CFMoto ATV CF500/CF500-A. Service Manual

6. Front Wheel, Front Brake, Suspension, Steering

Overhaul Info………………………..…………6-1
Troubleshooting ………………………………6-2
Front Wheel ………………………….………. 6-3

Front Brake…………………….…………..6-4
Suspension…………………………………6-7
Steering ………………………….…………6-12

Overhaul Information

Operating cautions

Notes

◆

Securely support the vehicle when overhauling the front wheel and suspension system.

◆

Refer to chapter 10 for overhaul and inspection of lighting, instruments and switches.

◆

Do not overexert on the wheel. Avoid any damage to the wheel.

◆

When removing tire, use the special tire lever and rim protector.

Maintenance Standard

Item Standard

Service

Limit

Longitudinal 0.8mm 2.0mm

Rim

Vibration

Lateral 0.8mm 2.0mm

Remained groove

3.0mm

Tire

Tire Pressure

35kpa(0.35kgf/cm

)

Front brake

Free play (brake lever)

0mm

Tightening torque

Nut, Tie-rod                                                                    40-50N.m
Lock nut, steering stem                                              110-120N.m
Nut, front wheel axle    110N.m
Fixing bolt/nut, absorber                                            40-50N.m
Nut, front rim                                                                50-60N.m
Nut, front wheel axle 110-130N.m

6-1

6. Front Wheel, Front Brake, Suspension, Steering

Special tools

Rod, bearing remover
Head 10mm, bearing remover
Handle A , Driving Tool
Sleeve, Driving Tool      28x30
Guide tool 10mm
Locknut spanner
Bearing remover set
Rotor puller
Remover shaft
Remover hammer
Assembling tool shaft

Troubleshooting

Heavy Steering

Upper thread is over tightened

Steering bearing is damaged or worn

Inner & outer bearing races are damaged, worn

or stepped

Steering stem is distorted

Tire pressure is too low

Low tire pressure

Worn

tire

Shaking Handlebar

Steering bearing is damaged, or not well

tightened

Right and left shock absorbers are not matched

Deflected

tires

Deformed

frame

Worn

tires

Shaking of wheel bearing

Vibration of Front Wheel

Wheel rim distorted

Faulty wheel bearing

Faulty

tire

Wheel Cannot Turn Freely

Steering bearing is damaged or worn.

Front wheel axle is bended

Brake

drag

Front Suspension Is Too Soft

Weakened front shock absorbers

Tire pressure is too low

Front Suspension Is Too Hard

Front shock absorber is bended

Tire pressure is too high

Noise With Front Absorbers

Faulty front shock absorbers

Loosened tightening parts of front shock

absorbers

Poor Brake Efficiency

Faulty

brake

adjustment

Stained brake disc

Worn brake shoes

Improper tightening of wheel axle

Improper balance of wheels

6-2

6. Front Wheel, Front Brake, Suspension, Steering

Front wheel

Removal

Securely support the front wheels
Remove:
-- Wheel cap.
--4 bolt from wheel hub
--Front wheel.

Inspection
Rim

Damage, warpage or serious scrapes:

→

Replace

Replace with a new one, if any.
Slowly turn the wheel, measure the rim vibration
with a dial gauge.

Service limit: Axial: 2.0mm
Radial: 2.0mm

Assembling:

Press rim into wheel.
Install rim on the wheel hub.

Tightening Torque:

Bolt, Wheel hub: 50-60 N.m

Front Wheel Hub

Disassembly

Remove:
--Front wheel(

→

6-3)

--Front brake caliper(

→

6-4)

--Rim axle nut
--Brake disc and wheel hub
--4 bolts of front brake disc
--Wheel hub

Installation

Reverse the removal procedure for installation

Torque, Rim axle nut: 110-130N.m

6-3

6. Front Wheel, Front Brake, Suspension, Steering

Brake System

Front caliper

Remove:

--Front wheel(

→

6-3)

--2 bolts from arm
-Front caliper

Inspection

Check cracks of brake calipers and oil leakage
from the tightening parts.

