KYMCO UXV 500i Service Manual
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KYMCO UXV 500i Service Manual

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Table of Contents

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Service Manual
UXV 500i
englisch
AMSLER & CO. AG
8245 FEUERTHALEN ZH
fon
fax
052 647 36 36
052 647 36 66
i n f o @ a m s l e r . c h
www.amsler.ch

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Summary of Contents for KYMCO UXV 500i

  • Page 1 Service Manual englisch UXV 500i AMSLER & CO. AG 8245 FEUERTHALEN ZH 052 647 36 36 052 647 36 66 i n f o @ a m s l e r . c h www.amsler.ch...

  • Page 2: Table Of Contents

    . GENERAL INFORMATION UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER---------------------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 3 TORQUE VALUES --------------------------------------------------------- 1-11 SPECIAL TOOLS ----------------------------------------------------------- 1-15 LUBRICATION POINTS -------------------------------------------------- 1-18...

  • Page 3: Serial Number

    . GENERAL INFORMATION UXV 500 SERIAL NUMBER (1) Location of Frame Serial Number (1) Location of Engine Serial Number...

  • Page 4: Specifications

    . GENERAL INFORMATION UXV 500 SPECIFICATIONS Forced pressure & Lubrication type Wet sump Model No. UAA0 Oil pump type Trochoid Name & Type UXV 500 Oil filter type Full-flow filtration Overall length 2870 mm 3.6 L Oil capacity Overall width 1500 mm Overall height 1850 mm...

  • Page 5: Service Precautions

    . GENERAL INFORMATION UXV 500 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
  • Page 6 . GENERAL INFORMATION UXV 500 Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
  • Page 7 . GENERAL INFORMATION UXV 500 If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 8 . GENERAL INFORMATION UXV 500 The connector shall be inserted completely. If the double connector has a lock, lock it Snapping! at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
  • Page 9 . GENERAL INFORMATION UXV 500 After clamping, check each wire to make sure it is secure. 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.
  • Page 10 . GENERAL INFORMATION UXV 500 Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
  • Page 11 . GENERAL INFORMATION UXV 500 After routing, check that the wire harnesses are not twisted or kinked. 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...
  • Page 12 . GENERAL INFORMATION UXV 500 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Engine Oil : Apply grease for lubrication. Grease : Transmission Gear Oil (90#) Gear Oil...

  • Page 13: Torque Values

    . GENERAL INFORMATION UXV 500 TORQUE VALUES STANDARD TORQUE VALUES Torque Torque Item Item kgf-m (N-m) kgf-m (N-m) 5mm bolt and nut 0.45-0.6 (4.5-6) 4mm screw(Round) 0.05-0.15 (0.5-1.5 ) 6mm bolt and nut 0.8-1.2 (8-12) 0.2-0.4 (2-4) 4mm screw(Sharp) 8mm bolt and nut 1.8- 2.5(18-25) 0.1-0.3 (1-3) 5mm screw(Round)
  • Page 14 . GENERAL INFORMATION UXV 500 Thread dia. Torque Item Remarks (mm) kgf-m (N-m) CYLINDER HEAD: Cylinder head bolt 4.8 (48) Apply oil Cylinder head bolt 2.3 (23) Apply oil Cylinder head nut 1 (10) Cylinder head cover 1 (10) Breather separator bolt 1.3 (13) Cam chain tensioner bolt 1.2 (12)
  • Page 15 . GENERAL INFORMATION UXV 500 FRAME Thread Torque Item Q‘ty Remarks dia. Kgf-m (N-m, (mm) lbf-ft) STEERING: Steering column and intermediate shaft 2.7 (27, 15) Steering assembly and intermediate shaft 2.7 (27,15) Steering assembly and frame 4.8 (48, 34) Steering column assembly and frame 3.2 (32, 23) Steering wheel and steering column 3.5 (35 25.)
  • Page 16 . GENERAL INFORMATION UXV 500 Thread Torque Item Q‘ty Remarks dia. Kgf-m (N-m, (mm) lbf-ft) BRAKE: Front caliper bracket mounting bolt 2.7 (27, 19) Rear caliper bracket mounting bolt 2.7 (27, 19) Front brake disc and wheel hub 3.5 (35, 25) FR/RR brake caliper bleed screw 0.6 (6, 4) Brake hose oil bolt...

  • Page 17: Special Tools

    . GENERAL INFORMATION UXV 500 SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Oil seal and bearing A120E00014 installer Valve adjuster A120E00036 (Refer to the “VALVE CLEARANCE”...
  • Page 18 . GENERAL INFORMATION UXV 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Driven pulley holder (Refer to the “DRIVEN PULLEY A120E00059 DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 10.) Flywheel puller (Refer to the “STARTER...
  • Page 19 . GENERAL INFORMATION UXV 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Crankshaft bearing puller A120E00068 Ball joint remover (Refer to the “STEERING KNUCKLE REMOVAL/ A120F00012 INSPECTION/ INSTALLATION”...
  • Page 20 . GENERAL INFORMATION UXV 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Pinion bearing lock nut wrench (Refer to the “REAR DRIVE A120F00020 DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 13.) Pinion puller (Refer to the “REAR DRIVE...

  • Page 21: Lubrication Points

    . GENERAL INFORMATION UXV 500 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE10W-30) Valve guide/valve stem movable part Camshaft protruding surface •API SJ Engine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt Piston surroundings and piston ring grooves...
  • Page 23 . FRAME COVERS/EXHAUST MUFFLER UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 TROUBLESHOOTING----------------------------------------------------- 2- 1 UXV 500 REMOVAL AND REINSTALLATION --------------------- 2- 2 FRAME COVERS ----------------------------------------------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2- 11...

  • Page 24: Service Information

    . FRAME COVERS/EXHAUST MUFFLER UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler mounting bolt 3.5 kgf-m (35 Nm, 25 lbf-ft) Exhaust pipe mounting nut...

  • Page 25: Uxv 500 Removal And Reinstallation

    . FRAME COVERS/EXHAUST MUFFLER UXV 500 UXV 500 REMOVAL AND REINSTALLATION REMOVAL Depress the head of plastic screws center piece . Pull out the .plastic screws INSTALLATION Let the center piece stick out toward the head so that the pawls close.

  • Page 26: Frame Covers

    . FRAME COVERS/EXHAUST MUFFLER UXV 500 FRAME COVERS SEAT REMOVAL To remove the seat, pull the seat lock board , upward and pull up the seat. Lock board Seat stay INSTALLATION To install the seat, into the seat stay then Press the seat lock board HOOD REMOVAL/INSTALLATION...
  • Page 27 . FRAME COVERS/EXHAUST MUFFLER UXV 500 FRONT BUMPER COVER REMOVAL/INSTALLATION Remove the 4 bolts from the front Bumper cover, then remove the front bumper cover. Installation is in the reverse order of removal. UNDER COVER REMOVAL/INSTALLATION Remove the 6 bolts from the under cover, then remove the under cover.
  • Page 28 . FRAME COVERS/EXHAUST MUFFLER UXV 500 ENGINE GUARD REMOVAL/INSTALLATION Remove the 6 bolts from the engine guard, then remove the engine guard,. Installation is in the reverse order of removal. GUARD BOOT REMOVAL/INSTALLATION Remove the 2 bolts from the guard boot, then remove the guard boot,.
  • Page 29 . FRAME COVERS/EXHAUST MUFFLER UXV 500 CENTER ASSY COVER REMOVAL/INSTALLATION Remove the 2 seats Remove the 1 bolts from the gear shaft lever, Remove the 2 bolts from the center cover, then remove the center cover,. Installation is in the reverse order of removal.
  • Page 30 . FRAME COVERS/EXHAUST MUFFLER UXV 500 PANEL R/L SIDE AND PROTECTOR SIDE REMOVAL/INSTALLATION Remove the 4 bolts from the panel L/R side, then,. Remove the 7 bolts from the protector side.. remove the panel L/R side and protector side Installation is in the reverse order of removal.
  • Page 31 . FRAME COVERS/EXHAUST MUFFLER UXV 500 PEDAL PLATE TUNNER COVER BRAKE PLATE SUPPORT R/L SIDE PANDEL Remove brake lever bolt. Remove brake plate 6 bolts.
  • Page 32 . FRAME COVERS/EXHAUST MUFFLER UXV 500 R FOOTREST PANEL LID GLOVE BOX COVER Remove bolts from panel R footrest Remove 8 screws from lid glove box cover L FOOTREST PANEL R/L WINKER COVER Remove bolts from panel L footrest Remove 2 bolts from front bumber LUGGAGE BOX Remove 4 bolts from box luggage.
  • Page 33 . FRAME COVERS/EXHAUST MUFFLER UXV 500 FRONT PANEL Remove steering wheel. Remove connecters and wires from panel front. Remove 4 bolts from panel front. Remove panel front. Installation is in the reverse order of removal. 2-10...

  • Page 34: Exhaust Muffler

    . FRAME COVERS/EXHAUST MUFFLER UXV 500 EXHAUST MUFFLER REMOVAL Loosen the exhaust pipe band bolt. Remove two muffler mounting bolts. Gasket Remove the muffler and gasket from the exhaust pipe Exhaust Muffler Remove the exhaust muffler body and stay ,exhaust muffler pipe joint nuts. 2-11...
  • Page 35 . FRAME COVERS/EXHAUST MUFFLER UXV 500 Remove the exhaust pipe nut and gasket. Exhaust Pipe nut INSTALLATION Replace the gaskets with new ones. Install the exhaust pipe and tighten the joint nuts. Torque: Exhaust pipe mounting nut: 3.5 kgf-m (35 N-m, 14 lbf-ft) Install the muffler and tighten the mounting Exhaust Pipe bolts...
  • Page 37 . INSPECTION/ADJUSTMENT UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 3 FUEL LINE/THROTTLE OPERATION --------------------------------- 3- 4 SPEED LIMITER/AIR CLEANER --------------------------------------- 3- 5 AIR BOX FOR DRIVE BELT --------------------------------------------- 3- 7 SECONDARY AIR SUPPLY SYSTEM --------------------------------- 3- 8 SPARK PLUG---------------------------------------------------------------- 3- 9 VALVE CLEARANCE ----------------------------------------------------- 3-11 CARBURETOR IDLE SPEED -------------------------------------------- 3-12...

  • Page 38: Service Information

    . INSPECTION/ADJUSTMENT UXV 500 SERVICE INFORMATION GENERAL ！ WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions.
  • Page 39 . INSPECTION/ADJUSTMENT UXV 500 Tire pressure 1 Rider Front 0.7 kgf/cm² (10 psi) Rear 0.98 kgf/cm² (14 psi) Tire size: Front : 25X8-12 Rear : 25X10-12 TORQUE VALUES Spark plug 1.2kgf-m (12 N-m, 8.6 lbf-ft) Tappet ADJ nut 0.9 kgf-m (9 N-m, 6.5 lbf-ft) Engine oil filter cap 1.5 kgf-m (15 N-m, 11 lbf-ft) Engine oil filter cartridge...

  • Page 40: Maintenance Schedule

    . INSPECTION/ADJUSTMENT UXV 500 MAINTENANCE SCHEDULE 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 41: Fuel Line/Throttle Operation

    . INSPECTION/ADJUSTMENT UXV 500 Fuel tubes FUEL LINE Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area. Fuel Filter THROTTLE OPERATION Check the throttle to swing for smooth movement.

  • Page 42: Speed Limiter/Air Cleaner

    . INSPECTION/ADJUSTMENT UXV 500 AIR CLEANER AIR CLEANER REPLACEMENT 1. Remove the seat. 2. Remove the center cover. 3. Remove the six screws and remove the air cleaner housing cover . 3. Loosen the screw and remove the air cleaner assembly from the air cleaner housing.
  • Page 43 . INSPECTION/ADJUSTMENT UXV 500 CLEAN AIR FILTER ELEMENT Wash the element gently, but throughly in solvent. ＊ Use parts cleaning solvent only. Never use gasoline or low flash point solvents which may lead to a Squeeze the excess solvent out of the element and let dry.

  • Page 44: Air Box For Drive Belt

    . INSPECTION/ADJUSTMENT UXV 500 AIR CLEANER HOUSING DRAIN 1. Remove the drain tube by removing the clip . 2. Drain the deposits. 3. Reinstall the drain tube, securing it with the clip. AIR BOX FOR DRIVE BELT Rear air To check the air box: Remove rider’s side seat.

  • Page 45: Secondary Air Supply System

    . INSPECTION/ADJUSTMENT UXV 500 SECONDARY AIR SUPPLY SYSTEM Check the AICV (air injection control valve) This model is equipped with a built-in hoses between the AICV control solenoid secondary air supply system. The pulse valve and cylinder head for deterioration, secondary air supply system is located on damage or loose connections.

  • Page 46: Spark Plug

    . INSPECTION/ADJUSTMENT UXV 500 Ignition Coil Cap SPARK PLUG Disconnect the spark plug cap and clean around the spark plug. ＊ Clean around the spark plug base with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber.
  • Page 47 . INSPECTION/ADJUSTMENT UXV 500 Measure the spark plug gap between the center and side electrodes with the feeler gauge. If necessary, adjust the gap by bending the side electrode carefully. 0.6~0.7 Spark plug gap: 0.6－0.7 mm (0.024－0.028 in) Install the spark plug in the cylinder head and hand tighten, then torque to the specification.

  • Page 48: Valve Clearance

    . INSPECTION/ADJUSTMENT UXV 500 Timing Hole Cap VALVE CLEARANCE ＊ Inspect and adjust the valve clearance while the engine is cold (Below 35°C/95°F). To adjust: Remove the right floorboard (refer to the “FRAME COVERS” section in the chapter Remove the cylinder head cover (refer to the “CYLINDER HEAD COVER REMOVAL/INSTALLATION”...

  • Page 49: Carburetor Idle Speed

    . INSPECTION/ADJUSTMENT UXV 500 Adjust by loosening the valve adjusting Wrench Thickness Gauge Valve Adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge. Valve clearance (when cold): IN.: 0.1 mm (0.004 in) EX.: 0.1 mm (0.004 in) Apply oil to the valve adjusting screw lock- nut threads and seating surface.

  • Page 50: Clinder Compression/Engine Oil

    (H) and minimum (L) marks. If the level is low, add oil to raise it to the proper level. Recommended engine oil: KYMCO 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 5W50 ＊ Other viscosities shown in the chart may...
  • Page 51 . INSPECTION/ADJUSTMENT UXV 500 ENGINE OIL REPLACEMENT AND OIL FILTER CLEANING 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4. Remove the oil filler cap (1). ＊...
  • Page 52 . INSPECTION/ADJUSTMENT UXV 500 ENGINE OIL REPLACEMENT (WITH OR WITHOUT OIL FILTER CARTRIDGE REPLACEMENT) 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4.
  • Page 53 . INSPECTION/ADJUSTMENT UXV 500 6. Remove the oil filter cartridge (5) with an oil cartridge wrench. Special tool: Oil cartridge wrench A120E00061 7. Apply a light coat of clean engine oil to the O-ring (6) of the new oil filter cartridge.

