CF MOTO CF500 Manuals

Manuals and User Guides for CF MOTO CF500. We have 1 CF MOTO CF500 manual available for free PDF download: Service Manual

CF MOTO CF500 Service Manual (259 pages)

Brand: CF MOTO | Category: Offroad Vehicle | Size: 9.66 MB

Index
2
Conversion Table
3
Cautions
4
Cautions for Disassembling and Assembling
4
VIN Number and Engine Number
7
Main Data Table
8
Overhaul Datasheet
10
Lubricating Device
10
Fuel Device
10
Cooling Device
10
Front Wheel
11
Rear Wheel
11
Brake System
11
Ignition System
11
Light Instrument Switch
12
Tightening Torque
13
Lubricant, Sealing Agent
14
Cable Routing
15
Vehicle Body, Muffler
19
Operation Cautions
19
Loud Exhaust Noise
19
Insufficient Power
19
Front Rack, Bolt Cap
20
Seat
21
Seat Support, Rear Rack
21
Ornament Panel, Front Rack
22
Ornament Panel, Rear Rack
22
Front Top Cover
22
Rear Top Cover
23
Left Side Panel
24
Right Side Panel
25
Top Cover, Fuel Tank
26
Front Fender
26
Left Footrest Board
27
Right Footrest Board
27
Rear Fender
28
Engine Skid Plate
29
Double Seat Protection Plate
29
Front Right Inner Fender
30
Front Left Inner Fender
30
Front Left Protector
30
Front Right Protector
30
Rear Left Protector
31
Rear Right Protector
31
Bumper, Bumper Protector
31
Bumper Protector
32
Bumper Cap
32
Front Vent Grille
33
Fuel Tank
33
Fuel Tank Bottom Plate
34
Muffler
35
Visible Parts
36
Overhaul Info
37
Periodic Maintenance Table
37
Steering Stem
41
Front Brake Lever Free Play
41
Master Cylinder
42
Brake Disc, Brake Pad
42
Change the Brake Fluid
42
Wheels
43
Front Toe-In-Size
43
Tire Pressure
44
Specified Pressure Tire
44
Tire Tread
44
Wheel Nut and Wheel Axle
45
Sway of Wheel Bearing
45
Suspension System
45
Adjusting the Absorber
46
Gear Shifting
46
Status of the Fuel System
46
Checking the Throttle Lever
47
Adjusting the Speed Limiter
47
Coolant Level
48
Recommended Coolant
49
Standard Density
49
Coolant Leakage
49
Check Water Temperature Gauge
50
Lighting System
50
Adjusting Headlight Light Beam
50
Sharp Rise of Water Temperature
52
Checking Coolant Density
53
Inspection of Radiator Cap
53
Opening Pressure of Radiator Cap
53
Pressure Testing of Cooling System
54
Replacing Coolant, Air Discharge
54
Standard Density of Coolant
54
Remove Drain Bolt
55
Reservoir Tank
55
Adding Coolant
56
Air Discharge
56
Cooling System Chart
57
Engine Removal
59
Engine Installation
62
Removal and Installation of Front and Rear Axle
62
Gearshift Unit
64
Heavy Steering
66
Wheel Cannot Turn Freely
66
Front Suspension Is too Soft
66
Shaking Handlebar
66
Brake Disc
69
Brake Hose T-Pipe
70
Brake Hose Cross Pipe
70
Front Suspension System
71
Front Left Suspension
71
Suspension Arms
73
Front Right Arm
73
Ball Pin
73
Right Steering Knuckle
73
Constant Velocity Drive Shafts
75
Left Constant Velocity Drive Shaft, Front Axle
75
Check Dust Boot
75
Steering System
76
Right Handlebar Switch
76
Left Handlebar Switch
77
Rear View Mirror
77
Handlebar, Dashboard Rear Cover
78
Installation of Throttle Cable
78
Installation of Left Handlebar Switch
79
Installation of Right Handlebar Switch
79
Installation of Left and Right Grip
80
Installation of Master Cylinder
80
Steering Column
82
Reverse the Removal Procedure for Installation
82
EPS Steering System
83
EPS Motor Remove
85
EPS Controller Removal
85
Installation
85
EPS System Fault Code Table
86
Fault Analysis & Emergency Countermeasure for EPS System
87
Rear Wheel Wobbles
89
Rear Shock Absorber Is too Soft
89
Rear Shock Absorber Is too Hard
89
Poor Brake Efficiency
89
Rear Brake
91
Rear Brake Disc
91
Rear Suspension System
92
Rear Right Suspension
92
Stabilizer Bar
92
Right Rear Absorber
93
Rear Right Arm
93
Charging System Layout
94
Overhaul Information
95
Overhaul Standard
96
Battery Overflow
96
Inspection of Charging System
98
Electric Leakage Test
98
Inspection of AC Magneto
101
Head Light Cannot Turn on
111
Replacing Bulb
112
Headlight Bulb
112
Disconnect Headlight
112
Brake Light/Tail Light Bulb
113
Front Turning Indicator Bulbs
113
Rear Turning Indicator Bulbs
113
Dashboard Lighter Bulb
114
Dashboard Indicator Bulb
114
Lighting Switch
116
Turning Light Switch
117
Brake Light Switch
117
Water Temperature Transducer
121
Install Transducer
121
Troubleshooting
123
Starting Failure/Hard Starting
123
Unstable Engine Running or Engine Stops