If any, replace.

Installation

Reverse the removal procedure for installation.

Tightening Torque
Fixing Bolt, Brake Caliper: 40-50N.m

6-4

6. Front Wheel, Front Brake, Suspension, Steering

Brake disc

Remove:

--Front wheel (

→

6-3)

--Brake caliper(

→

6-4)

--Front brake disc and wheel hub
--4 bolts from brake disc
--Brake disc.

Inspection:

Brake disc thickness: < 2.5mm

→

Replace

Installation

Install brake disc

Fixing bolt, brake disc: 25-30N.m

Front Brake Master Cylinder
Disassembly

Remove Bolt 1, Bolt 2

Separate front brake master cylinder from handlebar

Do not remove front brake master cylinder from
vehicle unless when replacing master cylinder
assembly.

NOTE:

Do not hang master cylinder on braking hose.

Do not put the master cylinder upside down to avoid
possible entrance of air into brake system.

Keep the master cylinder in the installation position
and fix it to the handlebar.

Refer to Chapter 1 for proper routing of brake hose.

Check brake efficiency after installation.

6-5

6. Front Wheel, Front Brake, Suspension, Steering

Disassembly

Remove:
--Footrest board(

→

2-9)

--Front right inner fender (

→

2-12)

--Bolt 1, Bolt 2
Separate foot brake master cylinder from vehicle

Assembly

Reverse the removal procedure for installation.

NOTE

Do not put the master cylinder upside down to avoid
possible entrance of air into brake system.

Keep the master cylinder in the installation position
and fix it to the frame.

Refer to Chapter 1 for proper routing of brake hose.

Check brake efficiency after installation.

Brake Hose T-Pipe

Remove:

--Front right inner fender (

→

2-12)

--Bolt 1
--T-Pipe

Installation

Reverse the removal procedure for installation

Note:

Check front and rear brake linkage after installation.

Brake Hose Cross Pipe

Remove:

--Front right inner fender (

→

2-12)

--Bolt 1, Bolt
--Brake hose cross pipe

6-6

6. Front Wheel, Front Brake, Suspension, Steering

Installation

Reverse the removal procedure for installation.

NOTE

Note:

Check front and rear brake linkage after installation.

Front Suspension system

Front left Suspension

NOTE
DO NOT remove both left and right suspension at
the same time to avoid fall down of the vehicle.

Park the vehicle on a level ground and securely
support front part of the vechicle.

Removal:

--Front wheel (

→

6-3)

--Front wheel hub (

→

6-3)

--Front brake caliper(

→

6-4)

--Bolt 1, Nut 1

--Bolt 2, Nut 2

--Bolt 3, Nut 3, Bolt 4, Nut 4

Remove slotted nut.
Remove tie-rod.

Pull out steering knuckle from CV joint.

Remove front left suspension.

6-7

6. Front Wheel, Front Brake, Suspension, Steering

(1)  Bolt 1
(2) Front right absorber
(3)  Nut 1
(4) Front right arm (upper)
(5) Circlip, bearing
(6) Upper ball pin
(7) Bearing, hub
(8) Brake disc guard
(9)  Bolt 2
(10) Bolt 3
(11) Bolt 4
(12) Circlip
(13) Right steering knuckle
(14) Circlip
(15) Bolt 5
(16) Bottom ball pin
(17) Nut 2
(18) Cap, buffering collar
(19) Buffering collar
(20) Bolt 6
(21) Bolt 3
(22) Nut 3
(23) Cap, buffering collar
(24) Buffering collar
(25) Bolt 7
(26) Bolt 4
(27) Slotted nut
(28) Front right arm (lower)

(29) Cotter pin
(30) Nut 5
(31) Cap, buffering collar
(32) Buffering collar
(33) Cap, buffering collar
(34) Bolt 8
(35) Nut 6
(36) Buffering collar
(37) Cap, buffering collar
(38) Bolt 9
(39) Bolt 10
(40) Rzeppa universal joint
(41) Big clamp, fixed end
(42) Bearing, fixed end
(43) Small clamp, fixed end
(44) Small clamp, fixed end
(45) Bearing, motion end
(46) Big clamp, motion end
(47) Rzeppa universal joint
(48) Wire circlip
(49) Wire circlip 2
(50) Spacing shim
(51) Dust boot, motion end
(52) Front left shaft
(53) Dust boot, fixed end
(54) Wire clamp I
(55) Left CV drive shaft left,

front axle

(56) Nut 7
(57) Nut 8

Disassembly:

Note:

Replacing the front

shock absorber does not
require removal of other parts.