  • Page 54: Rear Drive Gear Oil

    . INSPECTION/ADJUSTMENT UXV 500 13. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, turn the engine off immediately and check for the cause. 14. Turn the engine off, and then check the oil level through the inspection window (7) and correct it if necessary.

  • Page 55: Front Drive Gear Oil

    . INSPECTION/ADJUSTMENT UXV 500 6. Install the oil filler cap and oil level check bolt. Torque: Oil filler cap: 1.5 kgf-m (15 N-m, 12 lbf-ft) Oil level check bolt: 2 kgf-m (20 N-m, 15 lbf-ft) ＊ Be sure no foreign material enters the crankcase.

  • Page 56: Spark Arrester

    . INSPECTION/ADJUSTMENT UXV 500 . Remove the oil level check bolt (3). Make sure the oil level reaches the oil level check hole. 6. Install and tighten the oil filler bolt to the specified torque. Torque: Oil filler cap: 3.5 kgf-m (35 N-m, 25.5 lbf-ft) Oil level check bolt: 1 kgf-m (10 N-m, 7.2 lbf-ft) ＊...

  • Page 57: Drive Shaft Boots

    . INSPECTION/ADJUSTMENT UXV 500 3. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary. 4.

  • Page 58: Drive Belt/Brake Pads Inspection

    . INSPECTION/ADJUSTMENT UXV 500 DRIVE BELT Drive Belt Remove the left crankcase cover (refer to the “LEFT CRANKCASE COVER REMOVAL/INSTALLATION” section in the chapter 10). Inspect the drive belt for cracks, scaling, chipping or excessive wear. Measure the V-belt width Service limit (A): 30.8 mm (1.232 in) Replace the drive belt if out of specification.

  • Page 59: Brake Fluid Inspection/Headlight Aim

    . INSPECTION/ADJUSTMENT UXV 500 BRAKE FLUID INSPECTION Inspection Window Check if the fluid level is below the lower level mark through the inspection window. 1) Lower level mark (2) Upper level mark Adjust Screws HEADLIGHT AIM Turn the ignition switch ON and start the engine.

  • Page 60: Steering System Inspection

    . INSPECTION/ADJUSTMENT UXV 500 STEERING SYSTEM INSPECTION Place the machine on a level place. Check the steering column bushings and bearings: Turn the steering right and Left, Replace the steering column bushings and or bearings if excessive play Check the tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then slightly move the handlebar from left to right.

  • Page 61: Toe-In Adjustment

    . INSPECTION/ADJUSTMENT UXV 500 TOE-IN ADJUSTMENT Place the machine on a level place. Measure the toe-in Adjust if out of specification. Toe-in measurement steps: Mark both front tire tread centers. Raise the front end of the machine so that there is no weight on the front tires. Fix the handlebar straight ahead.

  • Page 62: Wheels/Tires

    . INSPECTION/ADJUSTMENT UXV 500 ＊ The threads on both rod-end must be of the same length. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. ＊ Tire pressure should be checked when tires are cold. TIRE PRESSURE 1 Rider Front...
  • Page 63 . INSPECTION/ADJUSTMENT UXV 500 Check the rear axle nut for looseness. If the axle nuts are loose, tighten them to the specified torque. Torque: Front: 7 kgf-m (70 N-m, 50 lbf-ft) Rear: 10 kgf-m (100 N-m, 72 lbf-ft) Rear Axle Nut Inspect the tire surfaces.

  • Page 64: Cooling System

    . INSPECTION/ADJUSTMENT UXV 500 COOLING SYSTEM COOLANT LEVEL INSPECTION Place the machine on the level ground. Remove the front hood cover Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature.
  • Page 65 . INSPECTION/ADJUSTMENT UXV 500 Check for any coolant leakage from the water pump, radiator hoses and hose joints. Check the radiator hoses for cracks or deterioration and replace if necessary. Check that all hose clamps are tight. Check the radiator air passages for clogs or damage.

  • Page 66: Parking Brake Adjustment

    . INSPECTION/ADJUSTMENT UXV 500 REAR PARKING BRAKE ADJUSTMENT Parking brake adjustment may be required if the parking brake does not work properly. Every time the brake pads are replaced, adjust the parking brake. To adjust: 1. Release the parking brake lever. Parking Brake lever 2.
  • Page 67 . INSPECTION/ADJUSTMENT UXV 500 3. Loosen the lock nut and adjuster on the cable. 4. Turn the adjuster until the caliper lever is about to rotate then Tighten the lock nut. Adjuster Parking brake cable end length: L: 53 ± 2 mm (2.12 ± 0.08 in) 5.
  • Page 69 . LUBRICATION SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM --------------------------------- 4- 1 SERVICE INFORMATION----------------------------------------------- 4- 2 TROUBLESHOOTING---------------------------------------------------- 4- 3 LUBRICATION CHECK HOLE ----------------------------------------- 4- 4 OIL PUMP REMOVAL/INSPECTION/INSTALLATION----------- 4- 5 OIL PUMP DISASSEMBLY/INSPECTION/ASSEMBLY ---------- 4- 9 RIGHT CRANKCASE COVER DISASSEMBLY/ASSEMBLY---- 4-12 OIL PRESSURE RELIEF VALVE--------------------------------------- 4-14 OIL PIPE REMOVAL/INSTALLATION ------------------------------- 4-15...

  • Page 70: Lubrication System Diagram

    UXV 500 . LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM...

  • Page 71: Service Information

    3.6 liter (3.17 lmp qt, 3.82 Us qt) capacity At draining and oil ⎯ filter cartridge change 3.2 liter (2.82 lmp qt, 3.39 Us qt) KYMCO 4-stroke oil or equivalent motor oil Recommended engine oil ⎯ API service classification SJ...

  • Page 72: Troubleshooting

    UXV 500 . LUBRICATION SYSTEM TROUBLESHOOTING Oil level low High oil pressure • Oil consumption • Pressure relief valve stuck closed • External oil leak • Plugged oil filter, gallery, or metering orifice • Worn piston ring • Faulty oil pump •...

  • Page 73: Lubrication Check Hole

    UXV 500 . LUBRICATION SYSTEM LUBRICATION CHECK HOLE Check Hole Plug/O-ring Remove the check hole plug/O-ring. Start the engine. Check the oil gushed from the hole. If not, stop the engine immediately and determine the cause.

  • Page 74: Oil Pump Removal/Inspection/Installation

    UXV 500 . LUBRICATION SYSTEM Oil Pump Drive Chain Guide OIL PUMP REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH REMOVAL/INSPECTION/INSTALLATI ON” section in the chapter 19). Remove the two bolts and oil pump drive chain guide.
  • Page 75 UXV 500 . LUBRICATION SYSTEM Dowel Pins Remove a bolt and then remove the oil pump holder. Remove the two dowel pins. Remove the two bolts and then remove the oil pump. Holder Oil Pump INSPECTION Oil pump drive chain guide Inspect the drive chain slipper surface of the drive chain guide for wear or damage.
  • Page 76 UXV 500 . LUBRICATION SYSTEM Dowel Pins Install and tighten the two bolts securely. Install two dowel pins Install the holder, then install a bolt but do not tighten. Oil Pump Holder Drive Chain Install the driven gear and drive chain. Driven Gear Install the snap ring.
  • Page 77 UXV 500 . LUBRICATION SYSTEM Oil Pump Drive Chain Guide Install the chain guide, then install and tighten the two bolts securely. Install the oil separator cover, then install and tighten the three bolts in a crisscross pattern in 2 or 3 steps. Oil Separator Cover...

  • Page 78: Oil Pump Disassembly/Inspection/Assembly

    UXV 500 . LUBRICATION SYSTEM Oil Pump Shaft OIL PUMP DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the oil pump shaft. Oil Pump Cover Remove the screw and oil pump cover. Screw Oil Pump Body Dowel Pin Inner Rotor Remove the dowel pin, oil pump outer rotor and inner rotor.
  • Page 79 UXV 500 . LUBRICATION SYSTEM INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. Service limit: 0.2 mm (0.008 in) ＊ Measure at several points and use the largest reading to compare the service limit.
  • Page 80 UXV 500 . LUBRICATION SYSTEM Dowel Pin Oil Pump Cover ASSEMBLY Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor. Install the oil pump shaft. Install the dowel pin onto the oil pump body.

  • Page 81: Right Crankcase Cover Disassembly/Assembly

    UXV 500 . LUBRICATION SYSTEM RIGHT CRANKCASE COVER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the right crankcase cover (refer to the “ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION” in the chapter 17) Right Crankcase Cover Remove the oil seal. Oil Seal Remove the snap ring. Remove the bearing by using the special tool. Special tool: Oil seal &...
  • Page 82 UXV 500 . LUBRICATION SYSTEM ASSEMBLY Install a new bearing by using the special tool. Special tool: Oil seal & bearing drive A120E00014 Bearing Drive Snap Ring Install a new oil seal. Oil Seal 4-13...

  • Page 83: Oil Pressure Relief Valve

    UXV 500 . LUBRICATION SYSTEM Oil Pressure Relief Valve OIL PRESSURE RELIEF VALVE REMOVAL Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in the chapter 11). Remove the pressure relief valve and O-ring from the right crankcase. O-ring Piston INSPECTION...

  • Page 84: Oil Pipe Removal/Installation

    UXV 500 . LUBRICATION SYSTEM Bolts/Washers (on the oil pipe) OIL PIPE REMOVAL/INSTALLATION REMOVAL Remove the two bolts, washers (on the oil pipe), oil pipe and washers (under oil pipe). Oil Pipe/Washer (under oil pipe) Washers INSTALLATIION Install the inner washers on the right crankcase.
  • Page 85 UXV 500 . LUBRICATION SYSTEM Bolts/Washers (on the oil pipe) Apply clean engine oil to the bolts, then install the outer washers and two bolts. Tighten the two bolts to the specified torque. Torque: 3.5 kgf-m (35 N-m, 25.2 lbf•ft) Oil Pipe/Washers (under oil pipe) 4-16...
  • Page 87 . FUEL SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5- 02 TROUBLESHOOTING----------------------------------------------------- 5- 03 FUEL TANK ----------------------------------------------------------------- 5- 04 CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION-- 5- 05 CARBURETOR DISASSEMBLY/INSPECTION/ASSEMBLY ----- 5- 07 AIR CLEANER HOUSING ------------------------------------------------ 5- 16 PAIR SOLENOID VALVE ------------------------------------------------ 5- 17 FUEL FILTER/FUEL PUMP ---------------------------------------------- 5- 18...
  • Page 88 . FUEL SYSTEM UXV 500 Fuel Pump Fuel Tank Fuel Filter...

  • Page 89: Service Information

    . FUEL SYSTEM UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS 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. •...

  • Page 90: Troubleshooting

    . FUEL SYSTEM UXV 500 TROUBLESHOOTING Engine cranks but won’t start Engine lacks power • No fuel in tank • Clogged air cleaner • No fuel to carburetor • Faulty carburetor • Cylinder flooded with fuel • Faulty ignition system •...

  • Page 91: Fuel Tank

    . FUEL SYSTEM UXV 500 FUEL TANK REMOVAL Warning • Keep sparks and flames away from the work area. • Wipe off any spilled gasoline. Key Switch “OFF”. Remove the seat, and center cover. cargo bed Up then remove the fuel cap. Remove the side panel .R.front and protector Fuel tank.

  • Page 92: Carburetor Removal/Choke Inspection/Installation

    . FUEL SYSTEM UXV 500 cleaner housing CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION REMOVAL Remove the center cover screws and center cover . Remove shifting automatic transaxle bolt. Remove the air cleaner housing (refer to the “AIR CLEANER HOUSING” section in this chapter). Disconnect the over flow hose.
  • Page 93 . FUEL SYSTEM UXV 500 O-ring CHOKE INSPECTION Inspection the choke plunger, spring and O- ring for bends, wear or damage. Spring Choke Plunger INSTALLATION Installation is in the reverse order of removal. ＊ Make sure the carburetor was horizontal assy on the intake pipe.

  • Page 94: Carburetor Disassembly/Inspection/Assembly

    . FUEL SYSTEM UXV 500 CARBURETOR DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the carburetor . Loosen the drain screw to drain the gasoline from the float chamber. ＊ • Keep sparks and flames away from the Fuel Drain Plug work area. • Drain gasoline into a clean container. •...
  • Page 95 . FUEL SYSTEM UXV 500 Remove the spring retainer, jet needle. Jet Needle Spring Retainer Piston Valve Remove the 3 screws and float chamber. Float Pull float pin outs, then remove the float and float valve. Float Pin Float Valve...
  • Page 96 . FUEL SYSTEM UXV 500 Slow Jet Needle Jet Holder Remove the slow jet. Remove choke jet. Remove main jet. Remove the needle jet holder. Main Jet Remove the needle jet. Remove the pilot screw, spring, washer and O-ring. ＊ Before pilot screw removal, slowly turn Needle Jet the pilot screw clockwise and count the...
  • Page 97 . FUEL SYSTEM UXV 500 INSPECTION CARBURETOR BODY/JETS CLEANING Check carburetor body and each jet for wear or damage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly-not just the perceived problem area.
  • Page 98 . FUEL SYSTEM UXV 500 Float Float Tang Check the float and float tang for deformation or damage. Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.
  • Page 99 . FUEL SYSTEM UXV 500 Check top cap and spring for cracks and damage. Top Cap Spring Spring Covers Check the diaphragms (coasting enrichment valve and accelerating pump) for tears. Check the spring (coasting enrichment valve and accelerating pump) and cover (coasting enricher and accelerating pump) for damage.
  • Page 100 . FUEL SYSTEM UXV 500 Insert the piston valve into the carburetor body, and check for free movement. If stick is found, replace the part with a new one. Check throttle valve for free movement. If stick is found, replace the part with a new carburetor.
  • Page 101 . FUEL SYSTEM UXV 500 ASSEMBLY (17) Carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the following instructions. ＊ ● Assemble the parts taking consideration of their function. ● Before assembling, wash all of the parts in a clean petroleum based solvent.
  • Page 102 . FUEL SYSTEM UXV 500 Fit a new O-ring in to the float chamber groove securely. O-ring O-ring Small Convex Accelerating Pump Cover Assemble the accelerating pump diaphragm and new O-ring. ＊ Install the accelerating pump diaphragm with the small convex facing Accelerating Pump Diaphragm 5-15...

