KYMCO UXV500I Repair Manual
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KYMCO UXV500I Repair Manual

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Table of Contents

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KYMCO Repair Manual
UXV 500i/700i
KYMCO UXV500I/UXV700I Service Information
Using this manual
This manual has been designed to assist trained mechanics in servicing the models listed
above. If you do not have the proper training or tools to perform a particular task it is best if
you seek out a service professional.
This manual was written using the latest information available at the time of publication.
Illustrations in this manual are shown to help you with the basics of performing the jobs
listed. The pictures in this manual may not depict the actual vehicle you're working on,
however the procedures will be similar.
Inexperienced technicians without the correct tools and knowledge may not be able to
perform these jobs as intended. Caution needs to be taken for the vehicle and its operator
as serious injury can occur. Always read a procedure in its entirety before attempting any
repairs.
Topics that are explained in greater detail are referenced and linked to.
1

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Summary of Contents for KYMCO UXV500I

  • Page 1 KYMCO Repair Manual UXV 500i/700i KYMCO UXV500I/UXV700I Service Information Using this manual This manual has been designed to assist trained mechanics in servicing the models listed above. If you do not have the proper training or tools to perform a particular task it is best if you seek out a service professional.
  • Page 2 KYMCO Repair Manual UXV 500i/700i While the instructions, photographs and illustrations in this manual have been reviewed for accuracy it is up to the individual performing the procedures to use good judgement when performing any procedures described. Every precaution has been taken in the manufacture of this manual however the publisher assumes no responsibility for errors and omissions.

  • Page 3: Table Of Contents

    KYMCO Repair Manual UXV 500i/700i 1.Quick Reference This chapter provides a quick reference source of technical specifications and information. 1.Diagnostic Trouble Codes ............1-2 2.General Information ..............1-4 3.General Specifications ...............1-21 4.Torque Specifications ..............1-30 5.VIN and Engine Number .............1-34...
  • Page 4 KYMCO Repair Manual UXV 500i/700i 2.Periodic Maintenance This chapter covers the location and servicing of the periodic maintenance items. This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life.
  • Page 5 KYMCO Repair Manual UXV 500i/700i 3.Fuel System This chapter covers the location and servicing of the fuel system components. 1.Airbox ...................3-2 2.Check Engine Lamp (CELP) ............3-8 3.Component Location ..............3-12 4.Diagnostic Tool ................3-19 5.Fuel Injection Sensors ..............3-35 6.Fuel Injector .................3-50 7.Fuel Pump ..................3-61 8.Fuel Tank ..................3-77...
  • Page 6 KYMCO Repair Manual UXV 500i/700i 4.External Components This chapter covers the location and servicing of the external components. 1.Boot Guard ..................4-5 2.Bumpers and Racks ..............4-7 3.Canopy Bars ................4-15 4.Cargo Bed ..................4-23 5.Center Cover ................4-36 6.Drive Selector ................4-42 7.Exhaust System ................4-48 8.Frame Covers ................4-62...
  • Page 7 KYMCO Repair Manual UXV 500i/700i 5.Engine UXV 500i This chapter covers the location and servicing of the engine components. 1.Engine Removal ................5-8 2.Engine Installation ..............5-16 3.Cylinder Head Cover ..............5-26 4.Camshaft ..................5-36 5.Camshaft Installation ..............5-56 6.Cylinder Head ................5-72 7.Valves ...................5-86 8.Cylinder and Piston ..............5-100 9.Crankcase Bearings ..............5-127...
  • Page 8 KYMCO Repair Manual UXV 500i/700i 5.Engine MXU700i This chapter covers the location and servicing of the engine components. 1.Rocker Cover ................5-8 2.Camshaft Removal ..............5-32 3.Camshaft Installation ..............5-42 4.Cylinder Head ................5-50 5.Valves ...................5-65 6.Cam Chain ...................5-77 7.Cylinder and Piston ..............5-81 8.Generator Cover ................5-103 9.Flywheel ..................5-121...
  • Page 9 2.Oil Cooler ..................6-11 3.Pressure Testing .................6-21 4.Radiator ..................6-23 5.Thermostat ..................6-35 6.Water Pump .................6-40 7.CVT Continuously Variable Transmission UXV500i This chapter covers the location and servicing of the CVT components. 1.Cooling Ducts ................7-3 2.Belt Case Cover ................7-9 3.Clutch Removal ................7-17 4.Clutch Installation ...............7-32 5.CVT Removal ................7-40...
  • Page 10 KYMCO Repair Manual UXV 500i/700i 8.Final Drive This chapter covers the location and servicing of the final drive components. 1.Universal Joints ................8-2 2.Front Drive Shafts ...............8-4 3.Rear Drive Shafts ................8-21 4.Front Differential Removal And Installation .......8-37 5.Front Differential Disassembly ..........8-47 6.Differential Assembly ..............8-73...
  • Page 11 KYMCO Repair Manual UXV 500i/700i 10.Wheels This chapter covers the location and servicing of the wheel components. 1.Wheel Specifications ..............10-2 2.Wheels ..................10-3 3.Wheel Bearings ................10-24 11.Steering This chapter covers the location and servicing of the steering components. 1.Steering Knuckles ...............11-2 2.Steering Rack ................11-21...
  • Page 12 KYMCO Repair Manual UXV 500i/700i 13.Rear Suspension This chapter provides the rear suspension specifications. 1.Shock Absorbers ................13-2 2.Suspension Arms ................13-7 14.Electrical Systems This chapter covers the location and servicing of the electrical systems. 1.Electrical Specifications .............14-12 2.Battery ..................14-13 3.Charging System .................14-19 4.Fuses ....................14-33...
  • Page 13 1.Quick Reference UXV 500i/700i 1.Quick Reference This chapter provides a quick reference source of technical specifications and information. 1.Diagnostic Trouble Codes ............1-2 2.General Information ..............1-4 3.General Specifications ...............1-21 4.Torque Specifications ..............1-30 5.VIN and Engine Number .............1-34...

  • Page 14: Diagnostic Trouble Codes

    1.Quick Reference UXV 500i/700i Diagnostic Trouble Codes (DTCs) To evaluate the DTCs see the Check Engine Lamp (CELP) Diagnostic Tool topics. Failure Blinks Fault description Priority Fault management Codes 1.Stop immediately and check CELP code. 2. Check if the engine temperature sensor or electric circuit is faulty. P0217 Engine temperature overheat 3.
  • Page 15 1.Quick Reference UXV 500i/700i Failure Blinks Fault description Priority Fault management Codes 1. Make sure the ignition coil connector is connected correctly. 2. Check if the ECU sends a signal to the ignition coil. Ignition coil or electric circuit P0350 3.

  • Page 16: General Information

    1.Quick Reference UXV 500i/700i General Information Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter and move to smaller ones. Tighten bolts evenly and tighten to the specified torque diagonally.
  • Page 17 1.Quick Reference UXV 500i/700i Use genuine parts and lubricants. When servicing the motorcycle, be sure to use the indicated special tools for removal and installation.
  • Page 18 1.Quick Reference UXV 500i/700i After disassembly, clean and inspect the removed parts. Lubricate sliding surfaces with engine oil before reassembly. Apply or add designated greases and lubricants to the specified lubrication points.
  • Page 19 1.Quick Reference UXV 500i/700i After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety.
  • Page 20 1.Quick Reference UXV 500i/700i Disconnect the battery negative (-) terminal before working on the vehicle. When using a spanner or other tools, make sure not to damage the motorcycle surface. After working on the vehicle, check all connecting points, fasteners, and lines for proper connection and installation.
  • Page 21 1.Quick Reference UXV 500i/700i If the fuse is burned out find the cause and repair it. Replace the fuse with a new one according to the specified capacity. After working on the vehicle make sure terminal caps shall have been installed securely.
  • Page 22 1.Quick Reference UXV 500i/700i Disengage the lock on locking electrical connectors before attempting to unplug them. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire. 1-10...
  • Page 23 1.Quick Reference UXV 500i/700i Check for faulty connector terminals. There shouldn't be any bent, protruding or loose terminals. Make sure the connector is plugged in completely. Make sure the connector locks correctly if a lock is present. Make sure there are not any loose wires. 1-11...
  • Page 24 1.Quick Reference UXV 500i/700i Before connecting an electrical connector, check for damaged terminal cover or loose negative terminal. Check the bullet connector cover for proper coverage and installation. Join the terminals completely in bullet connectors. Check the cover for proper coverage. Do not make the cover opening face up.
  • Page 25 1.Quick Reference UXV 500i/700i Secure wire harnesses to the frame with the respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses. After clamping, check each wire to make sure it is secure. 1-13...
  • Page 26 1.Quick Reference UXV 500i/700i Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. 1-14...
  • Page 27 1.Quick Reference UXV 500i/700i Secure the wire harness so that it will not make contact with parts which will generate high heat. Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. Route wire harnesses passing through the side of bolts and screws. 1-15...
  • Page 28 1.Quick Reference UXV 500i/700i Route harnesses so they are neither pulled tight nor have excessive slack. Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. 1-16...
  • Page 29 1.Quick Reference UXV 500i/700i Make sure rubber wire grommets are installed correctly. Do not break the sheath of wire. If a wire or harness has a broken sheath, repair it by wrapping it with protective tape or replace it if needed. 1-17...
  • Page 30 1.Quick Reference UXV 500i/700i When installing other parts, do not press or squeeze the wires. After routing, check that the wire harnesses are not twisted or kinked. 1-18...
  • Page 31 1.Quick Reference UXV 500i/700i Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
  • Page 32 1.Quick Reference UXV 500i/700i Be careful not to drop any parts. When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting. 1-20...

  • Page 33: General Specifications

    1.Quick Reference UXV 500i/700i KYMCO UXV500i/700i Specifications General Specifications Name & Type UXV 500i/700i Overall length 2870 mm Overall width 1500 mm Overall height 1850 mm Wheel base 1910 mm Engine type D.O.H.C. 498.5 CC (UXV 500i) Displacement 694.6 CC (UXV 700i)
  • Page 34 1.Quick Reference UXV 500i/700i 45° ABDC (at 1 mm lift) (UXV 500i) Intake valve Closes 54° BTDC (at 1 mm lift) (UXV 700i) 45° BBDC (at 1 mm lift) (UXV 500i) Exhaust valve Opens 50° BBDC (at 1 mm lift) (UXV 700i) 5°...
  • Page 35 1.Quick Reference UXV 500i/700i 6.464(UXV 500i) Low reduction ratio 5.42~18.21(UXV 700i) 5.31(UXV 500i) Reverse ratio 4.33~14.55 (UXV 700i) Front 0.7 kgf/cc (10 psi) Tire pressure (person 75 kg) 0.98 kgf/cc (14 psi) Rear Left 38.8° Turning angle Right 38.8° Front Disk brake Brake system type Rear...
  • Page 36 1.Quick Reference UXV 500i/700i Fuel Injection Specifications ITEM SPECIFICATIONS Throttle body identification number PTA1 Throttle cable free play 2-6 mm (1/16-1/4 in) Fuel injector resistance (at 20°C/68°F) 10.6 - 15.9 Ω Float at full position About 101 Ω Fuel pump resistance (at 20°C/68°F) Float at empty position About 3 Ω...
  • Page 37 1.Quick Reference UXV 500i/700i Lubrication Specifications Other engine oil viscosities shown in the chart may be used when the average temperature in the riding area is within the indicated range. 1-25...
  • Page 38 1.Quick Reference UXV 500i/700i Cooling System Specifications ITEM SPECIFICATIONS mm (in) Radiator and engine 2 liter (2.1 US qt, 1.76 Imp qt) Coolant capacity Reserve tank 0.45 liter (0.47 US qt, 0.39 Imp qt) Radiator cap relief pressure 90 kPa (0.9 kgf/cm , 12.8 psi) Begin to open 80 - 84°C (176 - 183°F)
  • Page 39 1.Quick Reference UXV 500i/700i COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate or equivalent Distilled Water -9 °C -15 °C 425cc 975cc -25 °C -37 °C -44.5 °C 1-27...
  • Page 40 1.Quick Reference UXV 500i/700i Wheel, Suspension, Tire, and Brake Specifications Tire pressure 1 Rider Front 0.7 kgf/cm (10 psi) Rear 0.98 kgf/cm (14 psi) Tire size: Front 25 X 8 - 12 Tire size: Rear 25 X 10 - 12 Item Standard mm (in) Service Limit...
  • Page 41 1.Quick Reference UXV 500i/700i Electrical Specifications ITEM SPECIFICATIONS Capacity 12V-18 Ah Current leakage 0.5 Ma max. Full charged 13.0 - 13.2 V Battery Voltage (20°C/68°F) Needs charging Below 12.3 V Normal 1.8 A/5 - 10 h Charging current Quick 9 A/1 h Alternator Charging coil resistance (20°C/68°F) 0.1 - 0.3 Ω...

  • Page 42: Torque Specifications

    1.Quick Reference UXV 500i/700i Torque Specifications Torque kgf-m Item Thread dia. (mm) Remarks (N-m, ft-lb) MAINTENANCE: Spark plug 1.2 (12, 8.6) Tappet ADJ nut 0.9 (9, 6.5) Engine oil filter cap 1.5 (15, 11) Apply oil Engine oil filter cartridge 1 (10, 7.2) Apply oil Engine drain plug...
  • Page 43 1.Quick Reference UXV 500i/700i Drive pulley nut 14 (140) Apply oil Wet clutch nut 14 (140) Driven pulley nut 10 (100) Apply oil Driven pulley assembly plate nut 7.5 (75) TRANSMISSION: Crankcase bolt 1.2 (12) Apply oil Drive bevel gear nut 14 (140) Apply oil Driven bevel gear nut...
  • Page 44 1.Quick Reference UXV 500i/700i Front lower arm and frame 4.8 (48, 34) Front shock absorber and frame 4.5 (45, 32.4) Front shock absorber and front upper arm 4.5 (45, 32.4) REAR SUSPENSION: Rear upper arm and frame 4.8 (48, 34) Rear lower arm and frame 4.8 (48, 34) Rear knuckle and rear upper arm...
  • Page 45 1.Quick Reference UXV 500i/700i R/L roof and frame 6.4 (64, 45) Cross pipe, roof 3.2 (32, 22.7) Shifter 2.2 (22, 15.6) Pedal assy.stay and frame 2.2 (22, 15.6) Seat belt and frame 7/16-20unf 5.9 (59, 42) Shifter rod assy 2.2 (22, 15.6) ENGINE: Rear gear box and caliper bracket 3.2(32, 22.7)

  • Page 46: Vin And Engine Number

    1.Quick Reference UXV 500i/700i VIN and Engine Number Location The VIN stamped into the front right side of the frame. The engine number is stamped into the back of the left crankcase half. 1-34...
  • Page 47 1.Quick Reference UXV 500i/700i Information and Warning Sticker Locations 1-35...
  • Page 48 1.Quick Reference UXV 500i/700i 1-36...

  • Page 49: Entire Chapter

    2.Periodic Maintenance UXV 500i/700i 2.Periodic Maintenance This chapter covers the location and servicing of the periodic maintenance items. This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.

  • Page 50: Periodic Maintenance Chart

    2.Periodic Maintenance UXV 500i/700i Periodic Maintenance Chart Periodic maintenance is required to keep the vehicle safe and performing properly. For use exceeding the chart repeat the service intervals. INITIAL EVERY WHICHEVER COMES FIRST 600 1200 ITEM 150 1000 2000 ROUTINE MONTH Engine oil •Replace (Warm engine before draining).
  • Page 51 2.Periodic Maintenance UXV 500i/700i •Adjust if necessary. •Check operation and brake fluid. Brake •Replace brake pad if necessary. •Check coolant leakage. Coolant •Replace if necessary. •Replace coolant every 24 months. •Check operation. V-belt •Replace if damage or excessive wear. •Check leakage. Exhaust system •Retighten if necessary.

  • Page 52: Air Filter Servicing

    2.Periodic Maintenance UXV 500i/700i Air Filter Servicing SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seats. See the Seat topic for more information. Remove the center cover. See the Center Cover topic for more information. There are seven airbox cover screws.
  • Page 53 2.Periodic Maintenance UXV 500i/700i Remove the airbox cover. Loosen the air filter clamp screw with a flat blade screwdriver or an 8 mm socket.
  • Page 54 2.Periodic Maintenance UXV 500i/700i Lift out the air filter. Clean out the airbox. Loosen the air filter holder screw with a #2 Phillips screwdriver. Remove the screw and washers from the air filter. Remove the air filter holders from the air filter.
  • Page 55 2.Periodic Maintenance UXV 500i/700i Slide out the air filter screen. Separate the inner and outer air filter element pieces.
  • Page 56 2.Periodic Maintenance UXV 500i/700i Servicing Place the filter in a container and saturate it with a foam air filter cleaner both inside and out. Products like Simple Green, dish soap, or most non-flammable solvents will work if foam air filter cleaner is unavailable. Let the filter soak for approximately 5 minutes - follow cleaning product instructions if different.
  • Page 57 2.Periodic Maintenance UXV 500i/700i Oil the filter with foam air filter oil or fresh engine oil. Squeeze out any excess oil. The element should be wet with oil, but not to the point of dripping. Clean the out the airbox. Installation Fit the inner air filter element into the outer element.
  • Page 58 2.Periodic Maintenance UXV 500i/700i Insert the screen into the air filter elements. Install the air filter holders into the air filter. The holders must fit together as shown. 2-10...
  • Page 59 2.Periodic Maintenance UXV 500i/700i Install the air filter holder screw and washers. Tighten the air filter holder screw securely with a #2 Phillips screwdriver. Fit the air filter into place as shown. 2-11...
  • Page 60 2.Periodic Maintenance UXV 500i/700i Tighten the air filter clamp screw securely with a flat blade screwdriver or an 8 mm socket. Fit the airbox cover into place. 2-12...
  • Page 61 2.Periodic Maintenance UXV 500i/700i Insert the seven airbox cover screws. Tighten the airbox cover screws securely with a #2 Phillips screwdriver. Inspect the airbox drain tube. 2-13...
  • Page 62 2.Periodic Maintenance UXV 500i/700i Remove the tube and drain away any fluid build up or debris that has collected. Return the tube and secure it with the clamp. Install the center cover. See the Center Cover topic for more information. Install the seats.

  • Page 63: Throttle Free Play

    2.Periodic Maintenance UXV 500i/700i Throttle Free Play SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Inspect the throttle free play by operating the throttle pedal. The end of the throttle pedal should travel 3 - 5 mm (0.12 - 0.20 in) before the cable slack is taken up and the throttle begins to open.
  • Page 64 2.Periodic Maintenance UXV 500i/700i Adjustment First Step Remove the pedal cover. See the Pedal Cover topic for more information. Loosen the lock nut with a 10 mm wrench. 2-16...
  • Page 65 2.Periodic Maintenance UXV 500i/700i Adjust the adjuster nut on the other side with a 10 mm wrench until the free play is within specification. Tighten the lock nut when finished. Proceed to the second step if the correct free play can not achieved. Second Step Slide back the rubber cover from the throttle cable.
  • Page 66 2.Periodic Maintenance UXV 500i/700i To adjust the throttle free play loosen the lock nut on the throttle cable with an 8 mm wrench and turn the adjuster with an 8 mm wrench. Turn the adjuster out to decrease free-play and turn it in to increase free-play.

  • Page 67: Brake Fluid

    UXV 500i/700i Brake Fluid The KYMCO UXV 500i/700i uses DOT 4 brake fluid. Do not mix the brake fluid types. The system should be bled whenever the brakes feel spongy, or if the brake system has been taken apart and rebuilt. Always use fresh brake fluid from a tightly sealed container.
  • Page 68 2.Periodic Maintenance UXV 500i/700i Remove the brake fluid panel at the bottom of the front cargo box. Unscrew the master cylinder cap. Make sure the brake fluid level is acceptable. Draining Lift the hood. See the Hood topic for more information. Remove the front cargo box.
  • Page 69 2.Periodic Maintenance UXV 500i/700i Place a suitable container under the master cylinder to catch the fluid. Remove the brake fluid drain bolt to drain the brake fluid. Note: Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts.
  • Page 70 2.Periodic Maintenance UXV 500i/700i Crack open the bleeder valve on the brake caliper using an 8 mm wrench. This valve is usually very tight so use a box end wrench or a 6 point socket and ratchet to prevent rounding off the head. Snug the bleeder valve back down. Place a length of 6 mm inside diameter clear hose on the bleeder valve and place the other end in a container to catch the old brake fluid.
  • Page 71 2.Periodic Maintenance UXV 500i/700i Fill the master cylinder with DOT 4 brake fluid from a fresh, newly opened container and bleed the brakes. Note: The front and rear brakes follow the same procedure. Pull off the rubber cap over the bleeder valve on the caliper you are working on. 2-23...
  • Page 72 2.Periodic Maintenance UXV 500i/700i Crack open the bleeder valve on the brake caliper using an 8 mm wrench. This valve is usually very tight so use a box end wrench or a 6 point socket and ratchet to prevent rounding off the head. Snug the bleeder valve back down. Place a length of 6 mm inside diameter clear hose on the bleeder valve and place the other end in a container.
  • Page 73 2.Periodic Maintenance UXV 500i/700i Tighten the bleeder valves to specification and push their rubber covers over the nipples. Item Kgf-m lbf-ft Bleeder valves Make sure the reservoir has the proper amount of fluid. Install the master cylinder cap. Check the function of the brakes before operating the machine. 2-25...

  • Page 74: Brake Inspection

    2.Periodic Maintenance UXV 500i/700i Brake Inspection SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Master Cylinder Place the vehicle on level ground so the front master cylinder reservoir is level. Lift the hood. See the Hood topic for more information. Remove the brake fluid panel at the bottom of the front cargo box.
  • Page 75 2.Periodic Maintenance UXV 500i/700i Check the level of brake fluid. Front Pads and Rotors Use a jack to raise the front wheels off the ground. Be sure it is on a level surface. Remove the front wheels. See the Wheels and Wheel Hubs topic for more information.
  • Page 76 2.Periodic Maintenance UXV 500i/700i Inspect the pad linings and rotors. Replace the pads if they are worn to the limit line. Replace the rotors if they are not within specification.To replace the front brake pads and/or rotors see the Front Caliper and/or Front Disc Brake topic.
  • Page 77 2.Periodic Maintenance UXV 500i/700i Rear Brake Pads and Rotors Use a jack to raise the rear wheels off the ground. Be sure it is on a level surface. Remove the rear wheels. See the Wheels and Wheel Hubs topic for more information. Inspect the pad linings and rotor.
  • Page 78 2.Periodic Maintenance UXV 500i/700i Replace the pads if they are worn to the limit line. Replace the rotor if it is damaged or out of specification. To replace the front brake pads and/or rotors see the Rear Brake Caliper and/or Rear Brake Disc topic.
  • Page 79 2.Periodic Maintenance UXV 500i/700i Parking Brake Measure the brake cable end length “L” and check it against the specification. See the Rear Parking Brake Adjustment topic for more information. 2-31...

  • Page 80: Rear Parking Brake Adjustment

    2.Periodic Maintenance UXV 500i/700i Rear Parking Brake Adjustment SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Make sure the parking brake doesn't drag when the lever is released, and the parking brake holds when the lever is applied. Adjust the inline cable adjuster as needed. Trace the cable up fro the parking brake until you reach the adjuster.

  • Page 81: Engine Oil

    At draining and oil filter 3.2 liter (2.82 Imp qt, 3.39 Us qt) (UXV 500i) cartridge change 2.6 liter (UXV 700i) KYMCO 4-stroke oil or equivalent Recommended engine oil motor oil API service classification SJ Viscosity: SAE 5W-50 Other engine oil viscosities shown in the chart may be used when the average temperature in the riding area is within the indicated range.
  • Page 82 2.Periodic Maintenance UXV 500i/700i Inspection Start the engine and let it warm up for 2 - 3 minutes. Park the vehicle on a level surface. Stop the engine and allow the oil to settle for 2 - 3 minutes. Inspect the oil level through the sight glass. The sight glass is located on the left side of the engine.
  • Page 83 2.Periodic Maintenance UXV 500i/700i If the oil level is at or below the "L" mark add more of the same type and brand of oil to the engine through the oil filler hole. Wipe down the area around the filler cap to prevent debris from entering the engine.
  • Page 84 2.Periodic Maintenance UXV 500i/700i Place a drain pan under the oil filter cap and drain plug. Loosen the oil filter cap with a 17 mm socket. Remove the drain plug, oil filter cap, strainer, spring and O-ring. Allow the oil to drain into the pan.
  • Page 85 2.Periodic Maintenance UXV 500i/700i Remove the oil cap for faster draining. Use a special oil filter wrench to remove the oil filter cartridge. Special Tool- Oil Cartridge Wrench: A120E00061 2-37...
  • Page 86 2.Periodic Maintenance UXV 500i/700i Remove the oil filter and the rubber oil filter seal from the engine case. Apply engine oil to the O-ring. When the oil has finished draining install the oil filter cap, strainer, spring and O-ring. Torque the oil filter cap to specification with a 17 mm socket. 2-38...
  • Page 87 2.Periodic Maintenance UXV 500i/700i Note: You can remove the drain plug to drain the engine oil also, but you will not be able to clean the strainer. This is a good way to drain engine oil if it was over-filled. Replace the sealing washer with a new item it it was removed.
  • Page 88 2.Periodic Maintenance UXV 500i/700i Install the oil filter onto the engine and tighten by hand until the oil filter contacts the engine. Tighten the oil filter with the special oil filter wrench to specification. Special Tool- Oil Cartridge Wrench: A120E00061 Item Torque kgf-m (N-m, ft-lb) Remarks...
  • Page 89 2.Periodic Maintenance UXV 500i/700i Refilling Add the proper type and quantity of oil and install the oil filler cap. Start the engine and let it run for several minutes. Check for any oil leaks. Check the oil level as describe above. If the oil level is too high drain the excess oil from the oil drain bolt.

  • Page 90: Oil Pressure

    2.Periodic Maintenance UXV 500i/700i Oil Pressure SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the center cover. See the Center Cover topic for more information Remove the check hole plug with O-ring. Inspect the O-ring and replace as needed. Start the engine.

  • Page 91: Final Drive / Differential Oil

    2.Periodic Maintenance UXV 500i/700i Final Drive Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Drive the vehicle until the rear drive gear oil is warm. Place the vehicle on a level surface. Rear Drive Gear Oil Draining Place a suitable oil drain pan under the rear differential.
  • Page 92 2.Periodic Maintenance UXV 500i/700i Remove the filler cap with a 17 mm socket. Inspect the filler cap O-ring and replace if needed. 2-44...
  • Page 93 2.Periodic Maintenance UXV 500i/700i Remove the drain plug with a 12 mm socket and allow the oil to completely drain. Fill Install a new sealing washer and the drain plug. Tighten the drain plug to specification with a 12 mm socket. Item kgf-m ft-lb...
  • Page 94 2.Periodic Maintenance UXV 500i/700i Add the proper rear gear oil into the filler hole. Type Capacity SAE 80~90 hypoid gear oil 250 cc (8.45 US oz) Remove the oil level check bolt and sealing washer with a 12 mm socket. Check that the oil level reaches the oil level check hole.
  • Page 95 2.Periodic Maintenance UXV 500i/700i Install the filler cap and O-ring. Tighten it to specification with a 17 mm socket. Item kgf-m ft-lb Rear drive filler cap Install the oil level check bolt with a new sealing washer and tighten to specification using a 12 mm socket .
  • Page 96 2.Periodic Maintenance UXV 500i/700i Front Drive Gear Oil Draining Remove the front skid plate. See the Skid Plates topic for more information. Place a suitable oil drain pan under the rear differential. Remove the filler cap with a 17 mm socket. 2-48...
  • Page 97 2.Periodic Maintenance UXV 500i/700i Inspect the filler cap O-ring and replace if needed. Remove the drain plug with an 8 mm socket and allow the oil to completely drain. 2-49...
  • Page 98 2.Periodic Maintenance UXV 500i/700i Fill Install a new sealing washer and the drain plug. Tighten the drain plug to specification with an 8 mm socket. Item kgf-m ft-lb Front drive drain plug 2-50...
  • Page 99 2.Periodic Maintenance UXV 500i/700i Add the proper type and amount of rear gear oil into the filler hole. Type Capacity SAE 80~90 hypoid gear oil 270 cc (9.13 US oz) Install the filler cap and O-ring. Tighten it to specification with a 17 mm socket. Item kgf-m ft-lb...

