CFMoto UTV Terracross CF500-6 4x4. Service Manual - part 6

-78-

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on

 Page 73, 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. 

 

Item 

Lube 

Method 

Engine Oil 

SAE15W/40 SG

 

Add to proper level on dipstick, See 

page 82 

Brake Fluid 

DOT3 or DOT4 

Maintain level between fill lines, See 

page 92 

Transmission Oil(main 

gearcase) 

SAE15W/40 SG or SAE80W/90 

GL-4

 

See page 85 

Transmission Oil(rear 

gearcase) 

SAE15W/40 SG or SAE80W/90 

GL-4

 

See page 86 

Prop Shaft 

U-joint lube 

Locate fittings and grease 

Control Arm Pivot Bushings, 

Front/Rear 

NLGI No.2 

Locate fittings and grease 

Stabilizer Bar Bushings, 

Front/Rear 

NLGI No.2 

Locate fittings and grease 

 

 

-79-

Lubrication Recommendations:

Control  Arm  Pivot
Bushings, Front/Rear

-80-

Engine Oil

Always check and change engine oil at intervals outlined in the Periodic Maintenance Chart beginning on
 page 72. Always change the oil filter whenever changing oil.

SAE15W/40 SG

 

Oil 

We strongly recommend use

 

of

 

SAE15W/40 SG

 

Oil

,

API certified 

“

S   

”

oil

. 

If

 

SAE15W/40 SG

 

Oil

 is 

unavailable,choose oil following

 

the

 

right

 

instructions

 

according  to  the  engine

 

ambient

 

temperature.

 

Oil may need to be changed more frequently if SAE15W/40 SG

 

oil is not used

. 

Follow

 

the

 

manufacture

'

s

 instructions for

ambient temperature operation.

 

CAUTION

Mixing brands or using a non-recommended oil may cause serious damage to the engine. We recommend use

 of

 

SAE15W/40 SG

 

Oil, never use substitute or mix oil brands.

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and
 may result in engine seizure, accident and injury. Always perform the maintenance procedure as  outlined in

 the Periodic Maintenance Chart.

G

-81-

Engine Oil

Always check and change engine oil at intervals outlined in the Periodic Maintenance Chart beginning on page
 72. Always change the oil filter whenever changing oil.

Oil Check

The oil dipstick and fill tube is located on the engine, behind the 
passenger seat.

1

. 

Position the vehicle on a level surface.

2

. 

Place the transmission in PARK.Apply the brakes.

3

. 

Start the engine.Allow it to idle for 20-30 seconds.

Stop the engine.

4

．

Remove both seats.Remove the rear service panel. 

See page 34. 

5

．

Remove the dipstick from the left side.

Wipe it dry with a clean cloth.
6

．

Reinstall the dipstick completely, but do not lock it.

The dipstick must be inserted completely to keep the angle and
depth

 

of

 

the

 

stick

 

consistent.

7

．

Remove the dipstick and

 

check

 

the

 

level

. 

Maintain

 

the

 

oil

 

level

 

within the

 

upper

 

and

 

lower

 

limit

.

 

Do not overfill.

NOTE：

Due to

 

the

 

dipstick

 

entry angle into the crankcase,

 

the oil level will read higher on the bottom side of the dipstick.
Always read the level on the upper surface of the dipstick.
8

．

Reinstall the dipstick. Seat the lever lock.

Dipstick

Oil dipstick

Upper  limit

Lower limit

-82-

Engine Oil
Oil and Filter Change
CAUTION

Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin.

Always check and change engine oil at intervals outlined in the Periodic Maintenance Chart beginning on 
page 72. Always change the oil filter whenever changing oil.

The engine drain plug

 

is

 

located

 

on

 

the

 

bottom

 

of

 

the

 

crankcase.

1

. 

Position

 

the

 

vehicle

 

on

 

a

 

level

 

surface

.

Place the transmission in PARK.Apply the brakes
2

. 

Start

 

the

 

engine

.

Allow

 

it

 

to

 

idle

 

for

 2-3

minutes

.

