CF MOTO CF500-5 Service Manual Download Page 253

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14-8

CFMOTO

Complaint

Symptom and Possible Causes

Remedy

Valve Chatter

1.  Excessive valve clearance
2.  Worn or broken valve spring
3.  Worn rocker arm or camshaft

Adjust
Replace
Replace

Noise from Piston
1. Worn

piston

2. Worn

cylinder

3.  Carbon deposit in combustion chamber
4.  Worn piston pin or pin hole
5.    Worn piston ring or piston ring groove

Replace
Replace
Clean
Replace
Replace

Noise from Timing chain
1. Stretched

chain

2. Worn sprocket wheel
3. Faulty chain tensioner

Replace chain & sprocket
Replace chain & sprocket
Repair or replace

Noise from Clutch
1. Worn or damaged crankshaft spline

2. Worn inner race spline

Replace crankshaft
Replace inner race

Noise from Crankshaft
1. Rattling

bearing

2. Worn or burnt crank pin bearing
3. Excessive thrust clearance

Replace
Replace
Replace

Noise from CVT

1. Worn or slipping drive belt

2. Worn rollers in primary sheave

Replace
Replace

Engine is

noisy

    Noise from Transmission
1.  Worn or damaged gear
2.  Worn or damaged input or output shafts
3. Worn

bearing

Worn

bushing

Replace
Replace
Replace
Replace

Slipping

Clutch

1.  Worn or damaged clutch shoes
2.  Weakened clutch shoe spring
3.  Worn clutch housing
4.  Worn or slipping drive belt

Replace
Replace
Replace
Replace

Difficulty or

locked gearshift

1. Broken drive or driven bevel gear teeth

2. Distorted shift fork
3. Worn shift cam
4. Improper gearshift rod

Replace
Replace
Replace
Adjust

Summary of Contents for CF500-5

Page 1: ...WWW CFMOTO COM CF500 5 SERVICE CF500 5A MANUAL...

Page 3: ...pter 1 general service information tools vehicle structure and technical data Chapter 2 key points for inspection and adjusting service guide Chapter 2 and after Chapter 3 disassembly of parts and com...

Page 4: ...ple Conversion Pressure 200 kPa 2 00kgf cm2 1kgf cm2 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 1cm3 1cc 1l 1000cm3 Force...

Page 5: ...king or fire Also keep against sparks Vaporized gasoline is also explosive Operate in a well ventilated place 7 When charged Battery may generate hydrogen which is explosive Charge the battery in a we...

Page 6: ...fter assembling check if all the tightened parts are properly tightened and can move smoothly 19 Brake fluid and coolant may damage coating plastic and rubber parts Flush these parts with water if spl...

Page 7: ...1 3 1 Maintenance Information 1 1 1 1 1 VIN Number and Engine Number CF500 5 CF500 5A VIN Number LCELDTZ Engine Number CF188...

Page 8: ...25 8 12 40J 185 80 12 40J Rear Tire 25 10 12 47J 270 60 12 47J Min Ground Clearance Min Ground Clearance Turning Diameter Turnin g Diameter Engine Starting Electrical starting Manual Starting Engine...

Page 9: ...atio 2 88 0 70 G ear R atio F inal Rati o 1 333 24 18 Bev el G ear Se condar y Ratio 1 952 41 21 G ears Low G ear 2 25 36 1 6 H i gh G ear 1 350 27 20 R ever se G ear 1 471 25 17 Total Low Gear 5 857...

Page 10: ...ding to the environmental temperature Oil Pump Rotor Gap between Inner and Outer Rotors 0 03 0 1mm 0 15mm Gap between Outer rotor and boday 0 03 0 1mm 0 12mm Oil pressure 130 170KPa at 3000r min Item...

Page 11: ...ensity 50 Opening pressure of radiator cap Thermostat Initial Temperature 72 2 Full opening Temperature 88 Full opening lift range 3 5 4 5mm 95 Temperature and Resistance of Water Temperature Sensor T...

Page 12: ...35k gf cm 2 Item Standard O peration Lim it Rear W heel P lay of wheel rim Vertical 1 0mm 2 0mm Horizonta l 1 0mm 2 0mm Tire G ro ove 3 0mm P res sure 30kP a 0 30k gf cm 2 Item Standard O perati on Li...

Page 13: ...lb Fuse Head Light Hi Lo 12V 35W 35W 2 Brake Light Tail Light 12V 5W 2 Turning Light 12V 21W 5W Dashboard Indicator Light 12V 10W 4 Indicators 5 LED Main LCD Item Standard AC Magneto Motor Model P e r...

Page 14: ...ead Seal Run out Intake Exhaust 0 03 Width of Valve Seats Seal Intake Exhaust 0 9 1 1 Length of Valve Spring Intake Exhaust 40 38 8 Valve Spring Tension Intake Exhaust Tension182 210N Length31 5mm Cam...

Page 15: ...d 8 9 Piston Ring Free Gap 2nd R ing R 12 round 9 5 Top R ing 0 15 0 30 0 60 Pis ton R ing C losed Gap 2 nd R ing 0 15 0 30 0 60 Top R ing 0 04 0 08 0 180 Piston Annular F it C learance 2nd R ing 0 0...

Page 16: ...oint Rotation 1800 2400r min Clutch lock up Rotation 3300 3900r min Drive Belt Width 35 2 33 5 Driven Disc Spring Free Length 168 160 Shifter and fit flute gap 0 10 0 40 0 50 Left Shifter Sliding Thic...

Page 17: ...0 Bolt Rear Absorber M10 1 25 50 4 40 50 Bolt Front Absorber M10 1 25 50 4 40 50 Bolt Rear Wheel Shaft Holder M10 1 25 100 4 40 50 Mounting Nut Rim 901 07 00 02 M20 16 50 60 Nut Rim Shaft 901 07 00 03...

Page 18: ...M18 1 5 70 Left handed Limiting Nut Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant Limiting Nut Front Output Shaft 1 M55 80 Apply screw thread sealant left handed Bolt Swing Arm Shaft 2...

Page 19: ...otor 2 M6 10 Bolt Cylinder Head 4 M10 38 Bolt Cylinder Head 2 sides 2 M6 10 1 M8 25 Upper and Lower Bolt Cylinder 4 M6 10 Bolt Cylinder Head Cover 12 M6 10 Bolt Chain Tensioner 2 M6 10 Nut Chain Tensi...

Page 20: ...h of carburetor 11 Plastic gauge Fit clearance 12 pull tension gauge Spring bounce 13 Tachometer Engine rotation rate 14 Cylinder Pressure Meter pressure in cyclinder 15 Oil Pressure Gage Oil pressure...

Page 21: ...ank shaft on left crankcase 9 Valve Spring Compressor CF188 022006 922 001 Disassemble install valve spring 10 Valve Former CF188 022004 922 001 Grind valve 11 Circle Nut Wrench CF188 052000 922 003 D...