  • Page 100: Spark Plug

    2.Periodic Maintenance UXV 500i/700i Spark Plug Item Standard Spark plug NGK-CR7E Spark plug gap 0.6 - 0.7 mm (0.024 - 0.028 in.) SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the center cover. See the Center Cover topic for more information.
  • Page 101 2.Periodic Maintenance UXV 500i/700i Remove the spark plug using a 5/8 in deep well spark plug socket. Inspection Inspect the spark plug for signs of damage. Always replace a spark plug if any part of it is damaged. 2-53...
  • Page 102 2.Periodic Maintenance UXV 500i/700i The color of the spark plug's porcelain tip can indicate how the mixture is burning. A white colored plug shows a lean mixture, where a dark plug shows a rich mixture. A light brown color is optimal. For more information see the spark plug trouble shooting chart. http://www.cyclepedia.com/spark-plug-troubleshooting/ If the plug is dirty or has carbon build up it can be cleaned with small wire brush.
  • Page 103 2.Periodic Maintenance UXV 500i/700i Always check the gap of the spark plugs before installation. If the gap needs to be adjusted bend the ground electrode carefully. Item Standard Spark plug gap 0.6 - 0.7 mm (0.024 - 0.028 in.) 2-55...
  • Page 104 2.Periodic Maintenance UXV 500i/700i Installation Install the spark plug by hand. Tighten it to specification a 5/8 in deep well spark plug socket. Item Torque kgf-m (N-m, ft-lb) Spark plug 1.2 (12, 8.6) Do not over tighten the spark plug. The cylinder head is made out of soft metal, and it can be easily damaged.

  • Page 105: Compression Check

    2.Periodic Maintenance UXV 500i/700i Compression Check SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Run the engine to warm it up before conducting a compression test. Make sure your compression gauge is in good working order and does not leak. Remove the center cover.

  • Page 106: Tires

    2.Periodic Maintenance UXV 500i/700i Tires SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Tire Size Tire size: Front 25 X 8 - 12 Tire size: Rear 25 X 10 - 12 2-58...
  • Page 107 2.Periodic Maintenance UXV 500i/700i Air Pressure Check the tire pressure with a low pressure gauge. Tire pressure (cold) 1 Rider Front 0.7 kgf/cm (10 psi) Rear 0.98 kgf/cm (14 psi) 2-59...
  • Page 108 2.Periodic Maintenance UXV 500i/700i Tire Tread Depth Check that the tire tread depth is within specification. Tire Tread Depth Service Limit Front Tire 4 mm (0.16 in) Rear Tire 4 mm (0.16 in) 2-60...
  • Page 109 2.Periodic Maintenance UXV 500i/700i Directional Rotation Check the "ROTATION" arrow on the tire's sidewall.The arrow indicates the direction in which the tire should turn going forward. 2-61...

  • Page 110: Valve Clearance

    2.Periodic Maintenance UXV 500i/700i Valve Clearance SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection The engine has to be cold (room temperature) to check the valve clearance. Remove the seats. See the Seat topic for more information. Remove the center cover.
  • Page 111 2.Periodic Maintenance UXV 500i/700i Remove the recoil starter cover bolts with an 8 mm socket. Remove the recoil starter cover. 2-63...
  • Page 112 2.Periodic Maintenance UXV 500i/700i Turn the crankshaft clockwise with a 19 mm socket. Align the "T" mark on the flywheel with the index mark on the right crankcase cover. This shows the piston is at Top Dead Center (TDC). 2-64...
  • Page 113 2.Periodic Maintenance UXV 500i/700i Make sure the punch marks on the ends of the camshafts are pointed up. With the marks pointing up the piston is at TDC on the compression stroke. If the punch marks are not pointing up rotate the crankshaft clockwise until the piston is at TDC on the compression stroke.
  • Page 114 2.Periodic Maintenance UXV 500i/700i Measure the valve clearance with a thickness feeler gauge. Insert the feeler gauge between the adjusting screw and the valve stem. The clearance is correct when there is a light drag on the feeler gauge. If the clearance is out of spec move on to the adjustment section.
  • Page 115 2.Periodic Maintenance UXV 500i/700i Adjustment Use a valve adjuster tool to adjust the valves. Special Tool- Valve Adjuster: A120E00036 2-67...
  • Page 116 2.Periodic Maintenance UXV 500i/700i Loosen the valve adjuster locknut with a wrench. Insert the valve adjuster tool through the opening as shown. If the valve clearance is too tight, back out the valve adjusting screw with the valve adjustment tool. If the clearance is too loose, turn in the valve adjusting screw until there is a light drag on the feeler gauge.
  • Page 117 2.Periodic Maintenance UXV 500i/700i Assembly Install the recoil starter cover. Tighten the recoil starter bolts securely with an 8 mm socket. 2-69...
  • Page 118 2.Periodic Maintenance UXV 500i/700i Install the timing cap on the right side of the engine and tighten it securely with a flat blade screwdriver. Install the cylinder head cover. See the Cylinder Head Cover topic for more information. Install the spark plug. See the Spark Plug topic for more information.

  • Page 119: Toe-In Adjustment

    2.Periodic Maintenance UXV 500i/700i Toe-In Adjustment SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Check that all tires are properly inflated at the same pressure. See the Tires topic for more information. Mark the center of both front tire treads. Raise the front tires off the ground.
  • Page 120 2.Periodic Maintenance UXV 500i/700i Measure the distances between the center of the tires with a toe-in-gauge on the front of the tires. Call this measurement A. Rotate the tires 180°. Measure the distances between the center of the tires with a toe-in-gauge on the rear of the front tires. Call the rear measurement B.
  • Page 121 2.Periodic Maintenance UXV 500i/700i Adjustment Mark the tie-rods for reference. Loosen the left and right outer tie-rod locknuts with a 19 mm wrench. Hold the tie-rod end and turn the tie-rod. Turn both the tie-rods evenly until the toe-in is within specification. Moving the tie-rods out towards the wheels will increase toe-in.

  • Page 122: Spark Arrestor

    2.Periodic Maintenance UXV 500i/700i Spark Arrestor SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 2-74...
  • Page 123 2.Periodic Maintenance UXV 500i/700i Removal Note: Always allow the exhaust system plenty of time to cool before touching it. Remove the three arrestor bolts with an 8 mm socket. Remove the spark arrestor and gasket. 2-75...
  • Page 124 2.Periodic Maintenance UXV 500i/700i Clean the carbon off of the spark arrestor screen with a wire brush. Inspect the spark arrestor screen for any damage and replace as needed. 2-76...
  • Page 125 2.Periodic Maintenance UXV 500i/700i Installation Install the spark arrestor with a new gasket. Install the spark arrestor bolts and tighten them securely with an 8 mm socket. 2-77...
  • Page 126 3.Fuel System UXV 500i/700i 3.Fuel System This chapter covers the location and servicing of the fuel system components. 1.Airbox ...................3-2 2.Check Engine Lamp (CELP) ............3-8 3.Component Location ..............3-12 4.Diagnostic Tool ................3-19 5.Fuel Injection Sensors ..............3-35 6.Fuel Injector .................3-50 7.Fuel Pump ..................3-61 8.Fuel Tank ..................3-77 9.Throttle Body Removal ...............3-88 10.Throttle Body Components ............3-104...

  • Page 127: Airbox

    3.Fuel System UXV 500i/700i Airbox SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the center cover. See the Center Cover topic for more information. Remove the air filter. See the Air Filter Servicing topic for more information. The airbox is mounted to the frame with two bolts.
  • Page 128 3.Fuel System UXV 500i/700i Squeeze the breather hose clip and slide it back. Free the breather hose from the airbox boot. Loosen the airbox boot clamp with a #2 Phillips screwdriver.
  • Page 129 3.Fuel System UXV 500i/700i Lift the airbox off of the frame. Free the airbox boot from the mouth of the throttle body. Lift out the airbox. Cover the mouth of the throttle body with a clean shop towel or tape to prevent debris from entering the engine.
  • Page 130 3.Fuel System UXV 500i/700i Installation Fit the airbox into place. Connect the airbox boot to the throttle body. Fit the airbox onto the frame as shown.
  • Page 131 3.Fuel System UXV 500i/700i Install the two airbox mounting bolts. Tighten the bolts securely with a 10 mm socket.
  • Page 132 3.Fuel System UXV 500i/700i Tighten the airbox boot clamp securely with a #2 Phillips screwdriver. Connect the breather hose to the airbox boot. Secure the hose with the clamp. Install the air filter. See the Air Filter Servicing topic for more information. Install the center cover.

  • Page 133: Check Engine Lamp (Celp)

    3.Fuel System UXV 500i/700i Check Engine Lamp (CELP) SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note: The check engine lamp (CELP) will come on for 2 seconds when the key is turned on and then it should go off. If it lights after this the system has detected a problem. The vehicle should be immediately diagnosed as to what is causing the light to come on.
  • Page 134 3.Fuel System UXV 500i/700i There are 3 priority levels of the CELP while the engine is running. Priority grade 1: The CELP blinks continuously letting you know this is the most severe condition. The rider must slow and immediately take the vehicle to the dealership service center for evaluation.
  • Page 135 3.Fuel System UXV 500i/700i ● There’re 22 failure codes for the Synerjet M3C system. If the vehicle gets multiple failure codes, the CELP will display the lower number code, then progress to the higher number after four seconds. The failure codes will display repeatedly. After the codes cycle four times the codes will clear from the system memory.
  • Page 136 3.Fuel System UXV 500i/700i With Special Tool See the Fuel Injection Diagnostic Tool topic. Self-Diagnosis Reset Procedure After the codes cycle four times the codes will clear from the system memory. Always clear the memory after fixing the problem to prevent the light from showing the next time the vehicle is used.

  • Page 137: Component Location

    3.Fuel System UXV 500i/700i Component Location SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Open the hood to access the ECU and battery. See the Hood topic for more information. The following components can be found here. The ECU is mounted to the frame with four bolts.
  • Page 138 3.Fuel System UXV 500i/700i • Roll Sensor • Fuel Pump Relay • Switch Power Relay • The regulator/rectifier is located under the hood. 3-13...
  • Page 139 3.Fuel System UXV 500i/700i Remove the four battery cover screws with a #2 Phillips screwdriver. Remove the battery cover. 3-14...
  • Page 140 3.Fuel System UXV 500i/700i The Hi Beam Relay, Lo Beam Relay and Starter Relay are next to the battery as shown. Many of the fuel injection components are located with the throttle body behind the cylinder head. Remove the center body covers to access these components. 3-15...
  • Page 141 3.Fuel System UXV 500i/700i The following components can be found here. • Throttle Body • T-MAP (Manifold Absolute Pressure) • Fuel Injector • Fuel Hose • TPS (Throttle Position Sensor) • ISC (Idle Speed Control) 3-16...
  • Page 142 3.Fuel System UXV 500i/700i The WTS (Water Temperature Sensor) is located on the right side of the engine cylinder. The ignition coil is located on the frame behind the right seat. Remove the plastic cover to access it. 3-17...
  • Page 143 3.Fuel System UXV 500i/700i The fuel pump is mounted in the fuel tank. 3-18...

  • Page 144: Diagnostic Tool

    Diagnostic tool Part Number: 3620A-LEB2-E00 CAN Linker Part Number: 3620A-LGC7-E000 This tool has been developed by KYMCO and for KYMCO vehicles only. The tool software can be updated for new models with a computer via the USB cable. Please refer to the specifications when servicing this vehicle.
  • Page 145 3.Fuel System UXV 500i/700i Plug the diagnostic tool connector into the CAN Linker as shown. 3-20...
  • Page 146 3.Fuel System UXV 500i/700i Free the diagnostic connector from the frame. Remove the dummy side of the connector. Set a multimeter to reads voltage (DCV). Measure the voltage as indicated. Terminal (+) Terminal (-) Normal BR/L Battery Voltage Battery Voltage - 1 Connect the CAN Linker to the diagnostic plug.
  • Page 147 3.Fuel System UXV 500i/700i The FI tool has three buttons and two lights below the screen. The left button is the up button that will move the selector up. The right button is the down button that moves the selector down. The middle button is ENTER. This will select the item you have chosen. The left light indicated the tool has power, and the right light indicates a Diagnostic Trouble Code (DTC) is present.
  • Page 148 UXV 500i/700i ECU Version The four functions will display when the tool is powered on. The model name will show LKC3 for the UXV500i. Pressing the enter button on the ECU version will show information on the ECU software and calibration.
  • Page 149 3.Fuel System UXV 500i/700i DTC (Diagnostic Trouble Code) INSPECTION PROCEDURE Press the down button (right) to move the item selector down to the DTC Inspect item. 3-24...
  • Page 150 3.Fuel System UXV 500i/700i Pressing the enter button on the DTC Inspect item will bring up the options shown above. Select the DTC Load option and press the enter button to display the DTC options. There are three DTC options - Active, Occurred, and History. Move the selector to the Active option and press enter to display current DTC.
  • Page 151 3.Fuel System UXV 500i/700i In this instance the indicated code is 12 (CELP blinks). This corresponds to the DTC P0230. 3-26...
  • Page 152 3.Fuel System UXV 500i/700i Failure Blinks Fault description Priority Fault management Codes 1. Make sure the relay connector is connected correctly. Fuel pump relay or electric 2. Check if the ECU sends a signal to P0230 circuit malfunction relay. 3. Check the fuel pump relay resistance Consult the DTC table for more information on how to troubleshoot the problem.
  • Page 153 3.Fuel System UXV 500i/700i Pressing the enter button on the DTC Inspect item will bring up the options shown above. Move the selector down to the Clear DTC option and press enter. The diagnostic tool will show when the DTC in memory is cleared. Also, the DTC indicator light will be off.
  • Page 154 3.Fuel System UXV 500i/700i Data Analysis Procedure When using the data analysis feature for running condition items such as ignition advance, ISC step, ect., make sure the engine temperature has reached 80° C. The engine temperature is displayed on data analysis page 03. Press the down button (right) to move the item selector down to the DATA Analyze item.
  • Page 155 3.Fuel System UXV 500i/700i Page 01 The 01 page shows engine speed, idle speed set point, and battery voltage. Page 02 The 02 page shows TPS position and TPI idle adapted. 3-30...
  • Page 156 3.Fuel System UXV 500i/700i Page 03 The 03 page shows engine temperature, air temperature, and intake pressure. 3-31...
  • Page 157 3.Fuel System UXV 500i/700i Page 04 The 04 page shows atmospheric pressure, fuel injection interval, and ignition advance. Page 05 The 05 page shows the rollover voltage. 3-32...
  • Page 158 3.Fuel System UXV 500i/700i Page 06 The 06 page shows the ISC step and ISC learn step. Page 07 The 07 page shows the ECU counter. 3-33...
  • Page 159 3.Fuel System UXV 500i/700i Diagnostic Report 3-34...

  • Page 160: Fuel Injection Sensors

    3.Fuel System UXV 500i/700i Fuel Injection Sensors SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the sensors. Water Temperature Sensor (WTS) Removal Remove the center cover. See the Center Cover topic for more information.
  • Page 161 3.Fuel System UXV 500i/700i Push in the spring and unplug the WTS sensor connector. Remove the sensor with a 22 mm wench. 3-36...
  • Page 162 3.Fuel System UXV 500i/700i Discard the O-ring seal. Installation Install a new O-ring onto the WTS. 3-37...
  • Page 163 3.Fuel System UXV 500i/700i Thread in the WTS. Tighten the WTS to specification with a deep well 22 mm socket. ITEM kgf-m ft-lb Inspection Input Voltage Turn the ignition switch to the OFF position. Push in the spring and unplug the WTS sensor connector. Set the multimeter to read voltage (DCV).
  • Page 164 3.Fuel System UXV 500i/700i Turn the ignition switch to the ON position. Measure the input voltage on the harness side of the connector. (WTS Input Voltage: 5 ± 0.1 V) If the input voltage is out of specifications check the offending wires for a short or open lead.
  • Page 165 3.Fuel System UXV 500i/700i Suspend the sensor and a thermometer in a pot of coolant with string. Make sure the WTS and the thermometer are not touching the pot. Bring the temperature up to the specification slowly and check the resistance between the sensor terminal and body. Temperature Standard Resistance (approximate) -20°...
  • Page 166 3.Fuel System UXV 500i/700i Temperature and Manifold Absolute Pressure (T-MAP) To remove and install the sensors on the throttle body see the Throttle Body Components topic. Input Voltage Inspection Turn the ignition switch to the OFF position. Unplug the T-MAP connector. Set the multimeter to read voltage (DCV).
  • Page 167 3.Fuel System UXV 500i/700i Resistance Set the multimeter to ohms of resistance (kΩ). Measure the resistance between the 3 and 4 pins of the T-MAP sensor. ITEM SPECIFICATION T-MAP sensor resistance (20°C) 1613 - 2544 Ω To replace the T-MAP sensor see the Throttle Body Components topic.
  • Page 168 3.Fuel System UXV 500i/700i Throttle Position Sensor Input Voltage Inspection Unplug the TPS connector. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector. Terminal Normal Violet/Red (+) – Violet/Green (-) 3-43...
  • Page 169 3.Fuel System UXV 500i/700i Resistance Inspection Set the multimeter to ohms of resistance (kΩ). Measure the resistance between the ground (A) and input (C) terminals of the TPS. Throttle Position Sensor (TPS) 3500 - 6500 Ω resistance (at 20°C/68°F) 3-44...
  • Page 170 3.Fuel System UXV 500i/700i Data Analysis Bring up data analysis page 02 to see information on the TPS. See the Diagnostic Tool topic for more information. The TPS voltage should display as indicated in the table per the throttle position. Throttle Position Opening Angle Standard...
  • Page 171 3.Fuel System UXV 500i/700i Ignition Pulse Generator / Crank Position Sensor To inspect the ignition pulse generator/crank position sensor see the Ignition System topic. To replace the ignition pulse generator/crank position sensor see the Generator Cover topic. Roll Sensor / Tip-Over Removal and Installation Remove the hood.
  • Page 172 3.Fuel System UXV 500i/700i Remove the two roll sensor screws with a #2 Phillips screwdriver. Unplug the roll sensor and remove it. Plug in the roll sensor and install it so the UP mark faces up. Tighten the two roll sensor screws securely with a #2 Phillips screwdriver.
  • Page 173 3.Fuel System UXV 500i/700i Inspection Turn the ignition switch to the OFF position. Remove the roll sensor screws, but leave the sensor plugged in. Set the multimeter to read voltage (DCV). Turn the ignition switch to the ON position. Measure the voltage of the roll sensor wires with the connector plugged in and the sensor in the regular upright attitude.
  • Page 174 3.Fuel System UXV 500i/700i Incline the roll sensor 65 ± 10 degrees to the left or right. Check the voltage. Terminal Normal Violet/Red (+) - Green (-) 5 V (ECU Voltage) Black/White (+) - Green (-) 0.4 - 1.4 V If this test is to be repeated the ignition switch must be turned OFF to reset the system.

  • Page 175: Fuel Injector

    3.Fuel System UXV 500i/700i Fuel Injector SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Removal Remove the center cover. See the Center Cover topic for more information.
  • Page 176 3.Fuel System UXV 500i/700i Disconnect the fuel hose from the fuel injector. Push in the spring clip and unplug the fuel injector connector. 3-51...
  • Page 177 3.Fuel System UXV 500i/700i Remove the two fuel injector mounting bolts with a 10 mm socket. Remove the fuel injector and pipe from the intake pipe. 3-52...
  • Page 178 3.Fuel System UXV 500i/700i Slide off the clip and pull the fuel injector out of its pipe. The O-rings should be replaced with new items on installation. 3-53...
  • Page 179 3.Fuel System UXV 500i/700i Inspection A digital multimeter is needed to test the fuel injector. Set the multimeter to read ohms of resistance (Ω). Measure the resistance between the fuel injector terminals ITEM SPECIFICATIONS Fuel injector resistance (at 20°C/68°F) 10.6 - 15.9 Ω Check for continuity between the fuel injector terminals and a ground.
  • Page 180 3.Fuel System UXV 500i/700i Measure the input voltage on the harness side of the connector. Touch one meter lead to the input hot wire terminal and the other to a ground. The voltage can only be measured within 3 seconds of the ignition switch being turned on. The battery voltage should show.
  • Page 181 3.Fuel System UXV 500i/700i 5. Wait for 20-30 minutes. 6. Clean the carbons completely from the injector. 3-56...
  • Page 182 3.Fuel System UXV 500i/700i Installation Install new O-rings to the fuel injector. Apply a light coat of fresh engine oil to the fuel injector O-ring seals. Install the fuel injector into the pipe. Install the clip to secure the fuel injector. 3-57...
  • Page 183 3.Fuel System UXV 500i/700i Install fuel injector and pipe onto the intake pipe. Guide the fuel injector into place, and be sure not to damage the O-ring. Install the two fuel injector mounting bolts and tighten them securely. 3-58...
  • Page 184 3.Fuel System UXV 500i/700i Plug in the fuel injector connector. Connect the fuel hose to the fuel injector pipe. 3-59...
  • Page 185 3.Fuel System UXV 500i/700i Tighten the fuel hose clamp securely with a #2 Phillips screwdriver. Install the center cover. See the Center Cover topic for more information. 3-60...

  • Page 186: Fuel Pump

    3.Fuel System UXV 500i/700i Fuel Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Fuel Line Inspection Remove the right seat. See the Seat topic for more information.
  • Page 187 3.Fuel System UXV 500i/700i Input Voltage Inspection Unplug the fuel pump connecter. Set the multimeter to read voltage (DCV). Touch the multimeter leads to the harness side of the fuel pump connector, with the positive lead touching the orange/red wire terminal and the negative lead touching the green wire terminal.
  • Page 188 3.Fuel System UXV 500i/700i If the battery voltage is not present check the following: ● Fuse B (10 A) ● Fuel pump relay ● ECU Removal Turn the ignition switch off. Unplug the fuel pump connecter. 3-63...
  • Page 189 3.Fuel System UXV 500i/700i Remove the gas cap to normalize the pressure in the tank. Install the gas gap. With the fuel pump connector still unplugged start the engine and allow it to run until it uses the remaining fuel in the line and stalls. Turn off the ignition switch after the engine stalls. 3-64...
  • Page 190 3.Fuel System UXV 500i/700i Clean the disconnect fitting and put a rag over it. Push down on the black release and disconnect the fuel fitting from the fuel tank. Place plastic bags over the fuel line ends to keep debris out and prevent damage. Remove the six fuel pump bolts with a 10 mm socket.
  • Page 191 3.Fuel System UXV 500i/700i Carefully lift out the fuel pump. Guide the fuel level float out of the fuel tank with the pump. Remove the O-ring from the fuel pump. Discard the fuel pump O-ring, and replace it with a new item on assembly.
  • Page 192 3.Fuel System UXV 500i/700i Fuel Level Gauge Inspection 3-67...
  • Page 193 3.Fuel System UXV 500i/700i Make sure the fuel level gauge float arm moves smoothly. Using a digital multimeter set to ohms of resistance (Ω). Measure the resistance between the gray wire fuel pump/level gauge connector terminals with the float raised to the positions indicted below. Fuel Level Float Position Approximate Resistance Full...
  • Page 194 3.Fuel System UXV 500i/700i Fuel Output Pressure Turn the key to the OFF position. Use a fuel hose clamp to block the flow of fuel to the fuel injector. Loosen the fuel injector hose clamp with a #2 Phillips screwdriver. 3-69...
  • Page 195 3.Fuel System UXV 500i/700i Disconnect the fuel hose from the fuel injector pipe. Connect the fuel pressure gauge to the fuel hose. Remove the fuel hose clamp. Turn the key to the ON position. Check the fuel pressure. ITEM SPECIFICATIONS Fuel pump standard pressure (at 80 L/Hr) 300 ±...
  • Page 196 3.Fuel System UXV 500i/700i Fuel Pump Relay Turn the key to the OFF position. Open the hood. See the Hood for more information. The fuel pump relay is located above the ECU. Lift the fuel pump relay off of the finger on the frame. 3-71...
  • Page 197 3.Fuel System UXV 500i/700i Remove the fuel pump relay from the connector. Continuity Test Set the multimeter to read ohms of resistance (Ω). 3-72...
  • Page 198 3.Fuel System UXV 500i/700i Check for continuity between the terminals of the relay that match up with the red/blue and orange/red wires. Jump a 12 V battery to the terminals of the relay that match up with red/yellow and black/red wires. There should be continuity only when 12 V battery connected.
  • Page 199 3.Fuel System UXV 500i/700i Installation Replace the O-ring with new item and apply a small amount of fresh engine oil to the new O-ring. Carefully insert the fuel pump into the tank. Avoid damaging the fuel pump wires and fuel strainer.
  • Page 200 3.Fuel System UXV 500i/700i The fuel delivery pipe should face to the rear as shown. Install the six fuel pump bolts. Tighten the bolts evenly to specification with a 10 mm socket. Item Torque Kgf-m (N-m, lbf-ft) Fuel Pump Bolts 0.35 (3.5, 2.5) 3-75...
  • Page 201 3.Fuel System UXV 500i/700i Connect the fuel hose to the outlet pipe on the fuel pump. Make sure the connector is securely attached to the outlet pipe. Plug in the fuel pump connecter. Install the center cover. See the Center Cover topic for more information.

  • Page 202: Fuel Tank

    3.Fuel System UXV 500i/700i Fuel Tank SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gasoline is extremely flammable. Work in an area that is free of open flames and sources of sparks. Properly clean up any spilled gasoline as soon as possible. Removal Turn the ignition switch OFF.
  • Page 203 3.Fuel System UXV 500i/700i Remove the right rear side cover. See the Side Covers topic for more information. Remove the right under seat frame cover. See the Frame Covers topic for more information. Remove the fuel tank frame plate bolts. 3-78...
  • Page 204 3.Fuel System UXV 500i/700i Remove the fuel tank frame plate. Release the straps. 3-79...
  • Page 205 3.Fuel System UXV 500i/700i Remove the two strap bolts on the other side. Remove the right fuel tank frame rail bolts. 3-80...
  • Page 206 3.Fuel System UXV 500i/700i Remove the right fuel tank frame rail. Move the fuel tank forward and lift it out. 3-81...
  • Page 207 3.Fuel System UXV 500i/700i Installation Install the fuel tank with the straps. Install the right fuel tank frame rail. 3-82...
  • Page 208 3.Fuel System UXV 500i/700i Install the right fuel tank frame rail bolts and tighten them securely. Install the two strap bolts on the side and tighten them securely. 3-83...
  • Page 209 3.Fuel System UXV 500i/700i Secure the straps. Install the fuel tank plate. 3-84...
  • Page 210 3.Fuel System UXV 500i/700i Install the fuel tank plate bolts and tighten them securely. Install the tank cover. 3-85...
  • Page 211 3.Fuel System UXV 500i/700i Install the tank cover screws with a Phillips screwdriver. Tighten them securely. Install the right rear side cover. See the Side Covers topic for more information. 3-86...
  • Page 212 3.Fuel System UXV 500i/700i Install the gas cap. Install the fuel pump or reconnect the fuel line as needed. See the Fuel Pump topic for more information. Install the center cover. See the Center Cover topic for more information. Install the seat. See the Seat topic for more information.

  • Page 213: Throttle Body Removal

    Do not damage the throttle body, it may cause the throttle and idle valve to fail synchronization. • The throttle body is preset in the KYMCO factory, do not disassemble it incorrectly. • Do not loosen or tighten the painted bolts and screws for the throttle body.
  • Page 214 3.Fuel System UXV 500i/700i Removal Remove the center cover. See the Center Cover topic for more information. Clamp the fuel hose with a fuel hose clamp or relive the fuel pressure in the fuel line as when removing the fuel pump. See the Fuel Pump topic for more information.
  • Page 215 3.Fuel System UXV 500i/700i Unplug the TPS connector. Unplug the T-MAP connector. 3-90...
  • Page 216 3.Fuel System UXV 500i/700i Loosen the fuel injector hose clamp with a #2 Phillips screwdriver. Disconnect the fuel hose from the fuel injector. 3-91...
  • Page 217 3.Fuel System UXV 500i/700i Push in the spring and unplug the fuel injector connector. Remove the two throttle drum cover screws with a #2 Phillips screwdriver. 3-92...
  • Page 218 3.Fuel System UXV 500i/700i Remove the throttle drum cover. Slide the throttle cable housing out of the throttle body. 3-93...
  • Page 219 3.Fuel System UXV 500i/700i Free the throttle cable from the throttle drum. Remove the two intake pipe bolts that hold the intake pipe to the cylinder head. 3-94...
  • Page 220 3.Fuel System UXV 500i/700i Remove the throttle body and intake pipe from the cylinder head. To remove the fuel injector see the Fuel Injector topic for more information. To disassemble the throttle body see the Throttle Body Components topic for more information.
  • Page 221 3.Fuel System UXV 500i/700i Installation Install a new intake pipe O-ring. If this O-ring allows an air leak the engine will not run correctly. Fit the throttle body and intake pipe onto the cylinder head. 3-96...
  • Page 222 3.Fuel System UXV 500i/700i Fit the intake pipe and throttle body to the cylinder head. Install the two intake pipe bolts and tighten them securely. Fit the end of the throttle cable into the throttle drum. 3-97...
  • Page 223 3.Fuel System UXV 500i/700i Fit the throttle cable into the throttle body as shown. Install the throttle drum cover. 3-98...
  • Page 224 3.Fuel System UXV 500i/700i Install the two throttle drum cover screws and tighten them securely with a #2 Phillips screwdriver. 3-99...
  • Page 225 3.Fuel System UXV 500i/700i Plug in the fuel injector connector. Connect the fuel hose to the fuel injector pipe. 3-100...
  • Page 226 3.Fuel System UXV 500i/700i Tighten the fuel hose clamp securely with a #2 Phillips screwdriver. Plug in the T-MAP connector. 3-101...
  • Page 227 3.Fuel System UXV 500i/700i Plug in the TPS connector. Plug in the ISC connector. 3-102...
  • Page 228 3.Fuel System UXV 500i/700i Plug in the fuel pump connecter if it was disconnected. Install the airbox. See the Airbox topic for more information. Install the center cover. See the Center Cover topic for more information. 3-103...

