[WCRiot]

New to me. 2007 XUV 500. I bought this to convert to electric and customize the appearance.


I guess because of the age I am not able to find much technical info. on this thing. I have search this site and haven't found much. Can anyone point me to a few documents to help:
Wiring diagram would be nice.
Drivetrain info. Differential gear ratio is the bare minimum of what i need.

I'm still sorting out the electric drivetrain parts. I made a basic sketch in MSPAint to show a motor layout with dual output shaft. I might not go that route as there are alot less motors when you go dual output shaft.

[NMKawierider]

Welcome. That's going to be a project for sure. Pretty tough to find info but I see Alpha-Sports still has parts for them and I did find this for a service manual on line. Might have what you need but none I know of talk about the gear ratios..but that's easy enough to figure-out...ie how many revolutions of a rear hub does it take to equal one revolution of the pinion. May need a degree wheel for the exact measurement.

https://www.yumpu.com/en/document/view/39764012/500-u5-cf500-3-technical-service-manualpdf-mojo

[WCRiot]

I’ll take a look thanks.
Some other info I forgot to ask is:
What is the weight of the vehicle? And is the engine/transmission/transfer case weight stated somewhere?

[NMKawierider]

I’ll take a look thanks.
Some other info I forgot to ask is:
What is the weight of the vehicle? And is the engine/transmission/transfer case weight stated somewhere?

The dry weight of the vehicle should be listed in the manual. That will include everything except fuel, oils and coolant.

[WCRiot]

I’ll take a look thanks.
Some other info I forgot to ask is:
What is the weight of the vehicle? And is the engine/transmission/transfer case weight stated somewhere?

The dry weight of the vehicle should be listed in the manual. That will include everything except fuel, oils and coolant.

You're right. I posted my follow up before looking at the link you sent.
The manual covered dry weight. It would be nice to know the weight of the powerplant. I could probably weigh it on a shipping scale but that would be tricking to do for me.

[WCRiot]

I got the special tool in last week. It took over a month to arrive.
Got everything apart and ready to finish up the modifications.

This is probably a big ask but, is there are parts list or blueprint that shows where the engine/transmission internal parts go? certain gears fell off, and those upside down U shape fingers for the transmission gears fell off. I can't remember how it goes back together.

[NMKawierider]

I got the special tool in last week. It took over a month to arrive.
Got everything apart and ready to finish up the modifications.

This is probably a big ask but, is there are parts list or blueprint that shows where the engine/transmission internal parts go? certain gears fell off, and those upside down U shape fingers for the transmission gears fell off. I can't remember how it goes back together.

That will all be in the shop/service manual. If you don't have one maybe one of my old CFM ATV 500 manuals will have a transmission break-down that will be..of some help anyway.

[WCRiot]

Do you have a digital copy of that manual you can share?

I used this link: https://cfmoto-forum.com/information-center/cfmoto-owner's-and-service-manuals/
I have a CF500 technical service manual. Not my specific vehicle but similar. That doesn't go into the engine.
I'm looking at that Engine CF250 manual on there. Its tough to read. It might help, but probably won't.

This darn vehicle is so old it's hard to find info for it.

[NMKawierider]

Do you have a digital copy of that manual you can share?

I used this link: https://cfmoto-forum.com/information-center/cfmoto-owner's-and-service-manuals/
I have a CF500 technical service manual. Not my specific vehicle but similar. That doesn't go into the engine.
I'm looking at that Engine CF250 manual on there. Its tough to read. It might help, but probably won't.

This darn vehicle is so old it's hard to find info for it.

PM sent with link.

[WCRiot]

DANG! I finally got around to testing the transmission after putting everything back together. Only one gear is working. Everything else is basically neutral.
I counted the turns of the output shafts relative the the splined transmission shaft and got a ratio of approximately 3.75:1. Not sure which gear that might be. I guess I will play with this thing a little more.

[WCRiot]

Do you have a digital copy of that manual you can share?

I used this link: https://cfmoto-forum.com/information-center/cfmoto-owner's-and-service-manuals/
I have a CF500 technical service manual. Not my specific vehicle but similar. That doesn't go into the engine.
I'm looking at that Engine CF250 manual on there. Its tough to read. It might help, but probably won't.

This darn vehicle is so old it's hard to find info for it.

PM sent with link.

Hey buddy
I need some more help. Do you have any idea how to remove the driveshaft from the transmission case?
Attached are a few pictures to hopefully figure this out. Unfortunately the pdf manual you gave me didn't go into this detail.

[NMKawierider]

Most bevel shaft removals are somewhat alike. This one is no exception..at least from what I see and read in the manual. From where you are now, that back cover comes off, then the bearing retainer (may need a special tool), then the entire shaft slides out. Be mindful of the shims and their placement. From the manual:

[WCRiot]

Yep that's right where I'm at.
Need a special tool for the Bearing Limit Nut.
Unfortunately there isn't much info out there. I can't find a part number for the tool. Was trying to find something generic but even that is is challenging
It would look similar to this:

[NMKawierider]

Plenty of them on ebay. Just need to get the size right.

https://www.ebay.com/itm/222311007652?epid=1166750404&hash=item33c2c4c5a4:g:2Q8AAOSw0aNfgS0t&amdata=enc%3AAQAHAAAA8AydaXyPo2OIfAaNYhbM0MDAKyddGzmwcgycL%2FaL%2BWp1m9PS54uvVE0R1oTfJOKoQAAOtw3zPmYdSE6Q4WPahwsKqOfa5QLjoUKP7SNBqewYiXMMnJdaqOuwD4E4iTSx9ej50DFv4FWouyqMwpikiAZd4jDaBl5GgFcUltje2sq5mTwx1F8cliqcca%2F5n49DuHWOYyoHRaT42ZtK%2BscEjqZSM1Y8LvSdFK5pvpIZzcWZ%2FVgCzSr9QjDFTA2%2BTGzRiz28aslIpm8S%2Frz3ZPQdf6YGt1R3pDMN4Wl47rZUc13OkzvjKWDtY6mRvOQV1Baytg%3D%3D%7Ctkp%3ABFBMovq1_-pg

[NMKawierider]

But the image looks to be a 4-tooth not a 6. Can you confirm. I think this is the part number: 0800-062206-922-001 Might just have to make one.