CFMoto UTV Terracross CF500-6 4x4. Service Manual - part 8

-110-

BatteryBattery 

Installation

Using a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. 
It can also hinder vehicleperformance. 
Follow the battery charging instructions on page 117 before installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. On conventional batteries, install the battery vent tube (sealed bat-teries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed. 
Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

 

Battery

 

gases

 

could

 

accumulate

 

in

 

an

 

improperly

 

installed

 

vent

 

tube

 

and

 

cause

 

an

 

explosion

, 

resulting

 

in

 

serious

 

injury

 

or

 

death

. 

Always

 

ensure

 

that

 

the

 

vent

 

tube

 

is

 

free

 

of

 

obstructions

 

and is securely

 installed as  recommended. 

4. Coat the terminals with dielectric grease or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed.
8. Reinstall the driver

'

s seat.

Battery
Battery Storage

Whenever the vehicle is not used for a period of three months or more, 
remove the battery from the vehicle, ensure that it's fully charged, and 
store it out of the sun in a cool, dry place. Check battery voltage each 
month during storage and recharge as needed to maintain a full charge. 
See page 112.

NOTE:

 Battery

 

charge

 

can

 

be

 

maintained

 

by

 

using

 

a

  

Battery

 

Tender

 

charger or by charging about once a month to make up for normal self-
discharge. Battery Tender can be left connected during the storage 
period, and will automatically charge the battery if the voltage drops 
below a pre-determined point. 

Battery

 

Fluid

 

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Battery

 

vol

:

12V 18Ah

 

-111-

CFMOTO

Battery

Battery Charging (Conventional Battery

)

1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 109

.

2. Charge the battery with a charging output no larger than 1/10 of the battery

'

s amp/hr rating. 

Charge as needed to raise the specific grav-ity to 1.270 or greater.
3. Reinstall the battery. See page 110

. 

Battery Charging (Sealed Battery

)

The following battery charging instructions apply only to the installa-tion of a sealed battery. 
Read all instructions before proceeding with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed 
and fully charged at the factory. Never try the sealing strip off or add 
any other fluid to this battery. 
The single most important thing about maintaining a sealed battery is to 
keep it fully charged. Since the battery is sealed and the sealing strip 
cannot be removed, you must use a voltmeter or multimeter to measure 
DC voltage.

An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. 
Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully 
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps 
or less until battery voltage is 12.8 or greater.

 

NOTE: When using an automatic charger, refer to the charger manufacturer's 
instructions for recharging. When using a constant current charger, 
use the guidelines on the next page for recharging.

 

-112-

Battery

Battery Charging (Sealed Battery)

NOTE: 

Always verify battery condition before and 1-2 hours after the end of charging.

。

State of

 

Charge

Voltage

Action

Charge Time

100%

12.8-13.0V

None, check at 3 
 None required

mos. from date of 
manufacture

None required

75%-100%

12.5-12.8V

May need slight  charge,

3-6 hours

if no 
charge given, 
check in 3 months

50%-75%

12.0-12.5V

Needs charge

5-11hours

25%-50%

11.5-12.0V

Needs charge

At  least  13  hours, 
verify state of charge

-113-

Cleaning and Storage

Washing the Vehicle
Keeping your vehicle clean will not only improve its appearance 
but it can also extend the life of various components.

 

CAUTION

High water pressure may damage components.CFMOTO recommends washing the vehicle by

 

hand

 

or

 

with

 

a

 

garden

 

hose

, 

using

 

mild

 

soap

. 

Certain

 

products

, 

including

 

insect

 

repellents

 

and

 

chemicals

, 

will

 

damage

 

plastic

 

surfaces

. 

Do not allow these types of products to contact the vehicle.

。

The best and safest way to clean your vehicle is with a garden 
hose and a pail of mild soap and water. 
1. Use a professional-type washing cloth, cleaning the upper body first 
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

* 

Avoid

 

the

 

use

 

of

 

harsh

 

cleaners

, 

which

 

can

 

scratch

 

the

 

finish

.

* 

Do

 

not

 

use

 

a

 

power

 

washer

 

to

 

clean

 

the

 

vehicle

.

* 

Do

 

not

 

use

 

medium

 

to

 

heavy

 

duty

 

compounds

 

on

 

the

 

finish

.

* 

Always

 

use

 

clean

 

cloths and pads for cleaning and polishing. Old or 

reused cloths and pads may contain dirt particles that will scratch the finish.