Page 22: ...00 m L replace oil filter 2600 m L engine overhaul Lubricant with molybdenum Piston pin valve rod part valve ring cam shaft Grease lubricant grease 3 MoS2 l ithium based grease Oil seal lip O ring and...

Page 23: ...1 19 1 Maintenance Information 1 1 1 1 1 Wirings Pipes Cable Routing Wirings Pipes Cable Routing Wirings Pipes Cable Routing Wirings Pipes Cable Routing Wirings Pipes Cable Routing...

Page 24: ...1 20 CFMOTO...

Page 25: ...1 21 1 Maintenance Information 1 1 1 1 1...

Page 26: ...1 22 CFMOTO...

Page 27: ...ead Seal Run out Intake Exhaust 0 03 Width of Valve Seats Seal Intake Exhaust 0 9 1 1 Length of Valve Spring Intake Exhaust 40 38 8 Valve Spring Tension Intake Exhaust Tension182 210N Length31 5mm Cam...

Page 28: ...M18 1 5 70 Left handed Limiting Nut Driven Bevel Gear Shaft 1 M60 110 Apply screw thread sealant Limiting Nut Front Output Shaft 1 M55 80 Apply screw thread sealant left handed Bolt Swing Arm Shaft 2...

Page 29: ...s Warning Gasoline is highly flammable therefore smoke and fire are strictly forbidden in the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vapor...

Page 30: ...bly bolts of front rack shall be seen Remove fixing Bolt 1 one for each on theleft and right Romove fixing Bolt 2 Remove front rack Installation Reverse the removal procedure for installation Tighteni...

Page 31: ...Note Shake seat left right front and back to make sure that the seat is firmly installed Remove seat 2 3 Bolt 1 bolt 2 Remove seat support Remove Bolt 3 for rear rack and rear fender from rear fender...

Page 32: ...er Remove Front Rack 2 2 6 nuts FrontTop Cover Assemble Reverse the removal process and direction Dashboard Cover Remove 2 pieces Bolt 1 2 pieces bolt 2 Dashboard Cover Installation Reverse the remova...

Page 33: ...2 5 2 Vehicle Body and Muffler 2 2 2 2 2 Front Side Support Left Remove Bolt 1 Front Side Support Assemble Reverse the removal process and direction Front Side Support Right Same as Left Side Support...

Page 34: ...p cover from rear fender Remove RearTop Cover Installation Reverse the remove procedure and direction for installation Gear Shift Unit Fender Remove Bolt 1 Bolt 1 Bolt 2 Remove Gear Shift Unit Fender...

Page 35: ...llation Rear Protector Remove Rear Rack 2 3 RearTopCover 2 6 Rear Link Plate 2 7 Rear Left Side Support 2 8 Rear Right Side Support 2 8 Rear Turning Light Connector Bolt 1 2 1 Rear Protector Installat...

Page 36: ...ender at bottom of Front Fender Remove Right Side Panel Installation Reverse the remove procedure and direction for installation Rear Right Side Support Remove Bolt 2 Remove Rear Right Side Support In...

Page 37: ...remove procedure and direction for installation Front Fender Remove Front Rack 2 2 FrontTopCover 2 4 Left Right Side Panel 2 7 2 8 Fuel Tank Top Cover 2 8 Left Right Side Support 2 5 Loosen Cable Conn...

Page 38: ...ee Bolt 1 and 3 nuts connecting with Front Fender Remove three Bolt 2 and 3 nuts connecting with Rear Fender Remove Bolt 1 Remove Left Footrest Installation Reverse the remove procedure for Installati...

Page 39: ...2 7 2 8 Lef RightSide Support 2 8 Rear Protector 2 7 Remove Battery Bracket and Fixing Plate 8 4 Remove Battery 8 4 Remove Bolt 1 Remove Nut 1 Remove Electonic Parts from Rear Fender Loosen Cable Conn...

Page 40: ...Skid Plate Installation Reverse the remove procedure for Installation Engine Skid Plate Middle Remove Bolt 5 and 6 Remove Middle Engine Skid Plate Installation Reverse the remove procedure for Install...

Page 41: ...th Clip of Right Inner Side Fender during Installation Left Front Inner Fender Removal Remove Bolt 1 and remove Left Front Inner Fender Installation Reverse the remove procedure for Installation Front...

Page 42: ...everse the remove procedure for Installation Front Right Inner Fender Removal and Installation same as Left Side Bumper Bumper Protector Remove Remove two Bolts of Engine Front Skid Plate fixing into...

Page 43: ...nector Remove Bumper and Bumper Protector Remove tapping screw 1 from Bumper Remove Bumper Protector Installation Reverse the remove procedure for Installation Bumper Protector Cap Remove Pull the two...

Page 44: ...bumper down Installation Reverse the removal procedure for instal lation Warning Gasoline is highly flammable therefore smoke and fire are strictly for bidden in the work place Special attention shoul...

Page 45: ...cable cables pipes and hoses should be routed properly according to the routing drawing Take precaution against fuel leakage when removing fuel Fuel Hose I Remove Fuel tank 2 16 Bolt 1 Bolt 2 Fuel tan...

Page 46: ...e muffler is cooled down Remove Seat 2 3 Right side panel 2 8 Nut1 Nut 2 for exhaust pipe elbow Remove Bolt Remove Bolt 2 Bolt 3 Remove muffler Installation Reverse the removal procedure for installat...

Page 47: ...2 19 2 Vehicle Body and Muffler 2 2 2 2 2 Visible Parts...

Page 48: ...the electrical sparks Besides vaporized gasoline is highly explosive so work should be done in a well ventilated place Be careful that your hands or clothes not get nipped by the turning or movable pa...

Page 49: ...ere conditions Km Initial 250km Every 500 km Every 1000 km Interval Item Hours Initial 20 hours Every 50 hours Every 100 hours Remark Valve Clearance I I IN 0 05 0 10 EX 0 17 0 22 Idle Speed I I 1300...

Page 50: ...of front brake disc is less than 2 5mm rear brake less than 6 5mm Tire pressure Front tire 35kPa 0 350kgf 2 Rear tire 30kPa 0 30kgf 2 Chap and damage Groove depth and abnormal wear No wear indication...

Page 51: ...s of joint parts O O Sway of Spline O Electrical System Ignition Device Spark plug O Spark plug gap 0 8 0 9mm Ignition timing O Battery Terminal Joint O Wiring Looseness and damage of joints O Fuel de...

Page 52: ...unction Alarm and lock device Function Instruments Function Looseness or damage caused by improper installation Exhaust pipe and muffler Function of muffler Frame Looseness and or damage O thers Lubri...

Page 53: ...or further check Park the vehicle on level place slowly turn the handle bar left and right to see if it can turn freely In case there is any hindrance check if it is from the main cable assembly or ot...

