KYMCO Kymco UXV 500i Service Manual Download Page 18

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. GENERAL INFORMATION

1-16

UXV 500

Tool Name

Tool No.

Illustration

(Note: the special tools may differ

slightly from those shown in the
figure of this manual.)

Driven pulley holder

(Refer to the “

DRIVEN PULLEY

DISASSEMBLY/INSPECTION/
ASSEMBLY

” section in the chapter

10.)

A120E00059

Flywheel puller

(Refer to the “

STARTER

CLUTCH REMOVAL/
INSPECTION/
INSTALLATION

” section in the

chapter 19.)

A120E00060

Oil filter cartridge wrench

(Refer to the “(Refer to the
“

ENGINE OIL

” section in the

chapter 3.)

A120E00061

Output shaft bearing nut
wrench

(Refer to the “(Refer to the
“

BEARING REPLACEMENT

IN THE RIGHT
CRANKCASE

” section in the

chapter 11.)

A120E00066

(Cont’d)

Summary of Contents for Kymco UXV 500i

Page 1: ...Service Manual englisch UXV 500i AMSLER CO AG 8245 FEUERTHALEN ZH fon 052 647 36 36 fax 052 647 36 66 info amsler ch www amsler ch...

Page 2: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 3: ...1 GENERAL INFORMATION 1 1 UXV 500 SERIAL NUMBER 1 Location of Engine Serial Number 1 Location of Frame Serial Number...

Page 4: ...peed rpm 1500 rpm Cooling type Liquid cooled Lubrication type Forced pressure Wet sump Oil pump type Trochoid Oil filter type Full flow filtration Oil capacity 3 6 L Oil exchanging capacity 3 L After...

Page 5: ...tening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants When servicing the motorcycle be sure t...

Page 6: ...mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting...

Page 7: ...cified capacity After operation terminal caps shall be installed securely When taking out the connector the lock on the connector shall be released before operation Hold the connector body when connec...

Page 8: ...d terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation Insert the terminal completely Check the terminal cover for proper coverage Do not mak...

Page 9: ...ke sure that it is not interfering with any moving or sliding parts When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp ed...

Page 10: ...tact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken shea...

Page 11: ...with adjacent or surrounding parts in all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions...

Page 12: ...ols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmi...

Page 13: ...bolt and nut 10mm flange bolt and nut 0 05 0 15 0 5 1 5 0 2 0 4 2 4 0 1 0 3 1 3 0 35 0 5 3 5 5 0 7 1 1 7 11 1 1 4 10 14 2 4 3 0 24 30 3 5 4 5 35 45 Torque specifications listed below are for importan...

Page 14: ...iven pulley nut Driven pulley assembly plate nut TRANSMISSION Crankcase bolt Drive bevel gear nut Driven bevel gear nut Stopper lever bolt Stopper lever boss nut Shift came stopper plug Output shaft b...

Page 15: ...and frame Front lower arm and frame Front shock absorber and frame Front shock absorber and front upper arm RR SUSPENSION Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper...

Page 16: ...ame Final drive gear case Fuel tank stay and frame Gas Damper FR bumper and frame R L roof and frame Cross pipe roof Shifter Pedal assy stay and frame Seat belt and frame Shifter rod assy ENGINE Rear...

Page 17: ...120E00036 Bearing puller A120E00037 Valve spring compressor Refer to the CYLINDER HEAD DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 8 A120E00040 Universal holder Refer to the DRIVE PULLEY DR...

Page 18: ...INSPECTION ASSEMBLY section in the chapter 10 A120E00059 Flywheel puller Refer to the STARTER CLUTCH REMOVAL INSPECTION INSTALLATION section in the chapter 19 A120E00060 Oil filter cartridge wrench Re...

Page 19: ...chapter 15 A120F00012 Left pivot lock nut wrench Refer to the REAR SWING ARM REMOVAL INSTALLATION section in the chapter 15 A120F00013 Joint yoke puller Refer to the FRONT DRIVE DISASSEMBLY INSPECTIO...

Page 20: ...wrench Refer to the REAR DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 13 A120F00020 Pinion puller Refer to the REAR DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 13 A12...

Page 21: ...inside wall Connecting rod piston pin hole Connecting rod big end Clutch Crankshaft Balance shaft Crankshaft one way clutch movable part Recoil starter pulley Oil pump drive chain Starter reduction ge...

Page 22: ......

Page 23: ...______________________________________________ __________________________________________________________________________________ ______________________________________________________________________...

Page 24: ...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 3 5 kgf m 35 Nm 25 lbf ft Exhaust muffler b...

Page 25: ...nter piece stick out toward the head so that the pawls close Insert the plastic screws into the installation hole Push in the head of center piece until it becomes flush with the plastic screws outsid...

Page 26: ...the seat INSTALLATION To install the seat into the seat stay then Press the seat lock board HOOD REMOVAL INSTALLATION Remove hood s L R side plastic screws and latches Slowly tilt the hood until stop...

Page 27: ...N 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 c...

Page 28: ...d 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 Installation is in the reverse order of removal GUAR...

Page 29: ...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 SIDE PANEL R L FOOTREST REMOVAL INSTALLATION Remove the 3 bo...

Page 30: ...el 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 SIDE PANEL R L FRONT REMOVAL INSTALLATION Remov...