-114-

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended), 
exercise extreme caution. The water may damage components and could 
remove paint and decals. Avoid directing the water stream at the follow-
ing items: 

* 

Wheel

 

bearings

* 

Radiator

* 

Transmission seals

* 

Brakes

* 

Cab

 

and

 

body

 

panels

* 

Labels

 

and

 

decals

* 

Electrical

 

components

 

and

 

wiring

 

NOTE:

 If warning and safety labels are damaged, contact your CFMOTO deal

for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine 
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
CFMOTO recommends the use of common household aerosol furniture 
polish for polishing the finish on your CFMOTO vehicle. Follow the 
instructions on the container.
Polishing Tips

* 

Avoid

 

the

 

use

 

of

 

automotive

 

products

, 

some

 

of

 

which

 

can

 

scratch

 

the

finish of your vehicle.

* 

Always

 

use

 

clean

 

cloths

 

and

 

pads

 

for

 

cleaning

 

and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the finish.

 

-115-

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre-
serve wheel life and ensure a 

“

like new

” 

appearance

 

for

 

many

 

years

.

NOTE:

 Chrome wheels exposed to road salt (or salt in the air in coastal areas) 

are more susceptible to corrosion if not properly cleaned. Clean 
chrome wheels more often if they're exposed to salt or

 

other

 

corrosive

 

elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use 
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and 
other elements can cause corrosion. 
3. Polish the clean chrome wheels periodically. Use an automotive 
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes. 
Read and follow the product labels

 

and

 

instructions

.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT 
grade) to remove it. Gently rub the affected areas with the steel wool 
until the corrosion has been removed. Clean and polish the wheel as out-
lined above.

 

-116-

Cleaning and Storage

Storage Tips 

CAUTION

Starting the engine during the storage period will disturb the protective film 
created by fogging and damage could occur. Never start the engine during 
the storage period.
lean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See  page 114.

Stabilize the Fuel
1. Fill the fuel tank.
2. Add CFMOTO Carbon Clean Fuel Treatment or CFMOTO Fuel Stabilizer. 
Follow the instructions on the container for the recommended amount.

NOTE: 

Carbon Clean removes water from fuel systems, stabilizes fuel and 

removes carbon deposits from pistons, rings, valves and exhaust sys tems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to 
disperse through the

 

entire

 

fuel

 

delivery

 

system

.

Oil and Filter
Change the oil and filter. See page 83.

 

Air Filter / Air Box
Inspect and clean or replace the pre-filter and air filter. See page 83. 
Clean the air box. Drain the sediment tube.
Fluid Levels
Inspect the fluid

 

levels

. 

Add

 

or

 

change

 

fluids

 

as

 

recommended

 

in

 

the

 

Periodic Maintenance Chart beginning on page 95

* 

Demand

 

drive

 

fluid

 (

front

 

gearcase

)

* 

Rear

 

gearcase

 

fluid

* 

Transmission

 

fluid

* 

Brake

 

fluid

 (

change

 

every

 

two

 

years

 

and

 

any

 

time

 

the

 

fluid

 

looks

 

dark or contaminated)

* 

Coolant

 (

test

 

strength

/

fill

)

-117-

Cleaning and Storage

Storage Tips

Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended

 

in the Periodic Maintenance Chart

 

beginning on page 72

.

Fog the Engine
1. Treat the fuel system with CFMOTO

 

Carbon

 

Clean

. 

Follow

 

the

 

instructions

 

on the container. Start the

 engine. Allow it to idle for several

 

minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Synthetic

 

0W40 engine oil. To access the

 plug holes, use a section of

 

clear 1/4" hose and a small plastic squeeze bottle filled with the premeasured

 

amount of oil.

NOTE: 

Do this carefully! If you miss the plug holes, oil will drain from the spark

 

plug cavities into the hole at 

the front of the cylinder head, and appear

 

to be an oil leak.

3. Reinstall the spark plugs. Torque to specification.

 

4. Apply dielectric grease to the inside of each spark plug cap. Do not

 

reinstall the caps onto the plugs at this 

step

.

5. Turn the engine over several times. Oil will be forced in and around

 

the piston rings and ring lands, coating

 the cylinder with a protective

 

film of fresh oil.

