KYMCO Kymco UXV 500i Manuals

Manuals and User Guides for KYMCO Kymco UXV 500i. We have 3 KYMCO Kymco UXV 500i manuals available for free PDF download: Repair Manual, Service Manual, Owner's Manual

KYMCO Kymco UXV 500i Repair Manual (1560 pages)

Brand: KYMCO | Category: Utility Vehicle | Size: 29.14 MB

Table of Contents
3
Diagnostic Trouble Codes
14
General Information
16
General Specifications
33
Torque Specifications
42
VIN and Engine Number
46
Entire Chapter
49
Periodic Maintenance Chart
50
Air Filter Servicing
52
Throttle Free Play
63
Brake Fluid
67
Brake Inspection
74
Rear Parking Brake Adjustment
80
Engine Oil
81
Oil Pressure
90
Final Drive / Differential Oil
91
Spark Plug
100
Compression Check
105
Tires
106
Valve Clearance
110
Toe-In Adjustment
119
Spark Arrestor
122
Airbox
127
Check Engine Lamp (CELP)
133
Component Location
137
Diagnostic Tool
144
Fuel Injection Sensors
160
Fuel Injector
175
Fuel Pump
186
Fuel Tank
202
Throttle Body Removal
213
Throttle Body Components
229
Boot Guard
247
Canopy Bars
257
Cargo Bed
265
Center Cover
278
Drive Selector
288
Exhaust System
290
Frame Covers
304
Front Bumper
319
Headlight
325
Hood
338
Instrument Cover
343
Pedal Cover
354
Rear Fender
358
Seats
369
Side Covers
372
Skid Plates
386
Engine Removal
399
Engine Installation
407
Cylinder Head Cover
417
Camshaft
427
Camshaft Installation
447
Cylinder Head
463
Valves
477
Cylinder and Piston
491
Crankcase Bearings
518
Recoil Starter Cover
523
Generator Cover
532
Oil Pump
561
Cam Chain
585
Output Shaft and Bevel Gear
592
Clutch Removal
626
Clutch Installation
641
Crankshaft
668
Transmission Removal
673
Transmission Shafts
698
Cam Chain
791
Generator Cover
816
Flywheel
844
Oil Pump
861
Crankcase Bearings
903
Crankshaft
907
Transmission Removal
915
Transmission Shafts
927
Oil Cooler
996
Pressure Testing
1008
Radiator
1008
Thermostat
1020
Water Pump
1025
Belt Case Cover
1045
Clutch Removal
1053
Clutch Installation
1068
CVT (UXV 500I)
1076
CVT (UXV 700I)
1076
Universal Joints
1163
Front Drive Shafts
1165
Rear Drive Shafts
1182
Front Differential Removal and Installation
1198
Front Differential Disassembly
1208
Differential Assembly
1234
Final Drive Gear Disassembly
1255
Front Caliper
1283
Front Disc Brake
1298
Front Brake Lines
1306
Master Cylinder
1313
Brake Pedal
1318
Parking Brake
1322
Rear Brake Caliper
1328
Rear Brake Disc
1345
Rear Parking Brake Adjustment
1351
Electrical Specifications
1489
Battery
1490
Charging System
1500
Fuses
1510
Ignition System
1513
Lights
1530
Starter Motor
1541
Switches
1554

KYMCO Kymco UXV 500i Service Manual (426 pages)

Brand: KYMCO | Category: Offroad Vehicle | Size: 22.33 MB

General Information

2
- Table of Contents
  2
- Serial Number
  3
- Specifications
  4
- Service Precautions
  5
- Torque Values
  13
- Special Tools
  17
- Lubrication Points
  21
Frame Covers/Exhaust Muffler

23
- Service Information
  24
- Troubleshooting
  24
- Uxv 500 Removal and Reinstallation
  25
- Frame Covers
  26
- Exhaust Muffler
  34
Inspection/Adjustment