Page 31: ...2 FRAME COVERS EXHAUST MUFFLER 2 8 UXV 500 PEDAL PLATE SUPPORT R L SIDE PANDEL TUNNER COVER BRAKE PLATE Remove brake lever bolt Remove brake plate 6 bolts...

Page 32: ...ST PANEL Remove bolts from panel R footrest L FOOTREST PANEL Remove bolts from panel L footrest LUGGAGE BOX Remove 4 bolts from box luggage LID GLOVE BOX COVER Remove 8 screws from lid glove box cover...

Page 33: ...ERS EXHAUST MUFFLER 2 10 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...

Page 34: ...0 EXHAUST MUFFLER REMOVAL Loosen the exhaust pipe band bolt Remove two muffler mounting bolts Remove the muffler and gasket from the exhaust pipe Remove the exhaust muffler body and stay exhaust muffl...

Page 35: ...ipe 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 bolts Torque Exhaust muffler mounting bolt 3 5 kgf m 35 N m 14 l...

Page 36: ......

Page 37: ...___________ 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 VA...

Page 38: ...ee play 3 5 mm 0 12 0 2 in Spark plug gap 0 6 0 7 mm 0 024 0 028 in Spark plug Standard CR7E NGK Valve clearance IN 0 1 mm 0 004 in EX 0 1 mm 0 004 in Idle speed 1500 100 rpm Engine oil capacity At di...

Page 39: ...ft Rear drive gear oil drain bolt 2 kgf m 20 N m 15 lbf ft Rear drive gear oil level check bolt 2 kgf m 20 N m 15 lbf ft Rear drive gear oil filler cap 1 5 kgf m 15 N m 11 lbf ft Front drive gear oil...

Page 40: ...ese 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 This information appli...

Page 41: ...de the rubber sleeve 1 back to expose the throttle cable adjuster 2 2 Loosen the lock nut 3 then turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the lock nut and rein...

Page 42: ...3 Loosen the screw and remove the air cleaner assembly from the air cleaner housing 4 Unscrew the clamp 5 Remove the outer air cleaner 7 6 Remove the screw washers 6 and remove the air cleaner assemb...

Page 43: ...let dry Apply the engine oil Squeeze out the excess oil More frequent replacement is required when riding in unusually dusty or rainy areas Use parts cleaning solvent only Never use gasoline or low fl...

Page 44: ...by removing the clip 2 Drain the deposits 3 Reinstall the drain tube securing it with the clip AIR BOX FOR DRIVE BELT To check the air box Remove rider s side seat Remove air hose Check air box for dr...

Page 45: ...ver there is negative pressure pulse in the exhaust system This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxi...

Page 46: ...ver removing the carbon deposits be sure to observe the operational color of the spark plug s porcelain tip This color tells you whether or not the standard spark plug is suitable for your type of usa...

Page 47: ...ecessary adjust the gap by bending the side electrode carefully 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 T...

Page 48: ...the STARTER PULLEY REMOVAL INSPECTION INSTALLATION section in the chapter 8 Turn the crankshaft clockwise and align the T mark on the flywheel with the index mark on the right crankcase cover The pun...

Page 49: ...0 9 kgf m 9 N m 6 5 lbf ft After tightening the lock nut recheck the valve clearance Install the removed parts in the reverse order of removal CARBURETOR IDLE SPEED Warm up the engine before this oper...

Page 50: ...ombustion chamber and the piston head ENGINE OIL OIL LEVEL Place the machine on a level place Warm up the engine for several minutes and stop it Check the oil level through the inspection window The o...

Page 51: ...all the O ring oil strainer compression spring and oil filter cap Tighten the oil filter cap to specification Torque 1 5 kgf m 15 N m 11 lbf ft 7 Fill the engine with oil and install the oil filler ca...

Page 52: ...e 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 fill cap 1 5 Remove the drain plug 2 to drain the oil Be sure no f...

Page 53: ...kgf m 10 N m 7 2 lbf ft 10 Install right side cover 11 Reinstall the drain plug and tighten the drain plug to the specified torque Torque 2 5 kgf m 25 N m 18 lbf ft 12 Add the specified amount of reco...

Page 54: ...Maintenance Schedule Change the oil with the rear drive gear case warm and the UXV on level ground to assure complete and rapid draining Rear drive gear oil replacement 1 To drain the oil first place...

Page 55: ...drive gear case warm and the UXV on level ground to assure complete and rapid draining Front drive gear oil replacement 1 To drain the oil first place an oil drain pan under the oil drain plug 1 2 Re...

Page 56: ...er 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 SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cl...

Page 57: ...he spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary 4 Install the spark arrester and the gasket in the muffler and t...

Page 58: ...th Service limit A 30 8 mm 1 232 in Replace the drive belt if out of specification Refer to the DRIVE PULLEY DRIVE V BELT AND DRIVEN PULLEY REMOVAL INSPECTION INSTALLATION section in the chapter 10 fo...

Page 59: ...elow the lower level mark through the inspection window HEADLIGHT AIM Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight ai...

Page 60: ...y 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 Replace the tie rod ends if tie rod end has any verti...

Page 61: ...rods ends This reference point will be needed during adjustment Loosen the lock nuts tie rod end of both tie rods The same number of turns should be given to both tie rods right and left until the spe...