Remove Bolt 10 (39) and Nut 8
(57)
Remove front right shock
absorber

Inspection:

Oil leakage, aged oil

seal, damage

→

Replace

6-8

6. Front Wheel, Front Brake, Suspension, Steering

Installation:

Reverse the removal procedure for installation.

Refer to

Front Right Shock Absorber

for disassembly, installation and inspection of

Front Left Absorber.

Suspension Arms

Note: This vehicle has 8 suspension arms. The removal, disassembly, inspection and installation of the 8 arms
are the same.
This service manual will only introduce the removal, disassembly, inspection and installation of

Front Left

Upper Arm, Front Left Lower Arm

Refer to

Front Left Upper Arm, Front Left Lower Arm

for removal, disassembly, inspection and installation of

other suspension arms.

Front Right Arm

Disassembly
Remove:
--Front right absorber (

→

6-8)

--Bolt 9 (38) and Nut 7 (56);
--Bolt 8 (34) and Nut 5 (30)
--Bolt 7 (25) and Nut 3 (22)
--Bolt 6 (21) and Nut 2 (17)

Remove wheel, brake caliper and wheel hub before removing absorber;

Remove tie-rod before removing bolts;

Pull out steering knuckle from CV drive shaft before removing front right arm.

Inspection
Ball Pin

Check if Upper Ball Pin (6) for Front Right Upper Arm (4) and Lower Ball Pin for Front Right Lower Arm (28)
can turn freely in all directions.
Check clearance of upper and lower ball pins.

Clearance out of range, no free turning:

→

Replace Ball pin

Right Steering Knuckle
Inspection:

Damaged steering knuckle:

→

Replace

Check wheel hub bearing for free turning and clearance.

Bearing cannot turn freely or clearance out of range:

→

Replace

6-9

6. Front Wheel, Front Brake, Suspension, Steering

(1) Bolt 1
(2) Front right absorber
(3) Nut 1
(4) Front right arm (upper)
(5) Circlip, bearing
(6) Upper ball pin
(7) Bearing, hub
(8) Brake disc guard
(9) Bolt 2
(10) Bolt 3
(11) Bolt 4
(12) Circlip
(13) Right Steering Knuckle
(14) Circlip
(15) Bolt 5
(16) Bottom ball pin
(17) Nut 2
(18) Cap, buffering collar
(19) Buffering collar
(20) Bolt 6
(21) Bolt 3
(22) Nut 3

(23) Cap, buffering collar
(24) Buffering collar
(25) Bolt 7
(26) Bolt 4
(27) Slotted nut
(28) Front right arm (lower)
(29) Cotter pin
(30) Nut 5
(31) Cap, buffering collar
(32) Buffering collar
(33) Cap, buffering collar
(34) Bolt 8
(35) Nut 6
(36) Buffering collar
(37) Cap, buffering collar
(38) Bolt 9
(39) Bolt 10
(40) Rzeppa universal joint
(41) Big clamp, fixed end
(42) Bearing, fixed end
(43) Small clamp, fixed end
(44) Small clamp, fixed end

(45) Bearing, motion end
(46) Big clamp, motion end
(47) Rzeppa universal joint
(48) Wire circlip
(49) Wire circlip 2
(50) Spacing shim
(51) Dust boot, motion end
(52) Front left shaft
(53) Dust boot, fixed end
(54) Wire clamp I
(55) Left CV drive shaft left, front

axle

(56) Nut 7

6-10

6. Front Wheel, Front Brake, Suspension, Steering

Constant Velocity Drive Shafts

NOTE: The disassembly, inspection and installation of left and right constant velocity drive shafts of

front rear axles are the same.