6. If CFMOTO

 

fuel system additive is not used, fuel tank, fuel lines, and

 

injectors should be completely drai-

ned of gasoline.
7. Reinstall the spark plug caps to the spark plugs.
Battery

 

Maintenance

See pages 110-112

 

for

 

storage

 

and

 

charging

 

procedures

.

Storage Area/Covers
Be sure the storage area is well ventilated. 

NOTE: 

Do not use plastic or coated materials. They do not allow enough ventilation

 

to prevent condensation,

 and may promote corrosion and oxidation.

-118-

Cleaning and Storage

Removal from Storage

1. Check the battery electrolyte level and charge the battery if necessary.
Install it in the vehicle. Make sure the battery vent hose is

 

routed properly and that it's not pinched or

 restricted in any way.

2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section

 

on page 56.

NOTE: Tightness of the bolts, nuts and other fasteners should be checked by

 

an authorized CFMOTO

 

dealer

.

5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 72

.

Engine exhaust contains poisonous carbon monoxide and can cause loss of

 

consciousness or death. Never

 run an engine in an enclosed area.

Transporting the Vehicle

Follow these procedures when transporting the vehicle.
1. Place the transmission in PARK. Stop the engine.
2. Remove the key to prevent loss during transporting.
3. Secure the fuel cap and seats.
4. Always tie the frame of the CFMOTO

 

vehicle

 

to

 

the

 

transporting

 

unit

 

securely with suitable straps or rope. 

Do not attach tie straps to the

 

front control arm bolt pockets.

-119-

SPECIFICATIONS

 

Item

 

CF625-3

 

CF500-6

 

Gross Vehicle Weight

 

495kg( With full  Engine Oil

 and fuel

)

 

495kg(With full  

Engine Oil

 and fuel

)

 

Fuel Capa

city

 

27L

 

27L

 

Engine Oil Capacity

 

2800ml

（

first time

），

2500ml

（

replace

）

  2800ml

（

first time

），

2500ml

（

replace

）

 

Coolant Capacity

 

2720ml

 

2720ml

 

Rear Gearcase Oil Capacity

 

300ml( first time

)

，

250ml(replace)

 

300ml(first time)

，

250ml(replace)  

Transfer Case Oil Cap acit

y 

330ml( first time )

，

280ml( replace) 

330ml( first time )

，

280ml( replace) 

L oadable Weight Capacity

 

100kg

 

100kg 

Maximum Weight Capacity

 

(Payload)

 

250kg (riders/cargo/accessories)

 

250kg (riders/cargo/accessories)

 

 

Receiver Hitch Tongue Capacity

 

50kg

 

50kg

 

Receiver Hitch Towing Capacity

 

125kg(including trailer and cargo)

 

125kg(including trailer and cargo)

 

Overall Length

 

2630mm

 

2630mm 

Overall Width

 

1320mm

 

1320mm

 

Overall Height

 

1800mm

 

1800mm

 

Wheelbase

 

1960mm

 

1960mm

 

M inimum  turning  radius 

5.0m

 

5.0m

 

Ground Clearance

 

240mm

 

240mm

 

           

    

 

-120-

-121-

Item

CF625-3

CF500-6

ENGINE NO.

196S-C

CF188-C

ENGINE TYPE

Single cylinder

、

4 valve 4 stroke with

counterbalance

Single cylinder

、

4 valve 4 stroke with

counterbalance

Displacement

594ml

493ml

Bore x Stroke

96mm

×

82mm

87.5mm

×

82mm

Alternator Output

300W

，

5000 r/min

300W

，

5000 r/min

Compression Ratio

10:1

10.2:1

Starting System

Electric

Electric

Fuel System

EFI

（

Electronic fuel injection

）

EFI

（

Electronic fuel injection

）

Ignition System

ECU

ECU

Spark Plug / Gap

NGK:DPR7EA-9/0.8-0.9

NGK:DPR7EA-9/0.8-0.9

Front Suspension

Independent double arm

Independent double arm

Rear Suspension

Independent double arm

Independent double arm

Lubrication System

Compression

 

Wet Sump

Compression

 

Wet Sump

Engine Oil

SAE

15

W

/40 

SG

SAE

15

W

/40 

SG

Driving System Type

Front/Rear gear output

Front/Rear gear output

Shift Type

Dual Range

/

L

－

H

－

N

－

R

Dual Range

/

L

－

H

－

N

－

R

Gear Reduction - Low

5.857

5.857

Gear Reduction 

–

 