Page 62: ...damages Check the tire pressure TIRE PRESSURE 1 Rider Front 0 7kgf cm 10psi Rear 0 98 kgf cm 14 psi TIRE SIZE Front 25X8 12 Rear 25X10 12 Check the front axle nut for looseness Front Axle Nut Tire pre...

Page 63: ...wear or damage Tire wear limit 4 mm 0 16 in WHEEL INSPECTION Inspect the wheel Replace if damage or bends Always balance the wheel when a tire or wheel has been changed or replaced Rear Axle Nut Never...

Page 64: ...evel line with 1 1 mixture of distilled water and antifreeze coolant mixture preparation refer to the chapter 6 COOLING SYSTEM Check to see if there are any coolant leaks when the coolant level decrea...

Page 65: ...r cracks or deterioration and replace if necessary Check that all hose clamps are tight Check the radiator air passages for clogs or damage Straighten any bent fins and remove insects mud or other obs...

Page 66: ...k properly Every time the brake pads are replaced adjust the parking brake To adjust 1 Release the parking brake lever 2 The rear brake caliper is adjusted automatically when has more clearance for th...

Page 67: ...rotate then Tighten the lock nut Parking brake cable end length L 53 2 mm 2 12 0 08 in 5 Slowly turn the adjusting bolt on the caliper clockwise until resistance is felt then turn adjusting bolt 1 8...

Page 68: ......

Page 69: ...____________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM _____________________________________________________________...

Page 70: ...4 LUBRICATION SYSTEM 4 1 UXV 500 LUBRICATION SYSTEM DIAGRAM...

Page 71: ...6 liter 3 17 lmp qt 3 82 Us qt Engine oil capacity At draining and oil filter cartridge change 3 2 liter 2 82 lmp qt 3 39 Us qt Recommended engine oil KYMCO 4 stroke oil or equivalent motor oil API s...

Page 72: ...nal oil leak Faulty water pump mechanical seal Non recommended oil used Faulty head gasket Water leak in crankcase Oil contamination Deteriorated oil No oil pressure Faulty oil filter Oil level too lo...

Page 73: ...N SYSTEM 4 4 UXV 500 LUBRICATION CHECK HOLE 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 Check Hole...

Page 74: ...ion in the chapter 19 Remove the two bolts and oil pump drive chain guide Remove the two bolts and oil separator cover Remove snap ring Remove the oil pump driven gear then remove the oil pump drive c...

Page 75: ...wo bolts and then remove the oil pump INSPECTION Oil pump drive chain guide Inspect the drive chain slipper surface of the drive chain guide for wear or damage INSTALLATION Install the oil pump Holder...

Page 76: ...and tighten the two bolts securely Install two dowel pins Install the holder then install a bolt but do not tighten Install the driven gear and drive chain Install the snap ring Driven Gear Drive Cha...

Page 77: ...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...

Page 78: ...ASSEMBLY INSPECTION ASSEMBLY DISASSEMBLY Remove the oil pump shaft Remove the screw and oil pump cover Remove the dowel pin oil pump outer rotor and inner rotor Oil Pump Shaft Outer Rotor Oil Pump Bod...

Page 79: ...to the oil pump body Measure the tip clearance Service limit 0 2 mm 0 008 in Measure the pump body clearance Service limit 0 25 mm 0 01 in Measure the side clearance with the straight edge and feeler...

Page 80: ...Install the inner rotor into the outer rotor Install the oil pump shaft Install the dowel pin onto the oil pump body Install the oil pump cover onto the oil pump body by aligning the dowel pin Install...

Page 81: ...the right crankcase cover refer to the ALTERNATOR STATOR REMOVAL INSPECTION INSTALLATION in the chapter 17 Remove the oil seal Remove the snap ring Remove the bearing by using the special tool Specia...

Page 82: ...4 LUBRICATION SYSTEM 4 13 UXV 500 ASSEMBLY Install a new bearing by using the special tool Special tool Oil seal bearing drive A120E00014 Install a new oil seal Bearing Drive Snap Ring Oil Seal...

Page 83: ...pter 11 Remove the pressure relief valve and O ring from the right crankcase INSPECTION Check the operation of the pressure relief valve by pushing on the piston INSTALLATION Apply oil to a new O ring...

Page 84: ...the two bolts washers on the oil pipe oil pipe and washers under oil pipe INSTALLATIION Install the inner washers on the right crankcase Install the oil pipe with the thick side face upward Oil Pipe W...

Page 85: ...500 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...

Page 86: ......

Page 87: ...______________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM __________________________________...

Page 88: ...5 FUEL SYSTEM 5 1 UXV 500 Fuel Pump Fuel Filter Fuel Tank...

Page 89: ...l jets the O rings and diaphragm must be removed first to avoid damage Then clean with compressed air When the machine is not used for over one month drain the residual gasoline from the float chamber...

Page 90: ...tle operation Float level too low Intake air leak Engine idles roughly stalls or runs poorly Clogged fuel tank cap breather hole Excessively used choke Kinked or restricted fuel line Ignition malfunct...

Page 91: ...front and protector Fuel tank Remove the tank frame Disconnect the fuel tube from fuel pump Disconnect the fuel unit connectors Remove the 4 screws and from the fuel tank then remove the fuel tank IN...

Page 92: ...EANER HOUSING section in this chapter Disconnect the over flow hose Loosen the carburetor clamp screw then remove carburetor from intake pipe Remove 2 screws then remove the throttle valve cover Disco...