The following will give instruction only on the disassembly, inspection, installation of Left

Constant Velocity Drive Shaft of front axle.

Refer to Left Constant Velocity Drive Shaft for disassembly, inspection, installation of other

drive shafts.

(55)Left Constant Velocity Drive Shaft, Front Axle

Disassembly
NOTE: Maintenance of Left Constant Velocity Drive Shaft of front axle only does not require removal of

front suspension.

Remove:
--Front wheel(

→

6-3)

--Front left brake caliper(

→

6-4)

--Front left wheel hub (

→

6-3)

Check dust boot.
Damaged dust boot:

→

Replace

Shake constant velocity drive shaft, check the agility of rzeppa universal joint, free turning of bearing, and any
gap between rzeppa constant velocity joint and spline.
Stagnated turning, noise, gap with spline:

→

Replace

Warning:
An accident may occur if the rzeppa constant velocity joint cannot run freely because of the loss of
control of wheel steering.

Installation

Press ball pin into arm with special tool.
Reverse the removal procedure for installation.

Note:
There should be no rocking or sway with the installed left and right arms.
Tightening Torque: 40~50 N•m

6-11

6. Front Wheel, Front Brake, Suspension, Steering

Steering system

Handlebar
Dashboard Front Cover

Disassembly
Remove
-- 2 tapping screws.



--Bolt1
--Dashboard front cover

Installation:

Reverse the removal procedure for installation

Right Handlebar Switch

Remove:
--Front top cover (

→

2-4)

--Right handlebar switch connector
--2 bolts
--Right handlebar switch

Installation:

Install right handlebar switch (

→

6-15)

6-12

6. Front Wheel, Front Brake, Suspension, Steering

Left Handlebar Switch

Disassembly
Remove

--2 screws
--Left handlebar switch connector
--Left handlebar switch

Installation

Install left handlebar switch (

→

6-15)

Rear View Mirror

Disassembly

Turn counter clockwise and loosen nut,
Remove left rear view mirror by turning it counter
clockwise.

Note:
Left rear view mirror is right-threaded.
Turn counter clockwise for removal.

Turn clockwise and loosen nut,
Remove right rear view mirror by turning it clockwise.

Note:
Right rear view mirror is left-threaded.
Turn clockwise for removal.

Installation:

Reverse the removal procedure for installation

6-13

6. Front Wheel, Front Brake, Suspension, Steering

Handlebar, Dashboard Rear Cover

Disassembly
Remove:

--Dashboard front cover (

→

6-12)

--Left & right handlebar switch (

→

6-12)

Separate left & right master cylinders from handlebar

Remove:

--Screw1, Screw2
--Dashboard rear cover
--4 fixing bolts
--Handlebar

Installation

Reverse the removal procedure for installation

Tightening Torque: 20-30N.m (2.0-3.0kgf.m)

Note
Main cable, throttle cable, brake hose, cable
wiring should be routed properly

Installation of Throttle Cable

Remove:

--3 screws
--Right handlebar top cover

Install:

--Throttle cable
--Right handlebar switch top cover

6-14

6. Front Wheel, Front Brake, Suspension, Steering

Installation of Left and Right Grip

Clean off stains and grease from handlebar and inner
left and right grips.

Dry completely.
Apply glue between handlebar and left and right grips.

Install left and right grips.

NOTE:
Wait several hours till the glue dries after the left
and right grips are installed.

Installation of Master Cylinder

Keep the UP mark on master cylinder upward.
Install master cylinder.

NOTE:
Main cable, throttle cable, brake hose and wiring
should be routed properly.

Install:

--Rear view mirror(

→

6-13)

--Dashboard(

→

6-10)

--Dashboard front and rear cover(

→

6-14)

6-16

CFMoto ATV CF500/CF500-A. Service Manual - part 5