Stop the engine.
3

. 

Clean the area around the drain

 

plug.

4

. 

Place a drain pan beneath engine crankcase

 

and

 

remove

 

the drain plug.
5

. 

Allow

 

the

 

oil

 

to

 

drain

 

completely

.

6

. 

Reinstall

 

the

 

sealing

 

washer

 

on

 

the

 

drain

 

plug

.

NOTE：

The sealing surface on drain plug and crankcase 

should

 

be

 

clean

 

and

 

free

 

of

 

burrs

,

nicks

 

or

 

scratches

.

7

．

Drain plug

，

torque

：

22ft

.

lbs

（

30Nm

）

Engine  oil  Drain  plug

-83-

Engine Oil

Oil and Filter Change

8.Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it.
9.Using a clean dry cloth, clean the filter sealing surface on

 

the

 

crankcase

.

10.Lubricate the o-ring on the new filter with a film of fresh engine oil.Check to make sure the o-ring is in good

 condition.

11.Install the new filter and turn by hand until the filter gascket contacts the sealing surface,then turn an

 additional 1/2 turn with special wrench. 

12.Remove the dipstick and fill with 2.5L

 

recommended

 

oil

.

13.Place the transmission in PARK.Apply the brakes
14. Start the engine.Allow it to idle for 2 minutes.
15.Stop the engine

. 

Inspect for leaks.

16.Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the

 dipstick.

17.Dispose of used filter and oil properly.

-84-

Gearcases

Demand Drive Unit

（

Front Gearcase

）

Always check and change engine oil at intervals outlined in the Periodic Maintenance Chart beginning on 

page 72

.

Refer to the Gearcase Specifications Chart on page 86 for
recommended lubricants, capacities and torque specifications. 

Fluid Check

The fill plug is located
On the bottom right side of the demand drive unit

.

Maintain

 

the

fluid level even with the bottom thread of the fill plug hole.
1

．

Position the vehicle on a level surface.

2

．

Remove the fill plug.Check the fluid level.

3

．

Add the recommended fluid as needed.

4

．

Reinstall the fill plug.Torque specifications.

Fluid Change

The drain plug is located on the bottom of the

 

gearcase

.

1

．

Remove the fill plug.

2

．

Place a drain pan under the drain plug.

3

．

Remove the drain plug.Allow the fluid to drain completely.

4

．

Clean the drain plug. 

5

．

Reinstall the drain plug with new o-ring.Torque to specification.

6

．

Add the recommended fluid.

 

Maintain

 

the

 

fouid

 

level

 

even

 

with

 

the

 

bottom

 

thread

 

of

 

the

 

fill

 

lpug

 

hole

. 

7

．

Reinstall the fill plug with new o-ring.Torque to specification.

8

．

Check for leaks.Discard used fluid properly.

Drain Plug

Fill Plug

Front Gearcase

-85-

Gearcases

Rear Gearcase

Always check and change engine oil at intervals outlined in the Periodic Maintenance Chart beginning on

 page 72.

Refer to the Gearcase Specifications Chart on page 86 for
recommended lubricants, capacities and torque specifications.

Fluid Check

The fill plug is located On the right side of the rear gearcase

.

Maintain

 

the

fluid level even with the bottom thread of the fill plug hole.
1

． 

Position

 

the

 

vehicle

 

on

 

a

 

level

 

surface

.

2

． 

Remove

 

the

 

fill

 

plug

.

Check

 

the

 

fluid

 

level

.

3

． 

Add

 

the

 

recommended

 

fluid

 

as

 

needed

.

4

． 

Reinstall

 

the

 

fill

 

plug

.

Torque

 

to

 

specification

.

Fluid Change

The drain plug is located on the bottom

 

right

 

side

 

of the

 

rear gearcase.
1

．

Remove the fill plug.

2

．

Place a drain pan under the drain plug. Remove drain plug.

3

．

Allow the fluid to drain completely.

4

．

Clean the drain plug. Torque to specification.

5

．

Add the recommended fluid. Maintain the fouid level even with the bottom

 

thread

 

of

 

the

 

fill

 

lpug

 

hole

.