  • Page 229: Throttle Body Components

    3.Fuel System UXV 500i/700i Throttle Body Components SAFETY FIRST: Protective gloves and eyewear are recommended at this point. To remove the throttle body. See the Throttle Body Removal and Installation topic for more information. To inspect the sensors see the Fuel Injection Sensors topic.
  • Page 230 3.Fuel System UXV 500i/700i T-MAP Sensor The T-MAP sensor sits on top of the throttle body. Remove the T-MAP sensor set plate screw with a #2 Phillips screwdriver. 3-105...
  • Page 231 3.Fuel System UXV 500i/700i Remove the T-MAP sensor. ISC (Idle Speed Control - Air Bypass Valve) Remove the two ISC screws with a #2 Phillips screwdriver. 3-106...
  • Page 232 3.Fuel System UXV 500i/700i Remove the ISC from the throttle body. Remove the O-ring from the ISC and discard it. Clean the tip of the ISC valve. 3-107...
  • Page 233 3.Fuel System UXV 500i/700i Inspection If the engine is hard to start, stops, or idles rough the ISC may be faulty. Use the data analysis feature of the FI Diagnostic Tool to see information on the ISC. See Diagnostic Tool topic for more information.
  • Page 234 3.Fuel System UXV 500i/700i TPS Sensor The TPS is located on the throttle shaft opposite the throttle drum. Remove the TPS sensor with a #2 Phillips screwdriver. 3-109...
  • Page 235 3.Fuel System UXV 500i/700i Assembly The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU have been reinstalled. TPS/ISC Reset Start the engine and let it idle until the engine temperature has reached 85° C (185° F). The ECU will learn the new setting.
  • Page 236 3.Fuel System UXV 500i/700i Install and tighten the screw securely with a #2 Phillips screwdriver. ISC (Idle Speed Control - Air Bypass Valve) Apply oil onto a new O-ring and place it on the ISC. 3-111...
  • Page 237 3.Fuel System UXV 500i/700i Install the ISC into the throttle body as shown, being careful not to damage the O-ring. Install the two ISC screws and tighten them securely with a #2 Phillips. 3-112...
  • Page 238 3.Fuel System UXV 500i/700i T-MAP Sensor Apply oil onto a new O-ring and place it on the T-MAP sensor. Install the T-MAP into the throttle body, being careful not to damage the O-ring. 3-113...
  • Page 239 3.Fuel System UXV 500i/700i Install the T-MAP sensor screw and tighten it securely with a #2 Phillips. Install the throttle body. See the Throttle Body Removal and Installation topic for more information. 3-114...
  • Page 240 3.Fuel System UXV 500i/700i WARNING Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. General Service Information ●...
  • Page 241 3.Fuel System UXV 500i/700i ● The electronic fuel injection system is equipped with the self-diagnostic system. If the Check Engine Lamp “CELP” lights while riding, follow the self-diagnostic procedures to solve the problem. ● A faulty fuel injection problem is often related to poorly connected or corroded connectors. Check those connections before proceeding.
  • Page 242 3.Fuel System UXV 500i/700i • Fuel contaminated/deteriorated • Pinched or clogged fuel hose • Idle speed problem • Wet spark plug Poor performance (drive ability) and poor fuel economy • Pinched or clogged fuel hose • Faulty injector 3-117...
  • Page 243 4.External Components UXV 500i/700i 4.External Components This chapter covers the location and servicing of the external components. 1.Boot Guard ..................4-5 2.Bumpers and Racks ..............4-7 3.Canopy Bars ................4-15 4.Cargo Bed ..................4-23 5.Center Cover ................4-36 6.Drive Selector ................4-42 7.Exhaust System ................4-48 8.Frame Covers ................4-62 9.Front Bumper ................4-75 10.Headlight ..................4-83 11.Hood ...................4-89...
  • Page 244 4.External Components UXV 500i/700i Lack of power • Caved exhaust muffler • Exhaust muffler air leaks • Clogged exhaust muffler Trim Clips Screw Type Back the screw out with a Phillips screwdriver to unlock the screw type trim clips. Install the trim clip and then turn in the screw to lock the clip in place.
  • Page 245 4.External Components UXV 500i/700i Button Type Depress the head of trim clip center piece (1). Pull out the trim clips.
  • Page 246 4.External Components UXV 500i/700i Let the center piece stick out toward the head so that the pawls (2) close. Insert the trim clip into the installation hole. To prevent the pawl (2) from damage, insert the fastener all the way into the installation hole. Push in the head of center piece until it becomes flush with the trim clip outside face.

  • Page 247: Boot Guard

    4.External Components UXV 500i/700i Boot Guard SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Note: The right and left side boot guards follow the same removal/installation procedure. Remove the boot guard mounting bolt with a 10 mm socket. Remove the boot guard.
  • Page 248 4.External Components UXV 500i/700i Installation Install the boot guard. Install the boot guard mounting bolt and tighten it securely with a 10 mm socket.
  • Page 249 4.External Components UXV 500i/700i Front Bumper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Front Bumper Cover The front bumper cover is held on with four mounting bolts. Remove the four front bumper cover bolts with a 10 mm socket.
  • Page 250 4.External Components UXV 500i/700i Remove the front bumper cover.
  • Page 251 4.External Components UXV 500i/700i Front Bumper On the winch equipped LE models disconnect the winch leads. The front bumper is mounted to the frame with four bolts and nuts on the inside of the frame rail.
  • Page 252 4.External Components UXV 500i/700i Support the front bumper. Remove the nuts and bolts with a 14 mm socket. 4-10...
  • Page 253 4.External Components UXV 500i/700i Remove the front bumper from the frame. 4-11...
  • Page 254 4.External Components UXV 500i/700i Installation Front Bumper Fit the front bumper into place. 4-12...
  • Page 255 4.External Components UXV 500i/700i Install the four front bumper mounting nuts and bolts. Tighten them securely with a 14 mm socket. Connect the leads to the winch on the LE models. 4-13...
  • Page 256 4.External Components UXV 500i/700i Front Bumper Cover Fit the front bumper cover into place. If there is a winch make sure to position the end of the cable as shown. Install the four front bumper cover mounting bolts and tighten them securely with a 10 mm socket.

  • Page 257: Canopy Bars

    4.External Components UXV 500i/700i Canopy Bars SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal The headrests are mounted to the canopy bars with three #3 Phillips screws. Note, some headrest may be mounted with Allen screws. 4-15...
  • Page 258 4.External Components UXV 500i/700i Remove the upper seatbelt covers. Remove the upper seatbelt mounting bolts and nuts with a 17 mm socket. 4-16...
  • Page 259 4.External Components UXV 500i/700i There are two upper crossbars. Support the bars as you remove the bolts. Remove the upper crossbar bolts with a 12 mm socket. Remove the upper crossbars. 4-17...
  • Page 260 4.External Components UXV 500i/700i Remove the eight headrest cross tube bolts with a 12 mm socket. Remove the headrest cross tube. Support the canopy bars. Loosen the bolts with an 8 mm Allen. Remove the four nuts and bolts for each canopy bar. Remove the canopy bars. 4-18...
  • Page 261 4.External Components UXV 500i/700i Installation Install the canopy bars. Install the nuts and bolts as shown. Tighten the bolts to specification with an 8 mm Allen. Item Torque Kgf-m (N-m, lbf-ft) Canopy Bar Bolts 6.4 (64, 47.2) 4-19...
  • Page 262 4.External Components UXV 500i/700i Install the headrest cross tube. Install the eight headrest cross tube bolts and tighten them to specification with a 12 mm socket. Item Torque Kgf-m (N-m, lbf-ft) Cross tube bolts 3.2 (32, 23.6) Install the two upper crossbars. 4-20...
  • Page 263 4.External Components UXV 500i/700i Install the eight headrest crossbar bolts and tighten them to specification with a 12 mm socket. Item Torque Kgf-m (N-m, lbf-ft) Crossbar bolts 3.2 (32, 23.6) Install the upper seatbelt mounting bolts and nuts. Tighten the fasteners to specification with a 17 mm socket.
  • Page 264 4.External Components UXV 500i/700i Install the upper seat belt covers. Install the headrests and tighten the fasteners securely. 4-22...

  • Page 265: Cargo Bed

    4.External Components UXV 500i/700i Cargo Bed SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Release the latch and lift up the bed. Unplug the taillight connectors. There is one for each side. 4-23...
  • Page 266 4.External Components UXV 500i/700i Remove the lift assist strut nuts with a 12 mm socket. Free the left and right lift assist struts from the bed. 4-24...
  • Page 267 4.External Components UXV 500i/700i With the help of an assistant support the bed in the closed position. Remove the locking clips and washers. Slide out the hinge pins. Lift off the bed with the help of an assistant. 4-25...
  • Page 268 4.External Components UXV 500i/700i Inspection Check the rubber dampers for wear and damage. Check the latching mechanism for damage. 4-26...
  • Page 269 4.External Components UXV 500i/700i Check the tailgate cables for wear and damage. 4-27...
  • Page 270 4.External Components UXV 500i/700i Disassembly Tie-Downs To remove the tie-down anchors loosen the nuts and bolts with a 10 mm socket. Remove the nuts, washers, bolts, and tie-down anchors. 4-28...
  • Page 271 4.External Components UXV 500i/700i Wheel Wells To remove the wheel well take out the seven bolts with a 10 mm socket. To remove the rear fenders and taillights see the Rear Fenders topic for more information. 4-29...
  • Page 272 4.External Components UXV 500i/700i Installation Wheel Wells Install the wheel wells. Install the seven bolts with a 10 mm socket. 4-30...
  • Page 273 4.External Components UXV 500i/700i Tie-Downs Fit the tie-down anchors into place. Install the bolts, washers, and nuts. Tighten the fasteners securely with a 10 mm socket. 4-31...
  • Page 274 4.External Components UXV 500i/700i Cargo Bed Fit the cargo bed into place with the help of an assistant. Slide in the hinge pins with the bed in the closed position. Install the washers and locking clips. 4-32...
  • Page 275 4.External Components UXV 500i/700i Connect the two left and right lift assist struts to the bed. Hold the lift assist strut with a 12 mm wrench and tighten the nut securely with a 12 mm socket. 4-33...
  • Page 276 4.External Components UXV 500i/700i Plug in the taillight connectors. There is one for each side. Close the cargo bed. 4-34...
  • Page 277 4.External Components UXV 500i/700i Make sure the latch closes correctly. 4-35...

  • Page 278: Center Cover

    4.External Components UXV 500i/700i Center Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seats. See the Seat topic for more information. Remove the gearshift lever knob bolt with a 4 mm Allen, and lift off the knob. 4-36...
  • Page 279 4.External Components UXV 500i/700i Remove the two trim clips from the front of the center cover cover. Lift up on the back of the center cover cover and free the posts from the frame. 4-37...
  • Page 280 4.External Components UXV 500i/700i Lift off the center cover cover. 4-38...
  • Page 281 4.External Components UXV 500i/700i Installation Lower the center cover cover into place. Guide the shift lever through the cover. 4-39...
  • Page 282 4.External Components UXV 500i/700i Fit the posts at the rear of the cover into the holes in the frame. Install the two trim clips at the front of the center cover cover. 4-40...
  • Page 283 4.External Components UXV 500i/700i Fit the shift knob into place. Install the gearshift lever knob bolt and tighten it securely with a 4 mm Allen. Install the seats. See the Seat topic for more information. 4-41...
  • Page 284 4.External Components UXV 500i/700i Drive Selector SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seats. See the Seat topic for more information. Remove the gearshift lever knob bolt with a 4 mm Allen, and lift off the knob. Remove the center cover.
  • Page 285 4.External Components UXV 500i/700i Hold the drive selector rod bolt with a wrench and remove the nut with a socket. Remove the two drive selector mounting bolts. Remove the drive selector assembly and rod. To remove the internal gearshift components see the Transmission Removal topic.
  • Page 286 4.External Components UXV 500i/700i Bracket Remove the bolts from the bracket. Remove the bracket. 4-44...
  • Page 287 4.External Components UXV 500i/700i Installation Bracket Install the bracket. Install the bracket bolts and tighten them securely. 4-45...

  • Page 288: Drive Selector

    4.External Components UXV 500i/700i Drive Selector Install the drive selector assembly. Install the two drive selector mounting bolts and tighten them securely. Install the bolt and nut onto the drive selector rod and tighten securely. Install the center cover. See the Center Cover topic for more information.
  • Page 289 4.External Components UXV 500i/700i Fit the shift knob into place. Install the gearshift lever knob bolt and tighten it securely with a 4 mm Allen. Install the seat. See the Seat topic for more information. 4-47...

  • Page 290: Exhaust System

    4.External Components UXV 500i/700i Exhaust System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Always allow the exhaust system plenty of time to cool before touching it. Removal Muffler Loosen the muffler clamp pipe with a 6 mm Allen socket. 4-48...
  • Page 291 4.External Components UXV 500i/700i Remove the two muffler mounting bolts and washers with a 14 mm socket. Slide off the muffler and gasket. 4-49...
  • Page 292 4.External Components UXV 500i/700i Exhaust Pipe Remove the center cover. See the Center Cover topic for more information Remove the heat shield panel bolts with a 14 mm socket. 4-50...
  • Page 293 4.External Components UXV 500i/700i Remove the heat shield panel. Remove the floor panel bolts with a 14 mm socket. 4-51...
  • Page 294 4.External Components UXV 500i/700i Remove the floor panel. 4-52...
  • Page 295 4.External Components UXV 500i/700i Remove the exhaust pipe mounting nut with a 14 mm socket. Remove the two header pipe joint nuts with a 12 mm socket. 4-53...
  • Page 296 4.External Components UXV 500i/700i Remove the header pipe. Remove the exhaust gasket from the cylinder head. 4-54...
  • Page 297 4.External Components UXV 500i/700i Installation Exhaust Pipe Install a new exhaust gasket into the exhaust port. A small dab of grease will help hold tit in place, just be aware that it will smoke and burn off when the engine is started. Fit the header pipe into place.
  • Page 298 4.External Components UXV 500i/700i Thread on the header pipe joint nuts. Tighten them securely with a 12 mm socket. Install the exhaust pipe mounting nut and tighten it to specification with a 14 mm socket. Item kgf-m ft-lb Exhaust pipe mounting bolt 4-56...
  • Page 299 4.External Components UXV 500i/700i Install the floor panel. Install the floor panel bolts and tighten them securely with a 14 mm socket. 4-57...
  • Page 300 4.External Components UXV 500i/700i Install the heat shield panel. 4-58...
  • Page 301 4.External Components UXV 500i/700i Install the heat shield panel bolts and tighten them securely with a 14 mm socket. Install the center cover. See the Center Cover topic for more information 4-59...
  • Page 302 4.External Components UXV 500i/700i Muffler Slide on the muffler and gasket. 4-60...
  • Page 303 4.External Components UXV 500i/700i Install the two muffler mounting bolts and washers. Tighten them to specification with a 14 mm socket. Item kgf-m ft-lb Exhaust muffler mounting bolt Tighten the muffler clamp pipe bolt to specification with a 6 mm socket. Item kgf-m ft-lb...

  • Page 304: Frame Covers

    4.External Components UXV 500i/700i Frame Covers SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the side covers. See the Side Covers topic for more information. Remove the seat/s. See the Seat topic for more information. Under Seat Frame Covers Remove the under seat frame cover trim clips with a #2 Phillips screwdriver.
  • Page 305 4.External Components UXV 500i/700i Remove the under seat frame cover. Remove the tank cover screws with a Phillips screwdriver. 4-63...
  • Page 306 4.External Components UXV 500i/700i Lift up on the under seat frame cover to free the tabs from the tunnel cover. Remove the remove the under seat frame cover. Remove the right and left under seat frame covers in the same manner. 4-64...
  • Page 307 4.External Components UXV 500i/700i Behind the Seat Frame Covers Right The right behind the seat frame cover is held in place by one bolt and four trim clips. Remove the bolt with a 10 mm socket. 4-65...
  • Page 308 4.External Components UXV 500i/700i Remove the two bottom trim clips with a #2 Phillips screwdriver. Remove the two inner trim clips with a #2 Phillips screwdriver. 4-66...
  • Page 309 4.External Components UXV 500i/700i Move the right behind the seat frame cover back and remove it from the vehicle. Left Free the final drive gear hose from the frame cover. The left behind the seat frame cover is held in place by seven trim clips and a bolt. 4-67...
  • Page 310 4.External Components UXV 500i/700i The left behind the seat frame cover is attached to the CVT cooling duct. Remove the three trim clip fasteners with a #2 Phillips screwdriver. Remove the two inner and two lower trim clips with a #2 Phillips screwdriver. 4-68...
  • Page 311 4.External Components UXV 500i/700i Remove the bolt with a 10 mm socket. Lift out the left behind the seat frame cover. 4-69...
  • Page 312 4.External Components UXV 500i/700i Installation Left Fit the left behind the seat frame cover into place. Install the two inner and two lower trim clips with a #2 Phillips screwdriver. 4-70...
  • Page 313 4.External Components UXV 500i/700i Install the three CVT cooling duct trim clip fasteners with a #2 Phillips screwdriver. Install the bolt and tighten it securely with a 10 mm socket. 4-71...
  • Page 314 4.External Components UXV 500i/700i Route the final gear case breather hose through its guide on the cover. Right Fit the right behind the seat frame cover into place. 4-72...
  • Page 315 4.External Components UXV 500i/700i Install the two inner trim clips with a #2 Phillips screwdriver. Install the two bottom trim clips with a #2 Phillips screwdriver. 4-73...
  • Page 316 4.External Components UXV 500i/700i Install the bolt and tighten it securely with a 10 mm socket. Install the side covers. See the Side Covers topic for more information. Install the seat/s. See the Seat topic for more information. 4-74...
  • Page 317 4.External Components UXV 500i/700i Front Bumper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Front Bumper Cover The front bumper cover is held on with four mounting bolts. Remove the four front bumper cover bolts with a 10 mm socket. 4-75...
  • Page 318 4.External Components UXV 500i/700i Remove the front bumper cover. 4-76...

  • Page 319: Front Bumper

    4.External Components UXV 500i/700i Front Bumper On the winch equipped LE models disconnect the winch leads. The front bumper is mounted to the frame with four bolts and nuts on the inside of the frame rail. 4-77...
  • Page 320 4.External Components UXV 500i/700i Support the front bumper. Remove the nuts and bolts with a 14 mm socket. 4-78...
  • Page 321 4.External Components UXV 500i/700i Remove the front bumper from the frame. 4-79...
  • Page 322 4.External Components UXV 500i/700i Installation Front Bumper Fit the front bumper into place. 4-80...
  • Page 323 4.External Components UXV 500i/700i Install the four front bumper mounting nuts and bolts. Tighten them securely with a 14 mm socket. Connect the leads to the winch on the LE models. 4-81...
  • Page 324 4.External Components UXV 500i/700i Front Bumper Cover Fit the front bumper cover into place. If there is a winch make sure to position the end of the cable as shown. Install the four front bumper cover mounting bolts and tighten them securely with a 10 mm socket.

  • Page 325: Headlight

    4.External Components UXV 500i/700i Headlight SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Bulb Replacement See the Lights topic. Adjustment Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjustment screws with a #2 Phillips screwdriver or an 8 mm socket. Removal To replace the headlight bulb see the Lights...
  • Page 326 4.External Components UXV 500i/700i Disconnect the headlight connectors if necessary. Remove the headlight assembly mounting bolts with a socket. 4-84...
  • Page 327 4.External Components UXV 500i/700i Remove the headlight assembly mounting screw with a #2 Phillips. 4-85...
  • Page 328 4.External Components UXV 500i/700i Remove the headlight assembly. Installation Install the headlight assembly. 4-86...
  • Page 329 4.External Components UXV 500i/700i Install the headlight assembly mounting screw and tighten them securely with a #2 Phillips. 4-87...
  • Page 330 4.External Components UXV 500i/700i Install the headlight assembly mounting bolts and tighten securely with a socket. Connect the headlight connectors if they were unplugged. Install the hood. See the Hood topic for more information. 4-88...
  • Page 331 4.External Components UXV 500i/700i Hood SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Lift There is a rubber retaining strap on each side of the hood. Free the retaining straps from each side. 4-89...
  • Page 332 4.External Components UXV 500i/700i Lift up on the back of the hood and free the hood post from the grommet. Pivot the hood forward. Removal Unplug the headlight connectors. 4-90...
  • Page 333 4.External Components UXV 500i/700i Remove the cotter pins and washers from the hood pivot pins. Slide the hood pivot pins out 4-91...
  • Page 334 4.External Components UXV 500i/700i Lift off the hood. To remove the pivot bracket take out the three bolts and washers with a 10 mm socket. To remove the headlights see the Headlight topic. 4-92...
  • Page 335 4.External Components UXV 500i/700i Front Cargo Box There are four bolts that hold the front cargo box in place. Remove the four front cargo box bolts with a 10 mm socket. 4-93...
  • Page 336 4.External Components UXV 500i/700i Lift out the front cargo box. 4-94...
  • Page 337 4.External Components UXV 500i/700i Installation Front Cargo Box Fit the front cargo box into place. 4-95...

  • Page 338: Hood

    4.External Components UXV 500i/700i Install the four front cargo box bolts and tighten them securely with a 10 mm socket. Hood Fit the pivot bracket onto the hood. Install the three bolts and washers. Tighten the three bolts securely with a 10 mm socket. 4-96...
  • Page 339 4.External Components UXV 500i/700i Position the hood in place. Line up the pivot bracket with the frame. Insert the pivot pins from the outside. 4-97...
  • Page 340 4.External Components UXV 500i/700i Install the washer on the inside of the pivot pin. Secure the washer and pin with a new cotter pin. Plug in the two headlight connectors. 4-98...
  • Page 341 4.External Components UXV 500i/700i Close the hood and guide the pin into the grommet. Guide the tabs on the side of the hood into place. 4-99...
  • Page 342 4.External Components UXV 500i/700i Secure the hood with the rubber retaining straps on each side. 4-100...

  • Page 343: Instrument Cover

    4.External Components UXV 500i/700i Instrument Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Lift the hood. See the Hood topic for more information. Remove the steering wheel. See the Steering Wheel topic for more information. Remove the seats.
  • Page 344 4.External Components UXV 500i/700i Disconnect the remote winch switch. Disconnect the 12 volt accessory leads. 4-102...
  • Page 345 4.External Components UXV 500i/700i Disconnect the regulator winch switch. Disconnect the display meter harness. 4-103...
  • Page 346 4.External Components UXV 500i/700i Disconnect the ignition switch. Remove the nut from the "DIFF LOCK" lever. Leave the lever as shown. 4-104...
  • Page 347 4.External Components UXV 500i/700i Disconnect the dimmer switch. Disconnect the 2WD/4WD switch. Remove the instrument cover. 4-105...
  • Page 348 4.External Components UXV 500i/700i Remove the fasteners to separate the dash from the instrument panel. Installation Install the instrument cover. Connect the 2wd/4wd switch. 4-106...
  • Page 349 4.External Components UXV 500i/700i Connect the dimmer switch. Install the nut onto the "DIFF LOCK" lever. Adjust if necessary. See the Front Differential Removal and Installation topic for more information. 4-107...
  • Page 350 4.External Components UXV 500i/700i Connect the ignition switch. Connect the display meter harness. 4-108...
  • Page 351 4.External Components UXV 500i/700i Connect the regulator winch switch. Connect the 12 volt accessory leads. 4-109...
  • Page 352 4.External Components UXV 500i/700i Connect the remote winch switch. Install the four mounting bolts and tighten securely with a 10 mm socket. Install the floor covers. See the Floor Covers topic for more information. Install the frame covers. See the Frame Covers topic for more information.
  • Page 353 4.External Components UXV 500i/700i Install the seats. See the Seat topic for more information. Install the steering wheel. See the Steering Wheel topic for more information. Close the hood. See the Hood topic for more information. 4-111...

  • Page 354: Pedal Cover

    4.External Components UXV 500i/700i Pedal Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Use a #2 Phillips screwdriver to push in the center of the push pin until it pops up. 4-112...
  • Page 355 4.External Components UXV 500i/700i Remove the push pins. Remove the pedal cover. 4-113...
  • Page 356 4.External Components UXV 500i/700i Installation Install the pedal cover. Install the push pins. 4-114...
  • Page 357 4.External Components UXV 500i/700i Use a #2 Phillips screwdriver to push in the center of the push pin until it locks. 4-115...

  • Page 358: Rear Fender

    4.External Components UXV 500i/700i Rear Fenders SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Fender Removal The rear fenders mount to the sides of the cargo bed. 4-116...
  • Page 359 4.External Components UXV 500i/700i Unplug the taillight connectors. There is one for each side. Loosen the nuts and bolts with a 10 mm socket. Remove the nuts, washers, bolts, and tie-down anchors. 4-117...
  • Page 360 4.External Components UXV 500i/700i Remove the trim clips from the top of the rear fender. Remove the bottom trim clip. 4-118...
  • Page 361 4.External Components UXV 500i/700i Lift off the rear fender and make sure it clears the latch handle. Taillights Bulb Replacement 4-119...
  • Page 362 4.External Components UXV 500i/700i Turn the bulb sockets and free them from the housing. Push in and turn counterclockwise to release the bulbs. Replace the bulbs as needed. Insert the bulb sockets with the tabs aligned with the cutouts and rotate them to lock them into place.
  • Page 363 4.External Components UXV 500i/700i Removal Remove the three taillight mounting screws with a #2 Phillips screwdriver. 4-121...
  • Page 364 4.External Components UXV 500i/700i Remove the taillight from the inside of the fender. Installation Fit the taillight into the rear fender from inside the rear fender. 4-122...
  • Page 365 4.External Components UXV 500i/700i Install the taillight mounting screws and tighten them securely with a #2 Phillips screwdriver. 4-123...
  • Page 366 4.External Components UXV 500i/700i Fender Installation Fit the rear fender/s into place. Install the bottom trim clip. 4-124...
  • Page 367 4.External Components UXV 500i/700i Install the top trim clips. Fit the tie-down anchors into place. 4-125...
  • Page 368 4.External Components UXV 500i/700i Install the bolts, washers, and nuts. Tighten the fasteners securely with a 10 mm socket. Plug in the taillight connectors. There is one for each side. 4-126...

  • Page 369: Seats

    4.External Components UXV 500i/700i Seat SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal The release lever for the seat is located under the front of the seat. Pull up on the seat release and lift up on the front of the seat. 4-127...
  • Page 370 4.External Components UXV 500i/700i Move the seat forward and free the three tabs from the bar on the frame. Lift out the seat. Installation Fit the seat into place. Slide the three tabs on the back of the seat under the bar on the frame.
  • Page 371 4.External Components UXV 500i/700i Guide the latch onto the pin. Push down on the front of the seat so that the latch closes securely. 4-129...

  • Page 372: Side Covers

    4.External Components UXV 500i/700i Side Covers SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Net Doors Disconnect the net door clips and free the Velcro strips. 4-130...
  • Page 373 4.External Components UXV 500i/700i Remove the two upper and two lower net door bolts with a 10 mm socket. Hold the rear clip strap bolt with an Allen and loosen the nut. Remove the rear clip strap. 4-131...
  • Page 374 4.External Components UXV 500i/700i Remove the three front clip strap bolts with a 10 mm socket. Remove the front clips strap. Lower Side Covers Remove the three lower side cover bolts with a 10 mm socket. Note: two of the bolts should already be removed with the net doors.
  • Page 375 4.External Components UXV 500i/700i Free the lower side cover tabs and remove the lower side covers. Front Side Covers Each side cover is held on by 5 bolts and a trim clips. The four lower bolts should be already be removed when taking off the net doors and lower side covers. 4-133...
  • Page 376 4.External Components UXV 500i/700i Remove the trim clip. Remove the upper bolt with a 10 mm socket. Remove the front side covers. 4-134...
  • Page 377 4.External Components UXV 500i/700i Rear Side Covers The rear side covers are held on by six trim clips and three bolts. The bolts should be already be removed when taking off the net doors and lower side covers. Temporarily remove the gas cap when removing the right rear side cover. 4-135...
  • Page 378 4.External Components UXV 500i/700i Remove the two rear trim clips. Remove the two lower trim clips. 4-136...
  • Page 379 4.External Components UXV 500i/700i Remove the two side trim clips. Remove the rear side covers. Install the gas cap. 4-137...
  • Page 380 4.External Components UXV 500i/700i Installation Rear Side Covers Temporarily remove the gas cap when installing the right rear side cover. Fit the rear side cover into place. Install the two side trim clips. 4-138...
  • Page 381 4.External Components UXV 500i/700i Install the two lower trim clips. Install the gas cap on the right side. 4-139...
  • Page 382 4.External Components UXV 500i/700i Front Side Covers Fit the front side cover into place. Install the upper bolt and trim clip. Tighten the bolts securely with a 10 mm socket. 4-140...
  • Page 383 4.External Components UXV 500i/700i Lower Side covers Fit the lower side cover into place. Guide the tabs on each end of the lower side cover into the front and rear side covers. Install the rear side cover bolt and tighten it to specification with a 10 mm socket. Install the other two bolts with the net doors.
  • Page 384 4.External Components UXV 500i/700i Net Doors Install the front clips strap. Insert the three front clip strap bolts and tighten them securely with a 10 mm socket. Install the two lower net door bolts and tighten them securely with a 10 mm socket. 4-142...
  • Page 385 4.External Components UXV 500i/700i Install the rear clip strap. Hold the rear clip strap bolt with an Allen and tighten the nut securely. Fasten the net door clips and Velcro strips. 4-143...

