheel. Wheel Installation Install the wheel and wheel nuts.
  • Page 94 All manuals and user guides at all-guides.com 1. Place the vehicle on a level surface when NOTE checking the brake fluid level through the Recommended brake fluid: DOT3 or DOT4 fluid level check window. 1. Refill with the same type of brake fluid. 2.

  • Page 95: Throttle Body

    All manuals and user guides at all-guides.com Throttle Body Idle Speed Throttle body is an important engine compo- The idle speed is controlled by EFI system and nent, which, requires professional adjustment. it does not require any adjustment. Have your dealer perform the adjustment as Improper adjustment of idle speed may affect they have professional knowledge and experi- the engine performance.

  • Page 96: Vehicle Identifications Vehicle Identifications

    All manuals and user guides at all-guides.com Record your vehicle identification number(VIN) and engine identification number(EIN) in the spaces provided. Remove the spare key and store it in a safe place. You can only use your existing key to duplicate a new one.

  • Page 97: Vehicle Identification Number

    All manuals and user guides at all-guides.com 1. Engine identification number: 2. Vehicle identification number:...
  • Page 98 All manuals and user guides at all-guides.com EPS Trouble Code Table Item No Diagnosis Solution Trouble Code Main torque sensor disconnected Check the wiring harness of sensor Main torque sensor output error(volta- Check the wiring harness of sensor ge is too high or low) Secondary Sensor disconnected Check the wiring harness of sensor Secondary torque sensor output error...
  • Page 99 All manuals and user guides at all-guides.com EPS fault diagnosis and solution Repair procedures Possible causes Ref No Trouble shooting Improper plug connection Check the plugs and connections No steering assist Burnt fuse Replace fuse(30A) to handlebar Contact authorized dealer and repl- Failure of Controller, Motor or sensor ace the parts.
  • Page 100 All manuals and user guides at all-guides.com EPS system EPS indicator on the Dashboard will be on when EPS system ① is equipped to the vehicle. Normally, EPS indicator will be on ② after ignition switch is turned to ON but EPS will not work.When the eng- ine is started, EPS indicator will be off ③...