  • Page 103: Air Cleaner Housing

    . FUEL SYSTEM UXV 500 AIR CLEANER HOUSING Band Screw REMOVAL/INSTALLATION Remove the seat and center covers Loosen the carburetor-to-air cleaner connecting tube band screw. Breather Hose Remove the clip and disconnect the crankcase breather hose from the crankcase. Remove the mounting bolts and then remove the air cleaner housing from the carburetor and the intake duct.

  • Page 104: Pair Solenoid Valve

    . FUEL SYSTEM UXV 500 AIR SOLENOID VALVE Vacuum Hose REMOVAL/INSTALLATION Disconnect air supply hose and vacuum hose from the air solenoid valve, then remove the air solenoid valve from frame. Air Supply Hose AIR Solenoid Valve Installation is in the reverse order of removal.

  • Page 105: Fuel Filter/Fuel Pump

    . FUEL SYSTEM UXV 500 FUEL FILTER/FUEL PUMP FUEL FILTER INSPECTION Visually check the fuel filter. If accumulation of sediment or clogging is found, replace the fuel filter with a new one. Install the fuel filter . Fuel filter Fuel pump coupler FUEL PUMP INSPECTION Measure resistance between the terminals of fuel pump lead wire coupler.
  • Page 106 . FUEL SYSTEM UXV 500 Fuel Pump FUEL PUMP REMOVAL/INSTALLATION Remove the seat. Disconnect the fuel hoses. Disconnect the fuel pump connector. Remove the fuel pump and filter. Installation is in the reverse order of removal. ＊ ● Install the fuel pump with the arrow mark facing up.
  • Page 107 . COOLING SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SYSTEM FLOW PATTERN----------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 4 COOLING SYSTEM TESTING------------------------------------------- 6- 5 COOLANT REPLACEMENT --------------------------------------------- 6- 5 THERMOSTAT-------------------------------------------------------------- 6- 8 WATER PUMP -------------------------------------------------------------- 6-11 RADIATOR ------------------------------------------------------------------ 6-14 FAN MOTOR SWITCH ---------------------------------------------------- 6-15 FAN MOTOR ---------------------------------------------------------------- 6-16...

  • Page 108: System Flow Pattern

    . COOLING SYSTEM UXV 500 SYSTEM FLOW PATTERN...

  • Page 109: Service Information

    . COOLING SYSTEM UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS WARING: Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
  • Page 110 -37℃ -44.5℃ Cautions for Using Coolant: • Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant concentrate + 975cc distilled water is 30%.) • Do not mix coolant concentrate of different brands. • Do not drink the coolant which is poisonous.

  • Page 111: Troubleshooting

    . COOLING SYSTEM UXV 500 TORQUE VALUES Water pump cover bolt 1.3 kgf-m (13 N-m, 9 lbf-ft) Fan motor bolt 0.53 kgf-m (5 N-m, 3.8 lbf-ft) Fan motor switch 1.8 kgf-m (17 N-m, 13 lbf-ft) TROUBLESHOOTING Engine temperature too high •...

  • Page 112: Cooling System Testing

    . COOLING SYSTEM UXV 500 COOLING SYSTEM TESTING Cap Tester RADIATOR CAP INSPECTION Remove the radiator cap (refer to the “COOLANT REPLACEMENT” section in this chapter). Pressure test the radiator cap. Replace the radiator cap if it does not hold Radiator Cap pressure, or if relief pressure is too high or too low.
  • Page 113 . COOLING SYSTEM UXV 500 Radiator Cap REPLACEMENT/AIR BLEEDING Remove the front center cover and right footboard (refer to the “FRAME COVERS” section in the chapter 2). ＊ When filling the system or reserve tank with coolant (checking the coolant level), place the machine in a vertical position on a flat, level surface.
  • Page 114 . COOLING SYSTEM UXV 500 Reserve Tank Cap Place the machine on a flat, level surface. Fill the reserve tank to the upper level (FULL) line. FULL Filler Neck Fill the system with the recommended coolant through the filler opening up to the filler neck.

  • Page 115: Thermostat

    . COOLING SYSTEM UXV 500 THERMOSTAT REMOVAL Remove the nut and thermostat housing stay from the frame. Remove the bolts, housing stay and thermostat housing cover. Housing stay Thermostat Housing Cover O-ring Remove the O-ring from the housing cover. Remove the thermostat. Thermostat Thermostat...
  • Page 116 . COOLING SYSTEM UXV 500 INSPECTION Visually inspect the thermostat for damage. Thermostat Heat the water with an electric heating Thermometer element to operating temperature for five minutes. Suspend the thermostat in heated water to check its operation. ＊ ● Keep flammable materials away from the electric heating element.
  • Page 117 . COOLING SYSTEM UXV 500 Install a new O-ring into the housing cover O-ring groove. Install the housing cover and housing stay to the housing. Tighten the bolts securely. Install the housing stay to the frame. Tighten the nut securely. Fill the system with recommended coolant and bleed the air (refer to the “COOLANT REPLACEMENT”...

  • Page 118: Water Pump

    . COOLING SYSTEM UXV 500 WATER PUMP MECHANICAL SEAL INSPECTION Inspect the coolant leakage. If there is leakage, the mechanical seal is defective, and water pump body should be replaced. Bypass Hose REMOVAL Water Hose Drain the coolant (refer to the “COOLANT REPLACEMENT”...
  • Page 119 . COOLING SYSTEM UXV 500 Water Pump Body Remove the water pump body from the crankcase. Align INSTALLATION Apply engine oil to a new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with oil pump shaft end.
  • Page 120 . COOLING SYSTEM UXV 500 Install the water pump cover and tighten the bolts to the specified toque. Torque: 1.3 kgf-m (13 N-m, 9 lbf-ft) Water Pump Cover/O-ring Water Hose Connect the water hoses and bypass hose, then tighten the hose bands. Fill the system with recommended coolant and bleed the air (refer to the “COOLANT REPLACEMENT”...

  • Page 121: Radiator

    . COOLING SYSTEM UXV 500 Fan Guide RADIATOR REMOVAL Drain the coolant Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2). Remove the four mounting bolt from fan guide and then remove fan guide. Water Filler Hose Fan Motor SW Loosen the hose bands and disconnect the radiator lower water hose, water filler hose,...

  • Page 122: Fan Motor Switch

    . COOLING SYSTEM UXV 500 FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors (refer to the “RADIATOR” section in this chapter). Remove the fan motor switch. Fan Motor Switch INSPECTION Place the fan motor switch in oil contained in a pan as shown and raise the oil temperature gradually to check for the temperature at which the switch starts to...

  • Page 123: Fan Motor

    . COOLING SYSTEM UXV 500 FAN MOTOR Fan Motor Connector REMOVAL Remove the front fender Disconnect the fan motor connector. Remove the four mounting bolts and then remove the fan motor INSPECTION Check the fan motor to operate using an available battery.

  • Page 124: Water Temperature Sensor

    . COOLING SYSTEM UXV 500 Water Temperature Sensor WATER TEMPERATURE SENSOR Remove the center cover and gear shift of lever bolt Disconnect the water temperature sensor connector. Remove the water temperature sensor from the water joint. INSPECTION Water joint Connect the water temperature sensor to the Water Temperature Sensor ohmmeter and dip it in oil contained in a pan which is placed on an electric heater.

  • Page 125: Raidator Reserve Tank

    . COOLING SYSTEM UXV 500 RADIATOR RESERVE TANK REMOVAL Remove the front fender . Remove the two mounting bolts and then remove the radiator reserve tank from frame. Siphon Hose Open the reserve tank cap and drain the coolant from the reserve tank. Disconnect the siphon hose.

  • Page 126: Oil Cooler

    . COOLING SYSTEM UXV 500 OIL COOLER REMOVAL Drain the engine oil and remove the oil filter Cartridge. Drain the coolant from the system. Loosen the hose bands and disconnect the oil Cooler water hose from the cooler. Water Hose Oil Hose Remove the oil cooler mounting bolts, Washers, oil cooler and gasket.
  • Page 127 . COOLING SYSTEM UXV 500 INSTALLATION Install the gasket and oil cooler. Install the washers and tighten the oil cooler bolts to the specified torque. Torque:35N.m(3.5kgf.m,25lbf.ft) Connect the oil cooler water hoses, tighten The hose band securely. Install the oil filter cartridge and fill the crankcase with recommended engine oil.
  • Page 129 7. ENGINE REMOVAL/INSTALLATION UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 7- 1 ENGINE REMOVAL ------------------------------------------------------- 7- 2 ENGINE INSTALLATION ------------------------------------------------ 7- 8...
  • Page 130 7. ENGINE REMOVAL/INSTALLATION UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the machine body, cables and wires during engine removal. • Use shop towels to protect the machine body during engine removal. •...
  • Page 131 7. ENGINE REMOVAL/INSTALLATION UXV 500 Lower Water Hose ENGINE REMOVAL Drain engine oil (refer to the “ENGINE OIL” section in the chapter 3). Remove frame covers and exhaust pipe (refer to the “FRAME COVERS” section in the chapter 2). Drain the engine coolant (refer to the “COOLANT REPLACEMENT”...
  • Page 132 7. ENGINE REMOVAL/INSTALLATION UXV 500 Temperature Sensor Connector Disconnect the water hose, bleed hose and water temperature sensor connectors from water joint. Bleed Hose Water Hose Spark Plug Cap Remove the spark plug cap from cylinder head. Gear Select Lever Guide Bolt Remove the bolt from drive select rod.
  • Page 133 7. ENGINE REMOVAL/INSTALLATION UXV 500 Disconnect the breather hose from cylinder Breather Hose head cover Disconnect the vacuum hose from intake Vacuum Hose Starter Cable pipe. Slide the rubber sleeve back to expose the starter motor wire nut. Remove the starter motor cable nut for disconnect the starter motor cable.
  • Page 134 7. ENGINE REMOVAL/INSTALLATION UXV 500 Disconnect the gear indicator light switch connector. Gear Indicator Light Switch Connector Speed Sensor Connector Disconnect the speed sensor connector. Front Propeller Shaft Remove the bolts and then remove the front propeller shaft from the engine assembly.
  • Page 135 7. ENGINE REMOVAL/INSTALLATION UXV 500 Remove the front lower engine mounting bolt/nut. Remove the four nuts under right and left engine hangers, then remove the engine hangers. Remove the rear lower engine mounting bolt/nut. Lower Engine Mounting Bolt/Nut Remove the upper engine mounting bolt/nut.
  • Page 136 7. ENGINE REMOVAL/INSTALLATION UXV 500 Tap the rear propeller shaft with rubber hammer and remove the rear propeller shaft from the engine assembly. ＊ Take care not to lose the compression spring in the rear drive gear case end. Rise the engine rear , then move the engine from the frame .
  • Page 137 7. ENGINE REMOVAL/INSTALLATION UXV 500 ENGINE INSTALLATION Install the engine assembly into the frame. Apply lightweight lithium-soap base grease to the rear propeller shaft splines. Rear Propeller Shaft Install the rear propeller shaft into the engine assembly. ＊ Apply lightweight lithium-soap base grease to the rear output shaft splines.
  • Page 138 7. ENGINE REMOVAL/INSTALLATION UXV 500 Apply grease Pinion Gear Install the compression spring into the pinion gear. ＊ Apply lightweight lithium-soap base grease to the pinion gear splines. Move the engine rearward and engage the rear propeller shaft into the pinion gear. ＊...
  • Page 139 7. ENGINE REMOVAL/INSTALLATION UXV 500 Apply lightweight lithium-soap base grease Front Propeller Shaft to the front propeller shaft splines and front output splines. Apply grease Install the front propeller shaft into the engine assembly. Front Cooling Duct Install the front cooling duct. ＊...
  • Page 140 7. ENGINE REMOVAL/INSTALLATION UXV 500 Cooling Duct Install the rear cooling duct. ＊ Make sure the lug on the left crankshaft case into the cutout on the rear cooling duct. Install the removed parts in the reverse order of removal. Route the water hoses, wire and cable properly (refer to the “CABLE &...
  • Page 141 8. CYLINDER HEAD/VALVES UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 3 CYLINDER COMPRESSION TEST ------------------------------------- 8- 4 CYLINDER HEAD COVER REMOVAL/INSTALLATION--------- 8- 5 CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY--------- 8- 6 CAMSHAFT REMOVAL/INSPECTION/INSTALLATION --------- 8- 7 ROCKER ARMS REMOVAL/INSPECTION/INSTALLATION ---- 8-15 CYLINDER HEAD REMOVAL/INSTALLATION-------------------- 8-17...

  • Page 142: Schematic Drawing

    8. CYLINDER HEAD/VALVES UXV 500 SCHEMATIC DRAWING...

  • Page 143: Service Information

    8. CYLINDER HEAD/VALVES UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

  • Page 144: Troubleshooting

    8. CYLINDER HEAD/VALVES UXV 500 TORQUE VALUES Cylinder head bolt (1 – 4) 4.8 kgf-m (48 N-m, 35 lbf-ft) Apply engine oil to threads Cylinder head bolt (5 – 13) 2.3 kgf-m (23 N-m, 17 lbf-ft) Apply engine oil to threads Cylinder head nut 1 kgf-m (10 N-m, 7 lbf-ft) Cylinder head cover bolt...

  • Page 145: Cylinder Compression Test

    8. CYLINDER HEAD/VALVES UXV 500 CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug (refer to the “SPARK PLUG” section in the chapter 3). Spark Plug Cap Install a compression gauge into the spark plug hole.

  • Page 146: Cylinder Head Cover Removal/Installation

    8. CYLINDER HEAD/VALVES UXV 500 CYLINDER HEAD COVER REMOVAL/INSTALLATION REMOVAL Disconnect the crankcase breather hose from the cylinder head cover (refer to the “ENGINE REMOVAL” section in the chapter 7). Remove the four bolts/rubber washers and cylinder head cover. Cylinder Head Cover Cylinder Head Cover Packing Remove the cylinder head cover packing.