Page 54: ...plastic and rubber parts Keep the fluid away from these parts Slightly turn the handlebar left and right till the mas ter cylinder is in horizontal then remove the fluid res ervoir cap Brake Disc Brak...

Page 55: ...tightened and check whether it sways Not tighten enough Tighten it Sway Replace the rocker arm Front Toe in size Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out...

Page 56: ...re pressure will reduce the comfort of operation and riding and may cause deflected wear of the tires Tire Tread Check the tire tread Tread Height 3mm Replace with new tires Note When the tread height...

Page 57: ...ring Lift the front wheel Make sure there is no loading on the vehicle Shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bearing Suspension...

Page 58: ...fting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the locknut to adjust the length of gearshift rod Fuel Device Status of the fuel system...

Page 59: ...free play could not be acquired by adjusting the regulator or if there is still stickiness with the throttle Adjusting the Speed Limiter The speed limiter is to limit the opening of throttle Check th...

Page 60: ...oolant gets into eyes rinse with plenty of water and go to consult the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach...

Page 61: ...ged before adding coolant Coolant Leakage Check radiator hose water pump water pipes and joints for leakage In case of any leakage disassemble and do further check Refer to Chapter 4 Check the radiato...

Page 62: ...If coolant splashes in your eyes or clothes thoroughly wash it away with water and consult a doctor If coolant is swallowed induce vomiting and get immediate medical attention Keep coolant away from...

Page 63: ...d be in the 0 position Start the engine to check if the indicator works If the indicator is not working do the maintenance in time Lighting System Adjusting headlight light beam Turn the headlight bea...

Page 64: ...kshaft until the line5 of T D C on rotor is aligned with mark6of inspection hole on left crankcase Insert feeler gauge to check the clearance between the valve stem end and the adjust bolt on the rock...

Page 65: ...at 20 hours run in and every 50 hours or 500km thereafter Start the engine and warm it up for several minutes measure engine speed with a tachometer Set the engine idle speed between 1200 1400 r min...

Page 66: ...hours or 500 km clean it every 1000km if necessary If the air cleaner is clogged with dust intake resis tance will be increased with a resultant decrease in power output and an increase in fuel consum...

Page 67: ...under dusty conditions clean the air filter element more frequently Remove the drain plug8 of air box to drain out any water Fuel Hose Inspect every 100 hours or 1000 km replace every 4 years Inspect...

Page 68: ...ding sheave and primary fixed sheave Hold secondary sheave with a special tool and tighten the nut to the specified torque Nut Secondary Sheave 115 N m Install primary sheave and nut Hold the primary...

Page 69: ...not tighten it Take out oil dip rod and check if oil is between upper and lower limit If the engine oil is insufficient fill more oil until the sufficient oil is obtained Engine Oil SAE15W 40 classifi...

Page 70: ...eplaced replace en gine oil at the same time Replacing Oil Filter Remove relative parts see Replacing Engine Oil Remove oil filter1with the special tool Install washer and drain bolt Install new oil f...

Page 71: ...too low check the above items Testing Cylinder Pressure Note Before testing of cylinder pressure make sure that cylinder head bolts are tightened to the specified torqueandvalveclearancehasbeenproper...

Page 72: ...ssage Combination of above items Testing Oil Pressure Remove bolt1 Connect tachometer2with ignition coil Install oil pressure gauge3 and joint seat to main oil gallery Warm up engine as per following...

Page 73: ...speed is out of the above range check the following Clutch shoes Clutch shoe wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch II Clutch Lock up Inspection Connect the ta...

Page 74: ...water and then with soap and water If coolant is swallowed voimt immediately and see a physician Store the coolant properly and keep it away from reach of the children Check radiator fins for mud bloc...

Page 75: ...amaged or clogged radiator fins zCoolant is not enough zFaulty or malfunction of fan motor No rise or slow rise of water temperature zMalfunction of thermostat thermostat isn t closed zFaulty circuit...

Page 76: ...fits the temperature of using place Check coolant for stains Inspection of the radiator cap Caution Be sure to open the radiator cap after coolant is cooled Remove Front top cover 2 4 Radiator cap 4 3...

Page 77: ...ly wash your eyes with water and consult a doctor If coolant splashed on your clothes quickly wash it away with water then with soap and water If coolant is swallowed induce vomit immediately and see...

Page 78: ...olant After drainage assemble new seal gasket and drain bolt and tighten Reservoir Tank Remove Seat 2 3 Left Side Cover 2 6 Two bolts of reservoir tank Water hoses of reservoir tank Remove reservoir t...

Page 79: ...evel when the vehicle is on an even ground Discharge Discharge the air from cooling system according to the following steps 1 Remove drain bolt 4 5 discharge air and install it 2 Start the engine and...

Page 80: ...4 7 4 Cooling and Lubrication system 4 4 4 4 4 Cooling System Chart...

Page 81: ...when the engine is still hot Or you may be injured by scalding fluid or steam zCoolant is harmful DO NOT swallow or stain your skin or eyes with coolant In case of accidental swal low or stain flush w...

Page 82: ...requirement repalce it Radiator Cap Valve Opening Pressure Standard 108kPa Tool Radiator Cap Tester Radiator Inspection and Cleaning zRemove dirt or trash from radiator with compressed air zCorrect th...

Page 83: ...zCheck the thermoswitch for closing or opening by testing it at the bench as illustrated Connect the thermoswitch1to the circuit tester place it in a vessel with engine oil Place the vessel above a st...

Page 84: ...e oil to raise the temperature slowly and take the reading from ohmmeter4 and thermometer3 Water Temperature and Resistance Temperature 50 80 100 120 Resistance 154 16 52 4 27 3 16 2 zInstallation App...

Page 85: ...the water temperature When the water temperature reaches the specified valve the thermostat valve should have been lifted by 3 5 4 5mm Lift standard of thermostat valve water temperature 95degrees C l...

Page 86: ...move clamps and water hoses lRelease bolts and remove water pump lRemoveO ring Note Do not reuse the O ring zRemove the overflow tube zReleasewaterpumpcoverscrews waterpumpcover and gasket zRemove rin...

Page 87: ...al tool Note The bearing does not need to be removed if there is no abnormal noise Note Do not reuse a removed bearing Inspection of Water Pump Bearing Bearing Bearing Bearing Bearing zCheck the beari...

Page 88: ...mating mace of water pump body with bearing and mechanical seal If damage replace it Water Pump Impeller zCheck the impeller and shaft for damage zIf the impeller or shaft are damaged replace a new pa...

Page 89: ...with special tool Tool Bearing Installer Note The stamped mark on the bearing faces outside zInstall seal ring to impeller zClean off the oil and grease from mechanical seal and install into the impel...

