500 - X5 (CF500-5A) - Technical Service Manual ... - Mojo Motorcycles

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CFMOTOEngine ToolsMeasuring ToolsNo Name Type Function Remark1 Vernier Calipers 0-150mm measure length and thickness2 Micrometers 0-25mmmeasure the outer diameters of swingarm, valve rod and camshaft3 Dial gauge 25-50mm Measure max. lift range of camshaft4 Dial gauge 75-100mm Measure piston skirt5 Inner dia. Gauge, Cylinder Measure inner dia. of cylinder head6 Inner dia. Gauge, 10-34mmInner dia. of swing arm, piston pin hole,and rod head hole7 Dial Test Indicator 1/100 Run-out8 Knife Straight Edge plainness9 Feeler Gauge Plainness, adjusting valve clearance10 Fuel Level Gauge Fuel level length of carburetor11 Plastic gauge Fit clearance12 pull tension gauge Spring bounce13 Tachometer Engine rotation rate14 Cylinder Pressure Meter pressure in cyclinder15 Oil Pressure Gage Oil pressure16 Barometer Opening pressure of radiator cover17 Ohmmeter Resistance and voltage18 Amperemeter Opening of currency / switch19 Thermometer Liquid temperature20 Timing Lights Test spark timing21 Torque Tester One Set Tightening torqueAuxiliary Measuring Instrument22 Alcohol Burner Warming up23 Magnet Stand Install dialgauge24 Slab Auxiliary measure supplementary25 V-Block Run-out supplementary26 Forcep Install valve clip27 Plier Disassemble and install circlip28 Joint Plier Disassemble and install flange29 Impact Driver Disassemble cross recessed bolt30 Slot Type Driver31 Cross Type Driver1-16
1 Maintenance InformationSpecial Purpose ToolsNo Name Type Function Remark11 Spark Plug Wrench 172MM-022400-922-004Disassemble/ install sparkplug2 CVT WrenchCF188-051000-922-001CF188-052000-922-001Disassemble/install CVTdrive/driven disc nut3 Oil Filter Wrench CF188-011300-922-001 Disassemble/ install oil filter4 Piston Pin Remover CF188-040004-922-002 Disassemble piston pin5Magneto statorRemoverCF188-031000-922-001Disassemble magnetostator6 Crankcase Dissociator Divide L/R crank case7 Crank Remover8 Crank ToolDisassemble crank shaftfrom left crankcaseInstall crank shaft on leftcrankcase9Valve SpringCompressorCF188-022006-922-001Disassemble/ install valvespring10 Valve Former CF188-022004-922-001 Grind valve11 Circle Nut Wrench CF188-052000-922-00312 Driven Disc Clamp CF188-052000-922-00413 Driven Disc Former CF188-052000-922-00214 Limiting nut Wrench CF188-062204-922-001Disassemble CVT drivendiscDisassemble CVT drivendiscDisassemble CVT drivendiscDisassemble driven bevelgear bearing limiting nut15 Bearing Tool One full set Install bearing and oil ring16 Bearing Remover One full set Disassemble bearing17 Oil Ring Remover Disassemble bearing18 Limiting Nut Wrench CF188-060008-922-001Disassemble front outputshaft bearing limiting nutDisassemble fan connector19 Fixing Wrench CF188-A-180003-922-003flange, adjust valveclearance1-17
Page 1 and 2: CF500-5 SERVICECF500-5A MANUALWWW.C
Page 8 and 9: CFMOTOMain Data TableItemParameterM
Page 10: CFMOTOMaintenance Data TableLubrica
Page 16 and 17: CFMOTOClutch + Transmission(mm)Item
Page 18 and 19: CFMOTOEngine Tightening Torque Tabl
Page 22 and 23: CFMOTOLubricant goose, Sealing OilC
Page 24 and 25: CFMOTO1-20
Page 26 and 27: CFMOTO1-22
Page 28 and 29: CFMOTOEngine Tightening Torque Tabl
Page 30 and 31: CFMOTOFront Rack, Bolt CapRemove:Up
Page 32 and 33: CFMOTOFront Top CoverRemoveFront Ra
Page 34 and 35: CFMOTORear Top CoverRemoveRear Rack
Page 36 and 37: CFMOTORear Side PanelRemove--Seat(2
Page 38 and 39: CFMOTOFootrest,Left SideRemoveLeft
Page 40 and 41: CFMOTODisasemblyNOTE:Side skid Plat
Page 42 and 43: CFMOTOFront Left Inner FenderRemova
Page 44 and 45: CFMOTOFront Vent GrillRemove--Loose
Page 46 and 47: CFMOTOMufflerCaution: Perform disas
Page 48 and 49: Overhaul Info…………………
Page 50 and 51: 3.Checks & AdjustmentInspection & M
Page 52 and 53: 3.Checks & Adjustment3PartItemItemI
Page 54 and 55: 3.Checks & AdjustmentMaster Cylinde
Page 56 and 57: 3.Checks & AdjustmentTire PressureC
Page 58 and 59: 3.Checks & AdjustmentAdjusting the
Page 60 and 61: 3.Checks & AdjustmentCooling System
Page 62 and 63: 3.Checks & AdjustmentInspection of
Page 64 and 65: 3.Checks & AdjustmentVALVE CLEARANC
Page 66 and 67: 3.Checks & AdjustmentIn case of car
Page 68 and 69: 3.Checks & AdjustmentInspection:Ins
Page 70 and 71:
3.Checks & Adjustment-Install oil d
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3.Checks & AdjustmentInspection of
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Overhaul Info...................4-1
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4 Cooling and Lubrication systemPer
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4 Cooling and Lubrication systemRem
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Cooling System Chart4 Cooling and L
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Inspection and Cleaning of Radiator
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4 Cooling and Lubrication systemIns
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4 Cooling and Lubrication systemlRe
Page 88 and 89:
4 Cooling and Lubrication systemOil
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4 Cooling and Lubrication system•
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4 Cooling and Lubrication system44-
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5 Removal and Installation of Engin
Page 96 and 97:
Page 98 and 99:
Page 100 and 101:
Page 102 and 103:
I Engine RemovalPreparation before
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•Remove C-ring1•Remove timing s
Page 106 and 107:
Oil Filter•Remove oil filter with
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Starting Motor Gear•Remove driven
Page 110 and 111:
CVT Case•Remove bolt 1 of CVT cas
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• Remove Oil seal1,Bearing limit