  • Page 147: Cylinder Head Cover Disassembly/Assembly

    8. CYLINDER HEAD/VALVES UXV 500 CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the three bolts and breather separator. Gasket Remove the gasket. ASSEMBLY Assembly is in the reverse order of disassembly. Torque: Breather separator bolt: 1.3 kgf-m (13 N-m, 9 lbf-ft)

  • Page 148: Camshaft Removal/Inspection/Installation

    8. CYLINDER HEAD/VALVES UXV 500 CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION Bolt Washer REMOVAL Remove the cylinder head cover (refer to the “CYLINDER HEAD COVER REMOVAL/INSTALLATION” section in this chapter). Turn the crankshaft clockwise and align the “T” mark on the flywheel with the index mark on the right crankcase cover (refer to the “VALVE CLEARANCE”section in the chapter 3).
  • Page 149 8. CYLINDER HEAD/VALVES UXV 500 Loosen and remove the eight camshaft holder Bolts bolts in a crisscross pattern in several steps. Camshaft Holder Bolts/Washers Loosen and remove the four camshaft holder bolts/washers in a crisscross pattern in several steps, then remove the camshaft holders.
  • Page 150 8. CYLINDER HEAD/VALVES UXV 500 Cam Chain Slipper INSPECTION Cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage. Camshaft Holders Camshaft holder ＊ Always replace the camshaft holder and cylinder head in pairs Inspect the camshaft surface of each camshaft holder for scoring, scratches, or evidence of insufficient lubrication.
  • Page 151 8. CYLINDER HEAD/VALVES UXV 500 Camshaft Support both ends of the camshaft with V- blocks and check the camshaft runout with a dial gauge. Service limit: 0.05 mm (0.002 in) Inspect camshaft lobes for pitting/scratches/blue discoloration. Measure the cam lobe height. Service Limits: IN : 37.11 mm (1.4844 in) EX: 36.86 mm (1.4744 in) If any defects are found, replace the camshaft...
  • Page 152 8. CYLINDER HEAD/VALVES UXV 500 Cam chain tensioner Check the one-way cam operation (tensioner) Unsmooth operation → Replace. INSTALLATION Turn the crankshaft clockwise, align the “T” mark on the flywheel with the index mark on the right crankcase cover (refer to the “VALVE CLEARANCE”...
  • Page 153 8. CYLINDER HEAD/VALVES UXV 500 Install the cam chain over the cam sprockets Punch Marks and then install the intake and exhaust camshafts. ＊ Install each camshafts to the correct locations. “IN”: no decompressor cam “EX”: has a decompressor cam Make sure the timing marks on the cam sprockets are flush with the cylinder head upper surface and punch marks...
  • Page 154 8. CYLINDER HEAD/VALVES UXV 500 Apply engine oil to cylinder head bolt (No. 1 – 8) threads. Install the four bolts (No. 5 – 8). Install the four bolts/washers (No. 1 – 4). Tighten the holder bolts (No. 1 – 8) in a crisscross pattern in five steps to the specified torque as follow diagram.
  • Page 155 8. CYLINDER HEAD/VALVES UXV 500 Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in five steps to the specified torque as follow diagram.

  • Page 156: Rocker Arms Removal/Inspection/Installation

    8. CYLINDER HEAD/VALVES UXV 500 Rocker Arms ROCKER ARMS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the camshafts (refer to the “CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the rocker arm shafts and washers, then remove the rocker arms. Rocker Arm Shafts/Washers INSPECTION Rocker Arm Shaft Rocker arm shaft...
  • Page 157 8. CYLINDER HEAD/VALVES UXV 500 Rocker Arm Shaft INSTALLATION Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms, rocker arm shafts and washers. Tighten the rocker arm shaft to the specified torque. Torque: 4.5 kgf-m (45 N-m, 32 lbf-ft) Rock Arm Washer 8-16...

  • Page 158: Cylinder Head Removal/Installation

    8. CYLINDER HEAD/VALVES UXV 500 CYLINDER HEAD Intake Pipe REMOVAL/INSTALLATION ＊ Always replace the camshaft holder and cylinder head in pairs Remove the camshafts (refer to the “CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the two bolts and intake pipe. Remove the five bolts, then remove the pair reed valve cover and holder.
  • Page 159 8. CYLINDER HEAD/VALVES UXV 500 Remove the two nuts under the cylinder head. Remove the bolt and then remove the cylinder head. Dowel Pins Remove the dowel pins and gasket. Gasket 8-18...
  • Page 160 8. CYLINDER HEAD/VALVES UXV 500 Dowel Pins INSTALLATION Install the dowel pins and new gasket as shown. Gasket Install the cylinder head. Apply engine oil to the cylinder head bolt (9) threads. Install the bolt (9) but do not tighten it. Camshafts Intake Camshaft Holder Install the camshafts, intake camshaft holder...
  • Page 161 8. CYLINDER HEAD/VALVES UXV 500 Apply engine oil to cylinder head bolt (No. 1 – 8) threads. Install the four bolts (No. 5 – 8). Install the four bolts/washers (No. 1 – 4). Tighten the holder bolts (No. 1 – 9) in a crisscross pattern in five steps to the specified torque as follow diagram.
  • Page 162 8. CYLINDER HEAD/VALVES UXV 500 Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in five steps to the specified torque as follow diagram.
  • Page 163 8. CYLINDER HEAD/VALVES UXV 500 Install and tighten the two nuts under the cylinder head to the specified torque. Torque: 1 kgf-m (10 N-m, 7 lbf-ft) Bolts Install the water stop collar, gasket and water joint. Install and tighten the two bolts to the specified torque.
  • Page 164 8. CYLINDER HEAD/VALVES UXV 500 O-ring Install the new O-ring onto the intake pipe. Intake Pipe Install the intake pipe and tighten the two bolts securely. 8-23...

  • Page 165: Cylinder Head Disassembly/Inspection/Assembly

    8. CYLINDER HEAD/VALVES UXV 500 CYLINDER HEAD DISASSEMBLY/INSPECTION/ Valve Spring Compressor ASSEMBLY Remove the cylinder head (refer to the “CYLINDER HEAD REMOVAL/INSTALLATION” section in this chapter). Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊...
  • Page 166 8. CYLINDER HEAD/VALVES UXV 500 INSPECTION Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D. Measure each valve guide I.D.
  • Page 167 8. CYLINDER HEAD/VALVES UXV 500 Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 3.5 kg (at 28.7 mm, 1.148 in) Outer: 13 kg (at 31.43 mm, 1.2572 in) Measure the spring tilt. Replace if out of specification. Standard: Inner: 1.2 mm (0.048) Outer: 1.2 mm (0.048)
  • Page 168 8. CYLINDER HEAD/VALVES UXV 500 Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters. ＊ Be careful not to damage the valves. 8-27...

  • Page 169: Cam Chain Removal/Inspection/Installation

    8. CYLINDER HEAD/VALVES UXV 500 CAM CHAIN REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cylinder (refer to the Guide Cam Chain “CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 9). Remove the oil pump drive chain (refer to “OIL PUMP REMOVAL/INSTALLATION” section in the chapter 4).
  • Page 170 8. CYLINDER HEAD/VALVES UXV 500 INSTALLATION Guide Cam Chain Installation is in the reverse order of removal. Install the cam chain guides to the right crankcase and tighten the bolts to the specified torque. Torque: 2 kgf-m (20 N-m, 15 lbf-ft) Guide 8-29...
  • Page 171 9. CYLINDER/PISTON UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 9-3...
  • Page 172 9. CYLINDER/PISTON UXV 500 SCHEMATIC DRAWING...
  • Page 173 9. CYLINDER/PISTON UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
  • Page 174 9. CYLINDER/PISTON UXV 500 Cylinder Block Pin CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD REMOVAL/INSTALLATION” section in the chapter 8). Take the block pin out. Remove the water hose from the cylinder. Remove the two cylinder bolts/washers. Water Hose Remove the cylinder.
  • Page 175 9. CYLINDER/PISTON UXV 500 Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
  • Page 176 9. CYLINDER/PISTON UXV 500 Piston/Piston pin Measure the piston O.D. at the point (A) from the bottom and 90° to the piston pin hole. 10 mm Service Limit: 91.9 mm (3.676 in) at (A): 10 mm Calculate the cylinder-to-piston clearance. Measure the piston pin hole.
  • Page 177 9. CYLINDER/PISTON UXV 500 Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
  • Page 178 9. CYLINDER/PISTON UXV 500 Measure the connecting rod small end I.D.. Service Limit: 22.06 mm (0.8824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing ＊...
  • Page 179 9. CYLINDER/PISTON UXV 500 Piston “IN” Mark Cylinder/Piston Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole. Install the piston with the “IN”...
  • Page 180 9. CYLINDER/PISTON UXV 500 Cam Chain Cylinder Block Pin Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. ＊ Be careful not to damage the piston rings and cylinder walls.
  • Page 181 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE PULLEY/DRIVEN PULLEY/CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 10- 1 SERVICE INFORMATION------------------------------------------------ 10- 2 TROUBLESHOOTING----------------------------------------------------- 10- 2 LEFT CRANKCASE COVER REMOVAL/INSTALLATION ------- 10- 3 DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/ INSTALLATION ------------------------- 10- 5 DRIVE PULLEY DISASSEMBLY/INSPECTION/ASSEMBLY ---- 10- 9 DRIVEN PULLEY DISASSEMBLY/INSPECTION/ASSEMBLY-- 10-13...
  • Page 182 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 SCHEMATIC DRAWING 10-1...

  • Page 183: Service Information

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.

  • Page 184: Left Crankcase Cover Removal/Installation

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 LEFT CRANKCASE COVER REMOVAL/INSTALLATION Bolts REMOVAL REMOVAL CTV PARTS ON VEHICLE Key Switch “OFF”. Remove the seat, and center cover. cargo bed Up then remove the fuel cap. Remove the side panel .R. front and protector Fuel tank.
  • Page 185 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Bolts Install the left crankcase cover and tighten the ten bolts diagonally to specified torque. Torque: 1 kgf-m (10 N-m, 7.2 lbf-ft) CVT Cover 10-4...

  • Page 186: Drive Pulley, Drive V-Belt And Driven Pulley Removal/Inspection/ Installation

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/ INSTALLATION Drive Pulley Holder REMOVAL Use the special tool to hold the drive pulley, then remove the nut and washer. Special tool: Drive pulley holder A120E00058 Remove the drive pulley.
  • Page 187 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Remove the five bolts and then remove the Bolts fan guide. Fan Guide INSPECTION Inspect the drive belt for cracks, scaling, Drive Belt chipping or excessive wear. Measure the V-belt width Service limit (A): 30.8 mm (1.232 in) Replace the drive belt if out of specification.
  • Page 188 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Place a block on the plate nut. Block Compress the spring by using a commercially available puller, install the drive belt. ＊ ● The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turning direction.
  • Page 189 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Install the drive pulley assembly. Drive Pulley Holder Install the washer and nut. ＊ Make sure the “OUT SIDE” marks on the washer faces the left crankcase cover. Use the special tool to hold drive pulley, then tighten the nut to the specified torque.

  • Page 190: Drive Pulley Disassembly/Inspection/Assembly

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 DRIVE PULLEY Drive Face Boss DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the drive pulley (refer to “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section) Remove the drive face boss. Ramp Plate Slide Pieces Remove the ramp plate and four slide pieces.
  • Page 191 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 29.5 mm (1.18 in) Movable drive face/Slide pieces/Drive pulley face Check the slide pieces and movable drive face splines for wear, cracks or damage. Check the ramp plate for cracks or damage.
  • Page 192 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Dust Seals Check the dust seals on the movable drive face for wear or damage. Movable Drive Face Drive Face Boss ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss.
  • Page 193 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Install the slide pieces and ramp plate. Ramp Plate Slide Pieces Install the drive face boss. Drive Face Boss 10-12...

  • Page 194: Driven Pulley Disassembly/Inspection/Assembly

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 DRIVEN PULLEY Spring Compressor DISASSEMBLY/INSPECTION/ ASSEMBLY Compressor Nut Nut Wrench DISASSEMBLY Remove the driven pulley (refer to the “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section in this chapter). Use the special tool to remove the nut. Special tool: Driven pulley spring compressor A120E00059...
  • Page 195 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Remove the O-rings and dust seals from the Dust Seal Dust Seal movable driven face. O-ring O-ring Grooves INSPECTION Check the driven pulley for smooth operation. If any scratches or damage is found then replace as a set.
  • Page 196 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Dust Seal Dust Seal ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Apply grease to lips of the new dust seals and install into the movable driven face. Coat new O-rings with grease and install them into the movable driven face grooves.
  • Page 197 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Install spring collar. Spring Compressor Use the special tool to install spring and Compressor Nut Nut Wrench spring seat, then install and tighten the nut to the specified torque. Torque: 7.5 kgf-m (75 N-m, 54 lbf-ft) Special tool: Driven pulley spring compressor A120E00059...

  • Page 198: Clutch Removal/Installation

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 One-way Clutch Bearing CLUTCH REMOVAL/INSTALLATION REMOVAL Remove the fan guide (refer to the “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section in this chapter). Remove the nine bolts and then remove the clutch housing assembly and one-way clutch bearing.
  • Page 199 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Use the special tool to hold clutch carrier assembly. Special tool: Y-type holder A120E00056 Not USA type: Use the 26mm socket wrench to remove the nut and washer. Wrench USA type: Remove the nut and collar. Remove the clutch carrier assembly and collar.
  • Page 200 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Collar INSTALLATION Apply clean engine oil to the clutch carrier assembly and collar, then install the collar and clutch carrier assembly. Clutch Carrier Assembly Install the washer Use the special tools to install and tighten the nut to the specified torque.
  • Page 201 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Dowel Pins Install the dowel pins and gasket. Gasket Nut/Washer One-way Clutch Bearing Apply molybdenum disulfide grease to the one-way clutch bearing, then install it. Install the clutch housing and tighten the bolts to the specified torque in a crisscross pattern in 2-3 steps.

  • Page 202: Clutch Disassembly/Inspection/Assembly

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 CLUTCH DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the clutch housing and clutch carrier assembly (refer to the “CLUTCH REMOVAL/INSTALLATION” section in this chapter). Remove the one-way clutch bearing from the clutch housing. One-way Clutch Bearing Oil Seal Clutch housing removal (not USA type): Remove the oil seal.
  • Page 203 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Clutch Housing Clutch housing removal (USA type): Remove the clutch housing. Oil Seal Remove the oil seal, then remove the bearing. Bearing 10-22...
  • Page 204 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 INSPECTION Check the clutch housing for heat damage, wear or damage. Check the one-way clutch bearing for chafing, wear or damage. ＊ Replace the one-way clutch assembly and clutch housing as a set. Check the clutch shoe for heat damage. Measure the clutch shoe thickness.
  • Page 205 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Check operation (not USA type): Install the one-way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly. When turning the clutch housing clockwise, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty.
  • Page 206 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Snap Ring ASSEMBLY Clutch housing installation (not USA type): Apply clean engine oil, then install the new bearing. Install the snap ring. Bearing Oil Seal Install the clutch housing. Install the snap ring. Apply lightweight lithium-soap base grease to the new oil seal lip, then install the new oil seal.
  • Page 207 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 Oil Seal Apply lightweight lithium-soap base grease to the new oil seal lip, then install the new oil seal. Clutch Housing Install the clutch housing. One-way clutch bearing installation: Install the one-way clutch bearing into the clutch housing.