124
Poor Engine Performance in Hi-Speed Range or Slow Speed Rising
125
Unstable Idle Speed
126
Poor Engine Performance in Middle or High Range
127
General Precautions
130
Fuel
131
Oil
131
Coolant
131
Break-In Procedures
131
Engine Exterior and Engine No.
132
Engine Specification
133
Overhaul Data
134
Clutch + Transfer
136
Carburetor
137
Electrical System
137
Materials for Operation and Fixing
142
Procedures of Maintenance & Adjustment
145
Valve Clearance
145
Engine Idle Speed
146
Spark Plug
146
Spark Plug Gap
147
Fuel Hose
148
Drive Belt
148
Inspection of Lubrication System
150
Check Engine Oil Level
150
Replacing Engine Oil
150
Replacing Oil Filter
151
Inspection of External Oil Pipe
151
Oil Filter Wrench
151
Inspection of Cooling System
152
Replacing Coolant
152
Inspection of Radiator Hose
153
Inspection of Cylinder Pressure
153
Testing Cylinder Pressure
153
Inspection of Oil Pressure
154
Oil Pressure Is too Low
154
Oil Pressure Is too High
154
Testing Oil Pressure
154
Inspection of Clutch Engagement and Lock-Up
155
Initial Engagement Inspeciton
155
Lock-Up Speed
155
Engine Removal, Inspection & Installation
156
Oil Filter
161
Sector Gear
161
Water Pump
162
Sheave Drum
162
Left Crankcase Cover
162
Magneto Rotor
162
Starting Motor Gear
163
Oil Pump Sprocket and Chain
163
CVT Cover
164
Cvt
164
CVT Case
165
Clutch
165
Timing Chain
165
Engine Center
166
Gear Position Bolt
166
Driven Bevel Gear, Front Output Shaft
166
Shift Cam, Fork/Shaft
167
Drive Shaft
167
Balancer Shaft
167
Crankshaft
168
Oil Bump, Relief Valve
168
Engine Components Inspection
169
Cylinder Head Cover
169
Cylinder Head Cover Distortion
169
Rocker Arm Shaft
169
Rocker Arm
170
Rocker Arm Shaft Bolt
170
Valve Spring Compressor
171
Cylinder Head Distortion
172
Valve Seat Width
172
Valve Stem and Valve Guide
172
Valve Stem O.D.
173
Valve Stem Run out
173
Valve Face Wear
173
Valve Stem End
173
Valve Spring
174
Assembly of Cylinder Head
174
Water Temperature Sensor
176
Automatic Decompression
177
Camshaft Journal Wear
177
Cam Wear
177
Camshaft Journal Oil Clearance
177
Camshaft Journal O.D.
178
Camshaft Run out
178
Timing Sprocket and Chain
178
Tensioner and Chain Guide
178
Chain Tensioner Inspection
179
Cylinder Distortion
179
Cylinder Bore
179
Piston
180
Piston Diameter
180
Piston Ring to Groove Clearance
180
Standard Width of Piston Ring Groove
180
Piston Ring Free End Gap and End Gap
181
Piston Ring Free End Gap Limit
181
Connecting Rod/Crankshaft
182
Connecting Rod Deflection
182
Crankshaft Run out
182
Clutch Shoes
183
Clutch Wheel
183
Primary and Secondary Sheave
184
Primary Sliding Sheave
185
Roller
185
Oil Seal
185
Primary Sliding Sheave and Fixed Sheave
186
Install Spacer
187
Secondary Sheave
187
O-Ring and Oil Seal
188
Secondary Sheave Spring
189
Secondary Sliding and Fixed Sheave
189
Transmission
192
Oil Strainer
197
Relief Valve
197
Drive Bevel Gear
197
Front Output Shaft
198
Driven Bevel Gear
198
Bevel Gear Washer Adjustment
198
Bevel Gear
199
Bevel Gear Backlash
199
Tooth Contact
200
Electric Starter Gear
203
Recoil Starter
203
Crankcase
207
Engine Assembly
208
Oil Pump and Relief Valve
208
Oil Pump Bolt
208
Connecting Rod
209
Main Shaft, Counter Shaft
209
Shift Cam
210
Primary Sheave, Secondary Sheave, Drive Belt
212
CVT Case Cover
213
Engine Left
214
Dual Gear
214
Starting Driven Gear
214
Carburetor Removal
226
Carburetor Installation
230
Engine Coolant
233
Inspection of Cooling Circuit
233
Radiator Cap
234
Radiator Cap Valve Opening Pressure
234
Radiator Inspection and Cleaning
234
Radiator Hose Inspection
234
Inspection of Fan Motor
235
Inspection of Thermoswitch
235
Thermoswitch Operating Temperature
235
Inspection of Water Temperature Sensor
236
Water Temperature and Resistance
236
Resistance of Generator Coil
247
Generator Non-Load Performance
247
Regulator/Recitfier
248
Starting System
249
Starting Motor
249
Brushes
250
Commutator
250
Armature Coil
250
Starter Relay
251
Auxiliary Starter Relay
251
Ignition Coil
252
Ignition Coil Primary Peak Voltage
252
Ignition Coil Resistance
253
Pickup Coil Peak Voltage
253
Pickup Coil Resistance
253

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CF MOTO CF500 Service Manual (259 pages)

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