Page 93: ...SPECTION Inspection the choke plunger spring and O ring for bends wear or damage INSTALLATION Installation is in the reverse order of removal Make sure the carburetor was horizontal assy on the intake...

Page 94: ...amber Remove the four screws and top cap Remove the spring and piston valve Fuel Drain Plug Keep sparks and flames away from the work area Drain gasoline into a clean container Do not loosen or tighte...

Page 95: ...5 8 UXV 500 Remove the spring retainer jet needle Remove the 3 screws and float chamber Pull float pin outs then remove the float and float valve Jet Needle Spring Retainer Piston Valve Float Float Pi...

Page 96: ...edle jet Remove the pilot screw spring washer and O ring Pilot Screw Before pilot screw removal slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated Ma...

Page 97: ...body dry using compressed air After cleaning reassemble the carburetor with new seals Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled ca...

Page 98: ...t for foreign substance clogging or damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination Check the operation of the float valve Check the piston v...

Page 99: ...ck the spring coasting enrichment valve and accelerating pump and cover coasting enricher and accelerating pump for damage Check jet needle needle jet slow jet needle jet holder main jet choke jet and...

Page 100: ...the part with a new carburetor Check the float level after checking the float valve valve seat and float Set the carburetor so that the float valve end just contacts the float arm lip Make sure the f...

Page 101: ...Needle jet 12 Slow jet 13 Float valve 14 Float 15 Float pin 16 Pilot screw 17 Cap 18 Cover 19 Float Chamber Assemble the parts taking consideration of their function Before assembling wash all of the...

Page 102: ...n to the float chamber groove securely Assemble the accelerating pump diaphragm and new O ring O ring Install the accelerating pump diaphragm with the small convex facing up O ring Small Convex Accele...

Page 103: ...e carburetor to air cleaner connecting tube band screw Remove the clip and disconnect the crankcase breather hose from the crankcase Remove the mounting bolts and then remove the air cleaner housing f...

Page 104: ...VALVE REMOVAL INSTALLATION Disconnect air supply hose and vacuum hose from the air solenoid valve then remove the air solenoid valve from frame Installation is in the reverse order of removal Vacuum...

Page 105: ...coupler If the measurement is out of specification replace the fuel pump Fuel pump resistance 1 2 5 As shown in the right illustration connect the battery to the fuel pump and measure the pump dischar...

Page 106: ...fuel pump and filter Installation is in the reverse order of removal Install the fuel pump with the arrow mark facing up Connect the fuel inlet hose between the inlet duct of the fuel pump and fuel f...

Page 107: ...____________________________________________________ __________________________________________________________________________________ COOLING SYSTEM _________________________________________________...

Page 108: ...6 COOLING SYSTEM 6 1 UXV 500 SYSTEM FLOW PATTERN...

Page 109: ...cate inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage This section covers service of the cooling system Add coolant at t...

Page 110: ...062 1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1 054 50 1 086 1 084 1 082 1 080 1 077 1 074 1 071 1 068 1 065 1 062 1 059 55 1 095 1 093 1 091 1 088 1...

Page 111: ...ir in system Thermostat stuck closed Insufficient coolant Passages blocked in radiator hoses or water jacket Faulty cooling fan motor Faulty fan motor switch Faulty water pump Engine temperature too l...

Page 112: ...r replace components if the system will not hold the specified pressure for at least six seconds COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rest or...

Page 113: ...nect the bypass hose from water pump or remove the drain plug and drain the coolant from the system Remove the reserve tank cap and drain the coolant from the reserve tank Reconnect the bypass hose se...

Page 114: ...to the filler neck Bleed air from the system as follow 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle three to four times to bleed air from the system 3 Stop the engine and add...

Page 115: ...Remove the nut and thermostat housing stay from the frame Remove the bolts housing stay and thermostat housing cover Remove the O ring from the housing cover Remove the thermostat Thermostat O ring T...

Page 116: ...perature or if it respond at temperatures other than those specified Thermostat begin to open 80 84 C 176 183 F Valve lift 8 mm 0 3 in minimum at 95 C 203 F INSTALLATION Install the thermostat into th...

Page 117: ...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 t...

Page 118: ...is defective and water pump body should be replaced REMOVAL Drain the coolant refer to the COOLANT REPLACEMENT section in this chapter Loosen the hose bands and disconnect the lower radiator hoses an...

Page 119: ...pped portion of the water pump Install the water pump into the crankcase while aligning the water pump shaft groove with oil pump shaft end Align the mounting bolt holes in the water pump and crankcas...

Page 120: ...pecified toque Torque 1 3 kgf m 13 N m 9 lbf ft 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 REPL...

Page 121: ...water hose water filler hose bleed hose and upper water hose from the radiator Disconnect the fan switch connectors Remove the two mounting bolts under radiator and two mounting bolts on the radiator...

Page 122: ...operate If the switch operating temperature is not within the specified range replace the switch with a new one OFF ON Over 88 92 C ON OFF Lower 88 92 C INSTALLATION Fit the O ring Tighten the coolin...

Page 123: ...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 INSTALLATION Installat...

Page 124: ...sured is out of specification replace the temperature gauge with a new one Temperature Standard resistance 50 C 123 9 478 9 100 C 26 29 3 After the water temperature sensor has been installed fill coo...