Page 90: ...ew gasket to water pump body zInstall water pump cover and tighten the bolts and bleed bolt Water Pump Cover Bolts Tightening Torque 6N m zCheck impeller for smooth turning zInstall the new O ring Not...

Page 91: ...ump and tighten the bolts to the speci fied torque Water pump bolts tightening torque 10N m Note Set the water pump shaft slot end B to oil pump shaft flat side A zConnect water hoses zAdd coolant zIn...

Page 92: ...4 19 4 Cooling and Lubrication system 4 4 4 4 4...

Page 93: ...to the engine parts piston cylinder body camshaft and so on which run at high speed Engine lubrication should be special oil Engine oil is not only used as lubrication but also used to wash rustproof...

Page 94: ...il pump Carburetor air filter Cylinder head cover cylinder head cylinder body camshaft CVT system CVT cover Gearbox Right side cover AC magneto water pump Piston piston ring piston pin Following opera...

Page 95: ...chapter Carburetor Engine service chapter Clamp Water Inlet Hose Remove screw Remove gearshift rod Remove clamp Remove water outlet hose Remove Sleeve Remove connectors of magneto enriching device lea...

Page 96: ...of Engine Drive Traina and Gearshift Unit 5 5 5 5 5 Remove spark plug cap from cylinder Remove protection sleeve of starter relay Remove Nut Disconnect positive wire of starter relay Remove nut Remove...

Page 97: ...5 4 CFMOTO Removal Bolt 4 units of Engine...

Page 98: ...hoses to engine with proper clamps Positive and negative starting wires to engine Connect all the connectors Spark plug cap Gearshift rod to engine Air filter carburetor and removed parts Removal and...

Page 99: ...5 6 CFMOTO Remove nut and bolt of front axle from frame Remove nut and bolt of rear axle from frame...

Page 100: ...for Installation Tightening torque Bolt front axle 40 50N m Bolt rear axle 40 50N m Bolt front and rear drive shafts 40 50N m Gearshift Unit Remove left and right side panel 2 6 Fuel tank top cover 2...

Page 101: ...tator 6 7 6 48 6 60 Magneto Rotor 6 7 6 47 6 60 Starting Driven Gear 6 8 6 47 6 59 Starting Dual Gear Idle Gear 6 8 6 48 6 59 Oil Pump Sprocket and Chain 6 8 6 59 Engine Right Side CVT Cover 6 9 6 51...

Page 102: ...ols Drain up engine oil 3 22 Drain up coolant 3 15 Remove water hose clamp1 and2 Remove water hose3 Water Hose Pipe Remove screw4 and water hose5 Recoil Starter Remove 4 bolts M6X12 of recoil starter...

Page 103: ...g1 insert a flat screw driver into slot of timing chain tensioner ad juster turn it clockwise to lock tensioner spring Remove tensioner fix bolt Remove tensioner and gasket Loosen timing sprocket bolt...

Page 104: ...e cylinder head bolt Cylinder Head Remove cylinder head bolts diagonally Remove cylinder head Remove dowel pin and cylinder head gas ket Cylinder Remove timing chain guide1 Note Take care not to drop...

Page 105: ...p into crankcase Notes When installing piston make sure its identi fication conforms to that of cylinder When removing piston pin clean off burrs of piston pin hole and groove If it s difficult to rem...

Page 106: ...gearshift rocker arm Sector Gear Remove gasket 2and gearshift rocker arm 3 Remove bolt of sector gear housing cover Remove wire clip and sector gear housing cover Remove dowel pin and gasket Remove d...

Page 107: ...ve Drum Remove the sheave drum by using a suit able bar Remove washer and sheave drum Left Crankcase Cover Remove bolts Remove left crankcase cover Remove dowel pin and gasket Magneto Rotor Install at...

Page 108: ...edle bearing Starting Motor Gear Remove idle gear and shaft 4 Remove dual gear and shaft 3 Oil Pump Sprocket and Chain Remove spacer 2 Remove drive sprocket nut 5 Remove C ring 6 Remove oil pump drive...

Page 109: ...gasket and dowel pin CVT Continuously Variable Transmission Remove primary sheave nut with special tool Remove primary sliding sheave Remove primary fixed sheave 1 Remove bolt for air guide plate lRe...

Page 110: ...uter clutch face and CVT case Clutch Remove clutch shoe fixing nut with special tool Remove dowel pin front and rear gasket Remove clutch shoe Note The clutch shoe nut has left hand threads Timing Cha...

Page 111: ...ar Front Output Shaft Remove bevel gear cover bolt Removedrivenbevelgear3 Removefrontoutputshaftnut4 Engine Center Gear position bolt Remove gear position bolt 1 Remove spring and steel ball Right Cra...

Page 112: ...ase Shift Cam Fork Shaft Drive Bevel Gear Remove Shift Cam 5 Fork Shaft Balancer Shaft Remove balancer shaft Drive Shaft Driven Shaft Remove Oil seal1 Bearing limit nut levorotation 2 Remove Front Out...

Page 113: ...3 6 Engine Removal Inspection Installation 6 6 6 6 6 Remove oil bump and relief valve Oil bump Relief Valve Separate crankshaft from left crankcase with spe cial tool Tool Crankshaft Separator Cranksh...

Page 114: ...ft by using M6 bolts B Cylinder Head Cover Distortion Clean off sealant from the fitting surface of cylinder head cover place cylinder head cover on a surface plate and measure distortion with a thick...

Page 115: ...aft contact surface Rocker Arm I D 12 000 12 018mm Tool Dial Calipers Assembly Cylinder Head Note Intake rocker arm shaft A has oil holes Disassembly Remove intake pipe Remove water temperature sensor...

Page 116: ...ess the valve spring and remove valve cotter with tweezers Tools Valve Spring Compressor Tweezers Remove valve stem seal ring and valve lower seat Remove valve spring upper seat and valve spring Remov...

Page 117: ...on the valve face should be continuous without any break The width of the dye ring which is the visualized seat width should be within the following range Cylinder Head Distortion Service Limit 0 05mm...

Page 118: ...t Valve head Radial Run out out of range Replace Service Limit 0 03mm Tool Dial Gauge 1 100 Magnetic Stand V Block Valve Face Wear Check each valve face for wear or damage Replace valve with a new one...

Page 119: ...alve spring tension out of range Replace Service Limit IN EX 182N 210N 31 5mm Tool Spring Scale Measure valve spring incline Spring incline out of range Replace Valve Spring Incline Limit 2 5o 1 7mm A...

Page 120: ...nd release compressor to allow the cotter 1to wedge in between seat and stem Make sure that the rounded lip NOTE Knock the valve end with rubber hammer Make sure valve cotter is fit into groove Check...

Page 121: ...torque Install intake pipe apply lubricant to 0 ring Camshaft Water temperature sensor Tightening torque 10 N m Check camshaft for wear and run out of cams and journals if the engines produces abnorma...