  • Page 386: Skid Plates

    4.External Components UXV 500i/700i Skid Plates SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Rear Skid plate Remove the four bolts from the rear skid plate with a 10 mm socket. Free the tabs from the center skid plate by sliding the rear skid plate back.
  • Page 387 4.External Components UXV 500i/700i Center Skid Plate Remove the 10 center skid plate bolts with a 10 mm socket. Slide the center skid plate back and free it from the front skid plate. Remove the center skid plate. 4-145...
  • Page 388 4.External Components UXV 500i/700i Front Skid Plate Remove the eight front skid plate bolts with a 10 mm socket. Move the front skid plate forward and remove it. 4-146...
  • Page 389 4.External Components UXV 500i/700i Installation Front Skid Plate Fit the front skid plate into place. Install the eight bolts and tighten them securely with a 10 mm socket. 4-147...
  • Page 390 4.External Components UXV 500i/700i Center Skid Plate Set the center skid plate into place. Install the eight outer bolts and tighten them securely. Wait to install the two rear bolts with the rear skid plate. 4-148...
  • Page 391 4.External Components UXV 500i/700i Rear Skid plate Install the rear skid plate so that its tabs engage with the center skid plate. Install the four bolts and tighten them securely with a 10 mm socket. 4-149...
  • Page 392 5.Engine UXV 500i UXV 500i/700i 5.Engine UXV 500i This chapter covers the location and servicing of the engine components. 1.Engine Removal ................5-8 2.Engine Installation ..............5-16 3.Cylinder Head Cover ..............5-26 4.Camshaft ..................5-36 5.Camshaft Installation ..............5-56 6.Cylinder Head ................5-72 7.Valves ...................5-86 8.Cylinder and Piston ..............5-100 9.Crankcase Bearings ..............5-127 10.Recoil Starter Cover ..............5-132 11.Generator Cover ................5-141...
  • Page 393 5.Engine UXV 500i UXV 500i/700i GENERAL INSTRUCTIONS Lubrication System The maintenance of lubrication system can be performed with the engine installed in the frame. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine If any portion of the oil pump is worn beyond the specified service limits.
  • Page 394 5.Engine UXV 500i UXV 500i/700i No oil pressure • Oil level too low • Oil pump drive chain broken • Oil pump drive sprocket broken • Oil pump damaged (pump shaft) • Internal oil leak Low oil pressure • Pressure relief valve stuck open •...
  • Page 395 5.Engine UXV 500i UXV 500i/700i Oil contamination • Deteriorated oil • Faulty oil filter • Worn piston ring (White appearance with water or moisture) - Damaged water pump mechanical seal - Damaged head gasket - Oil relief not frequent enough Cylinder Head, Camshaft, and Valves •...
  • Page 396 5.Engine UXV 500i UXV 500i/700i Poor performance at idle speed • Compression too low Compression too low • Incorrect valve clearance adjustment • Burned or bent valves • Incorrect valve timing • Broken valve spring • Poor valve and seat contact •...
  • Page 397 5.Engine UXV 500i UXV 500i/700i Cylinder and Piston • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
  • Page 398 5.Engine UXV 500i UXV 500i/700i Abnormal noisy piston • Worn cylinder, piston and piston rings • Worn piston pin hole and piston pin • Incorrectly installed piston...

  • Page 399: Engine Removal

    5.Engine UXV 500i UXV 500i/700i Engine Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the seats. See the Seat topic for more information. Remove the center cover. See the Center Cover topic for more information. Remove the frame covers.
  • Page 400 5.Engine UXV 500i UXV 500i/700i Push in the spring and unplug the WTS sensor connector. Squeeze the clamp on the air bleed hose and slide it back. Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Free the air bleed hose and thermostat hose from the WTS housing.
  • Page 401 5.Engine UXV 500i UXV 500i/700i Disconnect the crankcase breather hose from the cylinder head cover. Pull back the rubber cover from the starter motor terminal. Loosen the starter motor terminal nut with a 10 mm socket and free the lead from the terminal. 5-10...
  • Page 402 5.Engine UXV 500i UXV 500i/700i Remove the starter motor mounting bolt with the ground wire with an 8 mm socket. Free the ground wire from the engine. Trace the wires up from the generator cover. Unplug the 2-pin ignition pulse generator / crank position sensor connector.
  • Page 403 5.Engine UXV 500i UXV 500i/700i Disconnect the gear indicator switch connector. Disconnect the speed sensor connector. Pull the front propeller shaft away from the engine. Remove the front propeller shaft. 5-12...
  • Page 404 5.Engine UXV 500i UXV 500i/700i Hold the front engine mounting bolt with a 14 mm wrench. Loosen the front lower engine mounting nut with a 17 mm socket. Hold the rear engine mounting bolt with a 14 mm wrench. Loosen the rear lower engine mounting nut with a 17 mm socket.
  • Page 405 5.Engine UXV 500i UXV 500i/700i Remove the bolts and hangers. Slide the engine to the front. Remove the rear propeller shaft from the engine. Note: Take care not to lose the compression spring in the rear drive gear case end. 5-14...
  • Page 406 5.Engine UXV 500i UXV 500i/700i Secure the engine and lift it out of the frame with a suitable engine hoist or crane. To install the engine. See the Engine Installation topic for more information. 5-15...

  • Page 407: Engine Installation

    5.Engine UXV 500i UXV 500i/700i Engine Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Lubricate the propeller shaft splines with a lightweight lithium-soap based grease. Secure the engine and lower it into place with a suitable engine hoist or crane. 5-16...
  • Page 408 5.Engine UXV 500i UXV 500i/700i Apply lightweight lithium-soap base grease to the rear propeller shaft splines and output shaft splines. Guide the rear propeller shaft into place. Take up all the slack to allow for the installation of the front propeller shaft. 5-17...
  • Page 409 5.Engine UXV 500i UXV 500i/700i Install the engine hangers but wait to tighten the bolts. Install the front and rear engine mounting bolts and nuts. Tighten the eight engine hanger bolts to specification with a 12 mm socket. ITEM kgf-m ft-lb Engine hanger bolt 5-18...
  • Page 410 5.Engine UXV 500i UXV 500i/700i Hold the engine mounting bolts with a 14 mm wrench and tighten the engine mounting nuts to specification with a 17 mm socket. ITEM kgf-m ft-lb Engine hanger bolt 43.5 5-19...
  • Page 411 5.Engine UXV 500i UXV 500i/700i Apply lightweight lithium-soap base grease to the front propeller shaft splines and front output splines. Fit the front propeller shaft into place. Plug in the speed sensor connector. Plug in the 4-pin stator connector. 5-20...
  • Page 412 5.Engine UXV 500i UXV 500i/700i Plug in the 2-pin ignition pulse generator / crank position sensor connector. Plug in the gear indicator switch connector. Install the two starter motor mounting bolts and tighten them securely with an 8 mm socket. Be sure to slide the ground lead onto the mounting bolt before inserting it.
  • Page 413 5.Engine UXV 500i UXV 500i/700i Install the starter motor terminal nut and lead with a 10 mm socket. Tighten the nut securely. Slide on the rubber cover onto the starter motor terminal. Connect the crankcase breather hose to the cylinder head cover. Secure the hose with the clamp.
  • Page 414 5.Engine UXV 500i UXV 500i/700i Install the spark plug cap onto the spark plug. Connect the air bleed hose and thermostat hose to the WTS housing. Secure the hoses with the clamps. Plug in the WTS sensor connector. 5-23...
  • Page 415 5.Engine UXV 500i UXV 500i/700i Connect the bypass hose (smaller) and lower radiator hose (larger) to the water pump. Install the clamps. Tighten the clamps securely with a #2 Phillips screwdriver. 5-24...
  • Page 416 5.Engine UXV 500i UXV 500i/700i Install the following components: Drive Selector • CVT Cooling Ducts • Oil Cooler • Throttle Body Removal and Installation • Airbox • Exhaust System • Engine Oil • Coolant • Frame Covers • Center Cover •...

  • Page 417: Cylinder Head Cover

    5.Engine UXV 500i UXV 500i/700i Cylinder Head Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the center cover. See the Center Cover topic for more information. Disconnect the crankcase breather hose from the cylinder head cover. 5-26...
  • Page 418 5.Engine UXV 500i UXV 500i/700i Remove the four bolts, washers and rubber grommets with a 10 mm socket. 5-27...
  • Page 419 5.Engine UXV 500i UXV 500i/700i Remove the cylinder head cover. Remove the cylinder head cover gasket. Clean the mating surfaces of the cylinder head and cover. 5-28...
  • Page 420 5.Engine UXV 500i UXV 500i/700i Disassembly Remove the three breather separator bolts with a 10 mm socket. 5-29...
  • Page 421 5.Engine UXV 500i UXV 500i/700i Remove the breather separator. 5-30...
  • Page 422 5.Engine UXV 500i UXV 500i/700i Assembly Install the breather separator. 5-31...
  • Page 423 5.Engine UXV 500i UXV 500i/700i Install the three breather separator bolts and tighten them to specification with a 10 mm socket. ITEM kgf-m ft-lb Breather separator bolt 5-32...
  • Page 424 5.Engine UXV 500i UXV 500i/700i Installation Apply fluid gasket (threebond: 1215) to the mating surface of the cylinder head cover, then install the rubber gasket. Install the cylinder head cover. 5-33...
  • Page 425 5.Engine UXV 500i UXV 500i/700i Install the four grommets and washers onto the cylinder head cover. Install the four bolts. Tighten the cylinder head cover bolts a small amount at a time in a crisscross pattern. Tighten the bolts to specification with a 10 mm socket. ITEM kgf-m ft-lb...
  • Page 426 5.Engine UXV 500i UXV 500i/700i Connect the crankcase breather hose to the cylinder head cover. Secure the hose with the clamp. To remove the camshaft see the Camshaft topic for more information. Install the center cover. See the Center Cover topic for more information.

  • Page 427: Camshaft

    5.Engine UXV 500i UXV 500i/700i Camshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the cylinder head cover. See the Cylinder Head Cover topic for more information. Remove the right floor board. See the Floor Covers topic for more information.
  • Page 428 5.Engine UXV 500i UXV 500i/700i Remove the recoil starter cover bolts with an 8 mm socket. Remove the recoil starter cover. 5-37...
  • Page 429 5.Engine UXV 500i UXV 500i/700i Turn the crankshaft clockwise with a socket. Align the "T" mark on the flywheel with the index mark on the right crankcase cover. This shows the piston is at Top Dead Center. 5-38...
  • Page 430 5.Engine UXV 500i UXV 500i/700i Make sure the punch marks on the ends of the camshafts are pointed up. With the marks pointing up the piston is at TDC on the compression stroke. If the punch marks are not pointing up rotate the crankshaft clockwise until the piston is at TDC on the compression stroke.
  • Page 431 5.Engine UXV 500i UXV 500i/700i Cam Chain Tensioner Note: Do not remove the cam chain tensioner until the crank and piston have been turned positioned at TDC. Remove the cam chain tensioner sealing bolt with a 10 mm socket. 5-40...
  • Page 432 5.Engine UXV 500i UXV 500i/700i Remove the two cam chain tensioner bolts with an 8 mm socket. Remove the cam chain tensioner and gasket. 5-41...
  • Page 433 5.Engine UXV 500i UXV 500i/700i Camshafts Remove the two cam chain guide bolts with an 8 mm socket. 5-42...
  • Page 434 5.Engine UXV 500i UXV 500i/700i Remove the cam chain guide. Loosen the indicated eight camshaft holder bolts a small amount at a time in a crisscross pattern with a 12 mm socket. There are five short bolts, two medium bolts, and one long bolt.
  • Page 435 5.Engine UXV 500i UXV 500i/700i The five short bolts are size 8 X 71 mm. The two medium bolts are size 8 X 137 mm. 5-44...
  • Page 436 5.Engine UXV 500i UXV 500i/700i The size of the long bolt is 8 X 210 mm. Remove the cam chain side camshaft holder and the two dowel pins. 5-45...
  • Page 437 5.Engine UXV 500i UXV 500i/700i Slowly loosen and the remaining four camshaft holder bolts a small amount at a time in a crisscross pattern with a 14 mm socket. Remove the two 10 X 220 mm and two 10 X 210 mm camshaft holder bolts.
  • Page 438 5.Engine UXV 500i UXV 500i/700i Lift the cam chain and remove the cam shafts and sprocket. Note: Do not let the cam chain fall into the bottom end of the engine. Secure the cam chain with a piece of wire to keep if from falling into the bottom end of the engine.
  • Page 439 5.Engine UXV 500i UXV 500i/700i Rocker Arms Note the location of the rocker arm components so that they can be returned to their original positions. The rocker arms shafts must be removed from the side of the cylinder head opposite the cam chain.
  • Page 440 5.Engine UXV 500i UXV 500i/700i Loosen the rocker arm shafts with a 10 mm Allen. Remove the rocker arm shafts and washers from the cylinder head. 5-49...
  • Page 441 5.Engine UXV 500i UXV 500i/700i Remove the rocker arms from the cylinder head. 5-50...
  • Page 442 5.Engine UXV 500i UXV 500i/700i Inspection Inspect the cam chain slipper surface of the cam chain guide for wear or damage. Inspect the camshaft surface of each camshaft holder for scoring, scratches, or other damage. Note: Always replace the camshaft holders and cylinder head as a set. 5-51...
  • Page 443 5.Engine UXV 500i UXV 500i/700i Check the stop pin spring on the exhaust camshaft holder. The pin should move smoothly in and out without binding. Replace the stop pin assembly as needed. Check that the cam chain tensioner is functioning properly. Make sure the push rod slides smoothly when the locking mechanism is released.
  • Page 444 5.Engine UXV 500i UXV 500i/700i Inspect the camshaft sprocket for wear and damage. Inspect the camshaft lobes and journals wear and damage. If there are signs of damage or discoloration inspect the lubrication system. 5-53...
  • Page 445 5.Engine UXV 500i UXV 500i/700i Measure the maximum height of the cam lobes with vernier calipers or a micrometer. Item Standard mm (in) Service Limit 37.2614 (1.4905) 37.11 (1.4844) Cam lobe height 37.0084 (1.4803) 36.86 (1.4744) 5-54...
  • Page 446 5.Engine UXV 500i UXV 500i/700i Place the ends of the camshafts in V-blocks and check the runout with a dial gauge. Camshaft Runout Limit (IN & EX) 0.05 mm (0.002 in) Check the decompression system by turning the decompressor cam on the exhaust camshaft.

  • Page 447: Camshaft Installation

    5.Engine UXV 500i UXV 500i/700i Camshaft Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Installation Rocker Arms Lubricate the inside diameter of the rocker arms and the outside diameter of the rocker arm shaft pivot sections with fresh engine oil. Fit the rocker arms into their original locations.
  • Page 448 5.Engine UXV 500i UXV 500i/700i Apply Blue Loctite to the threads of the rocker arm shafts. Install the rocker arm shafts and washers. Tighten the rocker arm shafts to specification with a 10 mm Allen. Item Thread dia. (mm) Torque kgf-m (N-m, lbf-ft) Rocker arm shaft 4.5 (45, 32) 5-57...
  • Page 449 5.Engine UXV 500i UXV 500i/700i Camshafts Position the piston at TDC as with removal. See the Camshaft topic for more information. Align the "T" mark on the flywheel with the index mark on the right crankcase cover. This shows the piston is at Top Dead Center. 5-58...
  • Page 450 5.Engine UXV 500i UXV 500i/700i Apply molybdenum oil to the camshaft lobes, the journal holders in the camshaft holders and the cylinder head. Molybdenum oil: a mixture of molybdenum grease and fresh engine oil in a 50:50 ratio. Fit the camshafts into place. Note the exhaust camshaft has a decompressor cam and intake camshaft doesn't.
  • Page 451 5.Engine UXV 500i UXV 500i/700i Position the camshafts so that the punch marks on the end are pointing up. Minimize the amount of slack in the cam chain between the camshaft sprockets. The lines on the camshaft sprockets must align with the cylinder head cover mating surface as shown. Double check the timing after the cam chain tensioner is installed.
  • Page 452 5.Engine UXV 500i UXV 500i/700i Fit the intake camshaft holder into place with the two dowel pins. Lubricate the threads of the camshaft holder bolts with fresh engine oil. Insert the four largest camshaft holder bolts with new washers. 5-61...
  • Page 453 5.Engine UXV 500i UXV 500i/700i Position the four large cylinder head bolts as shown. Insert the intake and exhaust camshaft holder bolts. Wait to install the cam chain side camshaft holder and bolts. Long: 8 X 210 mm Medium: 8 X 137 mm Short: 8 X 71 mm 5-62...
  • Page 454 5.Engine UXV 500i UXV 500i/700i Tighten the bolts 1 - 9 in multiple steps in a crisscross pattern as shown below. Tighten the large bolts with a 14 mm socket and the smaller bolts with a 12 mm socket. Camshaft Holder / Cylinder Head Bolt Torque kgf-m (N-m, ft-lb) Bolts 1, 2, 3, 4...
  • Page 455 5.Engine UXV 500i UXV 500i/700i The cylinder head bolt is number 9. Fit the cam chain side camshaft holder into place. 5-64...
  • Page 456 5.Engine UXV 500i UXV 500i/700i The arrow on the camshaft holder must face out. 5-65...
  • Page 457 5.Engine UXV 500i UXV 500i/700i Tighten the 10 - 13 bolts to specification with a 12 mm socket in multiple steps as indicated. Camshaft Holder / Cylinder Head Bolt Torque kgf-m (N-m, ft-lb) Bolts 10, 11, 12, 13 Step 4 1.2 (12, 9) Step 5 2.3 (23, 17)
  • Page 458 5.Engine UXV 500i UXV 500i/700i Install the two cam chain guide bolts and tighten them securely with an 8 mm socket. 5-67...
  • Page 459 5.Engine UXV 500i UXV 500i/700i Cam Chain Tensioner Make sure the cam chain tensioner mating surface is clean. Install a new gasket with the cam chain tensioner. Use a small flat blade screwdriver to wind in the cam chain tensioner rod. Hold the screwdriver in place until both tensioner mounting bolts have been installed.
  • Page 460 5.Engine UXV 500i UXV 500i/700i Install the two cam chain tensioner mounting bolts and tighten them to specification with an 8 mm socket. Install a new O-ring. Item Thread dia. (mm) Torque kgf-m (N-m, ft-lb) Cam chain tensioner bolt 1.2 (12, 8.6) Install the cam chain tensioner sealing bolt and tighten it to specification with a 10 mm socket.
  • Page 461 5.Engine UXV 500i UXV 500i/700i Install the recoil starter cover. Tighten the recoil starter bolts securely with an 8 mm socket. 5-70...
  • Page 462 5.Engine UXV 500i UXV 500i/700i Install the timing cap on the right side of the engine and tighten securely with a flat blade screwdriver. Install the cylinder head cover. See the Cylinder Head Cover topic for more information. Install the spark plug. See the Spark Plug topic for more information.

  • Page 463: Cylinder Head

    5.Engine UXV 500i UXV 500i/700i Cylinder Head SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Drain the coolant. See the Coolant topic for more information. Remove the exhaust system. See the Exhaust System topic for more information. Remove the cylinder head cover.
  • Page 464 5.Engine UXV 500i UXV 500i/700i Squeeze the clamp on the air bleed hose and slide it back. Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Free the air bleed hose and thermostat hose from the WTS housing. 5-73...
  • Page 465 5.Engine UXV 500i UXV 500i/700i To remove the WTS housing remove the two bolts with an 8 mm socket. Remove the WTS housing and cylinder head coolant stopper from the cylinder head. Discard the WTS housing gasket. 5-74...
  • Page 466 5.Engine UXV 500i UXV 500i/700i Remove the two nuts under the cylinder head with a 10 mm socket. Loosen the cylinder head bolt with a 12 mm socket. 5-75...
  • Page 467 5.Engine UXV 500i UXV 500i/700i Remove the cylinder head bolt. Tap the reinforced areas of the cylinder head with a rubber mallet to free the dowel pins. 5-76...
  • Page 468 5.Engine UXV 500i UXV 500i/700i Lift off the cylinder head. Guide the cam chain through the opening, but do not allow it to fall into the bottom end of the engine. Remove the cylinder head gasket. 5-77...
  • Page 469 5.Engine UXV 500i UXV 500i/700i Remove the two cylinder head dowel pins. To remove the valves see the Valves topic. 5-78...
  • Page 470 5.Engine UXV 500i UXV 500i/700i Inspection Clean the combustion chamber with contact cleaner, a plastic knife, brush and/or rag. Take care to only remove carbon and not scrape the head. 5-79...
  • Page 471 5.Engine UXV 500i UXV 500i/700i Place a straight edge on the deck of the cylinder head and check for cylinder head warp with a feeler gauge. Cylinder head warpage limit 0.05 mm (0.002 in) Check for warp in several places on the head. If the cylinder head is warped it must be resurfaced by a qualified machine shop or replaced.
  • Page 472 5.Engine UXV 500i UXV 500i/700i Installation Make sure the cylinder head mating surface is clean. Install the two cylinder head dowel pins. Fit a new cylinder head gasket into place. 5-81...
  • Page 473 5.Engine UXV 500i UXV 500i/700i Install the cylinder head to the cylinder. Guide the cam chain and cam chain guides though the opening in the cylinder head. Remember to keep the cam chain from falling into the bottom end of the engine. Install the two nuts under the cylinder head with a 10 mm socket.
  • Page 474 5.Engine UXV 500i UXV 500i/700i Install the cylinder head bolt. Wait to tighten it in sequence with the cylinder head / camshaft holder bolts. Insert the coolant stopper into the cylinder head if it was removed. Install the WTS housing with a new gasket.
  • Page 475 5.Engine UXV 500i UXV 500i/700i Install the two WTS housing bolts and tighten them to specification with an 8 mm socket. Item Thread dia. (mm) Torque kgf-m (N-m, ft-lb) WTS Housing bolt 1.2 (12, 8.6) Install the camshaft. See the Camshaft Installation topic for more information.
  • Page 476 5.Engine UXV 500i UXV 500i/700i Plug in the WTS sensor connector. Install the throttle body. See the Throttle Body Removal and Installation topic for more information. Install the exhaust system. See the Exhaust System topic for more information. Fill the coolant. See the Coolant topic for more information.

  • Page 477: Valves

    5.Engine UXV 500i UXV 500i/700i Valves SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the cylinder head. See the Cylinder Head topic for more information. Note the location of all of the valve parts so that they can be returned to their original positions.
  • Page 478 5.Engine UXV 500i UXV 500i/700i Use a valve spring compressor to remove the valves. Special Tools- Valve Spring Compressor: A120E00040 Compress the valve springs only enough to remove the cotters. 5-87...
  • Page 479 5.Engine UXV 500i UXV 500i/700i Remove the cotters from the valve stem with tweezers or a magnet. Remove the spring retainers. 5-88...
  • Page 480 5.Engine UXV 500i UXV 500i/700i Lift out the valve springs. Push the valves out through the bottom of the cylinder head. Remove the stem seals with needle nose pliers and a pick. Discard the old stem seals. 5-89...
  • Page 481 5.Engine UXV 500i UXV 500i/700i Remove the spring seats. 5-90...
  • Page 482 5.Engine UXV 500i UXV 500i/700i Inspection Item Standard mm (in) Service Limit Inner valve spring free length 33.4 (1.336) Outer valve spring free length 38 (1.52) 4.975 - 4.99 (0.199 - 0.1996) 4.925 (0.197) Valve stem O.D. 4.955 - 4.97 (0.1982 - 0.1988) 4.915 (0.1966) 5 - 5.015 (0.2 - 0.2006) 5.03 (0.2012)
  • Page 483 5.Engine UXV 500i UXV 500i/700i Measure the force to compress the valve spring with a scale. Replace the valve spring if it is out of specification. Item Standard Inner valve spring compressed force 3.5 kg (@ 28.7 mm or 1.148 in) Outer valve spring compressed force 13 kg (@ 31.43 mm or 1.2572 in) 5-92...
  • Page 484 5.Engine UXV 500i UXV 500i/700i Check the valve spring for tilt. Replace the valve spring if it is out of specification. Item Standard mm (in) Inner valve spring tilt 1.2 mm (0.048) Outer valve spring tilt 1.2 mm (0.048) 5-93...
  • Page 485 5.Engine UXV 500i UXV 500i/700i Inspect the valve for damage. Measure the valve stem diameter with a micrometer or vernier calipers and compare the measurements with specification. Replace any valves that do not meet the standard. Item Standard mm (in) Service Limit 4.975 - 4.99 (0.199 - 0.1996) 4.925 (0.197)
  • Page 486 5.Engine UXV 500i UXV 500i/700i Measure the inside diameter of the valve guides. Replace the guides if the measurement is out of specification. Calculate the valve stem-to-guide clearance. Replace the guide and valve if the clearance is out of specification. Item Standard mm (in) Service Limit...
  • Page 487 5.Engine UXV 500i UXV 500i/700i Assembly Install the spring seats. Lubricate the new valve stem seals with fresh engine oil. Install new valve stem seals. Push the seals straight onto the guide. 5-96...
  • Page 488 5.Engine UXV 500i UXV 500i/700i Coat the valve stem and end in fresh engine oil. Insert the valve through the valve guide. Twist the valve slowly to work it through the stem seal without damaging the seal. The valve should move smoothly in the guide and make good contact with the seat. Install the valve springs with the tightly spaced coils facing down.
  • Page 489 5.Engine UXV 500i UXV 500i/700i Install the spring retainers to their original locations. Use a valve spring compressor to install the cotters. Compress the valve springs only enough to install the cotters. Special Tools- Valve Spring Compressor: A120E00040 5-98...
  • Page 490 5.Engine UXV 500i UXV 500i/700i Apply grease to the inside of the cotters. Apply a dab of grease to the end of a flat blade screwdriver. Set the keeper in the grease on the screwdriver and insert it onto the valve stem.