Page 125: ...lts and then remove the radiator reserve tank from frame Open the reserve tank cap and drain the coolant from the reserve tank Disconnect the siphon hose INSTALLATION Installation is in the reverse or...

Page 126: ...lter Cartridge Drain the coolant from the system Loosen the hose bands and disconnect the oil Cooler water hose from the cooler Remove the oil cooler mounting bolts Washers oil cooler and gasket INSPE...

Page 127: ...ers 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...

Page 128: ......

Page 129: ..._______________________________________________________________________________ __________________________________________________________________________________ _____________________________________...

Page 130: ...uire engine removal for serviced with the engine installed in the frame Oil pump Chapter 4 Water pump Chapter 6 Cylinder head Chapter 8 Cylinder Piston Chapter 9 Drive and driven pulleys clutch Chapte...

Page 131: ...leaner housing and carburetor refer to the CARBURETOR REMOVAL CHOKE INSPECTION INSTALLATION and AIR CLEANER HOUSING sectionsinthe chapter5 Disconnect the lower water hose and bypass hose from water pu...

Page 132: ...ensor connectors from water joint Remove the spark plug cap from cylinder head Remove the bolt from drive select rod Remove the mounting bolts from the drive select lever guide then remove the guide a...

Page 133: ...xpose the starter motor wire nut Remove the starter motor cable nut for disconnect the starter motor cable Remove the bolt and then disconnect the engine ground cable from starter motor Remove the A C...

Page 134: ...ct the gear indicator light switch connector Disconnect the speed sensor connector Remove the bolts and then remove the front propeller shaft from the engine assembly Gear Indicator Light Switch Conne...

Page 135: ...e hangers then remove the engine hangers Remove the rear lower engine mounting bolt nut Remove the upper engine mounting bolt nut Rise the engine and move the engine then remove the engine from the fr...

Page 136: ...Tap the rear propeller shaft with rubber hammer and remove the rear propeller shaft from the engine assembly Rise the engine rear then move the engine from the frame Take care not to lose the compress...

Page 137: ...gine assembly into the frame Apply lightweight lithium soap base grease to the rear propeller shaft splines Install the rear propeller shaft into the engine assembly Apply lightweight lithium soap bas...

Page 138: ...angers and four engine hanger nuts loosely Install the front lower engine mounting bolt and nut loosely Tighten the four engine hanger nuts to the specified torque Torque 3 5 kgf m 35 N m 25 lbf ft Ti...

Page 139: ...he front propeller shaft splines and front output splines Install the front propeller shaft into the engine assembly Install the front cooling duct Apply grease Front Propeller Shaft Make sure the lug...

Page 140: ...ses wire and cable properly refer to the CABLE HARNESS ROUTING section in the chapter 1 Adjusting the following items Engine oil refer to the ENGINE OIL section in the chapter 3 Engine coolant refer t...

Page 141: ..._______________________________________ CYLINDER HEAD VALVES __________________________________________________________________________________ SCHEMATIC DRAWING 8 1 SERVICE INFORMATION 8 2 TROUBLESHO...

Page 142: ...8 CYLINDER HEAD VALVES 8 1 UXV 500 SCHEMATIC DRAWING...

Page 143: ...all them in the reverse order of removal SPECIFICATIONS Unit mm in Item Standard Service Limit IN 0 1 mm 0 004 in Valve clearance cold EX 0 1 mm 0 004 in Cylinder head compression pressure 15 kg cm2 1...

Page 144: ...PECIAL TOOLS Valve spring compressor A120E00040 TROUBLESHOOTING The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle spe...

Page 145: ...rank the engine with the starter motor until the gauge reading stops rising The maximum reading is usually reached 4 7 seconds Compression pressure 15 kg cm2 1500 kPa 213 psi Low compression can be ca...

Page 146: ...ubber washers and cylinder head cover Remove the cylinder head cover packing INSTALLATION Apply fluid gasket threebond 1215 to the mating surface of the cylinder head cover then install the packing In...

Page 147: ...YLINDER HEAD COVER DISASSEMBLY ASSEMBLY DISASSEMBLY Remove the three bolts and breather separator Remove the gasket ASSEMBLY Assembly is in the reverse order of disassembly Torque Breather separator b...

Page 148: ...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 Remove the cam chain tensioner lif...

Page 149: ...Loosen and remove the four camshaft holder bolts washers in a crisscross pattern in several steps then remove the camshaft holders Remove the camshafts Bolts Camshaft Holder Camshaft Holder Camshaft H...

Page 150: ...Inspect the camshaft surface of each camshaft holder for scoring scratches or evidence of insufficient lubrication Check the stop pin spring on the exhaust camshaft holder for damage Replace the stop...

Page 151: ...ches 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 with a new one then inspect lubrication sys...

Page 152: ...TALLATION 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 in chapter 3 Apply molybdenum disulfide and oil t...

Page 153: ...s then inject in the holes onto the camshafts with oil until the oil overflowed Timing Marks Punch Marks Install each camshafts to the correct locations IN no decompressor cam EX has a decompressor ca...

Page 154: ...ps to the specified torque as follow diagram NOTE Install the camshafts a point for attention Tighten the bolts to the specified torque in sequence kgf m N m lbf ft 1 2 3 4 5 6 7 8 Step 1 2 4 24 17 1...