Page 122: ...shaft installed Camshaft journal oil clearance Install cylinder head cover and tighten bolts evenly and diagonally to the specified torque Service limit 0 15mm Clean off materials from cylinder head a...

Page 123: ...m 17 484mm Tool micrometer 0 25mm Camshaft Run out Measure the run out with a micrometer Replace camshaft is the run out is out of range Timing Sprocket and Chain Camshaft Run out Service limit 0 10mm...

Page 124: ...a new one Cylinder Cylinder Distortion Check the gasket face of cylinder for distortion with a straightedge and thickness gauge and take clearance readings at 7 points as illustrated If the largest re...

Page 125: ...ccording to the above measurement Piston Ring to Groove Clearance Use a thickness gauge to measure the side clearance of topt ring and 2nd ring If the clearance exceeds the limit replace both piston a...

Page 126: ...Top ring 8 9mm 2nd ring 9 5mm Piston ring end gap limit Top Ring 0 60mm 2nd ring 0 60mm Tool Vernier caliper Thickness gauge Piston Pin and Pin Bore Use a bore gauge to measure the inner diameter of...

Page 127: ...pection of big end Connecting Rod Deflection Connecting Rod Deflection 3 0mm Tools Dial Gauge Magnetic stand V block Connecting Rod Big End Side Clearance Push the big end to one side and use thicknes...

Page 128: ...1for scratches scuffs or blue discoloration or uneven wear If any damage is found replace the clutch wheel with a new one for scratches scuffs or blue discoloration or uneven wear If any damage is fou...

Page 129: ...6 29 6 Engine Removal Inspection Installation 6 6 6 6 6 Primary and Secondary Sheave...

Page 130: ...Cam1and Roller2 Check each roller and sliding face for wear and damage Wear and damage Replace Check oil seal lip for wear and damage Wear and damage Replace Note rollers should be replaced as a set...

Page 131: ...edure of primary sliding and fixed sheave for installation Pay attention to the following Apply grease to inner bore and oil seal lip Note Wipe off any excessive grease thoroughly Take care not to att...

Page 132: ...to the secondary sliding sheave and compress it by turning in the tool handle Note Make sure that spring end A is inserted into slot B of the tool handle Remove ring nut Tool Secondary sliding sheave...

Page 133: ...n Installation 6 6 6 6 6 Remove spring1 Remove spring seat2 Remove guide pin and spacer Remove secondary sliding sheave3 O ring and Oil Seal Check the O ring and oil seal for wear and damage Wear and...

Page 134: ...he length is shorter than the service limit replace with a new one Service Limit 145 4mm Assembly Secondary Sliding and Fixed Sheave Check drive face for any abnormal condition such as stepped wear or...

Page 135: ...e lip with a 0 1mm steel sheet as guide Install spring seat Align hole A with hole B Install spring and spring plate Insert spring end into the hole Compress spring with special tool Align the seconda...

Page 136: ...ch Sheave holder Drive belt Check contact surface of belt for any cracks and damage Check belt width with venire caliper Damage width out of range Replace Belt width service limit 33 5mm Tool vernire...

Page 137: ...AR HIGH RANGE 1 2 SHIFT CAM 1 11 DRIVEN GEAR LOW RANGE 1 3 RIGHT CRANKCASE 1 12 SPRING SHIFT FORK 1 4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1 5 DRIVEN SECTOR GEAR 1 14 GUIDE BAR 1 6 SPROCKET REVERSE GE...

Page 138: ...t for stains scratch or damage replace if necessary Inspect reverse gear chain for damage wear replace if necessary Disassemble counter shaft as illustration Inspect bearing surfaces for stains damage...

Page 139: ...e standard 0 10 0 30mm Service limit 0 50mm Measure shift fork groove width with vernier caliper Standard shift fork groove width 6 05 6 15mm Measure shift fork thickness with vernier calipers Standar...

Page 140: ...age Scratch or damage Replace Assembly Reverse the removal procedure for assembly Pay attention to the following Sharp Edge Thrust Note Use new retainers Pay attention to the direction of the retainer...

Page 141: ...asseble oil pump as illustrated Check oil pump housing and cover for cracks and damage Replace if necessary Top clearance 0 03 0 10mm Service limit 0 15mm Side clearance 0 03 0 10mm Service liimit 0 1...

Page 142: ...rive bevel gear nut 7 Bearing nut 4 Drive bevel gear 8 Bearing 8 Drive bevel gear nut tightening torque 145N m Loosen drive bevel gear nut 3 remove the drive bevel gear 4 and adjust washer 5 Check the...

Page 143: ...en bevel gear Place a clean rag1 under bevel gear cover Remove bearing limit nut 10 with special tool 2 and remove bearing Check driven bevel gear 8 surface for scratches wear Scratch or wear Replace...

Page 144: ...mm Correct Install special tool3 and micrimeter 4 Tool Bevel gear side clearance dial gauge micrometer a 46mm Turn the driven bevel gear in each direc tion and measure the backlash NOTE Measure four p...

Page 145: ...e coated teeth of the drive bevel gear Contact 1 tooth top Incorrect Contact2 tooth middle Correct Contact3 tooth bottom Correct If tooth contact is correct Contact2 continue next procedure If tooth c...

Page 146: ...starter clutch nut Magneto Rotor Remove the parts as illustrated on the right Check each part for abnormal wear or damage wear or damage Replace 1Balance shaft gear 2woodruf key 3Balance shaft 4Balan...

Page 147: ...locker to bolt and tighten to the specified torque Install the starter driven gear Tightening torque of starter clutch bolt 26N m Material Thread locker Make that the starter driven gear turns in the...

Page 148: ...t is stuck replace with a new one Apply thread locker to the bolt when assembling Tightening torque for magneto coil bolt 10N m Apply lubrication oil to bearing 4 and lubri cant grease to lip of oil s...

Page 149: ...il spring 10 Nut Recoil starter Disassembly Inspection Check all parts for damage Repalce if necessary Remove nut 10 and the parts from the starter housing Warning The coil spring may quickly unwind a...

Page 150: ...protec tion beforehand Install coil spring1and sheave drum2 Apply lubricant grease to spring Hook coil spring end 3 to the starter housing wind the coil spring clockwise Hook the other end 5 of coil...

Page 151: ...l limitator and tighten screw after applying thread locker Note Use a new oil seal Tool Bearing remover Oil seal remover Bearing installer CVT case CVT case CVT case CVT case CVT case Check bearing 5...

Page 152: ...k the play noise and smooth turning In case of any abnormal remove bearing with special tool and replace Check all the oil seals for over wear or damage In case of any over wear or damage remove with...

Page 153: ...torque 30N m IIIEngine assembly Reverse the engine removal procedure for installation Note Clean all the parts before assembly Make sure that the parts are in good con dition without any damage Apply...