  • Page 101: Specifications

    All manuals and user guides at all-guides.com ITEM CF500US Length 2870 mm Width 1310 mm Height 1790 mm Wheelbase 2040 mm Min. ground clearance 287 mm Min. turning radius 9500 mm Curb weight: 556±15 kg with fuel and oil Engine model 191R Type V-twin, 4-stroke, liquid-cooled, 4 valves, SOHC...
  • Page 102 All manuals and user guides at all-guides.com Engine oil: Grade SAE15W-40/SG Oil change: Oil change with oil filter replacement 2.9 L Overhaul 3.0 L Oil radiator: Oil replenishment after first start Oil replenishment after service 0.45 Rear gearcase oil: Grade SAE80W90 GL-4 Capacity: Periodic change...
  • Page 103 All manuals and user guides at all-guides.com Throttle body type: 0GRB-173000 Spark plug: Type DCPR8E(NGK) Spark plug gap 0.8 ~ 0.9 mm Clutch Wet, centrifugal Transmission type CVT + gearbox Shift operation Left hand/L-H-N-R-P Transmission CVT ratio 0.67 3.02 Low gear 38/15 = 2.533 Gearbox High gear...
  • Page 104 All manuals and user guides at all-guides.com Front Suspension: Type Double swing-arm Suspension travel Coil spring/oil damping or coil spring + gas spring/oil Shock type damping Rear Suspension: Type Double swing-arm Suspension travel Coil spring/oil damping or coil spring + gas spring/oil Shock type damping Cooling system:...
  • Page 105 All manuals and user guides at all-guides.com Battery Ca- 12V 30Ah pacity Neutral indicator light Green/diode Reverse indicator light Red/diode Park indicator light Red/diode High range indicator light Yellow/diode Low range indicator light Yellow/diode Panel light Color LCD Dashboard High beam indicator light Blue/diode Override indicator light Red/diode...
  • Page 106 All manuals and user guides at all-guides.com EPS specification Ref No Item Specification Motor type DC Permanent Magnet Motor Rated voltage 12 V 35 A Max. Input Current to Controller Motor Power 220 W 2N . m Max. Output Torque Worm reducer Reducer Type Reduction Ratio...
  • Page 107 All manuals and user guides at all-guides.com Troubleshooting Guidelines Drive Belt Wear/Burn POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. Drive at a higher speed or use low range more Driving at low RPM or ground speed (5 10 km/h) frequently.
  • Page 108 All manuals and user guides at all-guides.com Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to Climbing over large objects from a stopped posi- engage clutch. tion WARNING: Excessive throttle may cause loss of control and vehicle overturn.
  • Page 109 All manuals and user guides at all-guides.com Shift the transmission to low range and carefully use fast, aggressive throttle application to en- Stuck in mud or snow gage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn. Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to Climbing over large objects from a stopped posi-...
  • Page 110 All manuals and user guides at all-guides.com Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Engine Pings or Knocks POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range...
  • Page 111 All manuals and user guides at all-guides.com Kinked or plugged fuel tank vent line Inspect and Kinked or plugged fuel tank vent line replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer POSSIBLE LEAN FUEL CAUSE SOLUTION...
  • Page 112 All manuals and user guides at all-guides.com Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 V Incorrect fuel Replace with fresh recommended fuel...
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  • Page 119 All manuals and user guides at all-guides.com 3. EXCLUSIONS FROM WARRANTY COVERAGE. Any Damage resulting from the following acts or circum- stances is not covered by the CFMOTO POWERSPORTS, Inc., Limited Warranty: - Fire - Collision - Theft - Unavoidable natural disasters - Improper storage or transportation - Failure or negligence in the performance of periodic vehicle maintenance - Improper or negligent use or operation...
  • Page 120 All manuals and user guides at all-guides.com 6. WARRANTY REGISTRATION. The Dealer must register the vehicle online and provide the completed registration form to CFMOTO POWERSPORTS, Inc., within seven (7) days of completing the sale of the vehicle. Please note that NO warranty claims will be processed unless the product warranty online registra- tion form is completed and the form is received by CFMOTO POWERSPORTS, Inc., from the Dealer.
  • Page 121 All manuals and user guides at all-guides.com WRITTEN LIMITED WARRANTY. 12. INTEGRATION. This limited warranty supersedes any and all oral, express, or written warranties, statements, or undertakings that may previously have been made, and contains the entire agree- ment of the parties with respect to the warranty of CFMOTO vehicles. Any and all warranties not contained in this Agreement are specifically excluded.
  • Page 122 All manuals and user guides at all-guides.com U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the CFMOTO Powersports, Inc. standard limited warranty for your vehicle. CFMOTO Powersports, Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms to applicable U.S.
  • Page 123 All manuals and user guides at all-guides.com • Electronic control units The following parts are considered emission-related components for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* •...
  • Page 124 All manuals and user guides at all-guides.com The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of CFMOTO Power- sports, Inc., repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 125 All manuals and user guides at all-guides.com acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. CFMOTO Powersports, Inc. recommends that you contact an authorized CFMOTO Powersports, Inc.
  • Page 126 All manuals and user guides at all-guides.com TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 127 All manuals and user guides at all-guides.com INSPECTION SERVICING MUST BE CARRIED OUT ACCORDING TO THE SCHEDULE DE- FINED IN THE PRODUCTS USE AND MAINTENANCE BOOKLET REGISTRATION CARD INSPECTION NUMBER Date k m/Miles Stamp and Signature of the Dealer...
  • Page 128 All manuals and user guides at all-guides.com k m/Miles...
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  • Page 130 All manuals and user guides at all-guides.com EMISSION CONTROL SYSTEM WARRANTY: CFMOTO Powersports, Inc. warrants to the ultimate purchaser and each subsequent purchaser of each 2013 and later model CFMOTO ROV covered by this warranty that vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards appli- cable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below.
  • Page 131 All manuals and user guides at all-guides.com Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. MAINTENANCE INTERVAL REMARKS ITEM (WHICHEVER COMES FIRST) Hours Calendar (MILES) ■ Steering wheel — Pre-ride — ► Front suspension — Pre-ride —...
  • Page 132 All manuals and user guides at all-guides.com Check at the first 20 h or 750 km. Coolant — Replace every 2 years or 6000 km 1500(932) or 200 h. Headlights/tail lights Daily Check the operation. ►  Air filter element —...
  • Page 133 All manuals and user guides at all-guides.com ■ Steering system Lubricate (372) ► Front suspension Lubricate (372) ► Rear suspension Lubricate (372) Shift linkage Inspect, lubricate, adjust (372) Inspect, lubricate, adjust. Replace if ■ Throttle cable (372) necessary. ■ Drive belt —...
  • Page 134 All manuals and user guides at all-guides.com Radiator, radiator cap, Inspect at the first 750 km or 20 h. ► 200h 6000 (3728) cooling system pressure Clean the radiator fins as needed. ► 3000 Coolant hoses 100h — Inspect at the first 750 km or 20 h. (1864) ►...
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