37
- Service Information
  38
- Maintenance Schedule
  40
- Fuel Line/Throttle Operation
  41
- Speed Limiter/Air Cleaner
  42
- Air Box for Drive Belt
  44
- Secondary Air Supply System
  45
- Spark Plug
  46
- Valve Clearance
  48
- Carburetor Idle Speed
  49
- Clinder Compression/Engine Oil
  50
- Rear Drive Gear Oil
  54
- Front Drive Gear Oil
  55
- Spark Arrester
  56
- Drive Shaft Boots
  57
- Drive Belt/Brake Pads Inspection
  58
- Brake Fluid Inspection/Headlight Aim
  59
- Steering System Inspection
  60
- Toe-In Adjustment
  61
- Wheels/Tires
  62
- Cooling System
  64
- Parking Brake Adjustment
  66
Lubrication System

69
Fuel System 5

87
- Service Information
  89
- Troubleshooting
  90
- Fuel Tank
  91
- Carburetor Removal/Choke Inspection/Installation
  92
- Carburetor Disassembly/Inspection/Assembly
  94
- Air Cleaner Housing
  103
- Pair Solenoid Valve
  104
- Fuel Filter/Fuel Pump
  105
Cooling System

107
- System Flow Pattern
  108
- Service Information
  109
- Troubleshooting
  111
- Cooling System Testing
  112
- Thermostat
  115
- Water Pump
  118
- Radiator
  121
- Fan Motor Switch
  122
- Fan Motor
  123
- Water Temperature Sensor
  124
- Raidator Reserve Tank
  125
- Oil Cooler
  126
Cylinder Head/Valves

141
- Schematic Drawing
  142
- Service Information
  143
- Troubleshooting
  144
- Cylinder Compression Test
  145
- Cylinder Head Cover Removal/Installation
  146
- Cylinder Head Cover Disassembly/Assembly
  147
- Camshaft Removal/Inspection/Installation
  148
- Rocker Arms Removal/Inspection/Installation
  156
- Cylinder Head Removal/Installation
  158
- Cylinder Head Disassembly/Inspection/Assembly
  165
- Cam Chain Removal/Inspection/Installation
  169
Drive Pulley/Driven Pulley/Clutch

181
Transmission System 11

209
Drive Train

247
Front Wheel/Front Suspension Steering System

273
- Troubleshooting
  276
- Front Wheel Removal/Inspection/Installation
  277
- Front Wheel Hub Removal/Inspection
  278
- Installation
  278
- Installation
  279
- Installation
  281
- Removal/Inspection/Installation
  281
- Steering Knuckle Removal/Inspection
  281
Rear Wheel/Shock Absorber/Swing Arm

291
- Service Information
  293
- Troubleshooting
  293
- Rear Wheel Removal/Inspection/Installation
  294
- Installation
  295
- Rear Wheel Hub Removal/Inspection
  295
- Installation
  296
- Steering Knuckle Removal/Inspection/ Installation
  298
Brake System

303
- Service Information
  304
- Troubleshooting
  305
- Brake Pads Replacement
  306
- Front Brake Discs Removal/Inspection
  311
- Installation
  311
- Installation
  312
- Rear Brake Disc Removal/Inspection
  312
- Front Brake Fluid Change/Air Bleed
  313
- Rear Brake/Parking Brake Caliper Removal
  319
- Brake Master Cylinders Removal / Installation
  330
- Brake Padel
  331
- Brake Assy Parking
  332
- Rear Brake Disk
  333
Battery/Charging System

339
- Troubleshooting
  343
- Battery
  344
- Charging System Inspection
  345
- Alternator Charging Coil
  346
- Regulator/Rectifier
  347
- Alternator Stator Removal/Inspection/ Installation
  350
Ignition System

353
- Ignition System
  354
- Ignition Circuit
  355
- Service Information
  356
- Troubleshooting
  357
- Ignition Coil Inspection
  358
Starter System

361
- Starting System Layout
  362
- Starting Circuit
  363
- Service Information
  364
- Starter Motor
  365
- Starter Relay Switch/Starter Mag
  366
- Starter Clutch Removal/Inspection/ Installation
  368
Lights/Switches

373
- Bulbs Removal
  375
- Horn (on Road)
  377
- Ignition Switch
  378
- Speed Sensor
  380
- Front Drive Selector Actuator
  381
  - Fuel Unit
    382
Fuel Injection System