Page 155: ...s No 10 13 in a crisscross pattern in five steps to the specified torque as follow diagram Tighten the bolts to the specified torque in sequence kgf m N m lbf ft 10 11 12 13 Step 4 1 2 12 9 Step 5 2 3...

Page 156: ...on system Measure each rocker arm shaft O D Measure the I D of each rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 1 mm 0 004 in Inspect the rocker...

Page 157: ...ALLATION 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...

Page 158: ...e the two bolts and intake pipe Remove the five bolts then remove the pair reed valve cover and holder Remove the two nuts then remove the pair reed valve and gasket Remove the two bolts water joint g...

Page 159: ...8 CYLINDER HEAD VALVES 8 18 UXV 500 Remove the two nuts under the cylinder head Remove the bolt and then remove the cylinder head Remove the dowel pins and gasket Gasket Dowel Pins...

Page 160: ...Apply engine oil to the cylinder head bolt 9 threads Install the bolt 9 but do not tighten it Install the camshafts intake camshaft holder and exhaust camshaft holder refer to the CAMSHAFT REMOVAL IN...

Page 161: ...o 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 Tighten the bolts to the specified torque in...

Page 162: ...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 Arrow Mark Tighten the...

Page 163: ...10 N m 7 lbf ft Install the water stop collar gasket and water joint Install and tighten the two bolts to the specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Install gasket and pair reed valve Ins...

Page 164: ...8 CYLINDER HEAD VALVES 8 23 UXV 500 Install the new O ring onto the intake pipe Install the intake pipe and tighten the two bolts securely O ring Intake Pipe...

Page 165: ...move the valve spring cotters retainers springs spring seats oil seals and valves using a valve spring compressor Special tool Valve Spring Compressor A120E00040 Be sure to compress the valve springs...

Page 166: ...he corresponding guide I D to obtain the stem to guide clearance Service limits IN 0 08 mm 0 0032 in EX 0 1 mm 0 004 in Cylinder head Check the spark plug hole and valve areas for cracks Check the cyl...

Page 167: ...Y Install the valve spring seats and oil seal Lubricate each valve with engine oil and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using...

Page 168: ...8 CYLINDER HEAD VALVES 8 27 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...

Page 169: ...apter 9 Remove the oil pump drive chain refer to OIL PUMP REMOVAL INSTALLATION section in the chapter 4 Remove the cam chain from the right crankcase Remove the two bolts and cam chain guides INSPECTI...

Page 170: ...29 UXV 500 INSTALLATION 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...

Page 171: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 172: ...9 CYLINDER PISTON 9 1 UXV 500 SCHEMATIC DRAWING...

Page 173: ...n O D measuring position 10 mm from bottom of skirt Piston to cylinder clearance 0 01 0 0004 0 045 0 0018 0 1 0 004 Piston pin hole I D 22 002 0 8801 22 008 0 8803 22 04 0 8816 Piston pin O D 21 994 0...

Page 174: ...t Remove the water hose from the cylinder Remove the two cylinder bolts washers Remove the cylinder Remove the dowel pins and gasket Remove the piston pin clip Press the piston pin out of the piston a...

Page 175: ...out catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to groove clearance Service Limits Top 0 08 mm 0 003 in 2nd 0 065 mm 0 0026 i...

Page 176: ...3 676 in at A 10 mm Calculate the cylinder to piston clearance Measure the piston pin hole Take the maximum reading to determine the I D Service Limit 22 04 mm 0 8816 in Measure the piston pin O D at...

Page 177: ...at three levels in an X and Y axis Take the maximum reading to determine the cylinder wear Service Limit 92 1 mm 3 684 in Calculate the piston to cylinder clearance Take a maximum reading to determine...

Page 178: ...in INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing up Do not confuse the top and second rings To install the oil ring install the oil...

Page 179: ...on pin hole Install the piston with the IN mark face intake side and piston pin Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase Install the new pin clip In...

Page 180: ...l the two cylinder bolts washers and after the cylinder head and holders has installed refer to the CYLINDER HEAD REMOVAL INSTALLATION section in the chapter 8 then tighten the two cylinder bolts to s...

Page 181: ...___________________________________________________________________ DRIVE PULLEY DRIVEN PULLEY CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWI...

Page 182: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 1 UXV 500 SCHEMATIC DRAWING...

Page 183: ...Weight roller O D 29 9 1 196 30 1 1 204 29 5 1 18 TORQUE VALUES Drive pulley nut 14 kgf m 140 N m 100 8 lbf ft Apply oil to the threads Clutch nut 14 kgf m 140 N m 100 8 lbf ft Driven pulley nut 10 k...

Page 184: ...he fuel tube from fuel pump Disconnect the fuel unit connectors Remove the 4 bolts and from the fuel tank then remove the fuel tank Remove the CVT cover bolts Disconnect the CVT cover Remove the CVT p...

Page 185: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 4 UXV 500 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 Bolts...

Page 186: ...the driven pulley then remove the nut Special tool Y type holder A120E00056 Remove the driven pulley and V belt Remove the driven pulley washer Remove the drive pulley face Drive Pulley Nut Washer Dri...

Page 187: ...t 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 INSTALLATION Install the fan gui...

