Service Manual

CF500-6
CF625-3 (CF600-3)
CF625-6 (CF600-6)

WWW.CFMOTO.COM
 All rights reserved.
Zhejiang CFMOTO Power Co., Ltd.
May, 2012
 FOREWORD CONTENTS

This manual contains an introductory de- Maintenance Information 1

scription on the CFMOTO Z6/Z6EX/Z5 and
procedures for its inspection, service and Vehicle Body and Muffler 2
overhaul of its main components. 3
Check and Adjustment
Chapter 1 mainly introduces general opera-
Cooling and Lubrication System 4
tion information, service tools, vehicle struc-
ture and basic specifications. Engiene Removal and Installation 5
Chapter 2 mainly introduces check & adjust- Engine Disassembly, Inspection, Assembly 6
ment methods and how to do vehicle mainte-
nance. Fuel and Air Intake System 7
Chapter 3 and further chapters mainly intro- Front Wheels, Brakes, Suspension, Steering 8
duce removal, installation, adjustment, main-
Front Wheels, Brakes, Suspension 9
tenance and troubleshooting information.
Front and Rear Axle 10

Electrical System 11

Lights, Instrument, Switches 12

Troubleshooting 13

CFMOTO reserves right to make

improvements and modifications to the
products without prior notice. Overhaul
and maintenance should be done
according to actual condition of vehicle.
Units Conversion Table

Item Example Conversion

1 kgf/cm2=98.0665kPa 1kPa=1000Pa
Pressure 200kPa(2.00kgf/cm2)33kPa(250mmHg)
1mmHg=133.322Pa=0.133322kPs
Torque 18N·m(1.8kgf·m) 1 kgf·m=9.80665N·m
Volume 419ml(419cm3,419cc) 419ml(0.419l) 1 ml=1 cm3=1 cc 1l=1000 cm3
Force 12N(1.2kgf) 1 kgf=9.80665N
 1 Maintenance information
Cautions ................................. 1-1 Tightening Torque .................. 1-13
VIN Number & Engine Number. ..... 1-3 Lubricant, Sealing Agent.. .......... 1-18
Main Data Table ........................ 1-4
Overhaul Data Table .... ...... ........ 1-6
Wiring,pipes&cables ............... 1-19
Trouble signal light.. ....... ......... 1-27
II
Cautions
Safety Cautions
1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly venti-
lated place for long time.

2. Do not touch the engine or muffler with bare hands after the engine has just stopped to
avoid scalding. Wear long-sleeve work clothes and gloves for operation.

3. Battery liquid (dilute sulfuric acid) is highly caustic and may cause burns to skin and eyes.
Flush with water if splashed to skin and get immediate medical attention. Flush with water if
splashed to clothes to avoid burns. Keep battery and liquid away from reach of children

4.Coolant is poisonous. Do not drink or splash to skin, eyes or clothes. Flush with plenty of
soap water if splashed to skin. If splashed into eyes, flush with water and consult the doctor.
If drinking the coolant, induce vomit and consult the doctor. Keep coolant away from reach of
children.

5. Wear proper work clothes, cap and boots. If necessary, were dust-glass, gloves and mask.

6. Gasoline is highly flammable. No smoking or fire. Also keep against sparks. Vaporized

gasoline is also explosive. Operate in a well-ventilated place.

7.When charged, Battery may generate hydrogen which is explosive. Charge the battery in a
well-ventilated place.

8. Be careful not to get clamped by the turning parts like wheels and clutch.

9. When more than two people are operating, keep reminding each other for safety purpose.

Cautions for Disassembling and Assembling

1. Use genuine CFMOTO parts, lubricants and grease
2. Clean the mud, dust before overhauling
3. Store the disassembled parts separately in order for correct assemble.
4. Replace the disassembled washers, o-rings, piston pin retainer, cotter pin with new ones. I

5. Elastic retainers might get distorted after disassembled. Do not use the loosened retainers. 0
6. Clean and blow off the detergent after disassembling the parts. Apply lubricants on theS!
surface of moving parts. Measure the data during disassembly for correct assembling.
7 .If you do not know the length of screws, install the screws one by one and make sure theytt
are screwed in with same depth. U

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CFmOTO
14.Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly.
Replace if the axial or radial play is too big.
If the surface is uneven, clean with oil and replace if the cleaning does not help. When pressing
the bearing into the machine or to the shaft
15.lnstall the one-side dust-proof bearing in the right direction. When assembling the open type or
double-side dustproof bearing, install with manufactureq-s mark outward.
16. Keep the bearing block still when blowing dry the bearing after washing clean. Apply oil or lubri-
cant before assembling.
17.lnstall the elastic circlip properly. Turn the circlip after assembling to make sure is has been
installed into the slot.
18.After assembling, check if all the tightened parts are properly tightened and can move smoothly.
19.Brake fluid and coolant may damage coating, plastic and rubber parts. Flush these parts with
water if splashed.
20.lnstall oil seal with the side of manufacturer's mark outward.
Do not fold or scratch the oil seal lip.
Apply grease to the oil seal lip before assembling
21.When installing pipes, insert the pipe till the end of joint. Fit the pipe clip, if any, into the groove.
Replace the pipes or hoses that cannot be tightened.
22.00 not mix mud or dust into engine and/or the hydraulic brake system.
23.Clean the gaskets and washers of the engine casing before assembling. Remove the scratches
on the joint faces by polishing evenly with an oilstone.
24.00 not twist or bend the cables too much. Distorted or damaged cables may cause poor
25.When assembling the parts of protection caps, insert the caps to the grooves, if any.
Engine Brake-in
There're many movable components inside engine, such as piston, piston ring, cylinder,gears
and so on. During initial use period, good run-in for every critical component is necessary. Break-
in can help components match each other better and adjust working condition. Good engine per-
formance and reliability rely on good break-in. It's very important to break-in.
Recommended break-in period: 20 Hours
Operation guide:
0-10 Hours
Avoid to run continously at more than 50% throttle position. Change speed frequently and run
with different throttle position. Cool down engine 5 -10 minutes after every 1 hour running. Avoid
sudden acceleration, and operate throttle steadily.
10-20 Hours
Avoid long-time run at more than 75% throttle position. Do not open throttle completely during
the period.

Attention: Maintain and repair as regular procedures during break-in period.

-After break-in, do not forget check and maintain engine before normal use.

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 Maintenance information
Location of marking
Model CF625-3(CF600-3) CF625-6(CF600-6)/CF500-6
VIN No. LCELDUS3 LCELDTZ3
Engine No. 196S-C CF188-C
 Item Specifications
Vehicle Model CF625-3(CF600-3)/CF625-6(CF600-6)/CF500-6
Length 2630 mm
CF625-3(CF600-3)/CF500-6:1320 mm
Width CF625-6(CF600-6) with 12 - inch tires: 1565 mm
with 14 - inch tires: 1590 mm
CF625-3(CF600-3)/CF500-6:1800 mm
Height
CF625-6(CF600--6): 1860 mm
Wheel base 1960 mm
Engine Model 196S-C/CF188-C
Displacement 594ml/493ml
Fuel type RQ-93 or above grade gasoline
Gross weight 495 kg
Passengers 2 (including driver)
Max. load 250 kg
CF500 - 6 CF625 - 3(CF600-3), CF625 - 6(CF600-6)
Front tire 25 × 8 - 12 77J 26 × 9 -14 48J
Tire specifications 25 × 8 -12 77J
25×10-12 85J 26 × 11 -14 54J
Rear tire
25 × 10 -12 85J
Min. ground clearance 240 mm
Min. turning radius(from outer tire) 5000 mm
Starting type Electric starting
Single cylinder,4 stroke,water-cooled engine,
Engine type
4 - valve,SOHC
Chamber type Triangle
Valves system SOHC /chain-drive
196S-C: 96 mm×82.0 mm
Bore×Stroke
CF188-C:87.5 mm×82.0 mm
Engine
Compression ratio 196S-C:10:1/CF188:10.2:1
Lubricant type Pressure splash
Oil pump Rotor
Oil filter element Full flow filter paper
Oil type SAE15W-40/Sf or over
Cooling type Closed-loop cooling system
Coolant type -30 °C anti-freezing

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 1 Maintenance information
Item Parameters

II
Air filter type SponQe filter element
1965-C: 1965-B-173000
Fuel device
Throttle body Type
C F188-C: CF188-B-173000
Clutch type Wet shoe-type automatic centrifigal
Transmission (CVn + Gear shift when parking
Gear changes Two forward and one reverse
Gear
Manually/L-H-N-R
shift/orders
( cvn ratio 2.8~07
Final output 1.333 (24118, Bevel gear)
Second
1.952 (41/21)
Gear output
Powertrain ratio Gear shift Low gear: 2.25(36/16): High gear: 1.350(27/20); Reverse
ratio gear: 1.471 (25/17)
Other Low gear:5.857; High gear: 3.514; Reverse gear: 3.828
Front
axle
33/9 =3.667
Transmission ratio
Rear
axle
33/9 =3.667
Output type Front & Rear output
Clockwise (view from rear part of engine when gear in
Rotation direction
forward position)
Steering
Steering angle
Inner I 30°
device Outer I 30°
Travel of front
136mm
Suspension wheel
system Travel of rear
128mm
wheel
Toe-in 0-10mm
Travel of front
80mm
Suspension suspension
system Travel of rear
80mm
suspension
Kingpin
3.5"
angle
Brake system
Front I Hydraulic brake
Rear I Hydraulic brake
Suspension Type Double wishbone and independent
Frame type Steel tube and steel plate

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CFmOTO
Maintenance parameters
Lubricant device
Item standard Limit
Oil capacity Oil change 2500mL -

Full capacity 2800mL

Recommended oil ( See below ) . Specially for 4-stroke engine oil
SAE-15W-40/SF
If change used oil, please make
sure in below range .
-API: SF or SG grade oil
Grade ·SAE, Choose according to left
table
, ,,,
Temp_
'C
, " "11<1011

" 1I:t!r.a(';~0

Clearance O.03~1m O.15mm

between inner
and outer rotors
Rotor of oil Clearance O.03~1m O.12mm
pump between ou ter
rotor and pu mp
body
Oil pressure 130-170Kpa at 3000r I min

Air intake system

Item Standard

Fuel tank Full capacity 27L

1965-C, 1965-B-173000
Throttle body type
CFI88-C, CFI88-B-173OO0
Air pressure sensor type CFI88-B-175OO0
Air temp . sensor type CFI88-B-I77oo0
Air by-pass valve type CFI88-B-172oo0
Injector type CFI88-B-171OO0
Idle speed 1400±100r/min

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 1 Maintenance information
Cooling device

Item

Full capacity
Standard value

2720ml
Limit
Rem
arks II
Coolant Reservoir
250 ml -300ml
capacity capacity
Standard
50%
density
L
Opening pressure of thermostat 1 08kpa(1.1 kgf/cm )

Openging
71 ±3°C
temp.
Fully opening
88°C
Thermostat temp.
Travel if fully
95°C3.~4m
opening

Resistance Resistance of A
Temp. (OC) of B terminal & C terminal

CO) CkO)
Relations of
resistance of -20 ---- 13.71-16.94
water temp.
sensor and 25 ----- 1.825-2.155
water temp.
50 176-280 ----

80 63.4-81.4 0.303-0.326
110 24.6-30.6 0.138-0.145
Around
Working temp. OFF-ON Around 88°C
88°C
of thermal
switch Around
ON-OFF Around 82 °C
82°C

Coolant type -30°C anti-freezing and high boiling point

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Front wheel
Item Standard Limit
Longitude 1.0 mm 2.0 mm
Jump of rim
Transverse 1.0 mm 2.0 mm
Front Remaining
— 3.0 mm
wheel Tire groove
2
12-inch 70 kPa(0.70kgf/cm ) —
Air pressure
14-inch 50 kPa(0.50kgf/cm 2 ) —

Rear wheel
Item Standard Limit
Longitude 1.0 mm 2.0 mm
Jump of rim
Transverse 1.0 mm 2.0 mm
Rear Remaining
－ 3.0 mm
wheel groove
Tire 2
12-inch 84 kPa（0.84 kgf/cm ） －
Air pressure
14-inch 50 kPa(0.50kgf/cm 2 )

Braking system
Item Standard Limit
Diameter of master cylinder
Thickness of brake disc 4.0 mm 2.5 mm
Front brake Thickness of brake pad 6.0 mm Marking place

Thickness of brake disc 4.0 mm 2.5 mm

Rear brake Thickness of brake pad 6.0 mm Marking place
Play of brake pedal 0 mm －

1-8
 1 Maintenance information
Battery, Charging, Pick-up coil

Type
Output
Item

Resistance of charging coil C207 )

Standard
flywheel-rotor permanent-magnet generator
3 phase AC
0.50-1.50
II
Resistance of pick-up coil of flywheel 1100-1300

No-load voltage of flywheel Ccold

>100V CAC), 5000r/min
AC engine)
Flywheel
Max. output power 300W, 5000r/min

Stable voltage 13. 5V-1 5. OV, 5000r/mi n

Peak voltage of pick-up coil ~1.5V, 200r/min

three-phase supply power of thyristor trigger
Regulator
circuit
Capacity 12V 1BAh
Fully
12.BV
charged
Terminal voltage
Battery Underchar
Under 11.BV
ge
Charging cu rrent Standard 0.9A / 5 ~ 10H
/ time Quick 4A / 1 H

Ignition system
Item Standard
Ignition type ECU
Type Resistant-type
Standard DPR7EA-9(NGK)
Spark plug Optional DRBEA , D7RTC
Clearance 0.B-0.9mm
Characteristic >Bmm, under 1 Kpa
Ignition time BTDC100 1500r/min
Resistance of Fisrt 0.740-0.7BO
ignition coil Second 10.1kO-11.1 kO
Peak voltage First > 150V
Pulse voltage 2V
Resistance of starter relay coil 30-50
Resistance of auxiliary relay coil 900-1100

Lighting, Dashboard, Switch

Item Standard
Main 20A
Fuse
Auxiliary 10Ax3 15Ax2 7.5Ax 1
Headlight CHi/Lo) 12V-35W/35Wx2
Front position light 12V-5Wx2
Brake light / Retail light 12V-21W/5Wx2
Lighting and bulb Front turning light
Rear turning light
12V-21Wx2
12V-10Wx2 o
Dashboard LCD I-
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CFmOTO
Valves/Cylinderhead
(mm)

Item Standard Lim~ Remarks

1965-C CF188-C

Diameter of valve head Inlet 32.6 30.6 --

--
Outlet 29 27
--
Inlet 0.05-0.10
Valve clearance(cold condition)
--
Outlet 0.17-0.22
--
Clearance of valve guide and Inlet 0.010-0.037

--
valve stem Outlet 0.030-0.057
--
In ne r dia mete r of va Ive guide Inlet & Outlet 5.000-5.012
--
Inlet 4.975-4.990
Outer diameter of valve stem
--
Outlet 4.955-4.970

Jump of valve stem Inlet & Outlet 0.05

Length of valve stem end Inlet & Outlet 2.9-3.1 2.3

Thickness of valve head Inlet & Outlet 0.5

Jumpofseal band of valve head Inlet & Outlet 0.03

Width of seal band of valve seat Inlet & Outlet 0.9-1.1

Length of valve spring Inlet & Outlet 40 38.8

Elasticity is 182-210N when

Elasticity of valve spring Inlet & Outlet
pressing to 31 .50mm

Inlet 33.430-33.490 33.130

Height of Cam
Outlet 33.500-33.560 33.200

Clearance of outer diameter of <p22 0.032-0.066 0.150

camshaft and hole <p17.5 0.028-0.059 0.150

<p22 21.959-21.980
Outer diameter of camshaft
<p17.5 17.466-17.484

Inner diam eter of camshaft <p22 22.012-22.025

hole <p17.5 17.512-17.525

Jump of camshaft 0.10

Inner diameter of rocker hole Inlet & Outlet 12.000-12.018

Outer diameter of rocker shaft Inlet & Outlet 11.973-11.984

Contact flatness of cylinder head 0.03 0.05

Contact flatness of cylinder

0.03 0.05
head cover

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 1 Maintenance information
Cyl inder+P iston+P iston -ri ng+C ran ks haft
(mm)
Item

Cylinder pressure
Standard

1000kPa
Limit Remarks
II
Clearance of piston and 1965-C:0.048-0.068
0.15
cylinder CF188-C:0.030-0.051

1965-C:95.960-95.980

Measure position of 4mm away 95.880

from piston skirt end

Diameter of piston skirt
CF188-C:87.460-87.480

Measure position of 10mm away 87.380

from piston skirt end

1965-C: 96.018-96.038
Inner pressure of cylinder
CF188-C :87 .500-87 .522

Contact flatness of cylinder 0.015 0.05

1ring R Around 11.7 8.9

Free gap of piston ring
2ring R Around 12 9.5

1965-C:0.20-0 .35
Closed gap clearance of 1ring 0.60
CF188-C :0.15-0.30
piston ring
2ring 0.15-0.30 0.60

1ring 0.04-0.08 0.180

Clearance of piston groove
2ring 0.03-0.07 0.150

1ring 0.97-0.99
Thickness of piston ring
2ring 1.17-1.19

1ring 1.03-1.05

Width of piston groove 2ring 1.22-1.24

Oil ring 2.51-2.53

Inner diameter of piston pin

23.002-23.008 23.030
hole

Outer diameter of piston pin

22.995-23.000 22.980
hole

Inner diameter of small end of 1965-C:23.015-23.020

23.040
connecting rod CF188-C:23.006-23 .014

Side clearance of big end of

0.10-0.55 1.0
connecting rod

Thickness of big end of

24.95-25.00
connecting rod

Jump of crankshaft 0.03 0.08

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CFmOTO
Clutch+Powertrain
(mm)

Item Standard Limit Remarks

Inner diameter of dutch

140.00-140.15 140.50
disc

Contact rotation speed of

1800-2400r/min
clutch

Locked rotation speed of

3300-3900r/min
clutch

Width of drive belt 35.2 33.5

Free length of driven

168 160
pulley spring

Clearance of gear shift

0.10-0.40 0.50
fork and groove

Thickness of left gear shift

5.8-5.9
fork

Thickness of right gear

5.8-5.9
shift fork

Goove width of gear shift

6.0-6.2
guide

Goove width of driven

6.0-6.2
output gear

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 1 Maintenance information
Tightening torque
Torque Torque
Item
5mm Boll, Nut
6mm Boll, Nut
8mm Boll, Nut
N • m (kgf • m)
5 (0.5)
10 ( 1.0)
20 (2.0)
5mm Screw
6mm Screw
Item

6mmSH Flange bolt

N • m (kgf • m)
4 (0.4)
9 (0.9)
10 ( 1.0)
II
6mm Flange bolt, nut
10mm Boll, Nut 34(3.5) 12 (1.2)
8mm Flange bolt, nut
12mm Boll, Nut 54(5.5) 20 (2.0)
10mm Flange bolt, nut
39(4.0)
Tighten as standard torque If without torque Wrltteno
Note: Coat engine oil on screw thread and contact interface

Item Diameter of thread (mm) Qty Torque Remarks

MountinQ bolt of enQine GB5789 M12x1.25x145 2 50~6

9060-050103
Mounting shaft of front rocker M10x1.25x240 4 40~5

9060-060102
Mounting shaft of rear rocker M10x1.25x238 2

Bolt,rear rocker (lower) GB5789 M10x1.25x90 4

Bolt, front shock absorber M10x1.25x55 4 40~5

Bolt, rear shock absorber M10x1.25x55 4 40~5

Bolt, rear wheel axle bracket M10x1.25x90 4 40~5

Mounting nut, rim 901-07.00.02 M20 16 50~6

Nut, rim shaft 901-07.00.03 M1 0 4 10~3

Mounting screw, rear master

cylinder M6x25 2 18~2

Bolt, rear brake caliper M10x1.25x20 2 40~5

Bolt, rear brake disc 901-08.00.03 M8 x24 8 25~30

Bolt, rear brake caliper M8x35 4 16~20

Nut, steering rod M10x1.25 4 40~5

Locking nut, steering shaft M14x1.5 1 10~2

Bolt, exhaust pipe M8x14 1 16~20

Mounting bolt, rear axle M10x1.25x130 2 40~5

Mounting bolt, rear axle M10x1.25x90 1 40~5

Mounting bolt, rear axle M10x1.25x25 2 40~5

Thermal switch CF250T -420500 1 9~12

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 Inspection and Adjustment

Tire Pressure
Use pressure gauge to check the tire pressure

Caution:
Check the tire pressure when the tires are cold.
Operating a vehicle with worn tires will increase the
possibility of the vehicle skidding easily with pos-
sible loss of control. 3
Worn tires can cause an accident.

Standard Tire Pressure

Front tire Rear Tire

70 kPa 84 kPa
12 - in.
(0.70 kgf/cm2) (0.84 kgf/cm2)
Pressure
50 kPa 50 kPa
14 - in.
(0.50 kgf/cm2) (0.84 kgf/cm2)
25 × 8 - 12 77J 25 × 10 - 12 85J
Size
26 × 9 - 14 48J 26 × 11 - 14 54J

Tire Tread Depth

Always replace tires when tread depth is worn to
1/8” (3 mm) or less.

3-7
 Inspection and Adjustment

Shock Absorber Adjustment

The front and rear shock absorber springs are adjustable
by rotating the adjustment cam #2 to change spring ten-
sion preload. Turn the clicker clockwise to increase com-
pression damping. Turn the clicker counter-clockwise to
decrease compression damping.

Caution: Do not adjust the absorber when it is

not fully loaded. 3
After unload, adjust the absorber to normal.

1 2
Optional FR Shock Absorber Adjust-
ment 3
Spring preload adjustment: 4
loosen locknut #4. 5
Turn adjustment cam #5 to desired position and tighten
locknut #4.
Recovery damping adjustment:
Firstly turn adjustment knob #6 in “SLOW“ direction to
max and record the position.
Secondly turn the knob in “FAST“ direction to appropriate
position.
Compression damping Adjustment:
Firstly turn adjustment knob #3 in “HARD“ direction to
max and record the position.
Secondly turn the knob in “SOFT“ direction to appropri-
ate position.

Caution: Do not adjust the absorber when it is

not fully loaded.
6

Optional RR Shock Absorber Adjust-

ment 7
Spring preload adjustment:
loosen locknut #8.
Turn adjustment cam #9 to desired position and tighten
locknut #8.
Recovery damping adjustment:
Firstly turn adjustment knob #7 in “SLOW“ direction to
max and record the position.
Secondly turn the knob in “FAST“ direction to appropriate 8
position.
Compression damping Adjustment:
Non-adjustable
9
Caution: Do not adjust the absorber when it is
not fully loaded. 10

Gearshift linkage
Shift to check if gear shift mechanism #11 is smooth. If
not, adjust the length of shift rod #12 by adjusting locknut
#11.

Fuel System
Fuel System Condition
Remove the fuel tank(--->2-16)
Check the fuel line/rail for wear,damage.
Replace fuel/rail if the worn or damage found.
Check fuel line/rail for racking, bending. Replace
as needed. 12 11

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