385
- 22. Fuel Injection System
  387
- Specifications
  387
- Injection System Diagram
  388
- Parts Location
  389
- Troubleshooting
  393
- Codes
  395
- Celp Failure Codes List
  396
- Tps/Isc Reset
  400
- Fuel Pump
  401
- Fuel Pump Relay
  403
- Tilt Switch(Roll Sensor)
  404
- Fuel Injector
  407
- Wts Sensor
  409
- Throttle Body/T-Map Sensor/Isc/Tps
  410
- Diagnostic Tool Connector
  413

KYMCO Kymco UXV 500i Owner's Manual (103 pages)

Brand: KYMCO | Category: Utility Vehicle | Size: 4.54 MB

Battery & EFI Damage Alert
2
CELP Indication
2
Table of Contents
4
Safety Watchful
9
Serial Number Locations
10
Frame Number
10
Engine Serial Number
11
Ignition Switch Key/Fuel Cap Key Right Glove Compartment Key
12
Location of Parts
13
Warning Labels Location
17
Features and Controls
36
Fuel Lever Inspection/Refilling
36
- Features and Controls
  37
- Indicator Lights
  37
- Instruments and Indicators
  38
- Operation Instruction for Multi-Meter
  39
Auxiliary Outlet
45
- Seat Belts
  46
- Seat Removal
  46
- Pillows Adjust
  47
- Gear Selector
  48
- Ignition Switch
  49
- Light Switch
  50
- Drive Select Switch
  51
- Differential Lock Lever and Indicator
  52
- Turn Signal Lights Switch
  53
- Hazard Warn Flashers Switch
  54
- Switches
  55
- Horn
  55
Back Mirrors
55
- Brake Pedal
  56
- Throttle Pedal
  56
- Parking Brake Release
  57
- Cargo Bed (Lift and Lower the Cargo Bed)
  58
- To Lift
  58
- To Lower
  58
- Under-Hood (to Open)
  61
- Under-Hood (to Close)
  62
- How to Operate
  63
Daily Safety Checks
63
- Driving Safely(Driving Procedures)
  64
- Start the Engine
  65
- Braking/Stopping
  66
- Parking
  67
Driving Downhill
67
Driving Uphill
68
Crossing Water
69
- Driving in Reverse
  70
- Crankcase Emission Control System
  71
- Exhaust Emission Control System
  71
- Noise Exhaust Emission Control System
  71
- Spark Arrester
  72
- Remove Method
  72
- Clean Method
  72
- Oil Quantity
  73
- Maintenance and Lubrication
  73
Engine Oil
73
- Engine Oil Level Measurement
  74
- Engine Oil Replacement and Oil Filter Cleaning
  75
Changing the Rear Gear Box Oil
77
Changing the Front Gear Box Oil
78
- Brake Fluid Inspection
  79
- Air Cleaner
  80
- Battery Installation
  83
Battery Remove
83
Fuse Replacement
84
- Cooling System Inspection
  85
- Recommended Coolant Solution
  85
- Coolant Mixture Ratio
  85
- Wheel Removal
  86
- Wheel Installation
  86
- Spark Plug Inspection
  88
- Tool Kit
  89
- Specifications
  90
- Periodic Maintenance/Lubrication
  95

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KYMCO Kymco UXV 500i Manuals

KYMCO Kymco UXV 500i Repair Manual (1560 pages)

Table of Contents

KYMCO Kymco UXV 500i Service Manual (426 pages)

Table of Contents

General Information

Frame Covers/Exhaust Muffler

Inspection/Adjustment

Lubrication System

Fuel System 5

Cooling System

Cylinder Head/Valves

Drive Pulley/Driven Pulley/Clutch

Transmission System 11

Drive Train

Front Wheel/Front Suspension Steering System

Rear Wheel/Shock Absorber/Swing Arm

Brake System

Battery/Charging System

Ignition System

Starter System

Lights/Switches

Fuel Injection System

KYMCO Kymco UXV 500i Owner's Manual (103 pages)

Table of Contents

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