Page 154: ...to crankcase with plastic mallet Use special tool to avoid affect of conrod precision Balance shaft Install balance shaft Caution Balancer shaft driven gear should be aligned to the mark as illustrate...

Page 155: ...oil to each part Install drive bevel gear and tighten to the specified torque Drive bevel gear tightening torque 32N m Install driven bevel gear and tighten to the specified torque Install front outpu...

Page 156: ...en to the specified torque M6 10N m M8 25N m Gear positioning bolt Place the steel ball and install gear posi tioning bolt and tighten the bolt to the speci fied torque Tightening torque 18N m Timing...

Page 157: ...on the right Install drive belt between secondary sliding fixed sheave and tap with a plastic hammer to keep the belt as low as possible Note Install the drive belt with the arrow on the belt turn in...

Page 158: ...htening torque 115N m Tool Rotor Holder Tighten secondary sheave nut with special tool to the specified torque Secondary sheave tightening torque 115N m Tool Rotor holder Note Turn the primary fixed s...

Page 159: ...et and chain Install oil pump drive sprocket Install oil pump driven sprocket Install oil pump drive chain Tighten oil pump sprocket bolt Install sprocket retainer with a long nose pliers Tool Long no...

Page 160: ...or greasy matter and fully dry the surfaces Left crankcase cover Install dowel pin 2 and gasket 3 Apply lubricant grease to oil lip Install left crankcase cover Install bolts Note Use a new gasket Re...

Page 161: ...pin 3 Driven sector gear 4 Driven sector gear 5 Driven sector gear Note When the shift cam is in the neutral position the mark of drive sector gear should be between the two marks of the driven sector...

Page 162: ...y engine oil to new O ring Install starting motor Install bolt and tighten to the specified torque Tightening torque 10N m Engine top side Piston Install the piston rings in the order of oil ring 2rin...

Page 163: ...he gaps are so located Apply a light coat of moly oil to the piston pin Install piston pin into holes of piston and conrod small end Place a clean rag beneath piston and in stall piston pin circlip 1...

Page 164: ...Install chain guide1 Fit the dowel pin and new cylinder cover gasket Note Use a new cylinder cover gasket to prevent oil leakage Cylinder head Install the cylinder cover tighten the cylin der head bo...

Page 165: ...be tween sprocket and crankcase Align the mark A on the camshaft so that they are parallel with the mating surface of the cylinder head Note Do not rotate the magneto rotor while doing this when the s...

Page 166: ...to lock the bolts Cylinder head cover Clean the mating surface of cylinder head and cylinder head cover Install dowel pin to the cylinder head Apply sealant to the mating surface of the cylinder head...

Page 167: ...ter turn it clockwise to lock the tensioner spring Install the chain tensioner and the new washer 1 Install the bolt 2 tighten it to the specified torque Chain tensioner bolt tightening torque 10N m A...

Page 168: ...plug Install spark plug with special tool and tighten to the specified torque Note To avoid damage to the cylinder head thread screw in the spark plug with hand first then tighten it to the specified...

Page 169: ...6 69 6 Engine Removal Inspection Installation 6 6 6 6 6 Install left plastic cover 6 Left plastic cover Water pipe and hose Install water hose 5 Install bolt 4 Install water hose 3 Install clamp 1 2...

Page 170: ...rankcase cover is 64 98 then d 64 98 A 7 52 17 0 55 0 64 98 0 50 Drive bevel gear provides following spcs of thickness 0 15 0 20 0 25 0 30 0 35 So when the result is just 0 or 5 requirement is to be m...

Page 171: ...ear marking data is 6 then e 75 94 Driven bevel gear front face marking data is 0 then f 60 00 Driven bevel gear front face data is 13 then g 80 37 Marking data on leftcrank is 97 29 then h 97 29 Mark...

Page 172: ...7 1 7 Carburetor 7 7 7 7 7 Chapter 7 Carburetor Carburetor Removal 7 2 Inspection 7 3 Measurement and Adjustment 7 4 Carburetor Assembly 7 5 Carburetor Installation 7 6 Carburetor Parameters 7 6...

Page 173: ...Idle adjust shaft 1 10 Drain Screw 1 2 Vacuum chamber cover 1 11 Float Chamber 1 3 Spring 1 12 Float 1 4 Jet needle holder 1 13 Needle Valve Set 1 5 Spring 1 14 Main Jet MJ 1 6 Jet needle set JN 1 15...

Page 174: ...ge Damage Replace z z z z zCheck valve seat1 needle valve2 O ring3 for damage abnormal wear or dirt Damage or wear or dirty Replace Note Valve set1 needle valve2 should be re placed as a set z z z z z...

Page 175: ...valve into carburetor body and check the free movement z z z z zCheck free movement of throttle valve Replace with a new one if it s stuck 3 3 3 3 3 Measurement and Adjustment Float Height z z z z zKe...

Page 176: ...l level gauge1 with drain pipe2 Tool Fuel Level Gauge Loosen drain screw 3 z z z z zMeasure float height again till it s within the specification z z z z zKeep fuel level gauge vertical next to the fl...

Page 177: ...AJ MD13 24 35 Jet needle JN J8 5E26 Needle jet NJ 785 401011 P 0M Pilot jet PJ N224103 22 5 Pilot screw PS 604 16013 1A Pilot air jet1 PAJ1 MD13 24 65 Pilot air jet2 PAJ2 N211100 165 1 vacuum breather...

Page 178: ...rim you required to use special tyre lever and rim protector Overhaul standard Item Standard Service limits Portrait 0 8mm 2 0mm Rim jump Cross 0 8mm 2 0mm Remain groove 3 0mm Tyre Air pressure 35kPa...

Page 179: ...eel rotation dumb zwheel shaft bad zfront wheel shaft bend zbrake drag Front suspension too soft zfront suspension bounce weaken ztyre air too lower Front suspension too hard zfront suspension bend zt...

Page 180: ...e wheel slowly use centimeter measure rim jump Service limit axial direction 2 0mm Radial direction 2 0mm Installing Press the rim in the tyre on special matchin Fix the rim in hub Rim install nut tor...

Page 181: ...sassemble remove front wheel 8 3 remove the 2pcs nuts installed on the arm remove brake caliper Inspection Check if the brake caliper crack if the tightening area oil leakage replace if needed Install...

Page 182: ...lt torque 25 30N m Hand brake master cylinder front brake Disassemble remove bolt remove parking lever Seperate front hand brake master cylinder handlebar it is not need to remove the front hand brake...

Page 183: ...k ing the brake effort is required Brake Y joint Disassembling remove front inner fender RH 2 12 remove bolt 1 then the brake Y joint canbe remove form the body Assembling Assembling carry on to the o...

Page 184: ...d RH suspension at one time or else the body will fall down because lack of holding power Disassemble Put vehicle body into horizontal position use jack hold the wheel front firmly remove front wheel...