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IIEngine Components InspectionCylin
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•Remove thermostat•Compress the
Page 118 and 119:
Valve Stem O.D•Measure valve stem
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•Install valve spring with small-
Page 122 and 123:
Automatic Decompression•Move the
Page 124 and 125:
Chain TensionerInspection•Check t
Page 126 and 127:
Piston Ring Free End Gap and End Ga
Page 128 and 129:
Clutch•Check clutch for chipping,
Page 130 and 131:
Primary Sliding SheaveDisassembly
Page 132 and 133:
•Install spacerSecondary SheaveDi
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•Install oil seal with special to
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CFMOTO• Tighten the ring nut with
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CFMOTOInspection•Inspect drive be
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CFMOTO•Put the guide bar on a fla
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CFMOTOOil strainer inspection•Che
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CFMOTOBevel gearNote: Proper bevel
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CFMOTOBalance shaft•Remove the pa
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CFMOTOElectric Starter Gear•Check
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CFMOTOAssemblyReverse the removal p
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CFMOTOCrankcase1-Right crankcase 2-
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CFMOTOConnected rod•Install conne
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CFMOTO•Apply sealant1to the matin
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CFMOTO•Install secondary sheave
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CFMOTO•Install starting driven ge
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CFMOTOOil filter•Install oil filt
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CFMOTOCylinder•Apply engine oil t
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CFMOTO•Install crankshaft C-ring1
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CFMOTO•Install the new gasket 3
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6 Engine Removal, Inspection & Inst
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CFMOTO1 Carburetor RemovalDisassemb
Page 175 and 176:
CFMOTOCheck the diaphragm 1for tear
Page 177 and 178:
CFMOTO5 Carburetor Installation1-va
Page 179 and 180:
CFMOTOSpecial toolsBearing disassem
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CFMOTOBrake systemFront brake calip
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CFMOTODisassembleremove foot rest(2
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CFMOTODismantlingFront shock absorb
Page 187 and 188:
CFMOTOInspectionBall pinInspect if
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CFMOTOSteering systemHandlebarDashb
Page 191 and 192:
CFMOTOHandlebar pipeDisassemblingre
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CFMOTOInstall RH&LH gripremove dirt
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CFMOTOSteering stemDisassemblingrem
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9 Rear Wheel, Rear Brake, Suspensio
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Rear WheelRemovalRefer to Front Whe
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9 Rear Wheel, Rear Brake, Suspensio
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10 Front/Rear AxleOverhaul Informat
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10 Front/Rear AxleDisassembly of fr
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10 Front/Rear AxleFront axle assemb
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10 Front/Rear Axlec Use special equ
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10 Front/Rear AxleNeedle bearing re
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10 Front/Rear Axlef Adjust item 29
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CFMOTOOverhaul informationNote• U
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CFMOTOBatteryNote:Keep the ignition
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CFMOTORemove fuse box from inside o
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CFMOTOInspection of AC magnetoRemov
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12 Ignition SystemOverhaul Info....
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12 Ignition SystemTroubleshootingEn
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12 Ignition SystemIgnition Primary
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12 Ignition SystemPickup CoilRemova
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12 Ignition SystemBrushCheck if bru
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12 Ignition SystemIgnition System D
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CFMOTOTROUBLESHOOTINGHead Light Can
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CFMOTOBrake Light/Tail Light BulbRe
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CFMOTOIgnition SwitchInspectionRemo
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CFMOTOTurn switchHorn switchAcceler
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CFMOTOFuel SensorRemove:Fuel tank t
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CFMOTOWater Temperature SensorWarni
Page 247 and 248:
CFMOTO14-2
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CFMOTO14-4
Page 251 and 252:
CFMOTOEngine Troubleshooting1. Engi
Page 253 and 254:
CFMOTOComplaint Symptom and Possibl
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500 - X5 (CF500-5A) - Technical Service Manual ... - Mojo Motorcycles

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