  • Page 208: Removal Ctv Parts On Vehicle

    10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH UXV 500 REMOVAL CTV PARTS ON VEHICLE Key Switch “OFF”. Remove the seat, and center cover. cargo bed Up then remove the fuel cap. Remove the side panel .R.front and protector Fuel tank. Remove the tank frame. Disconnect the fuel tube from fuel pump.
  • Page 209 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION/TRANSMISSION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 11- 2 TROUBLESHOOTING----------------------------------------------------- 11- 2 SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/INSTALLATION -------------------------------- 11- 3 SECONDARY GEAR SHIMS ADJUSTMENT ------------------------ 11- 8 RIGHT CRANKCASE REMOVAL/INSTALLATION---------------- 11-10 BEARING REPLACEMENT IN THE RIGHT CRANKCASE ------- 11-12 TRANSMISSION REMOVAL/INSPECTION/INSTALLATION --- 11-17 UPPER SHIFT FORK DISASSEMBLY/ASSEMBLY ---------------- 11-25...
  • Page 210 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 11-1...

  • Page 211: Final Reduction/Transmission System

    .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The bevel gear and output shaft can be serviced with the engine installed in the frame. SPECIAL TOOL Y-type holder A120E00056 Bearing puller A120E00037 Bearing drive A120E00014 Nut wrench A120E00066 TORQUE VALUES Crankcase bolt...

  • Page 212: Secondary Drive/Driven Bevel Gear

    .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/INSTAL LATION REMOVAL Drain engine oil into a clean container. (Refer to the “ENGINE OIL” section in the chapter Move the engine assembly forward (refer to the “ENGINE REMOVAL” section in the chapter 6) or remove the rear propeller (refer to the “REAR PROPELLER SHAFT Bevel Gear Case Cover...
  • Page 213 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Front Drive Shaft Install the front drive shaft. Hold universal joint nut by using a suitable bar, then remove the rear propeller shaft nut. Universal Joint Remove the rear middle joint. Rear Middle Joint Output Shaft Tap the output shaft by using a rubber hammer, then remove the output shaft,...
  • Page 214 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Secondary Drive Bevel Gear/Shim Using a chisel, unlock the nut. Hold the driven pulley by using the special tool (refer to the “DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/INSTALLATIO N” section in the chapter 10), then remove the nut.
  • Page 215 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Inspect the rear middle joint splines for wear or damage. Inspect the output shaft splines for wear or damage. Secondary Drive Bevel Gear/Shim INSTALLATION Install the shim and secondary drive bevel gear. Holder the driven pulley by using the special tool, then install and tighten the nut to the specified torque.
  • Page 216 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Front Drive Shaft Install the output shaft, secondary driven bevel gear and shim Install the rear middle joint. Install the front drive shaft. Hold universal joint nut by using a suitable bar, then install and tighten the rear middle joint nut to the specified torque.
  • Page 217 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM SECONDARY GEAR SHIMS ADJUSTMENT Set a dial gauge on the driven bevel gear as shown. 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.
  • Page 218 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: ● Remove the driven bevel gear. ● Clean and degrease several teeth of the drive and driven bevel gears.

  • Page 219: Removal/Inspection/Installation

    .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM RIGHT CRANKCASE REMOVAL/INSTALLATION REMOVAL Remove the cam chain (refer to the “CAM CHAIN REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 8) Remove the secondary drive and driven bevel gear (refer to the “SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/ INSTALLATION”...
  • Page 220 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Remove the fifteen bolts from right crankcase. Remove the two dowel pins. INSTALLATION Apply a light but through coating of liquid gasket (Threebond 1215 or equivalent) to all crankcase mating surfaces except the oil passage area.

  • Page 221: Bearing Replacement In The Right Crankcase

    .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Install and tighten the bolts in a crisscross pattern in 2 or 3 steps Torque: 1.2 kgf-m (12 N-m, 8.6 lbf-ft) Apply oil Washer Plug Stopper Install the stopper, spring, washer and plug. Tighten the stopper plug to the specified torque.
  • Page 222 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Install the new balance Bearing Drive shaft/countershaft/primary drive shaft bearing by using the special tool. Special tool: Bearing driver A120E00014 Set Plate DRIVE SHAFT BEARING REPLACEMENT Remove the four bolts and two set plates. Remove the bearing.
  • Page 223 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Rear Side Bearing OUTPUT SHAFT FRONT/REAR BEARING REPLACEMENT ＊ The output shaft bearings can be replaced when the crankcase is assembly. Front Side Bearing REAR SIDE BEARING Remove the oil seal. Remove the nut by using the special tool. Special tool: Nut wrench A120E00066...
  • Page 224 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Install and tighten the nut to the specified torque by using the special tool. Torque: 11 kgf-m (110 N-m, 79.2 lb-ft) Special tool: Nut wrench A120E00066 Apply clean engine oil to the new oil seal lip then install the oil seal.
  • Page 225 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Install the snap ring. Apply clean engine oil to the new oil seal lip then install the new seal. Snap Ring Oil Seal 11-16...

  • Page 226: Transmission Removal/Inspection/Installation

    .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Shift Arm TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the bolt and then remove the shift arm. Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in this chapter) Bolt Shift Shaft Remove the shift shaft. Guide Bar Remove the transmission guide bar.
  • Page 227 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Upper Shift Fork Lower Shift Fork Remove the upper shift fork. Remove the lower shift fork. Remove the shift cam. Shift Cam Countershaft Assembly Remove the countershaft and driveshaft as an assembly. Disassemble the countershaft and the driveshaft.
  • Page 228 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Primary Drive Shaft Remove the primary drive shaft. Spring Remove the bolt/washer, then remove the stopper lever and spring. Stopper Lever Bolt/Washer INSPECTION Guide bar Measure the guide bar runout. Out of specification → Replace. Service Limit: Less than 0.03 mm (0.0012 in) ＊...
  • Page 229 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Pawl Cam Follower Upper shift fork Inspect the shift fork cam follower and shift fork pawl. Scoring/beads/wear → Replace a set. Inspection the spring. Cracks or damage→ Replace a set.. Spring Cam Follower Lower shift fork Inspect the shift fork cam follower and shift fork pawl.
  • Page 230 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Spring Stopper lever Check the stopper lever pawl for bends, damage or wear. Inspect the spring for cracks or damage. Stopper Lever Pawl Check the shift cam groove and shift cam gear. Wear or damage → Replace. Inspect shift shaft gear.
  • Page 231 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Stopper Lever Shaft INSTALLATION Make sure the shaft nut specified torque in the V-belt compartment while holds the stopper lever shaft. Torque: 3 kgf-m (30 N-m, 21.6 lbf-ft) Stopper Lever Hook the spring onto the hook part of the stopper lever, squeeze the spring in to the groove of the left crankcase.
  • Page 232 .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Primary Drive Shaft Countershaft Assembly Apply clean engine oil to the countershaft assembly, driveshaft assembly and primary drive shaft. Install the primary drive shaft. Install the countershaft and drive shaft assemblies as a set into the left crankcase. Drive shaft Assembly Apply clean engine oil to the shift cam, then install the shift cam.
  • Page 233 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Guide Bar Apply clean engine oil to the guide bar, install the guide bar. Align The Marks Install the shift shaft. ＊ Align the mark on the shift shaft gear with the mark on the shift cam gear. Shift Shaft Check the transmission operation.

  • Page 234: Upper Shift Fork Disassembly/Assembly

    .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Snap Ring/Washer Spring UPPER SHIFT FORK DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the upper shift fork (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the snap ring, washer and fork. Fork Washer Cam Pawl Remove the spring, cam pawl and washer.

  • Page 235: Drive Shaft Disassembly/Assembly/Inspection

    .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM Reverse Gear DRIVE SHAFT DISASSEMBLY/ASSEMBLY/ INSPECTION DISASSEMBLY Remove the drive shaft assembly (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the washer (thick) and reverse gear. Washer (Thick) Washer (Thin) Remove the washer (thin). ASSEMBLY/INSPECTION Inspect the gear teeth.

  • Page 236: Countershaft Disassembly/Assembly/Inspection

    .FINAL REDUCTION/ TRANSMISSION SYSTEM UXV 500 Washer Washer COUNTERSHAFT DISASSEMBLY/ASSEMBLY/ INSPECTION DISASSEMBLY Remove the countershaft assembly (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the washer and high drive gear. High Drive Gear High/Low Gear Clutch Remove the high/low gear clutch dog Stopper Wheel Remove the clip, then remove the washer and low drive gear.
  • Page 237 .FINAL REDUCTION/ UXV 500 TRANSMISSION SYSTEM ASSEMBLY/INSPECTION Washer Washer Washer Clip Countershaft Stopper Wheel Reverse Drive Gear High Drive Gear Washer High/Low Gear Clutch dog Clip Low Drive Gear Clip Reverse Gear Clutch dog Inspect the gear teeth. Clip Blue discoloration/pitting/wear → Replace. Inspect the mated dogs.
  • Page 239 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 12- 2 TROUBLESHOOTING----------------------------------------------------- 12- 2 CRANK SHAFT AND BALANCE SHAFT REMOVAL/INSPECTION/INSTALLATION -------------------------- 12- 3 BEARING/OIL SEAL REPLACEMENT IN THE LEFT CRANKCASE---------------------------------------------------------------- 12- 6 12-0...
  • Page 240 .LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 12-1...
  • Page 241 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. −Cylinder head ( Chapter 8) −Cylinder/piston ( Chapter 9) −Drive and driven pulleys ( Chapter 10) −A.C.
  • Page 242 .LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 Balance Shaft Crankshaft CRANKSHAFT AND BALANCE SHAFT REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in the chapter 11). Remove the crankshaft and balance shaft together. INSPECTION Balance shaft Inspect the balance shaft gear teeth.
  • Page 243 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 Measure the connecting rod small end free play (A). Out of specification: 0.8 ~ 1 mm (0.032 ~ 0.04 in) → Replace the crankshaft. Measure the crankshaft run out (B). Service Limit (replace if over): 0.1 mm (0.004 in) Measure the connecting rod big end side clearance (C).
  • Page 244 .LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 Mark (on the Balance Shaft) INSTALLATION Install the balance shaft and crankshaft into the left crankcase. ＊ Align the mark on the balance shaft with the mark on the crankshaft. Mark (on the Crankshaft) 12-5...
  • Page 245 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT UXV 500 Bearing Puller Primary Drive Shaft Bearing BEARING/OIL SEAL REPLACEMENT IN THE LEFT CRANKCASE BALANCE SHAFT/COUNTERSHAFT/ PRIMARY DRIVE SHAFT/BALANCE SHAFT BEARING REPLACEMENT Remove the balance shaft/countershaft/primary drive shaft /drive shaft bearing by using the special tool. Special tool: Bearing puller A120E00037...
  • Page 247 . DRIVE TRAIN UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE TRAIN __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 13- 2 TROUBLESHOOTING----------------------------------------------------- 13- 2 FRONT ASSY CVJ REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 13- 3 FRONT ASSY CVJ DISASSEMBLY/INSPECTION/ ASSEMBLY------------------------------------------------------------------ 13- 5 FRONT GEAR CASE REMOVAL/INSPECTION/INSTALLATION - 13-11 FRONT GEAR CASE DISASSEMBLY/INSPECTION/ASSEMBLY13-14 REAR ASSY GEAR CASE REMOVAL/INSPECTION/ INSTALLATION ---------------------------------------------------------------------------------- 13-19...
  • Page 248 . DRIVE TRAIN UXU 500 FRONT DRIVE REAR DRIVE 13-1...

  • Page 249: Service Information

    . DRIVE TRAIN UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • Too little backlash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. • Stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive assembly locking up, causing loss of control of the machine and possible injury to the rider.

  • Page 250: Front Assy Cvj Removal/Inspection/ Installation

    . DRIVE TRAIN UXU 500 FRONT CVJ ASSY REOMVAL/INSPECTION/ INSTALLATION REMOVAL Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14). Remove the front cvj assy from front assy gearcase. Front Cvj Assy SIEP 1:Drain gear oil SIEP 2:Pushing and pulling the front assy cvj from front assy gearcase.
  • Page 251 . DRIVE TRAIN UXV 500 Inspect the free play by using a push-and- pull motion (thrust movement). Excessive play → Replace the joint assembly. INSTALLATION Install a new circlip into its groove in the splines. Circlip Apply lightweight lithium-soap base grease to the splines of the drive shafts and install the cvj to the front assy gearcase.

  • Page 252: Assembly

    . DRIVE TRAIN UXU 500 FRONT DRIVE AXLE DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front drive axle Remove the boot band of the case side joint. Band Slide the boot toward the center of the front cvj assy and remove the circlip from the case side joint.
  • Page 253 . DRIVE TRAIN UXV 500 Wipe off any grease and remove the snap ring from the groove on the front drive axle. Snap Ring Remove the cage and boot from the front assy cvjs. ＊ Do not disassemble the wheel side joint. If any damages are found, replace the wheel side joint with a new one.
  • Page 254 . DRIVE TRAIN UXU 500 Inspect the front cvj assy spline for wear or damage. If any damages are found, replace them with a new one. Inspect the front cvj assy for bends. If any damages are found, replace them with a new one.
  • Page 255 . DRIVE TRAIN UXV 500 Fit a boot on the drive shaft end, fitting the small diameter side of the boot to the shaft groove, fix its end with a new band. Band Cage Install the cage on the shaft. ＊...
  • Page 256 . DRIVE TRAIN UXU 500 Apply molybdenum disulfide grease to the entire surface of the cage and the inside of the case side joint/wheel side joint. Position Case side joint Wheel side joint Grease Quantity 85 g (2.8 oz) 45 g (1.5 oz) ＊...
  • Page 257 . DRIVE TRAIN UXV 500 After fitting the boot on the case side joint, insert a screw driver into the boot on the case side joint and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure.

  • Page 258: Front Gear Case Removal/Inspection/Installation

    . DRIVE TRAIN UXU 500 FRONT ASSY GEARCASE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Drain the front assy gearcase oil (refer to the “FRONT DRIVE GEAR OIL” in the chapter 3). Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14).
  • Page 259 . DRIVE TRAIN UXV 500 Remove the shaft input from front propeller shaft. Front Propeller Shaft Remove 2 front gear case mounting bolts/nuts from frame, then remove the case out of the frame. INSPECTION Check the breather rubber case for wear or damage.
  • Page 260 . DRIVE TRAIN UXU 500 INSTALLATION Install the front drive case into the frame. Install and tighten the two mounting bolts/nuts to the specified torque. Torque: 4 kgf-m (40 N-m, 29 lbf-ft) Install the front propeller shaft. Front Propeller Shaft Connect all wire connectors and then install.