Page 188: ...en the nut to the specified torque Torque 10 kgf m 100 N m 72 lbf ft Apply oil to the threads Special tools Y type holder A120E00056 Apply lubricant to the drive face boss inner surface then install t...

Page 189: ...Use the special tool to hold drive pulley then tighten the nut to the specified torque Torque 14 kgf m 140 N m 100 8 lbf ft Apply oil to the threads Special tool Drive pulley holder A120E00058 Make su...

Page 190: ...ECTION ASSEMBLY DISASSEMBLY Remove the drive pulley refer to DRIVE PULLEY AND DRIVEN PULLEY REMOVAL INSTALLATION section Remove the drive face boss Remove the ramp plate and four slide pieces Remove t...

Page 191: ...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...

Page 192: ...Y Clean the movable drive face drive pulley face weight rollers slide pieces ramp plate and drive face boss Install the weight rollers Remove any excess grease The direction of all weight rollers is t...

Page 193: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 12 UXV 500 Install the slide pieces and ramp plate Install the drive face boss Drive Face Boss Ramp Plate Slide Pieces...

Page 194: ...collar on the movable driven face Remove the four guide pins rollers then remove the movable driven face Install the block and bolts then tighten the bolts Attach the block nut wrench and spring compr...

Page 195: ...ration If any scratches or damage is found then replace as a set Check the torque cam grooves for wear or damage Check guide pins and rollers for wear or damage If any scratches or damage is found the...

Page 196: ...als and install into the movable driven face Coat new O rings with grease and install them into the movable driven face grooves Install the movable driven face onto the driven face Install the guide r...

Page 197: ...cial tool Driven pulley spring compressor A120E00059 Attach the block nut nut wrench and spring compressor to the driven pulley assembly Place the block in a vise and secure it Tighten the spring comp...

Page 198: ...LLATION section in this chapter Remove the nine bolts and then remove the clutch housing assembly and one way clutch bearing Remove the two dowel pins and gasket Using a chisel unlock the nut Working...

Page 199: ...l 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 USA type Remove the nut and collar Remove the clutch carrie...

Page 200: ...ssembly and collar then install the collar and clutch carrier assembly Install the washer Use the special tools to install and tighten the nut to the specified torque Torque 14 kgf m 140 N m 100 8 lbf...

Page 201: ...olybdenum 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 Torque 1 kgf m 10...

Page 202: ...assembly refer to the CLUTCH REMOVAL INSTALLATION section in this chapter Remove the one way clutch bearing from the clutch housing Clutch housing removal not USA type Remove the oil seal Remove the...

Page 203: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 22 UXV 500 Clutch housing removal USA type Remove the clutch housing Remove the oil seal then remove the bearing Clutch Housing Bearing Oil Seal...

Page 204: ...Check the one way clutch bearing for chafing wear or damage Check the clutch shoe for heat damage Measure the clutch shoe thickness Service limit A 1 mm 0 04 in Only USA type Turn the crankshaft bear...

Page 205: ...Replace it Check operation USA type Install the one way clutch bearing and collar to the clutch housing and hold the collar When turning the clutch housing clockwise the clutch housing should turn fre...

Page 206: ...n install the new bearing Install the snap ring 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 Clutch...

Page 207: ...tall the new oil seal Install the clutch housing One way clutch bearing installation Install the one way clutch bearing into the clutch housing Oil Seal Clutch Housing The one way clutch bearing shoul...

Page 208: ...cap Remove the side panel R front and protector Fuel tank Remove the tank frame Disconnect the fuel tube from fuel pump Disconnect the fuel unit connectors Remove the 4 screws and from the fuel tank...

Page 209: ...______________________________________________________ FINAL REDUCTION TRANSMISSION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION 11 2 T...

Page 210: ...11 FINAL REDUCTION TRANSMISSION SYSTEM 11 1 UXV 500...

Page 211: ...8 6 lbf ft Apply engine oil Drive bevel gear nut 14 kgf m 140 N m 100 8 lbf ft Apply engine oil Driven bevel gear nut 14 kgf m 140 N m 100 8 lbf ft Apply engine oil Stopper lever boss nut 3 kgf m 30...

Page 212: ...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 DISASSEMBLY INSPECTION ASSEMBLY section in the chap...

Page 213: ...using a suitable bar then remove the rear propeller shaft nut Remove the rear middle joint Tap the output shaft by using a rubber hammer then remove the output shaft secondary driven bevel gear and s...

Page 214: ...o the DRIVE PULLEY DRIVE V BELT AND DRIVEN PULLEY REMOVAL INSPECTION INSTALLATIO N section in the chapter 10 then remove the nut Special tool Y type holder A120E00056 Remove the secondary drive bevel...

Page 215: ...s for wear or damage 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 Torque 14...

Page 216: ...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 Torque 14...

Page 217: ...ear backlash Standard 0 03 0 15 mm 0 001 0 006 in Secondary Drive Bevel Gear Shim Drive Driven bevel gear shims A 0 6 mm 0 024 in B 0 65 mm 0 026 in C 0 7 mm 0 028 in D 0 75 mm 0 03 in E 0 8 mm 0 032...

Page 218: ...correct example 2 then to complete installation 1 Incorrect contact at tooth top 2 Correct 3 Incorrect contact at tooth root If tooth contact is found to be incorrect examples 1 and 3 the shim thickn...

Page 219: ...L 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 section in this chapt...

