Content .. 2 3 4 5 ..

CFMoto ATV CF500/CF500-A. Service Manual - part 4

3. Checks & Adjustment

When the coolant level is below the LOWER limit,

remove reservoir tank cap and add coolant till upper limit.

(Add coolant or diluted original liquid).

Recommended coolant: CFMOTO coolant

Standard density: 50%

( Freezing temperature of coolant varies according to the

different mixture ratio. Adjust the mixture ratio according to

the lowest temperature in the place where the vehicle is

used.)

If the coolant reduces very fast, check if there is any leakage.

The cooling system may be mixed with air when there is no

coolant in the reservoir tank and the air should be discharged

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 radiator hose for aging, damages or cracks.

The rubber hose will naturally get aged after a period of service

time. The aged hose may get cracked when the cooling system

is heated. Nip the hose with fingers and check if there are any

tiny cracks.

In case of any abnormal, replace with a new hose.

Check the clamps of the coolant pipes and hose.

Tighten properly in case of any looseness.

Check radiator fins for mud and dust clog or damage.

Correct the bent fins; clean the mud with water and compressed

air. When the damaged area of the radiator fin is over 20%,

replace with a new radiator.

3-13

3. Checks & Adjustment

Check Water Temperature Gauge

When engine is not working, the water temperature should 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 beam adjusting screw with a cross
screwdriver and adjust the high/low beam to meet the
requirement.

3-14

4. Cooling System

Overhauling Info………………………………. 4-1
Trouble Shooting……………………………… 4-2
Check and Maintenance………………………4-3
Reservoir Tank……………………. …………..4-5

Adding Coolant…………………………………..4-7
Cooling System Chart…………………………..4-10

Overhaul Information

Note

●

If the radiator cap is opened when the coolant temperature is above 100

℃

, the pressure of coolant

will drop and get boiled rapidly. The steam jet may cause danger and injury. Cover the cap with a
piece of rag after the coolant temperature goes down and open the cap slowly.

●

Inspection of coolant should be done after the coolant is fully cooled.

●

Coolant is toxic. Do not drink or splash it to skin, eyes or cloth.

—

coolant splashes in your eyes, thoroughly wash your eyes with water and consult a doctor.

—

If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.

—

If coolant is swallowed, induce vomit immediately and see a physician.

—

Store the coolant properly and keep it away from reach of children.

●

Check radiator fins for mud block and/or damage. Correct the bent fins. Clean off the mud with water

and compressed air. Replace with a new one if the damaged fin area reached 20%.

●

The overhauling of the water pump can be done without removing the engine.

●

Add coolant through reservoir tank. Do not open the radiator cap except when disassembling the cooling

system for adding or drainage of coolant.

●

Do not stain the plastic parts with coolant. In case of any coolant stains, flush with water immediately.

●

After disassembly of the cooling system, check the joints for leakage with a radiator cap tester (available in

the market).

●

Refer to Chapter 10 for overhauling of temperature transducer.

Inspection standard

Item Standard

Full capacity

1140ml

Reservoir tank capacity

340ml

Coolant

Capacity

Standard density

30%

Opening pressure of radiator cap

108kpa(1.1kgf/cm

)

Valve open temperature

℃

Full open Temperature

℃

Thermostat

Full open lift

3.5-4.5mm

Tightening torque

Drainage bolt, water pump:

m(0.8kgf

Thermoswitch

10N

m(1.0kgf

4-1

4. Cooling System

Trouble Shooting

Sharp rise of water temperature

Faulty radiator cap

Air in cooling system

Faulty

water

pump

Faulty thermostat (thermostat is not open)

Clogged radiator pipe or cooling pipes

Damage or clogged radiator fin

Coolant is not enough

Faulty or malfunction of fan motor

No rise or slow rise of water temperature.

Faulty thermostat (thermostat is not closed)
Faulty circuit of water temperature display

Coolant leakage

Faulty

water

seal

O-rings are aged, damaged or improperly sealed.

Washers are aged, damaged or improperly sealed.

Improper installation of pipes or hoses

Pipes and/or hoses are aged, damaged or improperly sealed

4-2

4. Cooling System

Check and Maintenance

Checking coolant density

Note:
Open the radiator cap after coolant is fully cooled.

Remove:
--Front top cover (

→

2-4)

--Radiator cap (counter clockwise).

Check with a densimeter if the coolant density adapts to
the local temperature.

Check coolant for stains or impurities.

Inspection of radiator cap
Note
Open the radiator cap after the coolant is fully cooled.

Remove:
--Front top cover (

→

2-4)

--Radiator cap (

→

4-3).

Note
Apply coolant on the sealing surface of radiator cap
before attaching the tester to the radiator cap.

Install the radiator cap tester to the radiator cap;

Apply the specified pressure (radiator cap opening
pressure) for 6 seconds and make sure that there is drop in
pressure.

Opening pressure of radiator cap:

108kpa(1.1kgf/cm

)

4-3

4. Cooling System

Pressure testing of cooling system

Install the radiator cap tester to the radiator cap;

Apply the specified pressure (radiator cap opening
pressure) for 6 seconds and make sure that there is drop in
pressure.

Note
Do not apply pressure over the specified pressure
[108kpa(1.1kgf/cm

)], or the cooling system may be

damaged.

In case there is any pressure leakage, check the pipe, joint
parts, joints of water pump and drainage (

→

4-5).

Replacing Coolant, Air Discharge

Preparation of coolant
Coolant is toxic, DO NOT drink or splash it to skin,
eyes, and clothes.