  • Page 261: Front Gear Case Disassembly/Inspection/Assembly13-14

    . DRIVE TRAIN UXV 500 FRONT ASSY GEAR CASE DISASSEMBLY/INSPECTION/ ASSEMBLY Remove the front drive case assembly (refer to the “FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the 3 bolts and then remove the 2WD/4WD shifting motor assembly. Shifting Motor Assembly Remove the differential lock lever wire.
  • Page 262 . DRIVE TRAIN UXU 500 Remove the clip from shaft input Disconnect the shaft input Remove the nine bolts from left gear case in a crisscross pattern. Pry the case at the arrows as shown by using a screwdriver, then remove the right gear case.
  • Page 263 . DRIVE TRAIN UXV 500 Remove front gear ring from gear case Using the 48mm internal Hex Socket Into the housing gear case Disconnect the front gear ring Remove the 2WD/4WD shifting 13-16...
  • Page 264 . DRIVE TRAIN UXU 500 Using the SPECIAL TOOL:A120F00025 Tighten to 125 ft-lb And hammer./screwdriver Remove the pinion gear from the gear case housing. SPECIAL TOOL:A120F00025 SPECIAL TOOL:A120F00025 Secure the pinion gear in a bearing puller. Then remove the pinion bearing using a press.
  • Page 265 . DRIVE TRAIN UXV 500 Remove Needle Bearing Using the hammer./screwdriver Remove the Needle bearing. Remove and Installing Axle Bearing Using a hammer./tool Remove the bearing. Using a hammer./tool installing new bearing. Into the housing. 13-18...

  • Page 266: Rear Assy Gear Case Removal/Inspection/ Installation

    . DRIVE TRAIN UXU 500 REAR ASSY GEAR CASE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the left rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 15). Remove the cvj assy right rear using Suitable tools. Using hammer remove the cvj assy left rear 13-19...
  • Page 267 . DRIVE TRAIN UXV 500 Remove 2 rear gear case mounting bolts/nuts from frame, then remove the case out of the frame. Remove 1 bolt from holder disc rear brake, then remove the holder disc rear brake Remove 4 bolts from bracket caliper, then remove the bracket caliper 13-20...
  • Page 268 . DRIVE TRAIN UXU 500 Remove 7 bolts from R side case rear final, then remove R side case rear final L side case rear Gear Ring Shim Ring Gear 13-21...
  • Page 269 . DRIVE TRAIN UXV 500 Remove the bearing lock nut by using special tool. Special tool: Bearing lock nut wrench A120F00020 Using the SPECIAL TOOL:A120F00026 Remove the pinion gear from the gear case housing. 13-22...
  • Page 270 . DRIVE TRAIN UXU 500 SPECIAL TOOL:A120F00026 13-23...
  • Page 271 . DRIVE TRAIN UXV 500 Secure the pinion gear in a bearing puller. Then remove the pinion bearing using a press. Account for a collar and a bearing. Needle Bearing Remove the needle bearing. by using the special tools. Special tool: Bearing puller A120E00037 13-24...
  • Page 273 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 14- 2 TROUBLESHOOTING----------------------------------------------------- 14- 3 FRONT WHEEL REMOVAL/INSPECTION/INSTALLATION ---- 14- 4 FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 5 FRONT SHOCK ABSORBER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 7 STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 8...
  • Page 274 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 14-1...
  • Page 275 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake disk •...

  • Page 276: Troubleshooting

    FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •Insufficient tire pressure • Bent rim • Excessive wheel bearing play • Bent spoke plate • Faulty tire • Improperly tightened axle nut Steers to one side or does not track straight •...

  • Page 277: Front Wheel Removal/Inspection/Installation

    FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove four nuts from front wheel. Elevate the front wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is Wheel Hub Nut Cap no danger of it falling over.

  • Page 278: Front Wheel Hub Removal/Inspection

    FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 Nut/Washer FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove the front wheel ( refer to the “ FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Elevate the front wheels by placing a suitable stand under the frame.

  • Page 279: Installation

    FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 Nut/Washer INSTALLATION Install the wheel hub, washer and nut. ＊ Apply grease onto the wheel hub splines. Apply the front brake and then tighten the nut to the specified torque. Torque: 20 kgf-m (200 N-m, 145 lbf-ft) Install the cotter pin and band ends of cotter pin.
  • Page 280 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 FRONT SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION REMOVAL Remove the front shock absorber upper mount and lower mount bolts/nuts, then remove the front shock absorber. Shock Absorber INSPECTION Bush Collar/Bush/Dust Seals Inspect the shock absorber rod. Bends/damage →Replace the shock absorber assembly.

  • Page 281: Steering Knuckle Removal/Inspection

    FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Elevate the front wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over. Remove the front wheel hub Plate Remove the three bolts and brake disc protection plate.
  • Page 282 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 Release the tie-rod ball joint/upper arm ball Apply grease Tie-rod joint off the knuckle. Apply grease to the ball joint remover at the point shown. Remove the knuckle from the upper and lower arms 14-9...
  • Page 283 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 Knuckle End Boot INSPECTION Inspect the knuckle end boot for wear or damage. If any damages are found, replace the Inspect the dust seal lips for wear or knuckle end with a new one. damage.
  • Page 284 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 INSTALLATION Apply lightweight lithium-soap base grease to the bearings of the steering knuckle and lips of the dust seal before install the steering knuckle. Install the steering knuckle onto the upper and lower front arms and tighten the nuts to the specified torque.
  • Page 285 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 Install the brake disc protection plate and then tighten the three bolts securely. Plate 14-12...
  • Page 286 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 STEERING KNUCKLE DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the dust seals. Dust Seal Dust Seal nspect the inner race play of the bearing by hand while it is in the steering knuckle. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.
  • Page 287 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 ASSEMBLY Apply lightweight lithium-soap base grease to the new bearings of the steering knuckle and lips of the new dust seal before install them. Spacer Install the new inner bearing by using the special tool.
  • Page 288 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM UXV 500 STEERING WHEEL AND STEERING SHAHT REMOVAL Remove: Wheel cap(1) Steering wheel mounting nut and washer(2) Torque: 5.3 kgf-m ( 52N-m, 38 lbf-ft) Steering wheel(3) 14-15...
  • Page 289 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM UXV 500 Remove: Horn switch Main shaft mounting bolts(4) Main shaft clamp bolt(5) Main shaft(6) Torque(4): 3.2 kgf-m 32N-m, 23 lbf-ft) Remove: Steering gear shaft clamp bolt(7) Intermediate shaft(8) Torque: 2.7kgf-m ( 27N-m, 19.5 lbf-ft) STEERING WHEEL AND MAIN SHAFT INSTALLATION Grease:...
  • Page 291 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/SHOCK ABSORBER/SWING ARM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 15- 2 TROUBLESHOOTING----------------------------------------------------- 15- 2 REAR WHEEL REMOVAL/INSPECTION/INSTALLATION ------ 15- 3 REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 15- 4 REAR SHOCK ABSORBER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 15- 6 STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION...
  • Page 292 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 15-1...

  • Page 293: Service Information

    REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake disk •...

  • Page 294: Rear Wheel Removal/Inspection/Installation

    REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove four nuts from rear wheel. Elevate the rear wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over.

  • Page 295: Rear Wheel Hub Removal/Inspection

    REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 Nut/Washer REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove the rear wheel . Elevate the rear wheels by placing a suitable stand under the frame. ＊ Cotter Pin Support the machine securely so there is no danger of it falling over.

  • Page 296: Installation

    REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 Apply grease INSTALLATION Install the wheel hub and nut. ＊ Apply lightweight lithium-soap base grease onto the wheel hub splines, rear axle splines and dust seal lips of the axle housing. Apply grease Nut/Washer Apply the front brake and then tighten the nut to the specified torque.
  • Page 297 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 REAR SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION REMOVAL Remove the rear shock absorber upper mount nut and washer. Remove the lower mount bolt/nut, then remove the rear shock absorber. Shock Absorber INSPECTION Inspect the shock absorber rod. Bush Collar/Bush/Dust Seals Bends/damage →Replace the shock...

  • Page 298: Steering Knuckle Removal/Inspection/ Installation

    REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 Apply grease STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Elevate the rear wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over. Remove the rear wheel hub Remove the cotter pin and nut from the tie- rod end.
  • Page 299 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 Knuckle End Boot INSPECTION Inspect the knuckle end boot for wear or damage. If any damages are found, replace the knuckle end with a new one. Dust Seal Dust Seal 15-8...
  • Page 300 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 INSTALLATION Install the tie-rod onto the steering knuckle and tighten the nut to the specified torque. Torque: 4.8 kgf-m (48 N-m, 34 lbf-ft) Install the luck 2 bolts ＊ ● Do not apply oil to the seat of the nuts. ●...
  • Page 301 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 Dust Seal STEERING KNUCKLE DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the dust seals. nspect the inner race play of the bearing by hand while it is in the steering knuckle. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.
  • Page 302 REAR WHEEL/SHOCK ABSORBER/SWING ARM UXV 500 ASSEMBLY Apply lightweight lithium-soap base grease to the new bearings of the steering knuckle and lips of the new dust seal before install them. Install the new inner bearing by using the special tool. Special tool: Oil seal and bearing driver A120E00014...
  • Page 303 . BRAKE SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ BRAKE SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 16- 1 TROUBLESHOOTING----------------------------------------------------- 16- 2 BRAKE PADS REPLACEMENT----------------------------------------- 16- 3 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 16- 8 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 16- 9 FRONT BRAKE FLUID CHANGE/AIR BLEED ---------------------- 16-10 REAR BRAKE FLUID CHANG/AIR BLEED-------------------------- 16-13 REAR BRAKE/PARKING BRAKE CALIPER REMOVAL/ INSPECTION/INSTALLATION------------------------------------------ 16-20...

  • Page 304: Service Information

    . BRAKE SYSTEM UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake pads and brake disk. • Drain the brake fluid from the hydraulic brake system before disassembly. • Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads.

  • Page 305: Troubleshooting

    . BRAKE SYSTEM UXV 500 TROUBLESHOOTING Loose brake lever Tight brake Pedal • Air in hydraulic brake system •Seized piston • Brake fluid level too low •Clogged hydraulic brake system • Hydraulic brake system leakage •Smooth or worn brake pad Poor brake performance Brake noise •...

  • Page 306: Brake Pads Replacement

    . BRAKE SYSTEM UXV 500 BRAKE PADS REPLACEMENT FRONT BRAKE PADS Remove the front wheel. ( refer to the “ FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION ” section in the chapter 14 ). Remove the two brake pad pins from the brake caliper. Remove the two mounting bolts from brake caliper and then remove brake caliper.
  • Page 307 . BRAKE SYSTEM UXV 500 A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins. Install the brake caliper mounting bolts to the specified torque.
  • Page 308 . BRAKE SYSTEM UXV 500 REAR BRAKE PADS Rear brake Remove the rear wheel. ( refer to the “ REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION ” section in the chapter 15 ). The replacement of rear brake and front brake pads are the same. Rear brake (combined) Remove the rear wheel.
  • Page 309 . BRAKE SYSTEM UXV 500 Compress the brake caliper holder and remove brake pads. A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins.
  • Page 310 . BRAKE SYSTEM UXV 500 Install the brake caliper mounting bolts to the specified torque. Torque: 2.7 kgf-m (27Nm, 19.5 lbf-ft) Tighten the brake pad mounting pins. Torque: 1.8 kgf-m (18 Nm, 13 lbf-ft) 16-7...

  • Page 311: Front Brake Discs Removal/Inspection

    . BRAKE SYSTEM UXV 500 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the front wheel hub (refer to the “FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14). Remove the four bolts and then remove the brake disc. INSPECTION Measure the brake disc thickness.

  • Page 312: Rear Brake Disc Removal/Inspection

    . BRAKE SYSTEM UXV 500 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the rear wheel hub Remove the rear wheels. Remove the rear drive bolts. Disconnect the rear drive and shaft Rear propeller connect position(holder disk rear brake). Remove the rear drive Remove the 5 bolts and then remove the brake disc.(Use the impact driver remove it) INSPECTION...

  • Page 313: Front Brake Fluid Change/Air Bleed

    . BRAKE SYSTEM UXV 500 FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD) BRAKE FLUID CHANGE Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. ＊ Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
  • Page 314 . BRAKE SYSTEM UXV 500 Connect a transparent hose to the right caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose. Then, tighten the bleed valve nut.
  • Page 315 . BRAKE SYSTEM UXV 500 BRAKE SYSTEM BLEEDING 1. Connect a transparent hose to the bleed valves (right and left caliper). 2. Fully apply the brake pedal after continuously pull it several times. Then, loosen the right caliper bleed valve nut to bleed air from the brake system.
  • Page 316 . BRAKE SYSTEM UXV 500 REAR BRAKE FLUID CHANGE/AIR BLEED BRAKE LEVER Brake fluid change Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. ＊ Reservoir Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
  • Page 317 . BRAKE SYSTEM UXV 500 Brake system bleeding Bleed Valve 1. Connect a transparent hose to the bleed valve. 2. Fully apply the brake pedal after continuously to tread it several times. Then, loosen the caliper bleed valve nut to bleed air from the brake system. 3.
  • Page 318 . BRAKE SYSTEM UXV 500 Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.