  • Page 491: Cylinder And Piston

    5.Engine UXV 500i UXV 500i/700i Cylinder and Piston SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the cylinder head. See the Cylinder Head topic for more information. A coolant hose connects the cylinder cooling jacket to the water pump. 5-100...
  • Page 492 5.Engine UXV 500i UXV 500i/700i Loosen the cylinder coolant hose clamp with a #2 Phillips screwdriver. Free the coolant hose from the cylinder. There is a coolant block pin located in the cooling jacket of the cylinder. 5-101...
  • Page 493 5.Engine UXV 500i UXV 500i/700i Remove the block pin from the cylinder. There are two cylinder bolts with washers on the cam chain side of the cylinder. 5-102...
  • Page 494 5.Engine UXV 500i UXV 500i/700i Loosen the two cylinder bolts with an 8 mm socket. Remove the cylinder bolts and washers. Gently tap the cylinder to free it from the crankcases. 5-103...
  • Page 495 5.Engine UXV 500i UXV 500i/700i Lift the cylinder up and off of the crankcases. Guide the cam chain through its opening in the cylinder. Make sure the cam chain and dowel pins do not fall into the bottom end of the engine.
  • Page 496 5.Engine UXV 500i UXV 500i/700i Remove the two dowel pins. Place a clean shop towel around the base of the piston to prevent any parts or debris from falling into the crankcase. 5-105...
  • Page 497 5.Engine UXV 500i UXV 500i/700i Rotate the gap in the piston pin clip so that it sits in the access opening in the piston. Remove the piston pin clip with a pick or needle nose pliers. Discard the piston pin clips. 5-106...
  • Page 498 5.Engine UXV 500i UXV 500i/700i Slide out the piston pin. Do not use a punch and a hammer to remove the pin. Remove the piston. Clean off the cylinder mating surface, but take care to keep debris from falling into the crankcase. 5-107...
  • Page 499 5.Engine UXV 500i UXV 500i/700i Clean the carbon build up off of the piston with a stiff bristled plastic brush. Never use a wire brush to clean a piston. Spread the piston rings and lift them off opposite the gap. Spread the rings the minimum amount during removal.
  • Page 500 5.Engine UXV 500i UXV 500i/700i Inspection Cylinder Warp Test for cylinder warp with a straight edge and a feeler gauge. Try and insert the feeler gauge of the service limit under the straight edge. Place the straight edge in several places on the cylinder.
  • Page 501 5.Engine UXV 500i UXV 500i/700i Cylinder Bore Inspect the cylinder and measure side to side at three different height levels with a dial bore gauge or cylinder gauge set. 5-110...
  • Page 502 5.Engine UXV 500i UXV 500i/700i Calculate the cylinder taper. The taper is the maximum difference between either yellow and brown or blue and green. Calculate the cylinder out of round. The out of round is greatest out of yellow, purple, or brown minus the smallest of blue, red, or green. Item Standard Service Limit...
  • Page 503 5.Engine UXV 500i UXV 500i/700i Piston Diameter Measure the diameter of the piston 10 mm (A) up from the bottom of the skirt at a 90° angle to the piston pin. Measure the piston with a micrometer. Replace the piston if the measurement is out of specification.
  • Page 504 5.Engine UXV 500i UXV 500i/700i Piston-to-Cylinder Clearance Subtract the diameter of the piston from the maximum front to rear diameter measurement of the cylinder to calculate the piston-to-cylinder clearance. If the clearance is over the service limit the cylinder and piston must be replaced. ITEM STANDARD mm (in) LIMIT...
  • Page 505 5.Engine UXV 500i UXV 500i/700i Piston Ring End Gap Insert the top ring into the cylinder. Push the top ring in the cylinder. Use the piston to push in the ring to keep it square with the cylinder. 5-114...
  • Page 506 5.Engine UXV 500i UXV 500i/700i Measure the ring gap with a feeler gauge. Repeat this procedure with second ring. ITEM STANDARD mm (in) LIMIT 0.15 - 0.3 0.5 (0.02) (0.006 - 0.012) 0.03 - 0.45 Ring end gap Second 0.65 (0.026) (0.012 - 0.018) 0.2 - 0.7 Oil side rail...
  • Page 507 5.Engine UXV 500i UXV 500i/700i Piston Pin O.D. Measure the piston pin outside diameter with a micrometer. Item Standard Service Limit 21.994 - 22 21.96 Piston pin O.D (0.8798 - 0.88) (0.8784) 5-116...
  • Page 508 5.Engine UXV 500i UXV 500i/700i Piston Pin Bore I.D. Measure the piston pin bore diameter with vernier calipers or dial gauge with a small bore gauge. Special Tools- Dial Gauge (1/1000 mm, 1 mm): 09900-20602 Small Bore Gauge (18 - 35 mm): 09900-22403 Item Standard Service Limit...
  • Page 509 5.Engine UXV 500i UXV 500i/700i Connecting Rod Small End Measure the inside diameter of the small end of the connecting rod. Item Standard Service Limit Connecting rod small 22.016 - 22.034 22.06 end I.D. bore (0.8806 - 0.8814) (0.8824) 5-118...
  • Page 510 5.Engine UXV 500i UXV 500i/700i Assembly Clean the piston ring grooves, and apply fresh engine oil to the piston rings. Spread the rings the minimum amount possible to install them. Install the oil ring first then the steel rails above and below the oil ring. Install the second ring with the "RN"...
  • Page 511 5.Engine UXV 500i UXV 500i/700i Install the top ring with the "R" mark facing up. The top ring's upper inside edge is chamfered. 5-120...
  • Page 512 5.Engine UXV 500i UXV 500i/700i The top, second, and oil rings should be rotated so that their gaps divide the piston into thirds, or 120° apart. The gaps shouldn't line up with the gaps of any of the other rings. Also, none of the ring gaps should line up with the piston pin.
  • Page 513 5.Engine UXV 500i UXV 500i/700i Lubricate the piston pin and the small end of the connecting rod with fresh engine oil. Install the piston onto the connecting rod. The IN marks on the piston must sit on the intake side of the engine. Insert the piston pin.
  • Page 514 5.Engine UXV 500i UXV 500i/700i Place a clean shop towel around the base of the piston to prevent any parts or debris from falling into the crankcase. Install new piston pin clips securely into their grooves. Turn the gap in the clips away from the access gap. 5-123...
  • Page 515 5.Engine UXV 500i UXV 500i/700i Make sure the cylinder mating area is clean. Install the two dowel pins. Install the new base gasket. 5-124...
  • Page 516 5.Engine UXV 500i UXV 500i/700i Coat the inside of the cylinder, piston rings, and piston in fresh engine oil. Lower the cylinder into place and guide the piston into the cylinder while you are compressing the rings with your fingers. Be careful to not damage the rings during this step. Bring the cam chain and guides through the opening.
  • Page 517 5.Engine UXV 500i UXV 500i/700i Install the cooling block into the cooling jacket of the cylinder if it was removed. Install the cylinder head. See the Cylinder Head topic. 5-126...

  • Page 518: Crankcase Bearings

    5.Engine UXV 500i UXV 500i/700i Crankcase Bearings SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the engine from the frame. See the Engine Removal topic for more information. Remove the following engine components: Cylinder Head Cover •...
  • Page 519 5.Engine UXV 500i UXV 500i/700i Inspection Inspect the crankcase bearings. Turn the bearings with a finger. They should turn freely with out noise or binding, but also without excessive play. Make sure the outer races of the bearings are secure in the crankcase.
  • Page 520 5.Engine UXV 500i UXV 500i/700i Replacement Place the new bearing in the freezer at least a half hour before you plan to install them. Remove the bearings with a suitable bearing puller. Special Tool - Bearing Puller: A120E00037 5-129...
  • Page 521 5.Engine UXV 500i UXV 500i/700i To replace the drive shaft bearing first remove the set plates. Remove the set plate bolts with a 6 mm Allen. Install the bearing set plates after the bearing has been replaced and tighten new bolts securely with a 6 mm Allen. Replace the oil seal if its bearing is to be replaced.
  • Page 522 5.Engine UXV 500i UXV 500i/700i Drive in the new bearings with a suitable bearing driver that has the same outside diameter of the bearing. The manufactures markings on the bearing must face out. Special Tool - Bearing Driver: A120E00014 5-131...

  • Page 523: Recoil Starter Cover

    5.Engine UXV 500i UXV 500i/700i Recoil Starter Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note: The recoil starter mechanism is not installed on any UXV 500 models. Removal Remove the frame covers. See the Frame Covers topic for more information.
  • Page 524 5.Engine UXV 500i UXV 500i/700i Remove the recoil starter cover. Remove the belt case and hold the drive pulley to keep the crank from turning with a drive pulley holder. See the Belt Case Cover topic for more information. Special Tool - Drive Pulley Holder: A120E00058 Loosen the recoil starter nut with a 19 mm socket.
  • Page 525 5.Engine UXV 500i UXV 500i/700i Remove the recoil starter nut and washer. Slide out the recoil starter drum. Be careful to not damage the oil control rings. 5-134...
  • Page 526 5.Engine UXV 500i UXV 500i/700i Inspect the recoil starter oil control rings. To replace the oil control rings carefully unlock the rings and remove them. 5-135...
  • Page 527 5.Engine UXV 500i UXV 500i/700i Inspect the recoil starter bearing and seal. Remove the generator cover to replace the bearing and seal as needed. See the Generator Cover topic for more information. 5-136...
  • Page 528 5.Engine UXV 500i UXV 500i/700i Installation Install the oil control rings to the recoil starter. Lock the rings as shown above. Apply fresh engine oil to the oil control rings and the recoil starter seal. 5-137...
  • Page 529 5.Engine UXV 500i UXV 500i/700i Carefully install the recoil starter so that the oil control rings are not damaged. Install the washer and the recoil starter nut. Hold the drive pulley to keep the crank from turning with a drive pulley holder. Special Tool - Drive Pulley Holder: A120E00058 5-138...
  • Page 530 5.Engine UXV 500i UXV 500i/700i Tighten the recoil starter nut to specification with a 19 mm socket. ITEM kgf-m ft-lb Recoil starter nut Install the recoil starter cover. 5-139...
  • Page 531 5.Engine UXV 500i UXV 500i/700i Tighten the recoil starter bolts securely with an 8 mm socket. Install the frame covers. See the Frame Covers topic for more information. 5-140...

  • Page 532: Generator Cover

    5.Engine UXV 500i UXV 500i/700i Generator Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Generator Cover Remove the frame covers. See the Frame Covers topic for more information. Drain the coolant. See the Coolant topic for more information. Drain the engine oil if the water pump is to be removed.
  • Page 533 5.Engine UXV 500i UXV 500i/700i Loosen the 14 generator cover bolts evenly in a crisscross pattern. Remove the 14 generator cover bolts with an 8 mm socket. 5-142...
  • Page 534 5.Engine UXV 500i UXV 500i/700i Utilize the pry points and remove the generator cover from the crankcase. Remove the generator cover gasket. 5-143...
  • Page 535 5.Engine UXV 500i UXV 500i/700i Remove the two generator cover dowel pins. Inspect the oil jet and passages for clogging. Clean them out if needed. 5-144...
  • Page 536 5.Engine UXV 500i UXV 500i/700i Stator and Ignition Pulse Generator The stator and ignition pulse generator must be removed together. Remove the three stator coil mounting bolts with an 8 mm socket. 5-145...
  • Page 537 5.Engine UXV 500i UXV 500i/700i Remove the two ignition pulse generator bolts with an 8 mm socket. Free the ignition pulse generator and rubber wire grommet from the generator cover. 5-146...
  • Page 538 5.Engine UXV 500i UXV 500i/700i Lift out the stator and ignition pulse generator together. If the bearing in the generator cover needs to be replaced remove the snap ring. Drive the bearing out from the outside in. Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing.
  • Page 539 5.Engine UXV 500i UXV 500i/700i Installation Fit the stator and ignition pulse generator into the cover together. Install the three stator coil mounting bolts and tighten them to specification with an 8 mm socket. ITEM kgf-m ft-lb Stator coil bolt 5-148...
  • Page 540 5.Engine UXV 500i UXV 500i/700i Install the two ignition pulse generator bolts and tighten them to specification with an 8 mm socket. ITEM kgf-m ft-lb Ignition pulse generator 5-149...
  • Page 541 5.Engine UXV 500i UXV 500i/700i Generator Cover Apply a silicone sealant to the outside of the rubber wire grommet where it will fit into the generator cover and crankcase. Fit the grommet into the cover. Install the two dowel pins and a new generator cover gasket. 5-150...
  • Page 542 5.Engine UXV 500i UXV 500i/700i Fit the generator cover onto the crankcase. Install the 14 generator cover bolts. Tighten the bolts a small amount at a time in a crisscross pattern. 5-151...
  • Page 543 5.Engine UXV 500i UXV 500i/700i Tighten the generator cover bolts to specification with an 8 mm socket. Plug in the 4-pin stator connector. 5-152...
  • Page 544 5.Engine UXV 500i UXV 500i/700i Plug in the 2-pin ignition pulse generator / crank position sensor connector. Install the recoil starter. See the Recoil Starter Cover topic for more information. Install the water pump. See the Water Pump topic for more information. Fill the engine oil.
  • Page 545 5.Engine UXV 500i UXV 500i/700i Flywheel SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the frame covers. See the Frame Covers topic for more information. Drain the coolant. See the Coolant topic for more information. Drain the engine oil if the water pump is to be removed.
  • Page 546 5.Engine UXV 500i UXV 500i/700i Flywheel To remove the flywheel a special flywheel puller tool will be needed. Special Tool- Flywheel Puller: A120E00060 5-155...
  • Page 547 5.Engine UXV 500i UXV 500i/700i Apply grease to the threads of the flywheel puller. Hold the body of the puller with a large wrench and turn in the pusher bolt to separate the flywheel from the crankshaft. Remove the flywheel from the crankshaft. 5-156...
  • Page 548 5.Engine UXV 500i UXV 500i/700i Remove the woodruff key from the crankshaft. Slide off the starter driven gear. 5-157...
  • Page 549 5.Engine UXV 500i UXV 500i/700i Starter Reduction Gear Remove the starter reduction gear from the crankcase. 5-158...
  • Page 550 5.Engine UXV 500i UXV 500i/700i Inspect the starter reduction gear for wear and damage. Replace the part as a whole if needed. Starter Clutch The starter clutch and starter driven gear ride on the back of the flywheel. 5-159...
  • Page 551 5.Engine UXV 500i UXV 500i/700i Inspect the function of the starter clutch by turning the starter driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise. If the starter clutch allows the gear to turn either way, or will not turn smoothly it must be replaced.
  • Page 552 5.Engine UXV 500i UXV 500i/700i Inspect the starter driven gear for wear and damage. Measure the outside diameter of the starter driven gear boss and the inside diameter of the starter driven gear where it rides on the crankshaft. Item Service Limit Starter driven gear boss O.D.
  • Page 553 5.Engine UXV 500i UXV 500i/700i Loosen the starter clutch bolts from the outside of the flywheel with a 6 mm Allen. Remove the starter clutch bolts. 5-162...
  • Page 554 5.Engine UXV 500i UXV 500i/700i Remove the starter clutch and mounting plate from the back of the flywheel. Remove the starter clutch from the mounting plate. 5-163...
  • Page 555 5.Engine UXV 500i UXV 500i/700i Installation Starter Clutch Fit the starter clutch into the mounting plate. Place the starter clutch and mounting plate on the back of the flywheel. 5-164...
  • Page 556 5.Engine UXV 500i UXV 500i/700i Apply a thread locking agent to the threads of the six starter clutch bolts. Tighten the starter clutch bolts evenly and securely with a 6 mm Allen. 5-165...
  • Page 557 5.Engine UXV 500i UXV 500i/700i Lubricate the boss of the starter driven gear with a 50:50 mixture of engine oil and molybdenum grease. Rotate the starter driven gear clockwise as it is inserted into the starter clutch. 5-166...
  • Page 558 5.Engine UXV 500i UXV 500i/700i Starter Reduction Gear Lubricate the starter reduction gear shaft with fresh engine oil. Install the starter reduction gear into the crankcase as shown. 5-167...
  • Page 559 5.Engine UXV 500i UXV 500i/700i Flywheel Install the starter driven gear onto the crankshaft. Install the woodruff key into the crankshaft. Make sure the tapered area of the crankshaft is clean, oil free, and dry. 5-168...
  • Page 560 5.Engine UXV 500i UXV 500i/700i Guide the flywheel onto the crankshaft make sure the key lines up with the groove in the flywheel. Rotate the starter driven gear to fit it into the starter clutch if needed. Install the left crankcase cover. See the Generator Cover topic fore more information.

  • Page 561: Oil Pump

    5.Engine UXV 500i UXV 500i/700i Oil Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the frame covers. See the Frame Covers topic for more information. Drain the coolant. See the Coolant topic for more information. Drain the engine oil if the water pump is to be removed.
  • Page 562 5.Engine UXV 500i UXV 500i/700i Remove the two oil pump chain guide bolts with an 8 mm socket. 5-171...
  • Page 563 5.Engine UXV 500i UXV 500i/700i Remove the oil pump chain guide. Loosen the two oil pump oil separator bolts with an 8 mm socket. 5-172...
  • Page 564 5.Engine UXV 500i UXV 500i/700i Remove the oil separator bolts and the oil separator. Remove the snap ring with snap ring pliers. Slide the oil pump sprocket off of the oil pump shaft. 5-173...
  • Page 565 5.Engine UXV 500i UXV 500i/700i Free the oil pump chain from the crankshaft and remove the oil pump sprocket and chain. Remove the oil pump shaft holder bolt with an 8 mm socket. 5-174...
  • Page 566 5.Engine UXV 500i UXV 500i/700i Remove the oil pump shaft holder. Remove the two oil pump shaft holder dowel pins. 5-175...
  • Page 567 5.Engine UXV 500i UXV 500i/700i Remove the two oil pump bolts with an 8 mm socket. 5-176...
  • Page 568 5.Engine UXV 500i UXV 500i/700i Remove the oil pump. Turn the oil pump shaft and make sure it turns smoothly. 5-177...
  • Page 569 5.Engine UXV 500i UXV 500i/700i Disassembly Slide the oil pump shaft out of the oil pump. 5-178...
  • Page 570 5.Engine UXV 500i UXV 500i/700i Remove the oil pump cover screw. Remove the oil pump cover. 5-179...
  • Page 571 5.Engine UXV 500i UXV 500i/700i Remove the oil pump dowel pin. Remove the inner and outer oil pump rotors. 5-180...
  • Page 572 5.Engine UXV 500i UXV 500i/700i Inspection Check the oil pump chain guide for signs of excessive wear and damage. Replace it as needed. Inspect the oil pump chain and sprocket for excessive wear and damage. Replace these components as needed. 5-181...
  • Page 573 5.Engine UXV 500i UXV 500i/700i Use a feeler gauge set to check the clearance between the outer oil pump rotor and the body (body clearance). Use a feeler gauge set to check the clearance between the inner and outer rotors (tip clearance).
  • Page 574 5.Engine UXV 500i UXV 500i/700i Place a straight edge across the oil pump body and rotors. Check the side clearance with a feeler gauge. ITEM STANDARD mm (in) SERVICE LIMIT Tip clearance 0.15 (0.006) max 0.2 (0.008) Oil pump rotor Body clearance 0.15 - 0.2 (0.006 - 0.008) 0.25 (0.01)
  • Page 575 5.Engine UXV 500i UXV 500i/700i Assembly Lubricate the rotating parts in fresh engine oil. Fit the outer and inner rotors into the oil pump body. Install the oil pump dowel pin. 5-184...
  • Page 576 5.Engine UXV 500i UXV 500i/700i Install the oil pump cover. 5-185...
  • Page 577 5.Engine UXV 500i UXV 500i/700i Install the oil pump cover screw and tighten it to specification with a #2 Phillips screwdriver. ITEM kgf-m ft-lb Oil pump screw Slide the oil pump shaft into the oil pump. 5-186...
  • Page 578 5.Engine UXV 500i UXV 500i/700i Installation Fit the oil pump into place with the arrow pointing up. Insert the two oil pump mounting bolts and tighten them securely 5-187...
  • Page 579 5.Engine UXV 500i UXV 500i/700i Turn the oil pump shaft and make sure it turns smoothly. Install the two oil pump shaft holder dowel pins. 5-188...
  • Page 580 5.Engine UXV 500i UXV 500i/700i Fit the oil pump shaft holder into place. Install the oil pump shaft holder bolt. Do not tighten, yet. 5-189...
  • Page 581 5.Engine UXV 500i UXV 500i/700i Fit the oil pump sprocket and chain into place. Engage the chain to its drive sprocket on the crankshaft. Fit the oil pump sprocket onto the oil pump shaft. 5-190...
  • Page 582 5.Engine UXV 500i UXV 500i/700i Install the new snap ring with snap ring pliers. Install the oil separator and the two mounting bolts. Tighten the oil pump holder shaft bolt and two oil separator mounting bolts securely with an 8 mm socket. Tighten the bolts evenly in a crisscross pattern. 5-191...
  • Page 583 5.Engine UXV 500i UXV 500i/700i Fit the oil pump chain guide into place. 5-192...
  • Page 584 5.Engine UXV 500i UXV 500i/700i Install the two oil pump chain guide bolts and tighten them securely with an 8 mm socket. Install the flywheel. See the Flywheel topic for more information. Install the left crankcase cover. See the Generator Cover topic fore more information.

  • Page 585: Cam Chain

    5.Engine UXV 500i UXV 500i/700i Cam Chain SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the following components: Cylinder Head • Cylinder and Piston • Recoil Starter Cover • Generator Cover • Flywheel • Oil Pump •...
  • Page 586 5.Engine UXV 500i UXV 500i/700i Remove the two cam chain guide pivot bolts with an 8 mm Allen. 5-195...
  • Page 587 5.Engine UXV 500i UXV 500i/700i Inspect the cam chain guides for excessive wear and damage. Replace the guides as needed. Remove the cam chain. 5-196...
  • Page 588 5.Engine UXV 500i UXV 500i/700i Inspect the cam chain for kinking, fatigue, and damage. Replace the cam chain as needed. Installation Fit the cam chain into place. Of the two sprockets on the crankshaft the cam chain's timing sprocket is the inner sprocket. The outer sprocket is the oil pump drive chain sprocket. 5-197...
  • Page 589 5.Engine UXV 500i UXV 500i/700i Install the two cam chain guides. The larger guide is on the tensioner side. 5-198...
  • Page 590 5.Engine UXV 500i UXV 500i/700i Install the two cam chain guide pivot bolts and tighten them to specification with an 8 mm Allen. ITEM kgf-m ft-lb Cam chain guide pivot bolt 5-199...
  • Page 591 5.Engine UXV 500i UXV 500i/700i Install the following components: Oil Pump • - Oil pump sprocket and chain Flywheel • Generator Cover • Recoil Starter Cover • Cylinder and Piston • Cylinder Head • 5-200...

  • Page 592: Output Shaft And Bevel Gear

    5.Engine UXV 500i UXV 500i/700i Output Shaft and Bevel Gear SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the engine. See the Engine Removal topic for more information. Bevel Gear Cover Remove the five bevel gear case cover bolts with an 8 mm socket. 5-201...
  • Page 593 5.Engine UXV 500i UXV 500i/700i Remove the bevel gear cover. Remove the gasket and the two bevel gear cover dowel pins. 5-202...
  • Page 594 5.Engine UXV 500i UXV 500i/700i Inspect the oil sight glass and replace it as needed. Output Shaft and Bevel Gears Unstake the output shaft nut with a chisel and a hammer. 5-203...
  • Page 595 5.Engine UXV 500i UXV 500i/700i Insert the forward propeller shaft and hold it to keep the output shaft from turning. Loosen the output shaft nut with a 26 mm socket. 5-204...
  • Page 596 5.Engine UXV 500i UXV 500i/700i Remove output shaft nut. Remove the front propeller shaft coupler from the engine. 5-205...
  • Page 597 5.Engine UXV 500i UXV 500i/700i Tap the output shaft forward with a rubber mallet. Move the output shaft forward so that the driven bevel gear can be removed. 5-206...
  • Page 598 5.Engine UXV 500i UXV 500i/700i Remove the driven bevel gear and shim. Slide the output shaft out of the engine. 5-207...
  • Page 599 5.Engine UXV 500i UXV 500i/700i Unstake drive bevel gear nut with a chisel and a hammer. Remove the belt case cover. See the CVT Removal topic. Hold the driven pulley with a Y-type holder. Special Tool - Y-Type Holder: A120E00056 Loosen the drive bevel gear nut with a deep well 26 mm socket.
  • Page 600 5.Engine UXV 500i UXV 500i/700i Remove the drive bevel gear nut. Slide off the drive bevel gear. 5-209...
  • Page 601 5.Engine UXV 500i UXV 500i/700i Remove the drive bevel gear shim. Seals and Bearings Inspect the propeller shaft oil seals for leaks and damage. 5-210...
  • Page 602 5.Engine UXV 500i UXV 500i/700i Inspect the bearings by turning them with a finger. Replace the bearings if they do not turn smoothly. Remove the seals with a seal pick if needed. Replace the oil seals with new items if they are removed.
  • Page 603 5.Engine UXV 500i UXV 500i/700i If the front bearing needs to be replaced the lock nut must be removed. Remove the lock nut with the special tool. Special Tool - Nut Wrench: A120E00066 5-212...
  • Page 604 5.Engine UXV 500i UXV 500i/700i Remove the front bearing with a suitable bearing puller. Special Tool- Bearing Puller: A120E00037 Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing. The manufactures markings on the bearing must face out. Special Tool - Bearing Driver: A120E00014 5-213...
  • Page 605 5.Engine UXV 500i UXV 500i/700i Install the lock nut with the special tool. Special Tool - Nut Wrench: A120E00066 Torque the lock nut to specification with the special tool. ITEM kgf-m ft-lb Driven pulley nut 79.2 5-214...
  • Page 606 5.Engine UXV 500i UXV 500i/700i If the rear bearing is to be replaced the snap ring must be removed. Remove the bearing snap ring with snap ring pliers. 5-215...
  • Page 607 5.Engine UXV 500i UXV 500i/700i Remove the rear bearing with a suitable bearing puller. Special Tool- Bearing Puller: A120E00037 Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing. The manufactures markings on the bearing must face out. Special Tool - Bearing Driver: A120E00014 5-216...
  • Page 608 5.Engine UXV 500i UXV 500i/700i Install a new snap ring with snap ring pliers. Lubricate the lips of the new oil seals with fresh engine oil. Press in the new seals with a suitable driver with the same outside diameter as the seals. 5-217...
  • Page 609 5.Engine UXV 500i UXV 500i/700i Inspection Inspect the propeller shaft couplers for wear and damage. Inspect the bevel gears for wear and damage. 5-218...
  • Page 610 5.Engine UXV 500i UXV 500i/700i Inspect the output shaft for damage and wear. Bevel Gear Backlash Remove the bevel gear cover. The bevel gears must be installed as normal. Set a dial gauge on the driven bevel gear as shown. 5-219...
  • Page 611 5.Engine UXV 500i UXV 500i/700i Measure the backlash by turning the rear propeller shaft in each direction, reading the total backlash on the dial gauge. If the backlash is not within specification, the shim must be changed and the backlash should be rechecked until correct. Bevel gear backlash 0.03 - 0.15 mm (0.001 - 0.006 in) See the chart for appropriate shim thickness.
  • Page 612 5.Engine UXV 500i UXV 500i/700i Drive/Driven bevel gear shims 0.6 mm (0.024 in) 0.65 mm (0.026 in) 0.7 mm (0.028 in) 0.75 mm (0.03 in) 0.8 mm (0.032 in) 0.85 mm (0.034 in) 0.9 mm (0.036 in) 0.95 mm (0.038 in) 1 mm (0.04 in) 1.05 mm (0.042 in) 1.1 mm (0.044 in)
  • Page 613 5.Engine UXV 500i UXV 500i/700i Bevel Gear Tooth Contact After the backlash adjustment is carried out, the tooth contact must be checked as indicated below. • Remove the driven bevel gear. • Clean and degrease the teeth of the drive and driven bevel gears. Apply a coating of machinist's layout dye or paste to several teeth of the driven bevel gear.
  • Page 614 5.Engine UXV 500i UXV 500i/700i 2 - Correct • If tooth contact is found to be correct (example 2) complete the installation. • If tooth contact is found to be incorrect (examples 1 and 3), the shim thickness between the drive bevel gear and driven bevel gear must be changed and the tooth contact rechecked until correct.
  • Page 615 5.Engine UXV 500i UXV 500i/700i Drive Bevel Gear Shim Driven Bevel Gear Shim Tooth Contact Adjustment Adjustment Contact at tooth top (1) Increase shim thickness Increase shim thickness Contact at tooth root Reduce shim thickness Reduce shim thickness Make sure to check the backlash after the tooth contact has been adjusted. The tooth contact shim adjustment may have changed the backlash.
  • Page 616 5.Engine UXV 500i UXV 500i/700i Installation Output Shaft and Bevel Gears Install the drive bevel gear shim. Slide on the drive bevel gear. 5-225...
  • Page 617 5.Engine UXV 500i UXV 500i/700i Lubricate the new drive bevel gear lock nut threads with engine oil. Thread on the new drive bevel gear lock nut. Hold the driven pulley with a Y-type holder. Special Tool - Y-Type Holder: A120E00056 5-226...
  • Page 618 5.Engine UXV 500i UXV 500i/700i Tighten the drive bevel gear nut to specification with a deep well 26 mm socket. ITEM kgf-m ft-lb Drive bevel gear lock nut 100.8 Stake the drive bevel gear lock nut with a chisel and a hammer. 5-227...
  • Page 619 5.Engine UXV 500i UXV 500i/700i Slide the output shaft into the engine as shown. Fit the driven bevel gear and shim into place. 5-228...
  • Page 620 5.Engine UXV 500i UXV 500i/700i Guide the output shaft through the driven bevel gear and shim. The output shaft must protrude through the seal. 5-229...
  • Page 621 5.Engine UXV 500i UXV 500i/700i Install the front propeller shaft coupler. Lubricate the new output shaft nut threads with engine oil. Install the new output shaft nut. 5-230...
  • Page 622 5.Engine UXV 500i UXV 500i/700i Insert the rear propeller shaft and hold it to keep the output shaft from turning. Tighten the output shaft nut to specification with a 26 mm socket. ITEM kgf-m ft-lb Driven bevel gear lock nut 100.8 5-231...
  • Page 623 5.Engine UXV 500i UXV 500i/700i Stake the output shaft nut with a chisel and a hammer. Bevel Gear Cover Install two bevel gear cover dowel pins and a new gasket. 5-232...
  • Page 624 5.Engine UXV 500i UXV 500i/700i Fit the bevel gear cover into place. 5-233...
  • Page 625 5.Engine UXV 500i UXV 500i/700i Install the five bevel gear case cover bolts. Tighten the bolts evenly and securely with an 8 mm socket. Install the engine. See the Engine Installation topic for more information. 5-234...