6

．

Reinstall the fill plug.Torque to specification.

7

．

Check for leaks.Discard used fluid properly.

FILL Plug

Drain Plug

Rear Gearcase

-86-

Gearcase

Gearcase Specification Chart

Use of other fluids may result in improper operation of components.

Gearcase

Lubricant

Capacity

Fill Plug Torque

Drain Plug/Level
 Check Plug Torque

Transmission of 
Main Gearcase

（

CF188-C

）

SAE15W

/40 

SG

preliminary

：

2800ml

change

：

2500ml

30 Nm

Transmission of 
Transfer

 

Case

（

196S-C

）

SAE15W/40 SG

preliminary

：

2800ml

change

：

2500ml

30 Nm

Demand Drive Unit

（

Front Gearcase

）

SAE15W/40 SG

      

or

SAE80W/90 GL-4

330ml(preliminary

)，

280ml

 

change

 

(

)

25Nm

25Nm

25Nm

25Nm

Rear Gearcase

SAE15W/40 SG

      

or

SAE80W/90 GL-4

300ml(preliminary

)，

250ml

 

change

 

(

)

-87-

Spark Plugs

CAUTION

Using non-recommended spark plug can result in serious engine damage. 
Always use CFMOTO-recommended spark plug. Refer to the specifications section beginning on

 

page 120

.

Spark Plug Gap/Torque

 

Model 

Electrode Gap 

New Plug Torque 

Used Plug Torque 

DPR7EA-9(NGK) 

0.8-0.9mm 

18Nm 

18Nm 

 

Spark plug condition is indicative of engine operation

.

The

 

spark

 

plug

 

firing end condition should be read

 after the engine is warmed-up and the vehicle is driven at higher speeds.Immediately check the spark plug for
 correct color.See page 88.

A hot exhaust system and engine can cause serious burns.

 

Wear

 

protective

 

gloves

 

when

 

removing

 

a

 

spark

 

plug

 

for

 

inspection

.

-88-

Spark Plugs

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown.There will be few

 

combustion deposits. The electrodes are 

not burned or eroded.This indicates

 

the proper type and heat range for the engine and the service.

NOTE: 

The tip should not be white.

 

A white insulator tip indicates overheating,

 

caused by use of an improper

 spark plug or incorrect throttle body

 

adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black.

 

A damp oil film covers the firing

 

end.

 

There may be a carbon layer over

 the entire nose.Generally, the

 

electrodes are not worn.General causes of fouling are excessive oil,

 

use

 

of

 non-recommended injection oil or incorrect throttle body adjustments.

Spark Plug Removal and Replacement

1

.

 

Remove both seats.

2

.

 

Remove the rear service

 

panel. See page 34.

3

.

 

Remove the spark plug cap.

4.

 

Using the spark plug wrench

 

provided in the tool kit,

 

remove the plug by rotating

it counterclockwise.

5

.

 

Reverse the procedure for

 

spark plug installation.

Torque to specification.

 

See

 

page 87

.

SPARK PLUG

-89-

Cooling System

Operation

The engine coolant level is controlled or maintained by the recovery

 

system.

 

The recovery system compon-

ents are the overflow bottle, radiator

 

filler neck,

 

radiator pressure cap and connecting hose.

 

As coolant op-

erating temperature

 

increases, the expanding (heated)

 

excess coolant is forced out of the radiator, past the 

pressure cap, and

 

into the overflow bottle. As engine coolant temperature decreases, the

 

contracting

 

(

cooled

) 

coolant

 

is

 

drawn

 

back

 

up

 

from

 

the

 

tank

, 

past

 

the

 

pressure cap, and into the radiator.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine,

 

we

 

recommend that the system be co-

mpletely drained every two

 

years

 

and

 

a

 

fresh mixture of antifreeze and water added.

 

We

 

recommends the

 

use of

 

60/40

 

anti-freeze/coolant or a 50/50 mixture of

 

high quality aluminum compatible anti-freeze/coolant 

and distilled

 

water.