—

coolant splashes in your eyes, thoroughly wash

your eyes with water and consult a doctor.

—

If coolant splashes on your clothes, quickly wash it
away with water and then with soap and water.

—

If coolant is swallowed, induce vomit immediately
and see a physician.

—

Store the coolant properly and keep it away from
reach of children.

Note
Mix the coolant (undiluted) with soft water according
to the temperature 5

℃

lower than the actual lowest

local temperature.

Coolant should be made from undiluted coolant with soft
water.

Standard density of coolant: 30%

Recommended coolant: CFMOTO coolant
(Direct application without having to be diluted)

Drainage of coolant

Remove radiator cap cover

Note
Open the radiator cap after the coolant is fully cooled.

Remove:
--Front top cover(

→

2-8)

--Radiator cap. (

→

4-3)

4-4

4. Cooling System

Remove drain bolt

Remove drain bolt, seal gasket from water pump, and drain
coolant.
After drainage, assemble with a new seal gasket, drain bolt
and tighten.

Reservoir Tank

Remove:
--Seat (

→

2-3)

--Left side panel (

→

2-6)

--2 Mounting bolts
--Water hose of reservoir tank

Remove reservoir tank; discharge coolant;
Flush reservoir tank.

reservoir tank

Install reservoir tank;

bolt

Install water pipe.

4-5

4. Cooling System

Adding Coolant

Add coolant through filling port.

filling port

Start the engine and discharge air from cooling system.
Check from filling port that air is fully discharged from
cooling system and install the radiator cap.

Remove reservoir tank cap and add coolant till the upper
limit.

Note:

UPPER LIMIT

Check coolant level when the vehicle is on an even
ground.

LOWER LIMIT

Air 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 run it several minutes at idle

speed;

3. Quickly increase throttle 3~4 times to discharge air

from cooling system;

4.  Add coolant till filling port;
5.  Repeat step 2 & 3 till no more coolant can be refilled;
6.  Check coolant level in reservoir tank and refill till upper

limit.

7. Install reservoir tank cap.

4-6

4. Cooling System

Cooling System Chart

4-7

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Overhaul Info…..……………………………..5-1

Engine Removal and Installation…………...5-2

Removal and Installation of Front and Rear
Axle……………………………………………….5-5
Removal and Installation of Gearshift Unit……5-7

Overhaul info

Operation cautions

◆

Securely support the ATV with bracket when removing or installing engine.

Take care not to damage frame, engine body, bolts and cables.

◆

Wrap the frame to avoid any possible damage when removing or installing the engine.

◆

Following operation doesn’t require removal of engine from the vehicle:

—

Oil 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 operation require removal of engine from vehicle:

—

Crankshaft

Tightening torque:

Engine front upper mounting bolt:

35N

～

45N

Engine front rear mounting bolt:

～

50N

Bolt, engine front rear mounting bracket 35

～

45N

Bolt, engine front upper mounting bracket 35

～

45N

5-1

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Engine Removal

Remove:
--Plastic(

→

Chapter 2)

--Air Filter(

→

Engine service 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 lead,
pickup, water temperature transducer, gear sensor as
illustrated on the right.

5-2

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Remove spark plug cap from cylinder.

Remove protection sleeve of starter relay.

Remove Nut.

Disconnect positive wire of starter relay.

Remove nut.

Remove negative wire of starter relay.

Remove Bolt 1 and Nut 1 of upper engine hanger.

5-3

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Remove Bolt 2 and Nut 2 of upper engine hanger.

Remove Bolt 1 and Nut 1 of lower engine hanger.

Remove Bolt 2 and Nut 2 of lower engine hanger.

5-4

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Engine Installation

Put engine onto the frame

，

install the two lower mounting bolts and nuts.

Then install the upper and lower engine hangers.

Tightening torque:

Engine upper hanger bolt:35

～

45N.m

Engine lower hanger bolt:50

～

60N.m

Install:
--Water outlet and inlet 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 Installation of Front and Rear Axle

Support the vehicle with jack, make sure the vehicle will not fall.
Remove:
--Plastic parts for frame(

→

Chapter 2)

--Front and rear wheels and arms(

→

Chapter 6)

--Air filter(

→

engine service chapter)

--Carburetor(

→

engine service chapter)

--Engine
--Rear brake caliper(

→

7-4)

1.  Nut     2. Bolt 1    3. Bolt 2    4. Front Axle    5. Bolt 3     6. Front Drive Shaft
7. Clamp        8. Breather Hose, Front Axle   9. Bolt 4   10. Rear Axle
11. Breather Hose, Rear Axle
12. Rear Brake Disk    13. Bolt 5    14. Rear Drive Shaft

5-5

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Remove nut and bolt of front axle from frame.

Remove nut and bolt of rear axle from frame.

5-6

5. Removal and Installation of Engine, Drive Train and Gearshift Unit

Remove the 18 bolts

for drive shafts

and front and rear axles.
(Refer to P. 5-5, Bolt 3 of Part No.5)

Remove:
--Front and rear axles, drive shafts, rear brake disc

Installation:

Reverse the removal procedure 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 (

→

2-8)

--Front fender(

→

2-8)

--Bolt 1
--Gearshift rod

Remove the 2 bolts

Remove gearshift unit

Installation:

Reverse the removal procedure for installation.

Make sure that gearshift is flexible.

In case of any inflexibility, adjust the gearshift rod to
ensure the gear engagement.

5-7

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