  • Page 626: Clutch Removal

    5.Engine UXV 500i UXV 500i/700i Clutch Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the CVT belt case cover. See the Belt Case Cover topic for more information. Remove the CVT pulleys and belt. See the CVT Removal topic for more information.
  • Page 627 5.Engine UXV 500i UXV 500i/700i Remove the CVT fan cover. Loosen the 9 clutch cover bolts a little bit at a time and in a crisscross pattern. 5-236...
  • Page 628 5.Engine UXV 500i UXV 500i/700i Remove the clutch cover bolts. Remove the clutch cover assembly evenly. 5-237...
  • Page 629 5.Engine UXV 500i UXV 500i/700i Remove the two dowel pins and the clutch cover gasket. 5-238...
  • Page 630 5.Engine UXV 500i UXV 500i/700i Free the stake on the clutch nut with a chisel and a hammer. Hold the clutch with the Y-type holder and loosen the clutch nut with a commercially available 26 mm deep well socket. Special Tool - Y-Type Holder: A120E00056 5-239...
  • Page 631 5.Engine UXV 500i UXV 500i/700i Remove the clutch nut. Slide off the outer clutch collar. 5-240...
  • Page 632 5.Engine UXV 500i UXV 500i/700i Slide the clutch assembly off of the crankshaft. Slide off the inner clutch collar. 5-241...
  • Page 633 5.Engine UXV 500i UXV 500i/700i Inspection Remove the clutch outer and drive pulley shaft from the clutch cover. To check the one-way clutch in the clutch outer temporarily install the clutch and set the clutch outer in place without the cover. 5-242...
  • Page 634 5.Engine UXV 500i UXV 500i/700i When turning the clutch outer clockwise, the clutch outer should turn freely. If not, the one-way clutch assembly is faulty and should be replaced. When turning the clutch outer counterclockwise, the clutch outer and crankshaft should engaged by the one-way clutch.
  • Page 635 5.Engine UXV 500i UXV 500i/700i Inspect the inside of the clutch outer and needle bearing for wear and damage. Replace the components as needed. If the needle bearing is in poor condition remove the snap ring and replace the bearing. Press in a new bearing and secure it with a new snap ring.
  • Page 636 5.Engine UXV 500i UXV 500i/700i Check the clutch linings for abnormal wear and damage. Replace the clutch if the lining thickness is below 1 mm (0.04 in). 5-245...
  • Page 637 5.Engine UXV 500i UXV 500i/700i Inspect the clutch bearing by turning it with a finger. Replace the bearing if it doesn't turn smoothly or it has excessive play. Inspect the clutch cover oil seal and replace it as needed. 5-246...
  • Page 638 5.Engine UXV 500i UXV 500i/700i Inspect the large ball bearing in the clutch cover. Turn the bearing with a finger. Replace the bearing if it doesn't turn smoothly. Remove the seal cover to replace the bearing. Remove the four seal cover bolts with an 8 mm socket. Take off the seal cover and discard the gasket.
  • Page 639 5.Engine UXV 500i UXV 500i/700i Drive the bearing out from the outside of the clutch cover. Drive in the new bearing from the inside of the clutch cover. Use a suitable driver that is the same outside diameter as the bearing.
  • Page 640 5.Engine UXV 500i UXV 500i/700i Apply a light coat lightweight lithium-soap based grease to the lips of the oil seal. For clutch assembly and installation see the Clutch Installation topic for more information. Install the CVT belt case cover. See the Belt Case Cover topic for more information.

  • Page 641: Clutch Installation

    5.Engine UXV 500i UXV 500i/700i Clutch Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Fit the seal cover to the clutch cover with a new gasket. Install the four seal cover bolts and tighten them securely with an 8 mm socket. 5-250...
  • Page 642 5.Engine UXV 500i UXV 500i/700i Install the one-way clutch into the clutch outer if it was removed. Lubricate the one-way clutch bearings with molybdenum disulfide grease. Apply a light coat lightweight lithium-soap based grease to the lips of the oil seal. Lubricate the clutch bearings with fresh engine oil.
  • Page 643 5.Engine UXV 500i UXV 500i/700i Lubricate the inner clutch collar with fresh engine oil and slide it onto the crankshaft as shown. Slide the clutch onto the crankshaft. Be sure to align the splines. 5-252...
  • Page 644 5.Engine UXV 500i UXV 500i/700i Slide the outer clutch collar onto the crankshaft. Thread on a new clutch lock nut. 5-253...
  • Page 645 5.Engine UXV 500i UXV 500i/700i Hold the clutch with the Y-type holder and torque the clutch nut to specification with a deep well commercially available 26 mm socket. Special Tool - Y-Type Holder: A120E00056 ITEM kgf-m ft-lb Clutch nut 100.8 5-254...
  • Page 646 5.Engine UXV 500i UXV 500i/700i Stake the clutch nut at the groove on the crankshaft with a chisel and a hammer. Be careful to avoid damaging the threads. Install the two dowel pins and a new clutch cover gasket. 5-255...
  • Page 647 5.Engine UXV 500i UXV 500i/700i Guide the clutch cover assembly into place evenly. Insert the 9 clutch cover bolts. 5-256...
  • Page 648 5.Engine UXV 500i UXV 500i/700i Tighten the clutch cover bolts a little bit at a time in a crisscross pattern. Torque the bolts to specification with an 8 mm socket. ITEM kgf-m ft-lb Clutch cover bolt Install the CVT fan cover. 5-257...
  • Page 649 5.Engine UXV 500i UXV 500i/700i Install the five CVT fan cover bolts and tighten them securely with an 8 mm socket. Install the CVT pulleys and belt. See the CVT Installation topic for more information. 5-258...
  • Page 650 5.Engine UXV 500i UXV 500i/700i Crankcase SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Splitting Remove the engine from the frame. See the Engine Removal topic for more information. Remove the following engine components: Cylinder Head Cover •...
  • Page 651 5.Engine UXV 500i UXV 500i/700i Loosen the shift cam stopper plug with a 14 mm socket. Remove the stopper plug, washer, spring, and stopper ball. 5-260...
  • Page 652 5.Engine UXV 500i UXV 500i/700i Inspect the shift cam stopper components and replace them as needed. Remove the shift arm bolt with a 10 mm socket. 5-261...
  • Page 653 5.Engine UXV 500i UXV 500i/700i Remove the shift arm from the shift shaft. Remove the gear position indicator switch bolt with an 8 mm socket. 5-262...
  • Page 654 5.Engine UXV 500i UXV 500i/700i Remove the gear position indicator switch. Note its position so that it can be returned to its original orientation. Remove the four bolts from the CVT side of the crankcase. There are three bolts on the clutch end, and one bolt on the other end.
  • Page 655 5.Engine UXV 500i UXV 500i/700i Loosen the 15 generator side crankcase bolts evenly and in a crisscross pattern. Remove the generator side crankcase bolts with an 8 mm socket. 5-264...
  • Page 656 5.Engine UXV 500i UXV 500i/700i Utilize the pry points and separate the halves of the crankcases. Remove the two dowel pins from the crankcase. Remove the old crankcase gasket material. To remove the crankshaft and balancer see the Crankshaft topic. To remove the transmission see the Transmission Removal topic.
  • Page 657 5.Engine UXV 500i UXV 500i/700i Oil Relief Valve The oil relief valve is located in the crankcase. If it is necessary, remove the oil pipe; Remove the two bolts, washers (on the oil pipe), oil pipe and washers (under oil pipe). 5-266...
  • Page 658 5.Engine UXV 500i UXV 500i/700i Remove the oil relief valve from the crankcase. Push in on the oil relief valve piston and make sure it moves smoothly. Replace it if it sticks or refuses to move. 5-267...
  • Page 659 5.Engine UXV 500i UXV 500i/700i Discard the O-ring and replace it with a new item. Apply fresh engine oil to the new O-ring. Fit the oil relief valve into place in the crankcase. 5-268...
  • Page 660 5.Engine UXV 500i UXV 500i/700i Assembly Make sure the crankcase mating surfaces are clean. Install the inner washers on the right crankcase. Install the oil pipe with the thick side face upward. Apply clean engine oil to the bolts, then install the outer washers and two bolts. Tighten the two bolts to the specified torque.
  • Page 661 5.Engine UXV 500i UXV 500i/700i Apply Threebond 1215 or other equivalent sealant to the crankcase mating surface. Do not allow the sealant to get into oil passages or bearings. The crankcases must be joined in a few minutes or the sealant will not function correctly. Fit the generator side crankcase half onto the CVT crankcase half.
  • Page 662 5.Engine UXV 500i UXV 500i/700i Insert the 15 generator side crankcase bolts. Tighten the bolts evenly and in a crisscross pattern. Torque the 15 generator side crankcase bolts to specification with an 8 mm socket. ITEM kgf-m ft-lb Crankcase bolt 5-271...
  • Page 663 5.Engine UXV 500i UXV 500i/700i Install the four CVT side of the crankcase bolts and tighten them to specification with an 8 mm socket. ITEM kgf-m ft-lb Crankcase bolt Install a new O-ring to the gear position indicator switch if needed. Lubricate the O-ring with fresh engine oil.
  • Page 664 5.Engine UXV 500i UXV 500i/700i Install the gear position indicator switch bolt and tighten it securely with an 8 mm socket. Install the shift arm to the shift shaft. 5-273...
  • Page 665 5.Engine UXV 500i UXV 500i/700i Install the shaft arm bolt and tighten it securely with a 10 mm socket. Use a new sealing washer with the shift cam stopper plug. 5-274...
  • Page 666 5.Engine UXV 500i UXV 500i/700i Install the stopper plug, washer, spring, and stopper ball. Tighten the stopper plug to specification with a 14 mm socket. ITEM kgf-m ft-lb Shift cam stopper plug Make sure the engine shafts turn properly. 5-275...
  • Page 667 5.Engine UXV 500i UXV 500i/700i Install the following engine components: Starter Motor • Clutch Installation • CVT Installation • Output Shaft and Bevel Gear • Belt Case Cover • Cam Chain • Oil Pump • Flywheel • Generator Cover • Recoil Starter Cover •...

  • Page 668: Crankshaft

    5.Engine UXV 500i UXV 500i/700i Crankshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Split the crankcases. See the crankcase Crankcase topic for more information. Remove the transmission. See the Transmission Removal topic for more information. Remove the crankshaft and balancer shaft together.
  • Page 669 5.Engine UXV 500i UXV 500i/700i Inspection Inspect the balancer shaft for wear and damage. Inspect the crankshaft for wear or damage. Turn the crank bearings with a finger and make sure they turn smoothly. Replace the crankshaft if the bearings are faulty. 5-278...
  • Page 670 5.Engine UXV 500i UXV 500i/700i Measure the inside diameter of the small end of the connecting rod. Item Standard Service Limit Connecting rod small end I.D. bore 22.016 - 22.034 (0.8806 - 0.8814) 22.06 (0.8824) 5-279...
  • Page 671 5.Engine UXV 500i UXV 500i/700i Place the crankshaft on V-blocks and measure the runout on each side with a dial gauge. Check the side clearance of the big end of the connecting rod with a feeler gauge. Service Item Standard mm (in) Limit Not USA 0.01 - 0.4 (0.002 -...
  • Page 672 5.Engine UXV 500i UXV 500i/700i Installation Lubricate the crankshaft and balancer bearings with fresh engine oil. Fit the crank and balancer shafts into the crankcase together. The line on the balancer sprocket must align with the line on the crankshaft. Install the transmission.

  • Page 673: Transmission Removal

    5.Engine UXV 500i UXV 500i/700i Transmission Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Split the crankcases. See the Crankcase topic for more information. Remove the shift shaft. Remove the transmission guide bar. 5-282...
  • Page 674 5.Engine UXV 500i UXV 500i/700i Remove the upper and lower shift forks. Remove the shift cam. 5-283...
  • Page 675 5.Engine UXV 500i UXV 500i/700i Remove the transmission shafts together from the crankcase. To disassemble the transmission shafts see the Transmission Shafts topic for more information. Remove the stopper lever bolt and washer with a 6 mm Allen wrench. 5-284...
  • Page 676 5.Engine UXV 500i UXV 500i/700i Remove the stopper lever and spring. Remove the crankshaft and balancer shaft together. See the Crankshaft for more information. 5-285...
  • Page 677 5.Engine UXV 500i UXV 500i/700i Place the nut that was removed from the driven pulley back onto the transmission drive shaft to protect the threads and begin to press the shaft out. Remove the nut before it reaches the oil seal as it will not fit through. Remove the shaft. If the bearing comes out with the transmission drive shaft press it off as shown.
  • Page 678 5.Engine UXV 500i UXV 500i/700i If the transmission drive shaft bearing does not come out with the shaft and needs to be replaced; remove it with a bearing puller. See the Crankcase Bearings topic for more information. Note: Always replace the bearing if it is removed from the crankcase. Inspect the transmission drive shaft oil seal and replace if needed.
  • Page 679 5.Engine UXV 500i UXV 500i/700i If it is necessary to remove the stopper lever shaft use a 19 mm socket to remove the nut and washer on the other side. 5-288...
  • Page 680 5.Engine UXV 500i UXV 500i/700i Upper Shift Fork Disassembly Remove the snap ring with snap ring pliers. 5-289...
  • Page 681 5.Engine UXV 500i UXV 500i/700i Remove the washer. Remove the shift fork and spring. Remove the snap ring with snap ring pliers. 5-290...
  • Page 682 5.Engine UXV 500i UXV 500i/700i Remove the washer and cam pawl. Inspection Check the stopper lever pawl for bends, damage or wear. Inspect the spring for cracks or damage. 5-291...
  • Page 683 5.Engine UXV 500i UXV 500i/700i Check the transmission drive shaft gear teeth for blue discoloration, pitting or wear. Measure the guide bar runout. Replace the bar if it is out of specification. Item Service Limit Guide Bar Runout 0.03 mm (0.0012 in) 5-292...
  • Page 684 5.Engine UXV 500i UXV 500i/700i Inspect the upper shift fork cam followers, shift fork pawl and spring. If there is any damage or excessive wear replace the components as a set. Inspect the upper shift fork cam followers and shift fork pawl. If there is any damage or excessive wear replace the part.
  • Page 685 5.Engine UXV 500i UXV 500i/700i Check the shift cam grooves and shift cam gear. Check for wear and damage and replace if needed. Inspect shift shaft gear and shift shaft for damage, bends or wear. Check the return spring for fatigue or damage. Replace the parts if needed. Inspect the transmission bearings.
  • Page 686 5.Engine UXV 500i UXV 500i/700i Transmission Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Upper Shift Fork Assembly Install the cam pawl on the shaft and be sure to align the marks as shown. 5-295...
  • Page 687 5.Engine UXV 500i UXV 500i/700i Install the washer. Install the snap ring with snap ring pliers. 5-296...
  • Page 688 5.Engine UXV 500i UXV 500i/700i Install the spring. Install the shift fork on the shaft and be sure to align the marks as shown. 5-297...
  • Page 689 5.Engine UXV 500i UXV 500i/700i Install the washer. 5-298...
  • Page 690 5.Engine UXV 500i UXV 500i/700i Install the snap ring with snap ring pliers. Installation 5-299...
  • Page 691 5.Engine UXV 500i UXV 500i/700i Install the stopper lever shaft if it was removed. Install the shaft on the outside and the nut with washer on the inside. Carefully hold the stopper lever shaft with a wrench if necessary. Tighten the bolt to specification with a 19 mm socket. Item kgf-m lbf-ft...
  • Page 692 5.Engine UXV 500i UXV 500i/700i Install the washer and a new stopper lever bolt. Hold the shaft nut on the other side. Tighten the bolt to specification with a 6 mm Allen wrench. Item kgf-m lbf-ft Stopper lever bolt 5-301...
  • Page 693 5.Engine UXV 500i UXV 500i/700i Install the transmission drive shaft bearing with a bearing driver. Special Tool- Bearing Driver: A120E00014 Note: Apply clean engine oil to the transmission drive shaft, countershaft and drive shaft. Carefully press in the transmission drive shaft. 5-302...
  • Page 694 5.Engine UXV 500i UXV 500i/700i Install the transmission shafts together into the crankcase. Apply clean engine oil to the shift cam and install it. 5-303...
  • Page 695 5.Engine UXV 500i UXV 500i/700i Apply clean engine oil to the upper and lower shift forks and pawls. Install the lower gearshift fork into the lower shifter shift groove on the countershaft with its “LDB5” mark facing down. Fit the lower shift fork guide pin into the groove on the shift cam. 5-304...
  • Page 696 5.Engine UXV 500i UXV 500i/700i Install the upper gearshift fork into the upper shifter shift groove on the countershaft with its “LDB5” mark facing up. Fit the upper shift fork guide pin into the groove on the shift cam. Apply clean engine oil to the transmission guide bar and install it. Install the shift shaft.
  • Page 697 5.Engine UXV 500i UXV 500i/700i Check the transmission operation. Install the crankshaft and balancer shaft together (if they were removed). See the Crankshaft for more information. Assemble the crankcases. See the Crankcase topic for more information. 5-306...

  • Page 698: Transmission Shafts

    5.Engine UXV 500i UXV 500i/700i Transmission Shafts SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the transmission shafts from the transmission. See the Transmission Removal topic for more information. Disassembly When disassembling the transmission shafts be sure to keep track of the order and orientation of the parts as they come apart.
  • Page 699 5.Engine UXV 500i UXV 500i/700i Countershaft Remove the washer. Remove the high drive gear. Remove the bushing and washer. 5-308...
  • Page 700 5.Engine UXV 500i UXV 500i/700i Remove the high/low gear shifter. Remove the snap ring with snap ring pliers. Remove the washer and low drive gear. 5-309...
  • Page 701 5.Engine UXV 500i UXV 500i/700i On the other side of the countershaft; Remove the snap ring with snap ring pliers. Remove the stopper wheel. Remove the snap ring with snap ring pliers. 5-310...
  • Page 702 5.Engine UXV 500i UXV 500i/700i Remove the reverse gear shifter. Remove the snap ring with snap ring pliers. Remove the washer and reverse drive gear. 5-311...
  • Page 703 5.Engine UXV 500i UXV 500i/700i Inspect the countershaft, gear teeth and mated dogs. Check for blue discoloration, pitting or wear. Check for rounded edges, cracks or other damage. Replace as needed. 5-312...
  • Page 704 5.Engine UXV 500i UXV 500i/700i Bevel Gear Drive Shaft Remove the thick washer. Remove the reverse gear. 5-313...
  • Page 705 5.Engine UXV 500i UXV 500i/700i Remove the thin washer. Inspect the gear teeth. Check for blue discoloration, pitting or wear. Replace as needed. 5-314...
  • Page 706 5.Engine UXV 500i UXV 500i/700i Inspect the needle bearing in the reverse gear. Check for wear or damage. Replace as needed. 5-315...
  • Page 707 5.Engine UXV 500i UXV 500i/700i Assembly Use new snap rings when assembling the transmission shaft components. Install the snap ring (and thrust washer) so that the sharp edge is facing away from the gear that is putting thrust against it. The sharp edge is shown in the photo on the left. Also, make sure the snap rings are fully seated in their grooves as shown.
  • Page 708 5.Engine UXV 500i UXV 500i/700i Bevel Gear Drive Shaft Install the thin washer on the drive shaft. Install the reverse gear. Install the thick washer. 5-317...
  • Page 709 5.Engine UXV 500i UXV 500i/700i Countershaft Install the reverse drive gear and washer on the proper side of the countershaft. Install the snap ring with snap ring pliers. 5-318...
  • Page 710 5.Engine UXV 500i UXV 500i/700i Install the reverse gear shifter. Install the snap ring with snap ring pliers. 5-319...
  • Page 711 5.Engine UXV 500i UXV 500i/700i Install the stopper wheel. Install the snap ring with snap ring pliers. On the other side of the countershaft; Install the low drive gear and washer. 5-320...
  • Page 712 5.Engine UXV 500i UXV 500i/700i Install the snap ring with snap ring pliers. Install the high/low gear shifter. Install the washer and bushing. 5-321...
  • Page 713 5.Engine UXV 500i UXV 500i/700i Install the high drive gear. Install the washer. To install the transmission see the Transmission Installation topic. 5-322...
  • Page 714 5.Engine UXV 500i/700i 5.Engine This chapter covers the location and servicing of the engine components. 1.Rocker Cover ................5-8 2.Camshaft Removal ..............5-32 3.Camshaft Installation ..............5-42 4.Cylinder Head ................5-50 5.Valves ...................5-65 6.Cam Chain ...................5-77 7.Cylinder and Piston ..............5-81 8.Generator Cover ................5-103 9.Flywheel ..................5-121 10.Clutch ..................5-124 11.Oil Pump ..................5-148 12.Crankcase Splitting And Assembly...........5-172...
  • Page 715 5.Engine UXV 500i/700i GENERAL INSTRUCTIONS Lubrication System The maintenance of lubrication system can be performed with the engine installed in the frame. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine If any portion of the oil pump is worn beyond the specified service limits.
  • Page 716 5.Engine UXV 500i/700i No oil pressure • Oil level too low • Oil pump drive chain broken • Oil pump drive sprocket broken • Oil pump damaged (pump shaft) • Internal oil leak Low oil pressure • Pressure relief valve stuck open •...
  • Page 717 5.Engine UXV 500i/700i Oil contamination • Deteriorated oil • Faulty oil filter • Worn piston ring (White appearance with water or moisture) - Damaged water pump mechanical seal - Damaged head gasket - Oil relief not frequent enough Cylinder Head, Camshaft, and Valves •...
  • Page 718 5.Engine UXV 500i/700i TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed • Compression too low Compression too low • Incorrect valve clearance adjustment •...
  • Page 719 5.Engine UXV 500i/700i White smoke from exhaust muffler • Worn valve stem or valve guide • Damaged valve stem oil seal Cylinder and Piston • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection.
  • Page 720 5.Engine UXV 500i/700i Compression too high • Excessive carbon build-up in combustion chamber or on piston head. Excessive smoke from exhaust muffler • Worn or damaged piston rings • Worn or damaged cylinder and piston Abnormal noisy piston • Worn cylinder, piston and piston rings •...
  • Page 721 5.Engine UXV 500i/700i Rocker Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Loosen the timing inspection plug with a large flat blade screwdriver. Remove the timing inspection plug and inspect its O-ring. Remove the crankshaft cap on the left side of the engine with a 10 mm Allen socket.
  • Page 722 5.Engine UXV 500i/700i Inspect the O-ring and replace it as needed. The valve adjuster covers are each held on with three bolts.
  • Page 723 5.Engine UXV 500i/700i Remove the valve adjuster cover bolts with an 8 mm socket. Lift off the valve adjuster covers. 5-10...
  • Page 724 5.Engine UXV 500i/700i Inspect the valve adjuster cover O-rings and replace them as needed. The piston should be at TDC (Top Dead Center) on the compression stroke to check the valve clearance. Turn the crankshaft clockwise with a 19 mm socket. Observe the movement of the intake valves and check the position of the flywheel through the timing hole.
  • Page 725 5.Engine UXV 500i/700i The intake valves should open and close. Align the "T" mark on the flywheel with the index mark on the crankcase cover. This shows the piston is at Top Dead Center (TDC). 5-12...
  • Page 726 5.Engine UXV 500i/700i The piston should now be at TDC (Top Dead Center) on the compression stroke. You can make sure that it is on the compression stroke by checking that there is some slack in the rocker arms. If the rocker arms are rigid, rotate the crankshaft 360° until the "T" mark is once again aligned with the notch on the case cover.
  • Page 727 5.Engine UXV 500i/700i Loosen the rocker cover bolts evenly and in a crisscross pattern with an 8 mm socket. 5-14...
  • Page 728 5.Engine UXV 500i/700i Note the bolt sizes, locations and washers. 5-15...
  • Page 729 5.Engine UXV 500i/700i Lift off the rocker cover. Utilize the pry points if needed to free the rocker cover from the cylinder head. 5-16...
  • Page 730 5.Engine UXV 500i/700i Remove the dowel pins. Remove the camshaft end cap. 5-17...
  • Page 731 5.Engine UXV 500i/700i Rocker Arms and Shafts Keep the rocker arm components organized so that they can be returned to their original positions. Loosen the rocker arm shaft bolts with an Allen. Remove the rocker arm shaft bolts and sealing washers. Thread a bolt (8 mm thread diameter) into the rocker arm shaft and slide out the shaft with the bolt.
  • Page 732 5.Engine UXV 500i/700i Lift out the rocker arm as the shaft is removed. Inspection Inspect the rocker arms for wear and damage. Check the cam roller for signs of damage and excessive wear. The roller should not have excessive play on the arm. 5-19...
  • Page 733 5.Engine UXV 500i/700i Measure the inside diameter of the rocker arm. Item Standard mm (in) 12 - 12.018 (0.4724 - 0.4731) Valve rocker arm I.D. 12 - 12.018 (0.4724 - 0.4731) Inspect the rocker arm shafts for wear and damage. Measure the outside diameter of the rocker arm in several locations with a micrometer.
  • Page 734 5.Engine UXV 500i/700i Item Standard mm (in) Service Limit 11.975 - 11.987 (0.471 - 0.4719) Valve rocker arm shaft O.D. 11.975 - 11.987 (0.471 - 0.4719) Rocker arm to shaft clearance 0.009 - 0.042 (0.0004 - 0.0017) 0.1 (0.004) Place the rocker cover on a flat surface and check it for warp by inserting a feeler gauge under the mating surface.
  • Page 735 5.Engine UXV 500i/700i Assembly Rocker Arms and Shafts Lubricate the rocker arms and shafts with fresh engine oil. Set the rocker arms in place in their original positions. Insert the rocker arm shafts into the rocker cover and through the rocker arms. Make sure the intake and exhaust rocker arm shafts are returned to their correct positions.
  • Page 736 5.Engine UXV 500i/700i Install the rocker arm shaft bolts with new sealing washers. Tighten the rocker arm shaft bolts to specification with an Allen socket. TORQUE VALUES ITEM THREAD SIZE AND TYPE ft-lb SPECIAL SCREW SHAFT ROCKER ARM 39.2-49 28.9-36.1 M18 x 1.5 5-23...
  • Page 737 5.Engine UXV 500i/700i Installation Make sure the rocker cover mating surface is clean and free of old gasket material Position the piston at TDC as with removal. The camshaft lobes should be pointing down and the marks on the end of the camshaft should be level with the rocker cover mating surface.
  • Page 738 5.Engine UXV 500i/700i Install the rocker cover dowel pins. Apply fluid gasket (threebond: 1215) to the mating surface of the rocker cover. Do not allow the sealant to get on the rocker arms, camshaft, camchain, or into any oil passages. Install the rocker cover.
  • Page 739 5.Engine UXV 500i/700i Install the rocker cover bolts and washers to their original positions. 5-26...
  • Page 740 5.Engine UXV 500i/700i From the inside out, tighten the rocker cover bolts evenly and in a crisscross pattern. Torque the to specification with an 8 mm socket. TORQUE VALUES ITEM THREAD SIZE AND TYPE ft-lb ROCKER COVER M6 x 1.0 Check the valve clearance.
  • Page 741 5.Engine UXV 500i/700i Install the valve adjuster cover bolts. Tighten the bolts securely with an 8 mm socket. 5-28...
  • Page 742 5.Engine UXV 500i/700i Make sure the crankshaft cap O-ring is in good condition. Apply fresh engine oil to the O-ring. Install the crankshaft cap. 5-29...
  • Page 743 5.Engine UXV 500i/700i Tighten the crankshaft cap securely with a 10 mm Allen socket. Do not over tighten this cap. Make sure the timing plug O-ring is in good condition. Apply fresh engine oil to the O-ring. 5-30...
  • Page 744 5.Engine UXV 500i/700i Install the timing inspection plug and tighten it securely with a large flat blade screwdriver. 5-31...
  • Page 745 5.Engine UXV 500i/700i Camshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the cam chain tensioner sealing bolt with a 10 mm socket. 5-32...
  • Page 746 5.Engine UXV 500i/700i Remove the two cam chain tensioner bolts with an 8 mm socket. Remove the cam chain tensioner and gasket. 5-33...
  • Page 747 5.Engine UXV 500i/700i Flatten tabs on the camshaft sprocket retaining washer with a punch and hammer. Make sure the cam chain is taught if the crankshaft needs to be rotated while the cam chain tensioner is removed. 5-34...
  • Page 748 5.Engine UXV 500i/700i Remove the two camshaft sprocket bolts with a 10 mm socket. Remove the camshaft sprocket retaining washer. 5-35...
  • Page 749 5.Engine UXV 500i/700i Push the camshaft C-ring out with an awl. Remove the C-ring. Do not drop the C-ring into the crankcase. Free the cam chain from the camshaft sprocket. Slide the camshaft sprocket off of the camshaft. 5-36...
  • Page 750 5.Engine UXV 500i/700i Remove the camshaft and sprocket. Secure the cam chain with a piece of wire to keep if from falling into the bottom end of the engine. 5-37...
  • Page 751 5.Engine UXV 500i/700i Inspection Inspect the camshaft lobes and journals wear and damage. If there are signs of damage or discoloration inspect the lubrication system. 5-38...
  • Page 752 5.Engine UXV 500i/700i Measure the maximum height of the cam lobes with a micrometer. Item Standard mm (in) 37.9809 (1.4953) Camshaft cam height 37.3412 (1.4701) 5-39...
  • Page 753 5.Engine UXV 500i/700i Place the camshaft on V Blocks and measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the maximum. Item Standard mm (in) Service Limit Camshaft runout 0.05 (0.002) The camshaft is equipped with a decompression system. This serves to slightly open the exhaust valve and lower the engine compression for starting.
  • Page 754 5.Engine UXV 500i/700i Check the camshaft sprocket for wear and damage. Check that the cam chain tensioner is functioning properly. Use a flat blade screwdriver to wind back the rod. Make sure the push rod slides out smoothly when the locking mechanism is released.
  • Page 755 5.Engine UXV 500i/700i Camshaft Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Installation Align the "T" mark on the flywheel with the index mark on the crankcase cover. This shows the piston is at Top Dead Center (TDC). For more information on setting the piston to TDC see the Rocker Cover topic.
  • Page 756 5.Engine UXV 500i/700i Fit the camshaft into place with its lobes facing down. Do not fit the sprocket onto the camshaft until the engine timing is correct. The marks on the end of the camshaft should be level with the rocker cover mating surface. 5-43...
  • Page 757 5.Engine UXV 500i/700i Fit the sprocket onto the camshaft. Install the C-ring into the groove in the cylinder head. Make sure the C-ring stays in place if the camshaft rotates. It can fall out if the camshaft is rotated when the rocker cover is off. Install the new camshaft sprocket retaining washer over the sprocket pin.
  • Page 758 5.Engine UXV 500i/700i Apply a thread locking agent (Red Loctite #271) to the threads of the camshaft sprocket bolts. Tighten the camshaft sprocket bolts to specification with a 10 mm socket. TORQUE VALUES ITEM THREAD SIZE AND TYPE ft-lb SPECIAL BOLT SPROCKET CAMSHAFT 10.8-14.7 8-10.8...
  • Page 759 5.Engine UXV 500i/700i Bend the tabs of the retaining washer against the camshaft sprocket bolts with a punch and a hammer. 5-46...
  • Page 760 5.Engine UXV 500i/700i Cam Chain Tensioner Make sure the cam chain tensioner mating surface is clean. Install a new gasket with the cam chain tensioner. Use a small flat blade screwdriver to wind in the cam chain tensioner rod. Hold the screwdriver in place until both tensioner mounting bolts have been installed.
  • Page 761 5.Engine UXV 500i/700i Install the two cam chain tensioner mounting bolts and tighten them to specification with an 8 mm socket. Release the screwdriver so the tensioner rod will extend. TORQUE VALUES ITEM THREAD SIZE AND TYPE ft-lb TENSIONER LIFTER SHF M6 x 1.0 9.8-13.7 7.2-10.1...
  • Page 762 5.Engine UXV 500i/700i Turn the engine over and double check the cam timing. When the "T" mark on the flywheel is aligned in the timing hole the marks on the end of the camshaft should be level with the rocker cover mating surface. Make sure the C-ring stays in place if the camshaft rotates. It can fall out if the camshaft is rotated when the rocker cover is off.
  • Page 763 5.Engine UXV 500i/700i Cylinder Head SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Push in the spring and unplug the WTS sensor connector. Squeeze the clamp on the air bleed hose and slide it back. Loosen the coolant hose clamp with a #2 Phillips screwdriver.
  • Page 764 5.Engine UXV 500i/700i To remove the WTS housing remove the two bolts with an 8 mm socket. Remove the WTS housing from the cylinder head. Discard the WTS housing gasket. 5-51...
  • Page 765 5.Engine UXV 500i/700i Remove the three nuts under the cylinder head with a 12 mm wrench. Loosen the two long cylinder head bolts with an 8 mm socket. Loosen the larger diameter cylinder head bolt with a 12 mm socket. Remove the three cylinder head bolts.
  • Page 766 5.Engine UXV 500i/700i There are four large cylinder head nuts. Loosen the large cylinder head nuts evenly and in a crisscross pattern with a 14 mm socket. Remove the cylinder head nuts and washers. 5-53...
  • Page 767 5.Engine UXV 500i/700i Tap the reinforced areas of the cylinder head with a rubber mallet to free the dowel pins. Lift off the cylinder head. Guide the cam chain through the opening, but do not allow it to fall into the bottom end of the engine. 5-54...
  • Page 768 5.Engine UXV 500i/700i Remove the cylinder head gasket. Remove the two cylinder head dowel pins. 5-55...
  • Page 769 5.Engine UXV 500i/700i Lift out the front cam chain guide. Secure the cam chain so that it doesn't fall into the bottom end of the engine. To remove the valves see the Valves topic. 5-56...
  • Page 770 5.Engine UXV 500i/700i Inspection Inspect the cam chain guide for wear an damage. Replace the guide as needed. Clean the combustion chamber with contact cleaner, a plastic knife, brush and/or rag. Take care to only remove carbon and not scrape the head. Check the spark plug hole and threads for damage.
  • Page 771 5.Engine UXV 500i/700i Place a straight edge on the deck of the cylinder head and check for cylinder head warp with a feeler gauge. Cylinder head warpage limit 0.05 mm (0.002 in) Check for warp in several places on the head. If the cylinder head is warped it must be resurfaced by a qualified machine shop or replaced.
  • Page 772 5.Engine UXV 500i/700i Installation Install the front cam chain guide into the cylinder as shown. Keep tension on the cam chain to keep it out of the way while inserting the cam chain guide. Make sure the bottom of the cam chain guide fits securely in the crankcase boss. Install the two cylinder head dowel pins.
  • Page 773 5.Engine UXV 500i/700i Fit a new cylinder head gasket into place as shown. Install the cylinder head to the cylinder. Guide the cam chain and cam chain guides though the opening in the cylinder head. Remember to keep the cam chain from falling into the bottom end of the engine.
  • Page 774 5.Engine UXV 500i/700i Apply fresh engine oil to the threads and washers of the cylinder head nuts. Install the four cylinder head nuts with washers and torqu them to specification with a 14 mm socket. TORQUE VALUES THREAD SIZE AND TYPE REMARKS ft-lb NUT M10 x 1.0...
  • Page 775 5.Engine UXV 500i/700i Apply fresh engine oil to the threads of the three cylinder head bolts. Install the three cylinder head bolts. Tighten the cylinder head bolts to specification. TORQUE VALUES THREAD SIZE AND TYPE REMARKS ft-lb BOLT M6 x 1.0 11.8 APPLY OIL BOLT M8 x 1.25...
  • Page 776 5.Engine UXV 500i/700i Apply fresh engine oil to the threads of the cylinder head nuts. Install the three nuts under the cylinder head and tighten them to specification with a 12 mm wrench. TORQUE VALUES THREAD SIZE AND TYPE REMARKS ft-lb NUT M8 x 1.25 24.5±...
  • Page 777 5.Engine UXV 500i/700i Connect the air bleed hose and thermostat hose to the WTS housing. Secure the hoses with the clamps. Plug in the WTS sensor connector. 5-64...
  • Page 778 5.Engine UXV 500i/700i Valves SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note the location of all of the valve parts so that they can be returned to their original positions. Remove all of the valves in the same manner. Use a valve spring compressor to remove the valves.
  • Page 779 5.Engine UXV 500i/700i Compress the valve springs only enough to remove the cotters. Remove the cotters from the valve stem with tweezers or a magnet. 5-66...
  • Page 780 5.Engine UXV 500i/700i Remove the spring retainer. Lift out the outer and inner valve springs. Outer Valve Spring Length Inner Valve Spring Length 43 mm 37.5 mm 5-67...
  • Page 781 5.Engine UXV 500i/700i Push the valve out through the bottom of the cylinder head. Remove the stem seal with needle nose pliers and a pick. Discard old stem seals. 5-68...
  • Page 782 5.Engine UXV 500i/700i Remove the spring seat. 5-69...
  • Page 783 5.Engine UXV 500i/700i Inspection Caution: If valves are discolored or pitted or If the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur. If valves, valve guides, or valve seats require servicing this should be completed by a qualified machine shop.
  • Page 784 5.Engine UXV 500i/700i Inspect the valve for damage. Measure the valve stem diameter with a micrometer or vernier calipers and compare the measurements with specification. Replace any valves that do not meet the standard. Item Standard mm (in) 5.975 - 5.99 (0.235 - 0.2358) Valve stem O.D.
  • Page 785 5.Engine UXV 500i/700i Measure the inside diameter of the valve guides. Replace the guides if the measurement is out of specification. Calculate the valve stem-to-guide clearance. Replace the guide and valve if the clearance is out of specification. Item Standard mm (in) 6 - 6.012 (0.2362 - 0.2367) Valve guide I.D.
  • Page 786 5.Engine UXV 500i/700i Assembly Make sure to return the components to their original locations. Install the spring seat. Lubricate the new valve stem seals with fresh engine oil. Install new valve stem seals. Push the seals straight onto the guide. 5-73...
  • Page 787 5.Engine UXV 500i/700i Coat the valve stem and end in fresh engine oil. Insert the valve through the valve guide. Twist the valve slowly to work it through the stem seal without damaging the seal. The valve should move smoothly in the guide and make good contact with the seat. Install the valve springs with their tightly spaced coils facing down.
  • Page 788 5.Engine UXV 500i/700i Install the spring retainer. Use a valve spring compressor to install the cotters. Compress the valve springs only enough to install the cotters. Special Tools- Valve Spring Compressor: A120E00040 5-75...
  • Page 789 5.Engine UXV 500i/700i Apply grease to the inside of the cotters. Apply a dab of grease to the end of a flat blade screwdriver. Set the keeper in the grease on the screwdriver and insert it onto the valve stem. Repeat this with the other keeper. After the valves have been reassemble place a clean shop towel under the cylinder head in the combustion chamber area.
  • Page 790 5.Engine UXV 500i/700i Cam Chain SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the intake side cam chain guide bolt. Remove the intake side cam chain guide from above. Inspect the cam chain guide for excessive wear and damage. 5-77...