Premium 60/40 is already premixed and ready to use.

 

Do

 

not dilute with water.

NOTE: 

Always follow the manufacturer's mixing recommendations for the

 

freeze protection required in your

 area.

Any time the cooling system has been drained for maintenance or repair,

 

replace the coolant. If the recovery

 bottle has run dry, the level in the

 

radiator should be inspected. Add coolant as needed.

-90-

Cooling System

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined

 

in the Periodic Maintenance

 

Chart

 

beginning

 

on

 

page 72

. 

Do not

 

obstruct or deflect air flow through the radiator by installing unauth-

orized

 

accessories in front of the radiator or behind the cooling fan. Interference

 

with the radiator air flow can

 lead to overheating and consequent engine damage.

CAUTION

Washing the vehicle with a high-pressure hose could damage the radiator
fins and impair the radiator's effectiveness. Using a high-pressure system is
not recommended.

-91-

Cooling System

Coolant Level

Always check and change
the coolant at the intervals
outlined in the Periodic
Maintenance Chart beginning
on page 72

.

Maintain the coolant level between

the minimum and maximum
marks on the bottle

(

when

 

the

 

fluid

 

is

 

cool

).

1

.

 

Position the vehicle on

a level surface.
2

.

 

Remove the hood. See

 

page 36.

3

.

 

View the coolant level in the overflow bottle.

4

.

 

If the coolant level is below the safe operating range, remove the

cap and use a funnel to add coolant through the opening. Reinstall

 

the cap.

NOTE: 

If coolant must be added often, or if the overflow bottle runs completely

dry, there may be a leak in the system. Have the cooling system inspected by your dealer.

FILLER CAP

RESERVIOR

UPPER
LIMIT

LOWER
LIMIT

RADIATOR

ENGINE OIL RADIATOR

-92-

Cooling System

Radiator Coolant Level

Always check and clean the screen and radiator

 

fins

 

at

 

the

 

intervals

 

outlined

 

in

 

the

 

Periodic

 

Maintenance

 

Chart

 

beginning on page 72

. 

Do not

 

obstruct or deflect air flow through the radiator by installing unautho rized

accessories in front of the radiator or behind the cooling fan. InterInterference

 

with the radiator air flow can

 lead to overheating and

 

consequentially, engine damage.

Escaping steam can cause severe burns.

 

Never remove the pressure cap

 

while the engine is warm or hot.

 

Always allow the engine to cool before

 

removing the pressure cap.

1

.

 

Remove the hood. See page 36.

 

2

.

 

Slowly remove the radiator cap.

3

.  

View the coolant level through the opening.

4

.

 

Use a funnel and slowly add coolant as needed.

NOTE: 

This procedure is required only if the cooling system has been drained

for maintenance and/or repair. But if the overflow bottle has run dry,

 

the level in the radiator should also be 

inspected.

NOTE: 

Use of a non-standard pressure cap will not allow the recovery system

to function properly. See your dealer for the correct replacement part.

-93-

Continuously Variable Transmission (CVT) System

Belt slip is responsible for creating excessive heat that destroys belts,

 

wears clutch components and causes

 outer clutch covers to fail.

 

Switch

to low range while operating at slower speeds to extend the life of the

 

CVT components (belt, cover, etc.).

Failure to comply with the instructions in this warning can result in severe

 

injury or death.

Do not modify any component of the CVT system. Doing so may reduce its
strength so that a failure may occur at a high speed.

 

The CVT system has

 

been precision balanced. Any modification will cause the system to be out of

 

balance, 

creating vibration and additional loads on components

. 

The CVT system rotates at high speeds, creating large amounts of force on
clutch components.

 

Extensive engineering and testing has been conducted
to ensure the safety of this product.

 

However, as the owner, you have the

 

following responsibilities to make

 sure this system remains safe:

 

Always follow all recommended maintenance procedures. See your dealer

 

as outlined in the owner's manual.

This CVT system is intended for use on  CFMOTO  products only. Do not install

 

it in any other product.

Always make sure the CVT housing is securely in place during operation.