Page 185: ...on You donot need to remove any other parts if you only replace the front suspension Remove front left absorber s bolt 1 nut 1 installed in arm Remove front right shock absorber Inspection Inspect if...

Page 186: ...ssemble the front left upper arm and the front right lower arm Other arm assemble refers to the above Front right arm assy Disassemble Remove front right absorber 6 8 Remove front right upper arm s bo...

Page 187: ...right lower 12 Besides the gap between top ball pin and bottom if it cannot move freely or the gap too big ball pin replacement is needed Right knuckle Inspect if the right knuckle is damaged replace...

Page 188: ...ve front left brake caliper 8 4 remove fornt left rim hub 8 3 Examine duct boot replace with new ones if destroy costant velocity drive shaft shake inspect if the universal joint move freely the beari...

Page 189: ...hboardcover Assembling Assembling carry on the opposite sequence of disassembling RH handlebar switch Disassembling remove front top cover 2 4 remove RH handlebar switch connector remove the two bolts...

Page 190: ...mirror in counter clockwise and you can take off the rear view mirror Attention Left hand rear view mirror is right hand screw thread turn it in counter clock wise direction when dismantling Loosen t...

Page 191: ...tallation bolt take down the handlebar Assembling Assembling carry on according to the opposite sequence of disassembling Torque 20 30N m 2 0 3 0kgf m Attention Main cable assy throttle cable brake oi...

Page 192: ...onto the handlebar location hole use bolt 1 tightening from the bottom Insert the LH handlebar switch connector into the main cable Install RH handlebar switch Pair the RH handlebar switch stopped on...

Page 193: ...dry the joint cement Install brake pump upward the brake pump base UP mark then install the brake pump eyeballing the distance between brake pump and handlebar switch handlebar under hood to equality...

Page 194: ...8 FRONT WHEEL BRAKE SUSPENSION STEERING SYSTEM 8 8 8 8 8 8 17 Steering system Steering system Steering system Steering system Steering system...

Page 195: ...n Remove steering tie rod installation nut washer Press and separate the steering tie rod from the steering stem Removesteeringsteminstallationbolt Raise up the steering stem and the handlebar togethe...

Page 196: ...body Special tool bearing remover component rotor puller remover axle remover heavy bob Installation Installation carry on according to the opposite se quence of uninstallation Special tool Bearing ra...

Page 197: ...avoid possible damage to the wheels zWhen removing tires from rim use special tire lever and rim protector to avoid damage to the rim Overhaul Standard Tightening Torque Rear Wheel Axle Nut 110 130N m...

Page 198: ...r Tightening of Wheel Axle Nut zLoosened Wheel Nut Rear Shock Absorber is Too Soft zWeak Spring zOil Leakage from Rear Shock Absorber Rear Shock Absorber is Too Hard zBent Rear Shock Absorber zTire Pr...

Page 199: ...ious scrapes Replace Slowly turn the wheel measure the rim vitration with a dial gauge Service Limit Axial 2 0mm Radial 2 0mm Installation Refer to Front Wheel Installation 8 3 Wheel Hub Remove Rear W...

Page 200: ...apter 1 for brake hose routing Rear Brake Disc Remove Rear Left Wheel 9 3 Rear Drive Shaft Rear Brake Caliper 9 4 6 Shear Bolts Parking Brake 9 4 Rear Brake Disc 8 3 Inspection Brake Disc Thickness 6...

Page 201: ...left and right suspension at the same time to avoid fall down of the vehicle Stabilizer Bar Remove Bolt1 6 Bolt2 7 Bolt3 10 Bolt4 11 Bracket 8 and 5 Rubber Support 4 and 9 Nut2 2 Nut10 12 Left Ball Pi...

Page 202: ...Remove the following parts from rear right shock absorber Bolt10 25 Nut7 27 Bolt7 19 Nut8 28 Remove rear right shock absorber Installation Reverse the removal procedure for installation Rear Right Arm...

Page 203: ...10 13 With glue Nut front axle 1 M14 1 5 62 Differential bolt 6 M10 1 25 22 45 oil bolt front axle 1 M14 1 25 12 25 Drain bolt front axle 1 M10 1 25 25 Bolt rear axle 2 M10 1 25 25 40 Bolt rear axle...

Page 204: ...n b Constant abnormal sounds during accelerating or decelerating might be cause by gear clearance wrongly adjusted during assembling Note Wrong assembly or adjustment of the front or rear axle will ag...

Page 205: ...16007 1 20 Oil seal 18 65 9 1 5 Cir clip 62 1 21 Coupler 1 6 Drive clutch cover 1 22 O seal 14 6 8 1 7 Drive clutch 1 23 Nut washer 1 8 Washer 83 71 1 2 24 Nut washer M14 1 5 1 9 Dif gear assembly 1...

Page 206: ...ferential gear inspect worn surface Replace broken if necessary zCheck driven gears surface gear center differential bracket differential wearing situation on the differential gear assembly Replace pa...

Page 207: ...assembly Note Use engine oil for oil seal or bearing assembly zDifferential gear assembly M10 1 25 22Tightening torque45Nm Adjust washer thickness 0 1 0 2 0 3 0 4 0 5 1 0 16 23 24 10 Item 31 tightenin...

Page 208: ...urement Install support tools tighening bolts M10X1 25X60 put up dial indicator make sure 21 mm is between measuring point and support tools Turn support tools counter clock and read the data Standard...

Page 209: ...ar Axle 10 c Use special equipment or vehicle control circuit into two stroke position before gear motor assembly d Make sure b and c is assembled using il lustrated positionging bolt before gear moto...

Page 210: ...NS 2 12 Nut M12 1 25 1 13 Washer12 5 30 4 1 14 Coupler rear axle 1 15 BoltM8 35 4 16 Oil seal 35 61 9 5 14 1 17 Bevel gear bearing hous 1 18 O ring 64 5 3 1 5 Bearing 16017 C2 1 19 Bearing 6305 1 20...

Page 211: ...rn status of drive bevel gear and ring gear rear axle Replace if necessary zCheck oil seal lips o ring shape Replace parts if necessary zCheck cylndrical surface of rear axle and oil seal lips Replace...

Page 212: ...installing clearance by checking bevel gear clearance Standard 0 1 0 2 0 2 0 3 0 4 1 0 1 2 1 4 1 6 1 8 0 4 0 5 0 6 e Keep installing point bearing clearance 0 1 0 2 by choosing 8 thickness Rear axle...

Page 213: ...10 11 10 Front Rear Axle 10 f Adjust item 29 as illustrated and make sure its end and back clearance of drive gear is 0 3 0 6 Tighten item 31...

Page 214: ...11 11 11 11 1 Charging System Layout 11 1 Inspection of Charging System 11 5 Overhaul Info 11 2 Rectifier Regulator 11 6 Troubeshooting 11 3 Inspection of AC Magneto 11 8 Battery 11 4 Layout of Electr...