  • Page 791: Cam Chain

    5.Engine UXV 500i/700i Remove the cam chain. Inspect the cam chain for kinking, sticking, fatigue, and damage. Replace the cam chain as needed. 5-78...
  • Page 792 5.Engine UXV 500i/700i Installation Fit the cam chain into place on the timing sprocket located on the crankshaft. 5-79...
  • Page 793 5.Engine UXV 500i/700i Install the intake side cam chain guide and bolt. Tighten the bolt to specification. ITEM kgf-m ft-lb Cam chain guide pivot bolt 5-80...
  • Page 794 5.Engine UXV 500i/700i Cylinder and Piston SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Loosen the cylinder coolant hose clamp with a #2 Phillips screwdriver. Free the coolant hose from the cylinder. Gently tap the cylinder with a rubber mallet to free it from the dowel pins. 5-81...
  • Page 795 5.Engine UXV 500i/700i Lift the cylinder up and off of the crankcases. Guide the cam chain through its opening in the cylinder. Make sure the cam chain and dowel pins do not fall into the bottom end of the engine. Lift off the base gasket.
  • Page 796 5.Engine UXV 500i/700i Remove the two dowel pins. Place a clean shop towel around the base of the piston to prevent any parts or debris from falling into the crankcase. Remove the piston pin clip with a pick or needle nose pliers. Remove both piston pin clips and discard them.
  • Page 797 5.Engine UXV 500i/700i Slide out the piston pin. Use a suitable piston pin puller tool if needed. Do not use a punch and a hammer to remove the pin. Remove the piston. Clean off the cylinder mating surface, but take care to keep debris from falling into the crankcase.
  • Page 798 5.Engine UXV 500i/700i Spread the piston rings and lift them off opposite the gap. Spread the rings the minimum amount during removal. The rings can be easily damaged. There is a top ring, second ring, and oil expander ring with two side rails. Clean out the ring grooves.
  • Page 799 5.Engine UXV 500i/700i Inspection Cylinder Warp Test for cylinder warp with a straight edge and a feeler gauge. Try and insert the feeler gauge of the service limit under the straight edge. Place the straight edge in several places on the head. Item Service Limit Cylinder warpage across top...
  • Page 800 5.Engine UXV 500i/700i Piston Diameter Measure the diameter of the piston 10 mm (A) up from the bottom of the skirt at a 90° angle to the piston pin. Measure the piston with a micrometer. Replace the piston if the measurement is out of specification.
  • Page 801 5.Engine UXV 500i/700i Cylinder Bore Inspect the cylinder and measure side to side at three different height levels with a dial bore gauge or cylinder gauge set. 5-88...
  • Page 802 5.Engine UXV 500i/700i Subtract the diameter of the piston from the maximum front to rear diameter measurement of the cylinder to calculate the piston-to-cylinder clearance. Calculate the cylinder out of round. The out of round is greatest out of yellow, purple, or brown minus the smallest of blue, red, or green.
  • Page 803 5.Engine UXV 500i/700i Piston Ring Groove Width and Ring-to-Groove Clearance Check the ring groove width and ring-to-groove clearance with a feeler gauge. Make sure the ring is in the correct grove. Replace the piston if the ring groove width is out of specification.
  • Page 804 5.Engine UXV 500i/700i Piston Ring End Gap Insert the top ring into the cylinder. Push the top ring in the cylinder. Use the piston to push in the ring to keep it square with the cylinder. 5-91...
  • Page 805 5.Engine UXV 500i/700i Measure the ring gap with a feeler gauge. Repeat this procedure with second ring. Item Standard mm (in) Service Limit 0.25 - 0.35 (0.0098 - 0.0138) 0.5 (0.02) Ring end gap Second 0.7 - 0.9 (0.0276 - 0.0354) Oil side rail 0.2 - 0.7 (0.008 - 0.028) 1 (0.04)
  • Page 806 5.Engine UXV 500i/700i Piston Pin O.D. Measure the piston pin outside diameter with a micrometer. Measure in several locations to insure an accurate measurement. Piston pin O.D. 22.997 - 23 mm(0.9053 - 0.9055 in) 5-93...
  • Page 807 5.Engine UXV 500i/700i Piston Pin Bore I.D. Measure the piston pin bore diameter with vernier calipers or dial gauge with a small bore gauge. Measure in several spots to insure an accurate measurement. Item Standard mm (in) Service Limit Piston pin hole I.D. 23.006 - 23.012 (0.9057 - 0.9060) 23.04 (0.9071) 5-94...
  • Page 808 5.Engine UXV 500i/700i Connecting Rod Small End Measure the inside diameter of the small end of the connecting rod. If the small end of the connecting rod is out of specification the crankshaft and rod must be replaced. Item Standard mm (in) Service Limit Connecting rod small end I.D.
  • Page 809 5.Engine UXV 500i/700i Assembly Clean the piston ring grooves, and apply fresh engine oil to the piston rings. Spread the rings the minimum amount possible to install them. Install the oil ring first then the steel rails above and below the oil ring. Install the rings with their markings facing up.
  • Page 810 5.Engine UXV 500i/700i Position the ring end gaps as shown above. Caution: Incorrect installation of the piston rings will result in engine damage. 5-97...
  • Page 811 5.Engine UXV 500i/700i Lubricate the piston pin and the small end of the connecting rod with fresh engine oil. Install the piston onto the connecting rod. The IN marks on the piston must sit on the intake side of the engine. 5-98...
  • Page 812 5.Engine UXV 500i/700i Insert the piston pin. Place a clean shop towel around the base of the piston to prevent any parts or debris from falling into the crankcase. Install new piston pin clips securely into their grooves. 5-99...
  • Page 813 5.Engine UXV 500i/700i Make sure the piston pin clips sit with their turned out end in the gap as shown. Make sure the cylinder mating area is clean. Install the two dowel pins. 5-100...
  • Page 814 5.Engine UXV 500i/700i Install the new base gasket. Coat the inside of the cylinder, piston rings, and piston in fresh engine oil. Lower the cylinder into place and guide the piston into the cylinder while you are compressing the rings with your fingers. Be careful to not damage the rings during this step. Bring the cam chain through the opening.
  • Page 815 5.Engine UXV 500i/700i Connect the coolant hose to the cylinder. Tighten the cylinder coolant hose clamp securely with a #2 Phillips screwdriver. 5-102...

  • Page 816: Generator Cover

    5.Engine UXV 500i/700i Generator Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Trace the wires up from the generator cover. Unplug the 4-pin stator connector. Unplug the 2-pin ignition pulse generator / crank position sensor connector. Remove the crankshaft cap on the left side of the engine with a 10 mm Allen socket.
  • Page 817 5.Engine UXV 500i/700i Loosen the generator cover bolts evenly in a crisscross pattern with an 8 mm socket. Remove the generator cover bolts. 5-104...
  • Page 818 5.Engine UXV 500i/700i Hold the drive pulley with a drive pulley holder tool so the crankshaft doesn't turn. See the CVT Removal topic for more information. Loosen the flywheel nut with a socket. Remove the flywheel nut and washer. 5-105...
  • Page 819 5.Engine UXV 500i/700i Utilize the pry points to free the generator cover from the crankcase. 5-106...
  • Page 820 5.Engine UXV 500i/700i Remove the generator cover. Remove the dowel pins. Remove the generator cover gasket. 5-107...
  • Page 821 5.Engine UXV 500i/700i Remove the boss from the bearing in the generator cover. Inspect the boss and oil ring for wear and damage. Replace them as needed. 5-108...
  • Page 822 5.Engine UXV 500i/700i Stator and Crank Position Sensor The stator and crank position sensor must be removed together. Remove the three stator coil mounting bolts with an 8 mm socket. Remove the two crank position sensor bolts and wire guide bolt with an 8 mm socket. 5-109...
  • Page 823 5.Engine UXV 500i/700i Free the crank position sensor and rubber wire grommet from the generator cover. Lift out the stator and ignition pulse generator together. To remove the flywheel see the Flywheel topic 5-110...
  • Page 824 5.Engine UXV 500i/700i Bearing Insect the bearing in the generator cover. If the bearings in the generator cover needs to be replaced remove the snap ring. Drive out the old bearing from the outside. 5-111...
  • Page 825 5.Engine UXV 500i/700i Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing. Make sure the bearing is fully seated and square in the cover. Install a new snap ring into the groove with snap ring pliers. 5-112...
  • Page 826 5.Engine UXV 500i/700i Installation Stator and Ignition Pulse Generator Fit the stator and ignition pulse generator into the cover together. 5-113...
  • Page 827 5.Engine UXV 500i/700i Install the three stator coil mounting bolts and tighten them securely with an 8 mm socket. Install the two ignition pulse generator bolts. Tighten them securely with an 8 mm socket. Apply silicone sealant to the wire grommet and fit it into the groove in the cover. 5-114...
  • Page 828 5.Engine UXV 500i/700i Generator Cover Make sure the generator cover mating surface is clean and free of the old gasket material. Lubricate the bearing and the ring of the boss with fresh engine oil Fit the boss into the cover and bearing from the outside. 5-115...
  • Page 829 5.Engine UXV 500i/700i Install the two dowel pins and a new generator cover gasket. Fit the generator cover into place. Rotate the water pump impeller to line up the slot in the shaft with the projection on the oil pump. 5-116...
  • Page 830 5.Engine UXV 500i/700i Place the washer on the crankshaft and thread on the nut. Thread in the generator cover bolts. Install the wire clamp with the top bolt. 5-117...
  • Page 831 5.Engine UXV 500i/700i Hold the drive pulley with a drive pulley holder tool so the crankshaft doesn't turn. See the CVT Removal topic for more information. Tighten the generator flywheel nut to specification. TORQUE VALUES ITEM THREAD SIZE AND TYPE ft-lb ACG FLYWHEEL N.F.
  • Page 832 5.Engine UXV 500i/700i Install the crankshaft cap. Tighten the crankshaft cap securely with a 10 mm Allen socket. Do not over tighten this cap. 5-119...
  • Page 833 5.Engine UXV 500i/700i Plug in the 4-pin stator connector. Plug in the 2-pin ignition pulse generator / crank position sensor connector. 5-120...
  • Page 834 5.Engine UXV 500i/700i Flywheel SAFETY FIRST: Protective gloves and eyewear are recommended at this point. To remove the flywheel a special flywheel puller tool will be needed. Special Tool- Flywheel Puller: E073 Install the thread protector onto the crankshaft. Apply grease to the threads of the flywheel puller. Thread the puller onto the flywheel. 5-121...
  • Page 835 5.Engine UXV 500i/700i Hold the body of the puller with a large wrench and turn in the pusher bolt to separate the flywheel from the crankshaft. Remove the flywheel from the crankshaft. 5-122...
  • Page 836 5.Engine UXV 500i/700i Remove the woodruff key from the crankshaft. Remove the starter driven gear from the crankshaft. 5-123...
  • Page 837 5.Engine UXV 500i/700i Starter Clutch The starter clutch is on the back of the flywheel. Rotate the starter driven gear and fit in into the starter clutch as shown. Inspect the function of the starter clutch by turning the starter driven gear. The starter driven gear should only be able to rotate one direction.
  • Page 838 5.Engine UXV 500i/700i Rotate the starter gear and remove it from the starter clutch on the back of the flywheel. Inspect the starter driven gear for wear and damage. There are six bolts that hold the starter clutch to the back of the flywheel. Remove the starter clutch bolts from the outside of the flywheel with a 6 mm Allen.
  • Page 839 5.Engine UXV 500i/700i Remove the starter clutch and mounting plate from the back of the flywheel. Remove the starter clutch from the mounting plate. 5-126...
  • Page 840 5.Engine UXV 500i/700i Starter Reduction Gear Remove the starter reduction gear from the crankcase. Inspect the starter reduction gear components for wear and damage. Replace the parts as a needed. 5-127...
  • Page 841 5.Engine UXV 500i/700i Installation Starter Clutch Fit the starter clutch into the mounting plate. Place the starter clutch and mounting plate on the back of the flywheel. 5-128...
  • Page 842 5.Engine UXV 500i/700i Apply a thread locking agent to the threads of the six starter clutch bolts. Insert the starter clutch bolts. Tighten the starter clutch bolts evenly and securely with a 6 mm Allen. TORQUE VALUES ITEM THREAD SIZE AND TYPE REMARKS ft-lb ACG ONE WAY...
  • Page 843 5.Engine UXV 500i/700i Starter Reduction Gear Lubricate the starter reduction gear shaft with fresh engine oil. Install the starter reduction gear into the crankcase as shown. 5-130...

  • Page 844: Flywheel

    5.Engine UXV 500i/700i Flywheel Lubricate the starter driven gear boss and inside diameter with fresh engine oil. Install the starter driven gear onto the crankshaft. 5-131...
  • Page 845 5.Engine UXV 500i/700i Install the woodruff key into the crankshaft. Make sure the tapered area of the crankshaft is clean, oil free, and dry. Guide the flywheel onto the crankshaft make sure the key lines up with the groove in the flywheel.
  • Page 846 5.Engine UXV 500i/700i Clutch Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the CVT belt case cover. See the Belt Case Cover topic for more information. Remove the CVT pulleys and belt. See the CVT Removal topic for more information.
  • Page 847 5.Engine UXV 500i/700i Remove the CVT fan cover. Loosen the 9 clutch cover bolts a little bit at a time and in a crisscross pattern. 5-134...
  • Page 848 5.Engine UXV 500i/700i Remove the clutch cover bolts. Remove the clutch cover assembly evenly. 5-135...
  • Page 849 5.Engine UXV 500i/700i Remove the two dowel pins and the clutch cover gasket. 5-136...
  • Page 850 5.Engine UXV 500i/700i Free the stake on the clutch nut with a chisel and a hammer. Hold the clutch with the Y-type holder and loosen the clutch nut with a commercially available 26 mm deep well socket. Special Tool - Y-Type Holder: A120E00056 Lock Nut Wrench: A120E00079 5-137...
  • Page 851 5.Engine UXV 500i/700i Remove the clutch nut. Slide off the outer clutch collar. 5-138...
  • Page 852 5.Engine UXV 500i/700i Slide the clutch assembly off of the crankshaft. Slide off the inner clutch collar. 5-139...
  • Page 853 5.Engine UXV 500i/700i Inspection Remove the clutch outer and drive pulley shaft from the clutch cover. To check the one-way clutch in the clutch outer temporarily install the clutch and set the clutch outer in place without the cover. 5-140...
  • Page 854 5.Engine UXV 500i/700i When turning the clutch outer clockwise, the clutch outer should turn freely. If not, the one-way clutch assembly is faulty and should be replaced. When turning the clutch outer counterclockwise, the clutch outer and crankshaft should engaged by the one-way clutch. If not, the one-way clutch assembly is faulty and should be replaced.
  • Page 855 5.Engine UXV 500i/700i Inspect the inside of the clutch outer and needle bearing for wear and damage. Replace the components as needed. If the needle bearing is in poor condition remove the snap ring and replace the bearing. Press in a new bearing and secure it with a new snap ring. Make sure the snap ring is secure in its groove.
  • Page 856 5.Engine UXV 500i/700i Check the clutch linings for abnormal wear and damage. Replace the clutch if the lining thickness is below 1 mm (0.04 in). 5-143...
  • Page 857 5.Engine UXV 500i/700i Inspect the clutch bearing by turning it with a finger. Replace the bearing if it doesn't turn smoothly or it has excessive play. Inspect the clutch cover oil seal and replace it as needed. 5-144...
  • Page 858 5.Engine UXV 500i/700i Inspect the large ball bearing in the clutch cover. Turn the bearing with a finger. Replace the bearing if it doesn't turn smoothly. Remove the seal cover to replace the bearing. Remove the four seal cover bolts with an 8 mm socket. Take off the seal cover and discard the gasket.
  • Page 859 5.Engine UXV 500i/700i Drive the bearing out from the outside of the clutch cover. Drive in the new bearing from the inside of the clutch cover. Use a suitable driver that is the same outside diameter as the bearing. The manufactures markings on the bearing must face out. Press a new seal into the seal cover.
  • Page 860 5.Engine UXV 500i/700i Apply a light coat lightweight lithium-soap based grease to the lips of the oil seal. For clutch assembly and installation see the Clutch Installation topic for more information. Install the CVT belt case cover. See the Belt Case Cover topic for more information.