Reverse

3.828

3.828

Gear Reduction - High

3.514

3.514

-122-

Item

CF625-3

CF500-6

Drive Ratio - Front

3.667(33/9)

3.667(33/9)

Drive Ratio - Final

3.667(33/9)

3.667(33/9)

Tire Size - Front

25

×

8-12 77J

25

×

8-12 77J

205/80

-12 

77J

205/80

-12 

77J

Tire Size - Rear

25

×

10-12 85J

25

×

10-12 85J

255/65

-12 

85J

255/65

-12 

85J

Tire Pressure - Front

70kPa

70kPa

Tire Pressure - Rear

84kPa

84kPa

Brakes, Front/Rear

Foot Activated, 4-wheel hydraulic disc

Foot Activated, 4-wheel hydraulic disc

Front trunk Loadable

10kg

10kg

Headlight

35W/35W

×

2

35W/35W

×

2

Brake light/Tail light

21W/5W

×

2

21W/5W

×

2

Front turning light

21W

×

2

21W

×

2

Rear turning light

10W

×

2

10W

×

2

Front position light

5W

×

2

5W

×

2

Dashboard

LCD Dashboard

LCD Dashboard

Auxiliary DC Outlet

12V  Maximal

 

current

:

10A

12V  Maximal

 

current

:

10A

-123-

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. See warnings on page 63

.

Driving at low RPM or

 

ground speed (3

-7 

MPH

)

Drive at a higher speed or use low range more frequently.
See page

 

43

Insufficient warm-up at

 

low ambient temperatures

Warm the engine at least 5 minutes. With the transmission

 

in 

neutral, advance the throttle to about 1/8 throttle in

 

short bursts,

 5 to 7 times. The belt will become more flexible

 

and prevent belt

 burning.

Slow/easy clutch engagement

Use the throttle quickly and effectively.

Towing/pushing at low

 

RPM/low ground speed

Use low range only.

Use low range only.

Utility use/plowing

Stuck in mud or snow

Shift the transmission to low range and carefully use fast,

 

aggressive throttle application to engage clutch.

WARNING

: 

Excessive

 

throttle

 

may

 

cause

 

loss

 

of

 

control

 

and 

vehicle overturn

Climbing over large

 

objects from a stopped

 

position

Shift the transmission to low range and carefully use fast,

 

brief, 

aggressive throttle application to engage clutch

.

WARNING

: 

Excessive

 

throttle

 

may

 

cause

 

loss

 

of

 

control

 

and vehicle overturn.

Belt slippage from water

 

or snow ingestion into

 the

 

PVT system

Dry out the PVT. See page

 95. 

Inspect

 

clutch

 

seals

 

for

 

damage if repeated leaking occurs.

Clutch malfunction

See your dealer.

Poor engine performance

Check for fouled plugs or foreign material in gas tank or

 

fuel

 lines. See your dealer.

Slippage from failure to

 

warm up belt

Always warm up the belt by operating below 30 mph

 

for

 

one mile (5 miles or more when temperature is below

 

freezing).

TROUBLESHOOTING

-124-

Drive Belt Wear/Burn

Possible Cause

Solution

Wrong or missing belt

Install the recommended belt.

mproper break-in

Always break in a new belt and/or clutch. See
 pages 53 and 43

.

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Loose battery connections

Loose solenoid connections

Loose electronic control box connections

Recharge the battery to 12.8 VDC

Check all connections and tighten

Check all connections and tighten

Inspect, clean, reinstall connectors

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel

Clogged fuel filter

See your CFMOTO

 

dealer

Water is present in fuel

Drain the fuel system and refuel

Old or non-recommended fuel

Replace with fresh recommended fuel

Fouled or defective spark plugs

Inspect plugs and replace if necessary

Water or fuel in crankcase

Immediately see your CFMOTO

 

dealer

Low battery voltage

Recharge the battery to 12.8 VDC

Mechanical failure

See your dealer

-125-

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Inspect, clean and/or replace spark plugs

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Old or non-recommended fuel

Replace with fresh recommended fuel

Incorrectly installed spark plug wires

See your dealer

Incorrect ignition timing

Mechanical failure

See your dealer

See your dealer

Loose ignition connections

Check all connections and tighten

Water present in fuel

Replace with fresh recommended fuel

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Replace with recommended fuel

ncorrect ignition timing

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs