CFMoto CF500-3 UTV Service & Repair Manual (2013)

CFMOTO service manual for the CF500-3/UTV with the CF188-A engine. It covers the MIKUNI BSR36-89 vacuum-diaphragm carburetor configuration, with an automatic CVT, wet centrifugal clutch, parking function, and manual L-H-N-R selection. This is a carbureted-model manual, not an EFI manual.

PDF Search, Diagram Detail and Page Count

Search and diagram access: Main service text is searchable, but labels within routing images and circuit/wiring diagrams are not. There are no embedded PDF bookmarks. Small circuit labels require zooming; some dense connector and wire-color codes in the full wiring diagram remain pixelated and difficult to read.

One printable, English-language PDF with 250 pages total, including three introductory pages: the cover, foreword/index, and conversion table.

Engine, CVT, Chassis and Electrical Work

These selected coverage highlights outline the main workshop areas. Further topics include headlight-beam adjustment and fuel-hose inspection.

• Engine repair: Step-by-step engine removal, crankcase separation, top-end overhaul, timing-chain service, crankshaft inspection, and reassembly.

• CVT and transmission: Primary and secondary sheaves, drive belt, centrifugal clutch, internal shafts, reverse chain, shift cam and forks, bevel gears, and front output shaft.

• Carburetor service: Disassembly, jet and diaphragm inspection, float-height and fuel-level adjustment, reassembly, and installation.

• Cooling and lubrication: Pressure testing, coolant replacement and air discharge, thermostat and fan checks, water-pump overhaul, and oil-pressure testing.

• Brakes and chassis: Wheel hubs, hydraulic disc brakes, steering-stem and tie-rod checks, toe-in adjustment, suspension arms, and constant-velocity drive shafts.

• Front and rear axles: Differential and final-drive disassembly, bearing and seal inspection, gear-motor checks, washer selection, and backlash adjustment.

• Electrical diagnosis: Charging and ignition fault tracing, starter-motor inspection, relay testing, system circuit diagrams, and the complete vehicle wiring layout.

Suited to mechanics and experienced owners comfortable with precision measurements and electrical testing; internal overhaul work requires the listed special tools and workshop equipment.

Engine Inspection and Reassembly

Cylinder-head work includes rocker-arm disassembly, valve and seat inspection, and sealing-surface checks. Cylinder and piston measurements, piston-ring and pin inspection, connecting-rod checks, crankshaft runout measurements, and balancer-shaft indexing support internal repair work.

The oil-pump and relief-valve sections cover component inspection and rotor clearances. Recoil-starter inspection, magneto-rotor service, and electric-start drive checks are also included.

Camshaft and decompression: The automatic-decompression mechanism is checked with the camshaft, but the combined assembly is not internally serviceable and is replaced if faulty. Timing-chain cautions address the risk of trapping the chain between its sprocket and crankcase during top-end assembly.

CVT, Transmission and Gear Setup

Secondary-sheave instructions explain the spring-compressor requirement and the risk of abrupt release from the loaded assembly. Reassembly notes specify clean belt-contact surfaces free of oil and grease, alongside checks for sheave wear, roller condition, and belt damage.

Bevel-gear adjustment: Contact-pattern checks and washer readjustment accompany replacement of crankcases, gears, or covers. Incorrect setup can accelerate gear wear or cause binding. The front and rear axle sections provide their own bearing, seal, shim, and backlash checks, with front differential gear-motor inspection.

Fuel, Cooling and Lubrication Checks

Carburetor inspection distinguishes damaged vacuum diaphragms, worn needle valves and seats, and obstructed jets. Float and fuel-level measurements accompany the adjustment procedures.

Water-pump repair includes mechanical-seal, oil-seal, bearing, and impeller inspection. The pump can be overhauled without removing the engine. Cooling-system checks address leakage, radiator condition, fan operation, thermostat behavior, and temperature-sensor resistance.

Body, Brakes, Suspension and Steering

Removal instructions extend to the dump box, roll-over bar, seats, seat belts, skid plates, fuel tank, muffler, and winch cable/motor assembly.

Brake coverage includes pad and disc inspection, caliper removal, and master-cylinder handling. Chassis procedures address shock absorbers, suspension-arm ball joints, steering knuckles, wheel bearings, and drive-shaft boots and joints.

Charging, Ignition and Circuit Diagnosis

The permanent-magnet three-phase AC charging section covers battery condition, charging and leakage tests, regulator/rectifier checks, and magneto output. CDI diagnosis includes peak-voltage testing of ignition and pickup circuits; starter inspection covers brushes, the commutator, and armature continuity.

Switch-continuity tests, horn checks, dashboard service, fuel-sender checks, and water-temperature-transducer testing round out the electrical coverage.

The circuit section separates starter/ignition, charging/lighting, 2WD-4WD differential-lock, and signal circuits before the full wiring diagram. These layouts support tracing connections between the tested components and the vehicle harness.

Workshop Tables, Illustrations and Tools

Reference material includes scheduled maintenance, component torque tables, recommended lubricants and sealants, fluid capacities, engine and transmission clearances, wear limits, clutch test data, and electrical test specifications.

Troubleshooting charts address starting difficulty, unstable idle, high-speed power loss, overheating, engine and CVT noise, charging faults, braking, steering, and axle noise.

Illustrations include Cables, Pipes, Cable Routing, the Coolant System Chart, the Engine Oil Cooling and Lubricating System Illustration, and exploded views of the Primary and Secondary Sheave and Transmission. They help identify routing, fluid flow, component order, and assembly relationships when planning teardown and reassembly.

The tool charts identify the CF188-051000-922-001 CVT wrench, CF188-011300-922-001 oil-filter wrench, and CF188-040004-922-002 piston-pin remover. They also list the CF188-022006-922-001 valve-spring compressor and CF188-060008-922-001 front-output-shaft limiting-nut wrench.

Fuel vapor, hot coolant, brake fluid, battery electrolyte, ignition voltage, rotating CVT components, and vehicle lifting require the precautions described in the manual. Follow its ventilation, electrical-isolation, cooling, pressure-release, and support requirements.

Selected Valve-Clearance and Carburetor Data

For cold-engine valve-clearance inspection on the CF188-A, the manual lists intake clearance of 0.05–0.10 mm and exhaust clearance of 0.17–0.22 mm.

The MIKUNI BSR36-89 float-height specification is 10 ± 1 mm. Its measurement reference is the float-chamber mating surface without the gasket, with the carburetor inverted and the float resting on the needle valve without compressing it.