  • Page 319: Rear Brake/Parking Brake Caliper Removal

    . BRAKE SYSTEM UXV 500 Parking Brake Cable REAR BRAKE/PARKING BRAKE CALIPER REMOVAL/INSTALLATION (ON ROAD) Drain the brake fluid from the hydraulic brake system (refer to the “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter). Disconnect the parking brake cable from the caliper.
  • Page 320 . BRAKE SYSTEM UXV 500 BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front or rear brake caliper (refer to the “FRONT BRAKE CALIPERS REMOVAL/INSTALLATION” section or “REAR BRAKE CALIPERS REMOVAL/INSTALLATION” section in this chapter). Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper.
  • Page 321 . BRAKE SYSTEM UXV 500 Push the piston dust seal inward to remove. Dust Seal Inner Oil Seal Pushing the piston oil seal outward to remove it. Clean the seals groove with brake fluid. ＊ Be careful not to damage the piston surface.
  • Page 322 . BRAKE SYSTEM UXV 500 ASSEMBLY ＊ ● Wash the brake caliper components with new brake fluid before reassembly. ● Do not wipe the brake fluid off with a rag after washing the components. ● When washing the components, use the specified brake fluid (DOT 4).
  • Page 323 . BRAKE SYSTEM UXV 500 REAR BRAKE/PARKING BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY/INSPECTION Remove parking brake caliper (refer to the “REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION ” section in this chapter). (ON ROAD Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the...
  • Page 324 . BRAKE SYSTEM UXV 500 Dust Boot Inspect the dust boots for deterioration or damage. If any damages are found, replace them with a new ones. Remove the caliper bracket. Remove the dust boot. Caliper Bracket Dust Seal Piston Seal Remove the dust seal and piston seal.
  • Page 325 . BRAKE SYSTEM UXV 500 Dust Boot Drive Bolt Inspect the dust boot for deterioration or damage. If any damage is found, replace it with a new one. Remove the drive bolt and dust boot. Brake Shaft Shaft Guide Inspect the drive shaft and shaft guide for wear or damage.
  • Page 326 . BRAKE SYSTEM UXV 500 O-ring Remove the O-ring. O-ring Inspect the O-ring for wear or damage. If any damages are found, replace it with a new one. O-ring INSTALLATION Apply silicone grease to the new O-ring, then install the new O-ring. 16-23...
  • Page 327 . BRAKE SYSTEM UXV 500 Parking Brake Case Install the parking brake case and two bolts. Tighten the bolts securely. Piston Seal/Dust Seal Apply silicone grease to the new piston seal and new dust seal, then install them. Install the piston. Piston Dust Boot Apply silicone grease to the brake shaft, then...
  • Page 328 . BRAKE SYSTEM UXV 500 Dust Boot Press the piston and turn the brake shaft counterclockwise to expand boot, then the brake shaft does not touch piston. Piston Parking Brake Arm Spring Install the parking brake arm and spring. ＊ Align the parking brake arm with the brake fluid inlet hole as shown.
  • Page 329 . BRAKE SYSTEM UXV 500 Dust Boot Install the dust boots. Apply silicone grease to caliper bracket, then install it. Caliper Bracket Install the spring plate. Spring Plate Install the parking brake caliper (refer to the “REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION ”...

  • Page 330: Brake Master Cylinders Removal / Installation

    . BRAKE SYSTEM UXV 500 BRAKE MASTER CYLINDERS REMOVAL / INSTALLATION REMOVAL Front/rear master cylinder Remove the brake reservoir cap and drain the brake fluid from the hydraulic brake system Reservoir ＊ 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 331: Brake Padel

    . BRAKE SYSTEM UXV 500 Remove the rear stop switch spring and rin comp brake rod then remove the master cylinder. rear stop switch spring Installation is in the reverse order of removal. BRAKE PEDAL Remove the E -ring from the brake pedal Remove the rear stop switch spring and rin comp brake rod then remove the brake pedal.

  • Page 332: Brake Assy Parking

    . BRAKE SYSTEM UXV 500 BRAKE ASSY PARKING Remove the 2 bolts from the brake assy parking Remove the brake Parking switch connector and brake parking wire nuts then remove brake parking wire. Remove the brake assy parking switch Connector Connector 16-29...

  • Page 333: Rear Brake Disk

    . BRAKE SYSTEM UXV 500 REAR BRAKE DISK REMOVAL Remove the two bolts attaching the skid plate. Remove the skid plate. skid plate Drain out the rear gear box oil as picture Remove the three bolts attaching the muffler. Remove the muffler. bolts 16-30...
  • Page 334 . BRAKE SYSTEM UXV 500 Remove the four nuts attaching the rear wheels. Remove the rear wheels. Remove the cotter pin. Remove the hub nut. Remove the rear wheel hub. Cotter Pin Hub Nut Cotter Pin 16-31...
  • Page 335 . BRAKE SYSTEM UXV 500 Remove the bolts/nut. Remove the knuckle attaching the upper arm as picture. Bolt/nut knuckle Remove the CVJ ASSY attaching the rear gear box assembly. Rear Gear Box CVJ ASSY 16-32...
  • Page 336 . BRAKE SYSTEM UXV 500 Remove the two bolts attaching the rear gear box. Remove the caliper from rear gear box. Caliper Remove the boot attaching the transmission out shaft. 16-33...
  • Page 337 . BRAKE SYSTEM UXV 500 Remove two rear gear box mounting bolts/nuts from frame, pull the rear gear box back and rotate 90°then separate the rear gear box from transmission output shaft. Remove the rear gear box assembly. Remove the rear brake disk.. Remove the five bolts attaching the rear brake disk.
  • Page 339 . BATTERY/CHARGING SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT/CHARGING CIRCUIT ----------- 17- 1 SERVICE INFORMATION------------------------------------------------ 17- 2 TROUBLESHOOTING----------------------------------------------------- 17- 4 BATTERY -------------------------------------------------------------------- 17- 5 CHARGING SYSTEM INSPECTION ----------------------------------- 17- 6 ALTERNATOR CHARGING COIL-------------------------------------- 17- 7 REGULATOR/RECTIFIER------------------------------------------------ 17- 8 ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 17-11...
  • Page 340 . BATTERY/CHARGING SYSTEM UXV 500 CHARGING SYSTEM LAYOUT Regulator/ Rectifier Battery CHARGING CIRCUIT 17-1...
  • Page 341 . BATTERY/CHARGING SYSTEM UXV 500 SERVICE INFORMATION GENERAL CAUTION • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
  • Page 342 . BATTERY/CHARGING SYSTEM UXV 500 BATTERY CHARGING • This model comes with a maintenance free (MF) battery. Remember the following about MF batteries. ─ Use only the electrolyte that comes with the battery. ─ Use all of the electrolyte ─ Seal the battery properly ─...

  • Page 343: Troubleshooting

    . BATTERY/CHARGING SYSTEM UXV 500 TROUBLESHOOTING Battery is damaged or weak Remove the battery. •Faulty battery Incorrect Check the battery condition. Correct Disconnect the regulator/rectifier Incorrect connectors and recheck the battery Install the battery. current leakage. Check the battery current leakage. Correct Specified current leakage: 0.5 Ma Incorrect...

  • Page 344: Battery

    . BATTERY/CHARGING SYSTEM UXV 500 BATTERY REMOVAL/INSTALLATION Battery removal 1. Make sure the ignition switch is OFF. 2. Remove the under hood (refer to the “FRAME COVERS” section in the chapter 2) 3. Release the rings and remove the rubber band (1).

  • Page 345: Charging System Inspection

    . BATTERY/CHARGING SYSTEM UXV 500 BATTERY CHARGING Remove the battery. Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. ＊ Turn the power ON/OFF at the charger, not at the battery terminals.

  • Page 346: Alternator Charging Coil

    . BATTERY/CHARGING SYSTEM UXV 500 CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. ＊ Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.

  • Page 347: Regulator/Rectifier

    . BATTERY/CHARGING SYSTEM UXV 500 Measure the resistance between each Yellow wire terminals. Standard: 0.1－0.3 Ω (20ºC/68ºF) Check for continuity between each Yellow wire terminal of the alternator side connector and ground. There should be no continuity. Replace the alternator stator if resistance is out of specification, or if any wire has continuity to ground.
  • Page 348 . BATTERY/CHARGING SYSTEM UXV 500 Ground line Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Charging coil line Measure the resistance between each Yellow wire terminals. Standard: 0.1－0.3 Ω (20ºC/68ºF) Check for continuity between each Yellow wire terminal and ground.
  • Page 349 . BATTERY/CHARGING SYSTEM UXV 500 Regulator/Rectifier Connector REMOVAL/INSTALLATION Disconnect the regulator/rectifier connectors. Remove the two bolts and then remove the regulator/rectifier. Installation is in the reverse order of removal. Regulator/Rectifier 17-10...

  • Page 350: Alternator Stator Removal/Inspection/ Installation

    . BATTERY/CHARGING SYSTEM UXV 500 ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION REMOVAL Drain the engine oil .(refer to the “ENGINE OIL” section in the chapter 3). Disconnect the alternator stator connectors. Alternator Stator Connectors Oil Filler Plug Remove the starter pulley (refer to the “STARTER PULLEY REMOVAL/INSPECTION/INSTALLATI ON”...
  • Page 351 . BATTERY/CHARGING SYSTEM UXV 500 Dowel Pins Remove the two dowel pins and gasket. Gasket Remove the two pulse coil mount bolts. Remove the three stator mount bolts, grommet and the stator from the right crankcase cover. Stator Pulse Coil INSPECTION Check the stator and pulse coil for damage.
  • Page 352 . BATTERY/CHARGING SYSTEM UXV 500 INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1.2 kgf-m (12 N-m, 9 lbf-ft) Apply sealant to the grommet seating surface and install it to the cover groove properly. Install the pulse coil and tighten mount bolts to the specified torque.
  • Page 353 . IGNITION SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT------------------------------------------- 18-1 IGNITION CIRCUIT ------------------------------------------------------- 18-2 SERVICE INFORMATION------------------------------------------------ 18-3 TROUBLESHOOTING----------------------------------------------------- 18-4 IGNITION COIL INSPECTION ------------------------------------------ 18-5 IGNITION CONTROL MODULE ---------------------------------------- 18-6 18-0...

  • Page 354: Ignition System

    . IGNITION SYSTEM UXV 500 IGNITION SYSTEM LAYOUT Fuse Ignition Coil Spark Plug 18-1...

  • Page 355: Ignition Circuit

    . IGNITION SYSTEM UXV 500 IGNITION CIRCUIT 18-2...

  • Page 356: Service Information

    . IGNITION SYSTEM UXV 500 SERVICE INFORMATION GENERAL INSTRUCTIONS ● Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. ● The ignition timing cannot be adjusted since the ignition control module is factory preset. ●...

  • Page 357: Troubleshooting

    . IGNITION SYSTEM UXV 500 TROUBLESHOOTING LOW PEAK VOLTAGE ● Cranking speed is too low (battery is undercharged). ● Poorly connected connectors or an open circuit in the ignition system. ● Faulty ignition-coil. ● Faulty ignition control module. NO PEAK VOLTAGE ●...

  • Page 358: Ignition Coil Inspection

    . IGNITION SYSTEM UXV 500 IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Check cylinder compression and check that the spark plugs is installed correctly in the cylinder. Disconnect the spark plug cap from the spark plug. Spark Plug Cap Spark Plug Connect known good spark plug to the spark plug cap and ground the spark plugs to the...
  • Page 359 . IGNITION SYSTEM UXV 500 IGNITION PULSE GENERATOR INSPECTION Disconnect the ignition pulse generator connector. Measure the ignition pulse generator resistance between the Green/White wire and Blue/Yellow wire. Standard: 489±20% Ω (20ºC/68ºF) Ignition Pulse Generator Connector IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug cap from the spark plug .(page 18-4).
  • Page 360 . IGNITION SYSTEM UXV 500 ＊ Due to the semiconductor in circuit, it RESISTANCE INSPECTION is necessary to use a specified tester for accurate testing. Use of an improper Measure the resistance between the terminals. tester in an improper range may give false readings.
  • Page 361 . STARTER SYSTEM UXV 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTER SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19- 1 STARTING CIRCUIT ------------------------------------------------------ 19- 2 SERVICE INFORMATION------------------------------------------------ 19- 3 STARTER MOTOR --------------------------------------------------------- 19- 4 STARTER RELAY SWITCH/STARTER MAG ----------------------- 19- 5 STARTER CLUTCH REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 19- 7 19-0...

  • Page 362: Starting System Layout

    . STARTER SYSTEM UXV 500 STARTING SYSTEM LAYOUT Start Motor Battery Start Relay Start MAG 19-1...

  • Page 363: Starting Circuit

    . STARTER SYSTEM UXV 500 STARTING CIRCUIT 19-2...

  • Page 364: Service Information

    . STARTER SYSTEM UXV 500 SERVICE INFORMATION GENERAL • Always turn the ignition switch to “OFF” before servicing the starter motor. The motor could suddenly start, causing serious injury. • The starter motor can be serviced with the engine in the frame. •...

  • Page 365: Starter Motor

    . STARTER SYSTEM UXV 500 Starter Motor Cable STARTER MOTOR INSPECTION Disconnect the starter motor cable from the starter MAG. Turn the ignition switch to “ON”. Connect the starter motor cable directly to the battery positive terminal. If the starter motor does not turn, the starter motor is faulty.

  • Page 366: Starter Relay Switch/Starter Mag

    . STARTER SYSTEM UXV 500 Starter MAG STARTER RELAY SWITCH/STARTER MAG INSPECTION Turn the ignition switch to “ON”. Squeeze the brake lever or pedal fully. The coil is normal if the starter relay switch clicks. Squeeze and hold the brake lever or pedal fully then push the starter switch.
  • Page 367 . STARTER SYSTEM UXV 500 Starter MAG CONTINUTY INSPECTION Disconnect the starter MAG switch connector and cables. Connect a fully charged 12 V battery positive wire to the relay switch Yellow/Red wire terminal and negative wire to the Yellow/Green wire terminal. There should be continuity between the cable terminals while the battery is connected, and no continuity when the battery is...

  • Page 368: Starter Clutch Removal/Inspection/ Installation

    . STARTER SYSTEM UXV 500 Flywheel Puller STARTER CLUTCH REMOVAL/INSPECTION/ INSTALLATION REMVOAL Remove the right crankcase cover Remove the flywheel/driven gear by using the special tool. Flywheel/Driven Gear Special tool: Flywheel puller A120E00060 Woodruff Key Remove the woodruff key. Reduction Gear Remove the reduction gear.
  • Page 369 . STARTER SYSTEM UXV 500 INSPECTION Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise. Remove the starter driven gear by turning the driven gear.
  • Page 370 . STARTER SYSTEM UXV 500 Reduction Gear INSTALLATION Apply oil to the starter reduction gear. Install the starter reduction gear to the right crankcase. Woodruff Key Install the woodruff key in the crankshaft key groove. Apply molybdenum oil solution to the starter driven gear bushing.
  • Page 371 . STARTER SYSTEM UXV 500 Reduction Gear Driven Gear Clean any oil from the tappered portion of the flywheel I.D. Install the flywheel/driven gear onto the crankshaft, aligning the key way with woodruff key. Flywheel 19-10...
  • Page 373 20. LIGHTS/SWITCHES UXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/SWITHCES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 20- 1 BULBS REMOVAL--------------------------------------------------------- 20- 2 HORN (ON ROAD) --------------------------------------------------------- 20- 4 IGNITION SWITCH -------------------------------------------------------- 20- 5 GEAR INDICATOR SWITCH -------------------------------------------- 20- 6 SPEED SENSOR ------------------------------------------------------------ 20- 7 FRONT DRIVE SELECTOR ACTUATOR ------------------------------20- 8 FUEL UNIT ------------------------------------------------------------------ 20- 9 20-0...
  • Page 374 20. LIGHTS/SWITCHES UXU 500 SERVICE INFORMATION ● A continuity test can be made with the switches installed on the vehicle. ● All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. ● To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be made without removing the pat from the vehicle.