Page 215: ...not open the electrolyte cover Note Replace if the battery service life expired zKeep the ignition switch OFF when removing electrical parts z Disconnect the negative connection of battery if it is s...

Page 216: ...ect Correct Incorrect Incorrect Faulty rectifier Short circuit with AC magneto has short main cable Correct or open circuit Faulty ignition switch Correct Charging system is correct Incorrect Incorrec...

Page 217: ...lation Inspection Measure voltage between battery terminals and check test status Complete test 12 8V Insufficient test 11 8V Insufficient charge Recharge Note When recharging after normal charging me...

Page 218: ...ch at OFF position Connect voltmeter between battery s terminals after engine is started and warmed up Note Avoid short circuit when measuring Overvoltage may be generated when removing or joining the...

Page 219: ...ifting from the high to the low range zDo not turn on the ignition switch when measuring the current Current Leakage less than 1mA When current leakage is higher than specified limit there is fault wi...

Page 220: ...ing coil Resistance between yellow yellow yellow terminals is 0 2 0 3 at 20 C yellow IIgnition switch lead Black lead wire must be wire black connected with black terminal Installation Reverse the rem...

Page 221: ...r winding if it is not according to the standard of resistance zwhether it is insulated for stator winding and the cen ter of stator Performance of Magneto as unload situation zEngine working state 50...

Page 222: ...11 Battery Charging System 11 11 11 11 11 11 9 Layout of Electric parts...

Page 223: ...diagram Ignition advance is integrated in the CDI so the ignition system will automatically adjust ignition time Be careful with CDI overhaul Dropping or strong impact may cause damage to CDI In addi...

Page 224: ...ter available in the market with input resistance over Item Standard Ignition CDI Battery DC Digital Ignition Type Resistor Type Spark Plug Standard DPR7EA 9 NGK Optional DR8EA D7RTC Spark Plug Spark...

Page 225: ...obstructed between negative pole and thread or positive pole and input end 2 Faulty spark includes no spark and weak spark Inspect the following aspects if there is no spark 1 Inspect ignition coil w...

Page 226: ...tage Note Measure after all the wires are correctly connected Inspection should be done when the spark plug and spark plug cap are properly installed If the spark plug is removed the peak voltage will...

Page 227: ...2 1 2 1 2 1 2 12 5 Ignition Primary Coil Voltage Test Wiring Con necting Diagram Notes Ignition Coil Resistance Test Wiring Connecting Diagram Do not touch test probe head and spark plug when testing...

Page 228: ...t peak voltage oscillograph terminal with the following terminal of main cable Special Tool Peak Voltage Oscillograph 07HGJ 0020100 Use together with digital multimeter available from the market with...

Page 229: ...hed by the magnet of rotor Be careful not to hurt the fingers when removing Loosen bolt remove AC magneto stator and pickup Pickup resistance value Inatallation Reverse the removal procedure for insta...

Page 230: ...12 8 CFMOTO Starting Motor...

Page 231: ...oration on commutator surface polish it using sand paper and cleanse it using clean and dry cloth If there is overwear saw it using saw blade Insulator B the distance between B and A is d Armature Coi...

Page 232: ...relay coil Measure resistance between coils of starter relay using multimeter Replace the starter relay with a new one if the resistance is not within the specified value Set multimeter to position S...

Page 233: ...12 Ignition System 1 2 1 2 1 2 1 2 1 2 12 11 Ignition System Diagram...

Page 234: ...nd cause deformation of glass face and damage to bulb Pay attention to the following when replacing the bulb Do not replace the bulb when it is turned on Keep ignition switch in the OFF position and r...

Page 235: ...13 2 CFMOTO TROUBLESHOOTING Head Light Cannot Turn On Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch...

Page 236: ...lacing bulb Oil stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate Make sure that the three pins of the bulb should be in line with the three...

Page 237: ...cation 12V 21 5W Reverse the removal procedure for installation Front Turning Indicator Bulbs Removeheadlight 13 5 Remove cover of front turning light Replace front turning light bulbs Bulb Specificat...

Page 238: ...e If dashboard has something wrong it s recommended to replace whole dashboard Reverse the removal procedure for installation Headlight Remove nuts as picture shown Disconnect headlight connector Disa...

Page 239: ...13 6 CFMOTO Ignition Switch Inspection Remove front rear top cover 2 4 Disconnect 4P connector of ignition switch...

Page 240: ...ble Removefrontcover 2 4 Disconnect 4P connector of ignition switch Loosen bolt and remove ignition switch Reverse the removal procedure for installation Handlebar switch Remove front cover 2 4 Discon...

Page 241: ...or continuity Hold the brake lever Continuity Release the brake lever No continuity No continuity Replace brake light switch Horn Inspection Remove front vent grille 2 15 Disconnect horn Connect with...

Page 242: ...e 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 2 4 Disconnect dashboard wire conne...

Page 243: ...oat with hand locate the float position and check if it conforms to the fuel gauge reading Non conformity check main cable for damage or short circuit Check fuelsensorandfuelgauge Remove fuel sensor 2...

Page 244: ...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 245: ...ature sharply The thermometer should not contact the vessel bottom Disassembly Disassembly Disassembly Disassembly Disassembly Remove right side panel 2 8 Disconnect and remove temp sensor Put the sen...

Page 246: ...nce in Middle or High Range 12 5 Engine Troubleshooting 12 6 Operating Notice This chapter is a general explanation of major troubleshooting of the whole engine Refer to the relevant chapters for trou...

Page 247: ...14 2 CFMOTO...

Page 248: ...14 Troubleshooting 14 14 14 14 14 14 3...

Page 249: ...14 4 CFMOTO...

Page 250: ...14 Troubleshooting 14 14 14 14 14 14 5...

Page 251: ...valve 4 Clogged fuel hose 5 Clogged fuel filter Transfer is not in Neutral position Replace Replace Replace Repair or Replace Tighten Check electrical part Adjust Adjust Clean or Replace Clean and dry...

Page 252: ...ce Replace Engine lacks power 1 Improper valve clearance 2 Weak valve spring 3 Improper valve timing 4 Worn cylinder 5 Worn piston ring 6 Improper valve seating 7 Fouled spark plug 8 Improper spark pl...

Page 253: ...e 2 Worn inner race spline Replace crankshaft Replace inner race Noise from Crankshaft 1 Rattling bearing 2 Worn or burnt crank pin bearing 3 Excessive thrust clearance Replace Replace Replace Noise f...

Page 254: ...ow and fuel level fluctuation 1 Worn or damaged needle valve 2 Damaged needle valve spring 3 Improper working float 4 Foreign matter in needle valve Replace Replace Adjust or Replace Clean 3 Cooling S...

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CF MOTO CF500-5, Service Manual

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Summary of Contents for CF500-5

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