  • Page 861: Oil Pump

    5.Engine UXV 500i/700i Oil Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The oil pump is gear is driven by a chain from the crankshaft. Remove the two oil pump chain guide bolts. 5-148...
  • Page 862 5.Engine UXV 500i/700i Remove the oil pump chain guide. Inspect the chain guide for wear and damage. 5-149...
  • Page 863 5.Engine UXV 500i/700i Remove the three oil pump cover bolts with an 8 mm socket. 5-150...
  • Page 864 5.Engine UXV 500i/700i Remove the oil pump cover. Remove the snap ring with snap ring pliers. 5-151...
  • Page 865 5.Engine UXV 500i/700i Slide the oil pump sprocket off of the oil pump shaft. Free the oil pump chain from the crankshaft and remove the oil pump sprocket and chain. 5-152...
  • Page 866 5.Engine UXV 500i/700i Remove the oil pump shaft holder bolt with an 8 mm socket. Remove the oil pump shaft holder. Remove the two oil pump shaft holder dowel pins. 5-153...
  • Page 867 5.Engine UXV 500i/700i Remove the two oil pump bolts with an 8 mm socket. 5-154...
  • Page 868 5.Engine UXV 500i/700i Remove the oil pump. Turn the oil pump shaft and make sure it turns smoothly. Remove the oil pump gasket. 5-155...
  • Page 869 5.Engine UXV 500i/700i Disassembly Slide the oil pump shaft out of the oil pump. 5-156...
  • Page 870 5.Engine UXV 500i/700i Remove the oil pump cover screw. Remove the oil pump cover. 5-157...
  • Page 871 5.Engine UXV 500i/700i Remove the oil pump dowel pin. Remove the inner and outer oil pump rotors. 5-158...
  • Page 872 5.Engine UXV 500i/700i Inspection Check the oil pump chain guide for signs of excessive wear and damage. Replace it as needed. Inspect the oil pump chain and sprocket for excessive wear and damage. Replace these components as needed. 5-159...
  • Page 873 5.Engine UXV 500i/700i Use a feeler gauge set to check the clearance between the outer oil pump rotor and the body (body clearance). Use a feeler gauge set to check the clearance between the inner and outer rotors (tip clearance). 5-160...
  • Page 874 5.Engine UXV 500i/700i Place a straight edge across the oil pump body and rotors. Check the side clearance with a feeler gauge. ITEM STANDARD mm (in) SERVICE LIMIT Tip clearance 0.15 (0.006) max 0.2 (0.008) Oil pump rotor Body clearance 0.15 - 0.2 (0.006 - 0.008) 0.25 (0.01) Side clearance...
  • Page 875 5.Engine UXV 500i/700i Assembly Lubricate the rotating parts in fresh engine oil. Fit the outer and inner rotors into the oil pump body. Install the oil pump dowel pin. 5-162...
  • Page 876 5.Engine UXV 500i/700i Install the oil pump cover. 5-163...
  • Page 877 5.Engine UXV 500i/700i Install the oil pump cover screw and tighten it to specification with a #2 Phillips screwdriver. ITEM kgf-m ft-lb Oil pump screw Slide the oil pump shaft into the oil pump. 5-164...
  • Page 878 5.Engine UXV 500i/700i Installation Fit the oil pump into place with the arrow pointing up. Insert the two oil pump mounting bolts and tighten them securely 5-165...
  • Page 879 5.Engine UXV 500i/700i Turn the oil pump shaft and make sure it turns smoothly. Install the two oil pump shaft holder dowel pins. 5-166...
  • Page 880 5.Engine UXV 500i/700i Fit the oil pump shaft holder into place. Install the oil pump shaft holder bolt. Do not tighten, yet. 5-167...
  • Page 881 5.Engine UXV 500i/700i Fit the oil pump sprocket and chain into place. Engage the chain to its drive sprocket on the crankshaft. Fit the oil pump sprocket onto the oil pump shaft. 5-168...
  • Page 882 5.Engine UXV 500i/700i Install the new snap ring with snap ring pliers. Install the oil separator and the two mounting bolts. Tighten the oil pump holder shaft bolt and two oil separator mounting bolts securely with an 8 mm socket. Tighten the bolts evenly in a crisscross pattern. 5-169...
  • Page 883 5.Engine UXV 500i/700i Fit the oil pump chain guide into place. 5-170...
  • Page 884 5.Engine UXV 500i/700i Install the two oil pump chain guide bolts and tighten them securely with an 8 mm socket. 5-171...
  • Page 885 5.Engine UXV 500i/700i Crankcase SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Splitting Remove the gear position indicator switch bolt with an 8 mm socket. Remove the gear position indicator switch. Note its position so that it can be returned to its original orientation.
  • Page 886 5.Engine UXV 500i/700i Remove the shift arm bolt with a 10 mm socket. Remove the shift arm from the shift shaft. Loosen the shift cam stopper plug with a 14 mm socket. 5-173...
  • Page 887 5.Engine UXV 500i/700i Remove the stopper plug, washer, spring, and stopper ball. Inspect the shift cam stopper components and replace them as needed. 5-174...
  • Page 888 5.Engine UXV 500i/700i Remove the four bolts from the CVT side of the crankcase with an 8 and 12 mm socket. 5-175...
  • Page 889 5.Engine UXV 500i/700i Loosen the generator side crankcase bolts evenly and in a crisscross pattern. 5-176...
  • Page 890 5.Engine UXV 500i/700i Remove the generator side crankcase bolts with an 8 mm and 12 mm socket. Utilize the pry points to separate the halves of the crankcases. Do not place a screwdriver or pry bar against the mating surfaces of the crankcases. 5-177...
  • Page 891 5.Engine UXV 500i/700i Lift the generator half of the crankcase off the CVT side of the crankcase. Remove the two dowel pins from the crankcase. Remove the old crankcase gasket material. To remove the crankshaft and balancer see the Crankshaft topic.
  • Page 892 5.Engine UXV 500i/700i Oil Relief Valve and Oil Pipe The oil relief valve is located in the crankcase. If it is necessary, remove the oil pipe; Remove the two bolts, washers (on the oil pipe), oil pipe and washers (under oil pipe). 5-179...
  • Page 893 5.Engine UXV 500i/700i Remove the oil relief valve from the crankcase. Push in on the oil relief valve piston and make sure it moves smoothly. Replace it if it sticks or refuses to move. 5-180...
  • Page 894 5.Engine UXV 500i/700i Discard the O-ring and replace it with a new item. Apply fresh engine oil to the new O-ring. Fit the oil relief valve into place in the crankcase. 5-181...
  • Page 895 5.Engine UXV 500i/700i Assembly Make sure the crankcase mating surfaces are clean. Install the inner washers on the right crankcase. Install the oil pipe with the thick side face upward. Apply clean engine oil to the bolts, then install the outer washers and two bolts. Tighten the two bolts to the specified torque.
  • Page 896 5.Engine UXV 500i/700i Install the two dowel pins into the left crankcase half. Apply Threebond 1215 or other equivalent sealant to the crankcase mating surface. Do not allow the sealant to get into oil passages or bearings. The crankcases must be joined in a few minutes or the sealant will not function correctly. 5-183...
  • Page 897 5.Engine UXV 500i/700i Fit the generator side crankcase half onto the CVT crankcase half. Make sure the shafts line up correctly. Watch the shift shaft and make sure it doesn't push out or roll up its oil seal when the cases are joined. 5-184...
  • Page 898 5.Engine UXV 500i/700i Lubricate the threads of the crankcase bolts with oil. Insert the generator side crankcase bolts. Tighten the bolts evenly and in a crisscross pattern. Torque the generator side crankcase bolts to specification with an 8 mm and 12 mm socket. TORQUE VALUES ITEM THREAD SIZE AND TYPE...
  • Page 899 5.Engine UXV 500i/700i Install the four crankcase bolts into the CVT side of the crankcase with an 8 and 12 mm socket. TORQUE VALUES ITEM THREAD SIZE AND TYPE REMARKS ft-lb M6 x 1.0 11.8 APPLY OIL M6 x 1.0 11.8 APPLY OIL CRANKCASE SET...
  • Page 900 5.Engine UXV 500i/700i Use a new sealing washer with the shift cam stopper plug. Install the stopper plug, washer, spring, and stopper ball. 5-187...
  • Page 901 5.Engine UXV 500i/700i Tighten the stopper plug to specification with a 14 mm socket. ITEM kgf-m ft-lb Shift cam stopper plug Install the shift arm to the shift shaft. Install the shaft arm bolt and tighten it securely with a 10 mm socket. 5-188...
  • Page 902 5.Engine UXV 500i/700i Install a new O-ring to the gear position indicator switch if needed. Lubricate the O-ring with fresh engine oil. Install the gear position indicator switch. Install the gear position indicator switch bolt and tighten it securely with an 8 mm socket. Install the remaining engine components and return the engine to the frame.

  • Page 903: Crankcase Bearings

    5.Engine UXV 500i/700i Crankcase Bearings SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Inspect the crankcase bearings. Turn the bearings with a finger. They should turn freely with out noise or binding, but also without excessive play. Make sure the outer races of the bearings are secure in the crankcase.
  • Page 904 5.Engine UXV 500i/700i Replacement Place the new bearing in the freezer at least a half hour before you plan to install them. Remove the bearings with a suitable bearing puller. Special Tool - Bearing Puller: A120E00037 5-191...
  • Page 905 5.Engine UXV 500i/700i To replace the drive shaft bearing first remove the set plates. Remove the set plate bolts with a 6 mm Allen. Install the bearing set plates after the bearing has been replaced and tighten new bolts securely with a 6 mm Allen. Replace the oil seal if its bearing is to be replaced.
  • Page 906 5.Engine UXV 500i/700i Drive in the new bearings with a suitable bearing driver that has the same outside diameter of the bearing. The manufactures markings on the bearing must face out. Special Tool - Bearing Driver: A120E00014 5-193...

  • Page 907: Crankshaft

    5.Engine UXV 500i/700i Crankshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Split the crankcases. See the crankcase Crankcase topic for more information. Remove the transmission. See the Transmission Removal topic for more information. Remove the crankshaft and balancer shaft together. 5-194...
  • Page 908 5.Engine UXV 500i/700i Inspection Inspect the balancer shaft for wear and damage. Inspect the crankshaft for wear or damage. Turn the crank bearings with a finger and make sure they turn smoothly. Replace the crankshaft if the bearings are faulty. 5-195...
  • Page 909 5.Engine UXV 500i/700i Measure the inside diameter of the small end of the connecting rod. Item Standard mm (in) Service Limit Connecting rod small end I.D. bore 22.016 - 22.034 (0.8806 - 0.8814) 22.06 (0.8824) 5-196...
  • Page 910 5.Engine UXV 500i/700i Place the crankshaft on V-blocks and measure the runout on each side with a dial gauge. Check the side to side movement of the small end of the connecting rod. Replace the crankshaft if it is out of specification. Item Standard mm (in) Service Limit...
  • Page 911 5.Engine UXV 500i/700i Check the side clearance of the big end of the connecting rod with a feeler gauge. Service Item Standard mm (in) Limit Not USA 0.01 - 0.4 (0.002 - 0.6 (0.024) type 0.016) Connecting rod big end side Crankshaft clearance 0.3 - 0.6 (0.012 -...
  • Page 912 5.Engine UXV 500i/700i Inspect the radial clearance of the big end of the connecting rod with a dial gauge. Item Standard mm (in) Service Limit Connecting rod big end radial clearance 0 - 0.008 (0 - 0.00032) 0.05 (0.002) 5-199...
  • Page 913 5.Engine UXV 500i/700i Installation Lubricate the crankshaft and balancer bearings with fresh engine oil. Fit the crank and balancer shafts into the crankcase together. 5-200...
  • Page 914 5.Engine UXV 500i/700i The line on the balancer sprocket must align with the line on the crankshaft. Install the transmission. See the Transmission Installation topic for more information. Assemble the crankcases. See the Crankcase topic for more information. 5-201...

  • Page 915: Transmission Removal

    5.Engine UXV 500i/700i Transmission Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Split the crankcases. See the Crankcase topic for more information. Remove the shift shaft. Remove the transmission guide bar. Remove the upper and lower shift forks. 5-202...
  • Page 916 5.Engine UXV 500i/700i Remove the shift cam. Remove the transmission shafts together from the crankcase. To disassemble the transmission shafts see the Transmission Shafts topic for more information. 5-203...
  • Page 917 5.Engine UXV 500i/700i Remove the stopper lever bolt and washer with a 6 mm Allen wrench. Remove the stopper lever and spring. 5-204...
  • Page 918 5.Engine UXV 500i/700i Remove the crankshaft and balancer shaft together. See the Crankshaft for more information. Place the nut that was removed from the driven pulley back onto the shaft to protect the threads and begin to press the shaft out. Remove the nut before it reaches the oil seal as it will not fit through.
  • Page 919 5.Engine UXV 500i/700i If the bearing comes out with the transmission drive shaft press it off as shown. Note: Always replace the bearing if it is removed from the crankcase. If the transmission drive shaft bearing does not come out with the shaft and needs to be replaced;...
  • Page 920 5.Engine UXV 500i/700i Inspect the transmission drive shaft oil seal and replace if needed. If it is necessary to remove the stopper lever shaft use a 19 mm socket to remove the nut and washer on the other side. 5-207...
  • Page 921 5.Engine UXV 500i/700i Upper Shift Fork Disassembly Remove the snap ring with snap ring pliers. Remove the washer. 5-208...
  • Page 922 5.Engine UXV 500i/700i Remove the cam pawl. Remove the spring. 5-209...
  • Page 923 5.Engine UXV 500i/700i Remove the snap ring with snap ring pliers. Remove the washer and shift fork. Inspection Check the stopper lever pawl for bends, damage or wear. Inspect the spring for cracks or damage. 5-210...
  • Page 924 5.Engine UXV 500i/700i Check the transmission drive shaft gear teeth for blue discoloration, pitting or wear. Measure the guide bar runout. Replace the bar if it is out of specification. Item Service Limit Guide Bar Runout 0.03 mm (0.0012 in) 5-211...
  • Page 925 5.Engine UXV 500i/700i Inspect the upper shift fork cam followers, shift fork pawl and spring. If there is any damage or excessive wear replace the components as a set. Inspect the upper shift fork cam followers and shift fork pawl. If there is any damage or excessive wear replace the part.
  • Page 926 5.Engine UXV 500i/700i Check the shift cam grooves and shift cam gear. Check for wear and damage and replace if needed. Inspect shift shaft gear and shift shaft for damage, bends or wear. Check the return spring for fatigue or damage. Replace the parts if needed. Inspect the transmission bearings.

  • Page 927: Transmission Shafts

    5.Engine UXV 500i/700i Transmission Shafts SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the transmission shafts from the transmission. See the Transmission Removal topic for more information. Disassembly When disassembling the transmission shafts be sure to keep track of the order and orientation of the parts as they come apart.
  • Page 928 5.Engine UXV 500i/700i Countershaft Remove the washer. Remove the high drive gear. Remove the bushing and washer. 5-215...
  • Page 929 5.Engine UXV 500i/700i Remove the high/low gear shifter. Remove the snap ring with snap ring pliers. Remove the washer and low drive gear. 5-216...
  • Page 930 5.Engine UXV 500i/700i On the other side of the countershaft; Remove the snap ring with snap ring pliers. Remove the stopper wheel. Remove the snap ring with snap ring pliers. 5-217...
  • Page 931 5.Engine UXV 500i/700i Remove the reverse gear shifter. Remove the snap ring with snap ring pliers. Remove the washer and reverse drive gear. 5-218...
  • Page 932 5.Engine UXV 500i/700i Inspect the countershaft, gear teeth and mated dogs. Check for blue discoloration, pitting or wear. Check for rounded edges, cracks or other damage. Replace as needed. Organize the parts in the order and orientation as removed. Bevel Gear Drive Shaft Remove the thick washer.
  • Page 933 5.Engine UXV 500i/700i Remove the reverse gear. Remove the thin washer. 5-220...
  • Page 934 5.Engine UXV 500i/700i Inspect the gear teeth. Check for blue discoloration, pitting or wear. Replace as needed. Inspect the needle bearing in the reverse gear. Check for wear or damage. Replace as needed. 5-221...
  • Page 935 5.Engine UXV 500i/700i Organize the parts in the order and orientation as removed. Assembly Use new snap rings when assembling the transmission shaft components. Install the snap ring (and thrust washer) so that the sharp edge is facing away from the gear that is putting thrust against it.
  • Page 936 5.Engine UXV 500i/700i Also, make sure the snap rings are fully seated in their grooves as shown. Spread the new snap rings only enough to slide them down the shaft and into their grooves. Note: Coat the gears and shafts lightly with fresh engine oil before installation. Bevel Gear Drive Shaft Install the thin washer on the drive shaft.
  • Page 937 5.Engine UXV 500i/700i Install the reverse gear. Install the thick washer. 5-224...
  • Page 938 5.Engine UXV 500i/700i Countershaft Install the reverse drive gear and washer onto the countershaft as shown. Install the snap ring with snap ring pliers. 5-225...
  • Page 939 5.Engine UXV 500i/700i Install the reverse gear shifter. Install the snap ring with snap ring pliers. 5-226...
  • Page 940 5.Engine UXV 500i/700i Install the stopper wheel. Install the snap ring with snap ring pliers. On the other side of the countershaft; Install the low drive gear and washer. 5-227...
  • Page 941 5.Engine UXV 500i/700i Install the snap ring with snap ring pliers. Install the high/low gear shifter. Install the washer and bushing. 5-228...
  • Page 942 5.Engine UXV 500i/700i Install the high drive gear. Install the washer. To install the transmission see the Transmission Installation topic. 5-229...
  • Page 943 5.Engine UXV 500i/700i Transmission Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Upper Shift Fork Assembly Install the cam pawl on the shaft and be sure to align the marks as shown. 5-230...
  • Page 944 5.Engine UXV 500i/700i Install the washer. Install the snap ring into the groove with snap ring pliers. 5-231...
  • Page 945 5.Engine UXV 500i/700i Install the spring. Install the shift fork on the shaft and be sure to align the marks as shown. Install the washer. Install the snap ring with snap ring pliers. 5-232...
  • Page 946 5.Engine UXV 500i/700i Installation Install the stopper lever shaft if it was removed. Install the shaft on the outside and the nut with washer on the inside. Carefully hold the stopper lever shaft with a wrench if necessary. Tighten the bolt to specification with a 19 mm socket. Item kgf-m ft-lb...
  • Page 947 5.Engine UXV 500i/700i Apply clean engine oil to a new drive shaft oil seal lip. Install the transmission drive shaft oil seal. Use a suitable driver that is the same outside diameter as the seal. Install the stopper lever and spring on the shaft. Note: Hook the spring onto the hook part of the stopper lever, squeeze the spring in to the groove of the left crankcase.
  • Page 948 5.Engine UXV 500i/700i Install the washer and a new stopper lever bolt. Hold the shaft nut on the other side. Tighten the bolt to specification with a 6 mm Allen wrench. Item kgf-m ft-lb Stopper lever bolt 5-235...
  • Page 949 5.Engine UXV 500i/700i Install the transmission drive shaft bearing with a bearing driver. Special Tool- Bearing Driver: A120E00014 Note: Apply clean engine oil to the transmission drive shaft, countershaft and drive shaft. Carefully press in the transmission drive shaft. 5-236...
  • Page 950 5.Engine UXV 500i/700i Install the transmission shafts together into the crankcase. Apply clean engine oil to the shift cam and install it. 5-237...
  • Page 951 5.Engine UXV 500i/700i Apply clean engine oil to the upper and lower shift forks and pawls. Install the lower gearshift fork into the lower shifter groove on the countershaft as shown. Fit the lower shift fork guide pin into the groove on the shift cam. 5-238...
  • Page 952 5.Engine UXV 500i/700i Install the upper gearshift fork into the upper shifter groove on the countershaft. Fit the upper shift fork guide pin into the groove on the shift cam. Apply clean engine oil to the transmission guide bar and install it. 5-239...
  • Page 953 5.Engine UXV 500i/700i Install the shift shaft. Be sure to align the shift shaft mark with the shift cam gear marks as shown. Check the transmission operation. 5-240...
  • Page 954 5.Engine UXV 500i/700i Install the crankshaft and balancer shaft together (if they were removed). See the Crankshaft for more information. Assemble the crankcases. See the Crankcase topic for more information. 5-241...
  • Page 955 5.Engine UXV 500i/700i Output Shafts and Bevel Gear SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Bevel Gear Cover Remove the bevel gear case cover bolts with an 8 mm socket. Remove the bevel gear cover. Utilize the pry points as needed. 5-242...
  • Page 956 5.Engine UXV 500i/700i Remove the gasket and the two bevel gear cover dowel pins. Output Shaft and Bevel Gears Unstake the output shaft nut with a chisel and a hammer. 5-243...
  • Page 957 5.Engine UXV 500i/700i Insert the front propeller shaft and hold it to keep the output shaft from turning. Loosen the output shaft nut with a 26 mm socket. 5-244...
  • Page 958 5.Engine UXV 500i/700i Remove output shaft nut. Remove the rear propeller shaft coupler from the engine. 5-245...
  • Page 959 5.Engine UXV 500i/700i Tap the output shaft forward with a rubber mallet. Move the output shaft forward so that the driven bevel gear can be removed. Remove the driven bevel gear and shim. 5-246...
  • Page 960 5.Engine UXV 500i/700i Slide the output shaft out of the engine. Unstake drive bevel gear nut with a chisel and a hammer. Remove the belt case cover. See the CVT Removal topic. Hold the driven pulley with a Y-type holder. Special Tool - Y-Type Holder: A120E00056 5-247...
  • Page 961 5.Engine UXV 500i/700i Loosen the drive bevel gear nut with a deep well 26 mm socket. Remove the drive bevel gear nut. 5-248...
  • Page 962 5.Engine UXV 500i/700i Slide off the drive bevel gear. Remove the drive bevel gear shim. 5-249...
  • Page 963 5.Engine UXV 500i/700i Seals and Bearings Inspect the propeller shaft oil seals for leaks and damage. Inspect the bearings by turning them with a finger. Replace the bearings if they do not turn smoothly. 5-250...
  • Page 964 5.Engine UXV 500i/700i Remove the seals with a seal pick if needed. Replace the oil seals with new items if they are removed. If the rear bearing needs to be replaced the lock nut must be removed. 5-251...
  • Page 965 5.Engine UXV 500i/700i Remove the lock nut with the special tool. Special Tool - Nut Wrench: A120E00066 Remove the rear bearing with a suitable bearing puller. Special Tool- Bearing Puller: A120E00037 5-252...
  • Page 966 5.Engine UXV 500i/700i Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing. The manufactures markings on the bearing must face out. Special Tool - Bearing Driver: A120E00014 Install the lock nut with the special tool. Special Tool - Nut Wrench: A120E00066 5-253...
  • Page 967 5.Engine UXV 500i/700i Torque the lock nut to specification with the special tool. ITEM kgf-m ft-lb Driven pulley nut 79.2 If the front bearing is to be replaced the snap ring must be removed. 5-254...
  • Page 968 5.Engine UXV 500i/700i Remove the bearing snap ring with snap ring pliers. Remove the bearing with a suitable bearing puller. Special Tool- Bearing Puller: A120E00037 5-255...
  • Page 969 5.Engine UXV 500i/700i Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing. The manufactures markings on the bearing must face out. Special Tool - Bearing Driver: A120E00014 Install a new snap ring with snap ring pliers. Lubricate the lips of the new oil seals with fresh engine oil.
  • Page 970 5.Engine UXV 500i/700i Press in the new seals with a suitable driver with the same outside diameter as the seals. Inspection Inspect the propeller shaft couplers for wear and damage. Inspect the bevel gears for wear and damage. 5-257...
  • Page 971 5.Engine UXV 500i/700i Inspect the output shaft for damage and wear. Bevel Gear Backlash Remove the bevel gear cover. The bevel gears must be installed as normal. Set a dial gauge on the driven bevel gear as shown. 5-258...
  • Page 972 5.Engine UXV 500i/700i Measure the backlash by turning the rear propeller shaft in each direction, reading the total backlash on the dial gauge. If the backlash is not within specification, the shim must be changed and the backlash should be rechecked until correct. Bevel gear backlash 0.03 - 0.15 mm (0.001 - 0.006 in) 5-259...
  • Page 973 5.Engine UXV 500i/700i See the chart for appropriate shim thickness. Backlash Shim Adjustment under 0.03 mm (0.001 in) Reduce shim thickness 0.03 - 0.15 mm (0.001 - 0.006 in) Correct shim thickness over 0.15 mm (0.006 in) Increase shim thickness Drive/Driven bevel gear shims 0.6 mm (0.024 in) 0.65 mm (0.026 in)
  • Page 974 5.Engine UXV 500i/700i Bevel Gear Tooth Contact After the backlash adjustment is carried out, the tooth contact must be checked as indicated below. • Remove the driven bevel gear. • Clean and degrease the teeth of the drive and driven bevel gears. Apply a coating of machinist's layout dye or paste to several teeth of the driven bevel gear.
  • Page 975 5.Engine UXV 500i/700i 2 - Correct • If tooth contact is found to be correct (example 2) complete the installation. • If tooth contact is found to be incorrect (examples 1 and 3), the shim thickness between the drive bevel gear and driven bevel gear must be changed and the tooth contact rechecked until correct.
  • Page 976 5.Engine UXV 500i/700i Drive Bevel Gear Shim Driven Bevel Gear Shim Tooth Contact Adjustment Adjustment Contact at tooth top (1) Increase shim thickness Increase shim thickness Contact at tooth root Reduce shim thickness Reduce shim thickness Make sure to check the backlash after the tooth contact has been adjusted. The tooth contact shim adjustment may have changed the backlash.
  • Page 977 5.Engine UXV 500i/700i Installation Output Shaft and Bevel Gears Install the drive bevel gear shim. Slide on the drive bevel gear. 5-264...
  • Page 978 5.Engine UXV 500i/700i Lubricate the new drive bevel gear lock nut threads with engine oil. Thread on the new drive bevel gear lock nut. old the driven pulley with a Y-type holder. Special Tool - Y-Type Holder: A120E00056 Tighten the drive bevel gear nut to specification with a deep well 26 mm socket. ITEM kgf-m ft-lb...
  • Page 979 5.Engine UXV 500i/700i Stake the drive bevel gear lock nut with a chisel and a hammer. Slide the output shaft into the engine as shown. 5-266...
  • Page 980 5.Engine UXV 500i/700i Fit the driven bevel gear and shim into place. Guide the output shaft through the driven bevel gear and shim. 5-267...
  • Page 981 5.Engine UXV 500i/700i The output shaft must protrude through the seal. Install the rear propeller shaft coupler. 5-268...
  • Page 982 5.Engine UXV 500i/700i Lubricate the new output shaft nut threads with engine oil. Install the new output shaft nut. Insert the forward propeller shaft and hold it to keep the output shaft from turning. 5-269...
  • Page 983 5.Engine UXV 500i/700i Tighten the output shaft nut to specification with a 26 mm socket. ITEM kgf-m ft-lb Driven bevel gear lock nut 100.8 Stake the output shaft nut with a chisel and a hammer. 5-270...
  • Page 984 5.Engine UXV 500i/700i Bevel Gear Cover Install two bevel gear cover dowel pins and a new gasket. Fit the bevel gear cover into place. 5-271...
  • Page 985 5.Engine UXV 500i/700i Install the five bevel gear case cover bolts. Tighten the bolts evenly and securely with an 8 mm socket. 5-272...
  • Page 986 6.Cooling System UXV 500i/700i 6.Cooling System This chapter covers the location and servicing of the external components. 1.Coolant ..................6-4 2.Oil Cooler ..................6-11 3.Pressure Testing .................6-21 4.Radiator ..................6-23 5.Thermostat ..................6-35 6.Water Pump .................6-40 GENERAL INSTRUCTIONS WARING:Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
  • Page 987 6.Cooling System UXV 500i/700i TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or sensor • Faulty radiator cap • Air in system • Faulty thermostat (stuck closed) • Insufficient coolant • Passages blocked in hoses or water jacket • Clogged radiator fins •...
  • Page 988 6.Cooling System UXV 500i/700i Cooling System Diagram...
  • Page 989 6.Cooling System UXV 500i/700i Coolant SAFETY FIRST: Antifreeze is highly toxic and can kill pets and animals if drank. Do not leave coolant where animals (including children) can get to it. CAUTION: Never remove the radiator cap when the engine is hot. SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
  • Page 990 6.Cooling System UXV 500i/700i Inspection Lift the hood. See the Hood topic for more information. Check the coolant when cold. The coolant level should be between the two indicator lines. Fill the reservoir tank to the FULL line with the appropriate coolant mixture if needed. Draining Note: The engine should be at room temperature to prevent coming into contact with scalding coolant.
  • Page 991 6.Cooling System UXV 500i/700i Remove the radiator cap by pushing down and turning it. Remove the radiator cap in two stages. Allow any built up pressure to vent and then open the cap all the way and remove it.
  • Page 992 6.Cooling System UXV 500i/700i Place a drain pan underneath the water pump and remove the drain plug using an 8 mm wrench. Be prepared the coolant will spurt out quickly. Install the drain plug and tighten it securely after the cooling system has been drained.
  • Page 993 6.Cooling System UXV 500i/700i Remove the two mounting bolts and drain the reservoir tank. Install the tank and tighten the two mounting bolts securely.
  • Page 994 6.Cooling System UXV 500i/700i Refilling ITEM SPECIFICATIONS Radiator and engine 2 liter (2.1 US qt, 1.76 Imp qt) Coolant capacity Reserve tank 0.45 liter (0.47 US qt, 0.39 Imp qt) Standard coolant concentration 1:1 mixture with soft water Slowly pour the new coolant into the radiator filler neck until it reaches the bottom of the neck.
  • Page 995 6.Cooling System UXV 500i/700i Fill the reservoir tank to the FULL line. With the reservoir cap and the radiator cap off, start the engine and let it run for several minutes. Blip the throttle and rev the engine a few times. This will purge any air out of the cooling system.

  • Page 996: Oil Cooler

    6.Cooling System UXV 500i/700i Oil Cooler SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Drain the engine oil. See the Engine Oil topic for more information. Drain the engine coolant. See the Coolant topic for more information. Remove the center cover.
  • Page 997 6.Cooling System UXV 500i/700i Loosen the oil hose clamps with a #2 Phillips screwdriver. Free the oil hoses from the back of the engine. 6-12...
  • Page 998 6.Cooling System UXV 500i/700i Loosen the bypass hose (smaller) clamp with a #2 Phillips screwdriver. Free the bypass hose from the water pump. Loosen the oil cooler to thermostat hose clamp with a #2 Phillips screwdriver. Remove the oil cooler hose from the thermostat. 6-13...
  • Page 999 6.Cooling System UXV 500i/700i Loosen the clamps with a #2 Phillips screwdriver to remove the hoses from the oil cooler. Remove the two bolts with an 8 mm socket to free the oil cooler from the mounting bracket. 6-14...
  • Page 1000 6.Cooling System UXV 500i/700i Oil Pipe Fitting The oil cooler and its oil pipe fitting can be separated if needed. Loosen the two bolts with a 14 mm socket. 6-15...

This manual is also suitable for:

Uxv 700i

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