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

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CFMOTORear Top CoverRemoveRear Rack(2-3)Seperate clasps of rear top cover from rearfender;Remove Rear Top CoverInstallationReverse the remove procedure anddirection for installation .Gear Shift Unit FenderRemove--Bolt 1--Bolt 1--Bolt 2Remove Gear Shift Unit FenderInstallationReverse the remove procedure anddirection for installation .2-6
2 Vehicle Body and MufflerLeft Side CoverRemove--Seat(2-3)--Left Side Cover fixing bolt--Left Side Cover2InstallationReverse the remove procedure anddirection for installation .Rear ProtectorRemove--Rear Rack(2-3)--Rear Top Cover(2-6)--Rear Link Plate(2-7)--Rear Left Side Support(2-8)--Rear Right Side Support(2-8)--Rear Turning Light Connector--Bolt 1,2,1--Rear ProtectorInstallationReverse the remove procedure and directionfor installation.Rear Link PlateRemove--Bolt 3Rear Link PlateInstallationReverse the remove procedure and directionfor installation.2-7
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 20 and 21: CFMOTOEngine ToolsMeasuring ToolsNo
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 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
Page 72 and 73: 3.Checks & AdjustmentInspection of
Page 74 and 75: Overhaul Info...................4-1
Page 76 and 77: 4 Cooling and Lubrication systemPer
Page 78 and 79: 4 Cooling and Lubrication systemRem
Page 80 and 81: Cooling System Chart4 Cooling and L
Page 82 and 83: Inspection and Cleaning of Radiator
Page 84 and 85:
4 Cooling and Lubrication systemIns
Page 86 and 87:
4 Cooling and Lubrication systemlRe
Page 88 and 89:
4 Cooling and Lubrication systemOil
Page 90 and 91:
4 Cooling and Lubrication system•
Page 92 and 93:
4 Cooling and Lubrication system44-
Page 94 and 95:
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
Page 104 and 105:
•Remove C-ring1•Remove timing s
Page 106 and 107:
Oil Filter•Remove oil filter with
Page 108 and 109:
Starting Motor Gear•Remove driven
Page 110 and 111:
CVT Case•Remove bolt 1 of CVT cas
Page 112 and 113:
• Remove Oil seal1,Bearing limit
Page 114 and 115:
IIEngine Components InspectionCylin
Page 116 and 117:
•Remove thermostat•Compress the
Page 118 and 119:
Valve Stem O.D•Measure valve stem
Page 120 and 121:
•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
Page 134 and 135:
•Install oil seal with special to
Page 136 and 137:
CFMOTO• Tighten the ring nut with
Page 138 and 139:
CFMOTOInspection•Inspect drive be
Page 140 and 141:
CFMOTO•Put the guide bar on a fla
Page 142 and 143:
CFMOTOOil strainer inspection•Che
Page 144 and 145:
CFMOTOBevel gearNote: Proper bevel
Page 146 and 147:
CFMOTOBalance shaft•Remove the pa
Page 148 and 149:
CFMOTOElectric Starter Gear•Check
Page 150 and 151:
CFMOTOAssemblyReverse the removal p
Page 152 and 153:
CFMOTOCrankcase1-Right crankcase 2-
Page 154 and 155:
CFMOTOConnected rod•Install conne
Page 156 and 157:
CFMOTO•Apply sealant1to the matin
Page 158 and 159:
CFMOTO•Install secondary sheave
Page 160 and 161:
CFMOTO•Install starting driven ge
Page 162 and 163:
CFMOTOOil filter•Install oil filt
Page 164 and 165:
CFMOTOCylinder•Apply engine oil t
Page 166 and 167:
CFMOTO•Install crankshaft C-ring1
Page 168:
CFMOTO•Install the new gasket 3
Page 171 and 172:
6 Engine Removal, Inspection & Inst
Page 173 and 174:
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
Page 181 and 182:
CFMOTOBrake systemFront brake calip
Page 183 and 184:
CFMOTODisassembleremove foot rest(2
Page 185 and 186:
CFMOTODismantlingFront shock absorb
Page 187 and 188:
CFMOTOInspectionBall pinInspect if
Page 189 and 190:
CFMOTOSteering systemHandlebarDashb
Page 191 and 192:
CFMOTOHandlebar pipeDisassemblingre
Page 193 and 194:
CFMOTOInstall RH&LH gripremove dirt
Page 195 and 196:
CFMOTOSteering stemDisassemblingrem
Page 197 and 198:
9 Rear Wheel, Rear Brake, Suspensio
Page 199 and 200:
Rear WheelRemovalRefer to Front Whe
Page 201 and 202:
9 Rear Wheel, Rear Brake, Suspensio
Page 203 and 204:
10 Front/Rear AxleOverhaul Informat
Page 205 and 206:
10 Front/Rear AxleDisassembly of fr
Page 207 and 208:
10 Front/Rear AxleFront axle assemb
Page 209 and 210:
10 Front/Rear Axlec Use special equ
Page 211 and 212:
10 Front/Rear AxleNeedle bearing re
Page 213 and 214:
10 Front/Rear Axlef Adjust item 29
Page 215 and 216:
CFMOTOOverhaul informationNote• U
Page 217 and 218:
CFMOTOBatteryNote:Keep the ignition
Page 219 and 220:
CFMOTORemove fuse box from inside o
Page 221 and 222:
CFMOTOInspection of AC magnetoRemov
Page 223 and 224:
12 Ignition SystemOverhaul Info....
Page 225 and 226:
12 Ignition SystemTroubleshootingEn
Page 227 and 228:
12 Ignition SystemIgnition Primary
Page 229 and 230:
12 Ignition SystemPickup CoilRemova
Page 231 and 232:
12 Ignition SystemBrushCheck if bru
Page 233 and 234:
12 Ignition SystemIgnition System D
Page 235 and 236:
CFMOTOTROUBLESHOOTINGHead Light Can
Page 237 and 238:
CFMOTOBrake Light/Tail Light BulbRe
Page 239 and 240:
CFMOTOIgnition SwitchInspectionRemo
Page 241 and 242:
CFMOTOTurn switchHorn switchAcceler
Page 243 and 244:
CFMOTOFuel SensorRemove:Fuel tank t
Page 245 and 246:
CFMOTOWater Temperature SensorWarni
Page 247 and 248:
CFMOTO14-2
Page 249 and 250:
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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