  • Page 375: Bulbs Removal

    20. LIGHTS/SWITCHES UXU 500 Headlight Connector BULBS REMOVAL HEADLIGHT Remove the rubber boot . Disconnect the headlight wire connector. from the headlight case. Lock Clip Relax the lock clip to remove the bulb and replace with a new one. Install the bulb, aligning the bulb socket groove with the bulb tab and set the lock clip.
  • Page 376 20. LIGHTS/SWITCHES UXU 500 TAIL/BRAKE LIGHT Remove 7 pu-screws and near release lever nuts. Disconnect cargo bed cover. Remove the bulb socket by turning it counterclockwise. Remove the bulb. Install the bulb in the reverse order of removal. TURN SIGNAL LIGHT (ON ROAD) FRONT Remove the rubber boot from the turn signal light case.

  • Page 377: Horn (On Road)

    20. LIGHTS/SWITCHES UXU 500 REAR(ON ROAD) Remove the bulb socket by turning it counterclockwise. Remove the bulb. Install the bulb in the reverse order of removal. HORN (ON ROAD) REMOVAL Disconnect the horn wire leads. Remove the bolt and remove horn. INSTALLATION The installation sequence is the reverse of Horn...

  • Page 378: Ignition Switch

    20. LIGHTS/SWITCHES UXU 500 IGNITION SWITCH INSPECTION Disconnect the ignition switch connectors. Check for continuity between the switch side connector terminals in each switch position. Continuity should exist between the color coded wires as right: REPLACEMENT Remove the ignition switch from the cover Install a new ignition switch locating mark place with the groove in the cover.
  • Page 379 20. LIGHTS/SWITCHES UXU 500 GEAR INDICATOR LIGHT SWITCHES INSPECTION Gear Disconnect the gear indicator light switch wire connector. Check for continuity between the switch side connector terminal and engine ground. Gear Indicator Light Switch REPLACEMENT Disconnect the gear indicator light switch connector.

  • Page 380: Speed Sensor

    20. LIGHTS/SWITCHES UXU 500 SPEED SENSOR Disconnect the connector. Remove the bolt then remove the speed sensor. If the speedometer, odometer or trip meter does not function properly. Inspect the connection of speed sensor connector. If the connection is all right, replace the speedometer with a new one.

  • Page 381: Front Drive Selector Actuator

    20. LIGHTS/SWITCHES UXU 500 FRONT DRIVE SELECTOR ACTUATOR VOLTAGE Select the 2WD position on the front drive selector switch；then disconnect the connector on the actuator wiring harness. With the ignition switch in the OFF Position, connect the black tester lead to the black wire in the supply harness；then connect the red tester lead to the brown/lavender wire in the supply harness.

  • Page 382: Fuel Unit

    20. LIGHTS/SWITCHES UXU 500 FUEL UNIT REMOVAL Remove the seat Remove the fuel unit connectors. Remove fuel unit from fuel tank. INSPECTION Measure the resistance between the Yellow/White and Blue/White terminals of the fuel unit connector. Standard (at 20°C/68°F): Float at full position 1100 ±...
  • Page 383 . WIRING DIAGRAMS UXV 500 21-0...
  • Page 384 . WIRING DIAGRAMS UXV 500 21-1...
  • Page 385 22. FUEL INJECTION SYSTEM UXV 500i __________________________________________________________________________________ __________________________________________________________________________________ FUEL INJECTION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 22- 1 SPECIFICATIONS ---------------------------------------------------------- 22- 2 INJECTION SYSTEM DIAGRAM --------------------------------------- 22- 3 PARTS LOCATION -------------------------------------------------------- 22- 4 TROUBLESHOOTING----------------------------------------------------- 22- 8 SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL------------------------------------------------------- 22- 7...
  • Page 386 22. FUEL INJECTION SYSTEM UXV500i SERVICE INFORMATION GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.

  • Page 387: 22. Fuel Injection System

    22. FUEL INJECTION SYSTEM UXV 500i SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number PTA1 Idle speed 1400±100 rpm Throttle grip free play 2～6 mm (1/16～1/4 in) Fuel injector resistance (at 20°C/68°F) 10.6~15.9Ω Fuel pump resistance Float at full position About 101 Ω...

  • Page 388: Injection System Diagram

    22. FUEL INJECTION SYSTEM UXV500i INJECTION SYSTEM DIAGRAM Key Switch On FUEL PUMP Input T-MAP SENSOR VOLTAGE Signal (ECU) Output Inductive Fuel Injector Ignition Coil Signal KEY OFF? 22-3...

  • Page 389: Parts Location

    22. FUEL INJECTION SYSTEM UXV 500i PARTS LOCATION Connector Fuel Injector T-MAP Sensor Inlet Pipe Throttle Body 22-4...
  • Page 390 22. FUEL INJECTION SYSTEM UXV500i Inductive ignition coil Air/C Fuel Pump Fuel Hose Fuel Pump Coupler Fuel Hose Connector Fuel Pump 22-5...
  • Page 391 22. FUEL INJECTION SYSTEM UXV 500i Inductive Ignition Coil Hi Beam Relay Battery Lo Beam Start Relay Relay 22-6...
  • Page 392 22. FUEL INJECTION SYSTEM UXV500i Hazard Control Winker Relay REG/REC Roll Sensor Switch Power Relay Fuel Pump Relay 22-7...

  • Page 393: Troubleshooting

    22. FUEL INJECTION SYSTEM UXV 500i TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration • Battery voltage too low • Ignition system malfunction • Fuel level too low • Pinched or clogged fuel hose Poor performance (drive ability) and poor •...
  • Page 394 13. FUEL INJECTION SYSTEM UXV500i CHECK ENGINE LAMP (CELP) When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to know the lamp is available and connect to ECU. But after then or during riding, if the CELP start to blink or keep lighting, it means something wrong with this vehicle, you better do the further check...

  • Page 395: Codes

    22. FUEL INJECTION SYSTEM UXV 500i How To Show Failure Code You can read the failure code by as below : Turn switch on. The CELP will be lighted for 2 seconds then off. The CELP start to blink to show the failure codes (The number of blinks from 1 to 22).

  • Page 396: Celp Failure Codes List

    13. FUEL INJECTION SYSTEM UXV500i CELP FAILURE CODES LIST Failure Blinks Fault description Priority Fault management Codes Engine temperature 1.Slow down the vehicle and go to workshop for overheat checking immediately. P0115 2.Confirm if the engine temperature sensor or electric circuit is abnormality.
  • Page 397 22. FUEL INJECTION SYSTEM UXV 500i Blinks Failure Fault description Priority Fault management Codes Throttle position sensor 1.Make sure if the connector of Throttle position movement speed sensor is connected correctly. P1122 2.Check if the Throttle position sensor is adjusted.
  • Page 398 13. FUEL INJECTION SYSTEM UXV500i Blinks Failure Fault description Priority Fault management Codes 1. Check if the connector of ignition coil is loosen. Ignition coil or electric 2. Check if the ECU send signal to Ignition coil. circuit malfunction 3. Check if the power source and resistance is P0350 malfunction 1.
  • Page 399 22. FUEL INJECTION SYSTEM UXV 500i Blinks Failure Fault description Priority Fault management Codes 1. Check if the lamp of CELP is broken. 2. Check if wires of CELP is broken. P0650 CELP electric circuit malfunction 1. Check if the connector of sensor is loosen.

  • Page 400: Tps/Isc Reset

    13. FUEL INJECTION SYSTEM UXV500i TPS/ISC RESET ● If close or open the throttle grip randomly, the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled. It can cause hard to start engine or idling speed is not smooth when engine installation.

  • Page 401: Fuel Pump

    22. FUEL INJECTION SYSTEM UXV 500i FUEL PUMP INSPECTIION Put the side stand up and the engine stop switch is at “RUN” Disconnect fuel pump/fuel unit connector. Connect the multimeter (+) probe to the Red terminal and the multi-meter (-) probe to the Gray terminal.
  • Page 402 13. FUEL INJECTION SYSTEM UXV500i Screw Hose quick band REMOVAL Disconnect the connector and fuel band from the fuel pump. Remove the six screws onto the fuel pump. Remove the fuel pump and O-ring. Fuel Pump Connector INSTALLATION Replace a new O-ring on the fuel tank. Don’t damage the fuel pump wire and ensure the connector rearward carefully.

  • Page 403: Fuel Pump Relay

    22. FUEL INJECTION SYSTEM UXV 500i Battery FUEL PUMP RELAY INSPECTION Remove the fuel pump relay. Connect the ohmmeter to the fuel pump relay connector terminals. Connection: R/L-B/R Connect 12 V battery with the fuel pump Fuel Pump Relay relay connector.

  • Page 404: Tilt Switch(Roll Sensor)

    13. FUEL INJECTION SYSTEM UXV500i TILT SWITCH(ROLL SENSOR) INSPECTION Support the ATV level surface. Turn the ignition switch to “OFF” Remove the screws, washers and tilt switch. ＊ Do not disconnect the tilt switch connector during inspection. Place the tilt switch vertical as shown, and turn the ignition switch to “ON”.
  • Page 405 22. FUEL INJECTION SYSTEM UXV 500i ELECTRIC CONTROL UNIT (ECU) REMOVAL/INSTALLATION ＊ ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damaged. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when throttle body, MAP, TPS, ISC or ECU has been reinstalled.
  • Page 406 13. FUEL INJECTION SYSTEM UXV500i INSPECTION Outlook checking Checking for ECU pin(1-48) if has damage. Checking for ECU part number if is correct. 3920A-LKC3-E00 is correct Voltage inspection Connect the meter (+) probe to the B4(R/W)wire and the meter (-) probe to the M3(G/B) wire to measure the voltage MAP content (edition issue no.) Performance confirmed...

  • Page 407: Fuel Injector

    22. FUEL INJECTION SYSTEM UXV 500i FUEL INJECTOR INSPECTION Disconnect the fuel injector connector. Measure the resistance between 2 pins of the fuel injector connector. Standard: 10.6~15.9 Ω (at 20°C/68°F) REMOVAL Bolt Disconnect the connector from the fuel injector. Remove the bolts of the fuel injector.
  • Page 408 Tighten the fuel pipe mounting bolts. FUEL INJECTOR CLEANING PROBLEM 1. Fuel Injector cannot output the fuel. O-ring 2. The Injector injection time (ms) is shorter or longer. Fuel Standard: See the KYMCO Diagnostic Injector report Container Injector ANALYSIS cleaner Injector block (With some carbons).

  • Page 409: Wts Sensor

    22. FUEL INJECTION SYSTEM UXV 500i WTS SENSOR (Water Temperature Sensor) REMOVAL / INSTALLATION Drain the coolant from the cooling system. Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring. Install a new O-ring and WTS sensor.

  • Page 410: Throttle Body/T-Map Sensor/Isc/Tps

    ● Do not damage the throttle body, it may cause the throttle and idle valve isn’t synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it by a wrong way. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
  • Page 411 22. FUEL INJECTION SYSTEM UXV 500i TPS INSPECTION Support the ATV on a level surface. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector. Terminal Normal V/R (+) -V/G(-) Throttle position sensor (TPS) resistance (at 20°C/68°F) 3500~6500Ω...
  • Page 412 13. FUEL INJECTION SYSTEM UXV500i Screw T-MAP sensor DISASSEMBLY Remove the screws and then remove the ISC . Remove the screw.. Remove the T-MAP sensor. Remove the screw and then remove the TPS. ASSEMBLY ＊ Screws The throttle position sensor (TPS) and idle air bypass valve (ISC) have to reset when the throttle body T-MAP sensor, TPS, ISC or ECU has been reinstalled.

  • Page 413: Diagnostic Tool Connector

    22. FUEL INJECTION SYSTEM UXV 500i Apply oil onto a new O-ring. T-MAP sensor When install the T-MAP sensor onto the throttle body, being careful not to damage the O-ring. ＊ Always replace an O-ring with a new one. Install the set plate and tighten the screw securely.
  • Page 414 22. FUEL INJECTION SYSTEM UXV 500i UXV 500i SF : Customer : Eng. No: Production Service Mileage : Date : Date : Reason of repair: □ maintenance □ breakdown Item Memo Date Reference ECU No LKC3 Hardware Ver Software Ver...
  • Page 415 22. FUEL INJECTION SYSTEM UXV 500i UXV500 i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A-LEB2-E00(ENGLISH VERSION) version:V1.0.7 22-30...
  • Page 416 22. FUEL INJECTION SYSTEM UXV 500i 1. FI DIAGNOSTIC TOOL This tool is developed by KYMCO and for KYMCO vehicle only. Please refer to the specification when serving this vehicle. This tool is without battery inside. The power is provided from vehicle.
  • Page 417 22. FUEL INJECTION SYSTEM UXV 500i 2. DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power. LKC3 is for UXV500i A). ECU version: Including of model name, ECU number, identifications number and software version. Press the Enter button Press the "...
  • Page 418 22. FUEL INJECTION SYSTEM UXV 500i B). Press the " Down " button and then turn to the first page. C). Press the " Enter " button to check the DTC failure code 22-33...
  • Page 419 22. FUEL INJECTION SYSTEM UXV 500i D). Press the " Enter " button E). Press the " Enter " button F). Display what's DTC number on this DTC-List. Press the " Enter " button and then turn to the previous page...
  • Page 420 22. FUEL INJECTION SYSTEM UXV 500i G). Press the " UP " button H). Press the " Enter " button and then turn to the previous page . I). Press the " UP " button 22-35...
  • Page 421 22. FUEL INJECTION SYSTEM UXV 500i J). Press the " Enter " button and then turn to the first page. 22-36...
  • Page 422 22. FUEL INJECTION SYSTEM UXV 500i 3. DTC CLEAR PROCEDURE ). Check the DTC ). Press the " Enter " button ). Choose " DTC Load " Press the " Down " button 22-37...
  • Page 423 22. FUEL INJECTION SYSTEM UXV 500i ). Press the " Enter " button and the indicator is lighting. ). Clearing DTC completed if the indicator is off. 22-38...
  • Page 424 22. FUEL INJECTION SYSTEM UXV 500i 4. DATA ANALYSIS PROCEDURE ). Press the " Down " twice ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 ). Down-page 01 The measure figures including of Engine speed, Battery voltage and Engine speed.
  • Page 425 UXV 500i 22. FUEL INJECTION SYSTEM ). Down-page 02 The measure figures including of TPS position, TPI idle adapted and ISC step . Press the “ Down” button to enter page 03. ). Down-page 03 The measure figures including of engine temperature ,air temperature and intake pressure .Press the “...
  • Page 426 UXV 500i 22. FUEL INJECTION SYSTEM ). Down-page 05 The measure figures including of gear position and gear ratio. Press the “ Down” button to enter page 06. ). Down-page 06 The measure figures including of rollover voltage( The function setting is not allowed).

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