Page 220: ...o 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 Install the right crankcase and t...

Page 221: ...topper plug to the specified torque Torque 4 8 kgf m 48 N m 35 lbf ft BEARING REPLACEMENT IN THE RIGHT CRANKCASE BALANCE SHAFT COUNTERSHAFT PRIMARY DRIVE SHAFT BEARING REPLACEMENT Remove the balance s...

Page 222: ...he special tool Special tool Bearing driver A120E00014 DRIVE SHAFT BEARING REPLACEMENT Remove the four bolts and two set plates Remove the bearing Install the new bearing by using the special tool Spe...

Page 223: ...al Remove the nut by using the special tool Special tool Nut wrench A120E00066 Remove the bearing by using the special tool Special tool Bearing Puller A120E00037 Install the new bearing Oil Seal Nut...

Page 224: ...rench A120E00066 Apply clean engine oil to the new oil seal lip then install the oil seal FRONT SIDE BEARING Remove the oil seal Remove the snap ring Remove the bearing by using the special tool Speci...

Page 225: ...11 FINAL REDUCTION TRANSMISSION SYSTEM 11 16 UXV 500 Install the snap ring Apply clean engine oil to the new oil seal lip then install the new seal Snap Ring Oil Seal...

Page 226: ...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 Remove the shift sha...

Page 227: ...hift cam Remove the countershaft and driveshaft as an assembly Disassemble the countershaft and the driveshaft Driveshaft Assembly Countershaft Assembly Upper Shift Fork Lower Shift Fork Shift Cam Kee...

Page 228: ...Remove the bolt washer then remove the stopper lever and spring INSPECTION Guide bar Measure the guide bar runout Out of specification Replace Service Limit Less than 0 03 mm 0 0012 in Primary Drive S...

Page 229: ...ork pawl Scoring beads wear Replace a set Inspection the spring Cracks or damage Replace a set Lower shift fork Inspect the shift fork cam follower and shift fork pawl Scoring beads wear Replace Prima...

Page 230: ...l for bends damage or wear Inspect the spring for cracks or damage Check the shift cam groove and shift cam gear Wear or damage Replace Inspect shift shaft gear Damage Replace Inspect shift shaft Dama...

Page 231: ...m 30 N m 21 6 lbf ft Hook the spring onto the hook part of the stopper lever squeeze the spring in to the groove of the left crankcase Install the washer and a new bolt Tighten the bolt to the specifi...

Page 232: ...gine oil to the shift cam then install the shift cam Apply clean engine oil to the gearshift fork sliding surface and gearshift fork pawl Install the lower gearshift fork into the clutch dog countersh...

Page 233: ...ply clean engine oil to the guide bar install the guide bar Install the shift shaft Check the transmission operation Unsmooth operation Repair Guide Bar Shift Shaft Align The Marks Align the mark on t...

Page 234: ...ction in this chapter Remove the snap ring washer and fork Remove the spring cam pawl and washer ASSEMBLY Install the washer and cam pawl Install the spring Install the fork Install the washer and sna...

Page 235: ...bly refer to the TRANSMISSION REMOVAL INSPECTION INSTALLATION section in this chapter Remove the washer thick and reverse gear Remove the washer thin ASSEMBLY INSPECTION Inspect the gear teeth Blue di...

Page 236: ...e the washer and high drive gear Remove the high low gear clutch dog Remove the clip then remove the washer and low drive gear Remove the clip then remove the stopper wheel Remove the clip then remove...

Page 237: ...teeth Blue discoloration pitting wear Replace Inspect the mated dogs Rounded edges cracks missing portions Replace Washer High Drive Gear Washer High Low Gear Clutch dog Clip Washer Low Drive Gear Co...

Page 238: ......

Page 239: ..._______________________ __________________________________________________________________________________ __________________________________________________________________________________ LEFT CRANK...

Page 240: ...12 LEFT CRANKCASE CRANKSHAFT BALANCE SHAFT 12 1 UXV 500...

Page 241: ...er head Chapter 8 Cylinder piston Chapter 9 Drive and driven pulleys Chapter 10 A C generator Chapter 17 Starter clutch Chapter 19 Oil pump Chapter 4 SPECIFICATIONS Unit mm in Item Standard Service Li...

Page 242: ...NSTALLATION section in the chapter 11 Remove the crankshaft and balance shaft together INSPECTION Balance shaft Inspect the balance shaft gear teeth Burrs chips roughness wear Replace Crankshaft inspe...

Page 243: ...0 004 in Measure the connecting rod big end side clearance C Service Limit replace if over Not USA type 0 6 mm 0 024 in USA type 0 8 mm 0 032 in Measure the crank width D Out of specification 72 72 05...

Page 244: ...AFT BALANCE SHAFT 12 5 UXV 500 INSTALLATION Install the balance shaft and crankshaft into the left crankcase Mark on the Balance Shaft Align the mark on the balance shaft with the mark on the cranksha...

Page 245: ...shaft countershaft primary drive shaft drive shaft bearing by using the special tool Special tool Bearing puller A120E00037 Install the new bearing by using the special tool Special tool Bearing driv...

Page 246: ......

Page 247: ..._______________ DRIVE TRAIN __________________________________________________________________________________ SERVICE INFORMATION 13 2 TROUBLESHOOTING 13 2 FRONT ASSY CVJ REMOVAL INSPECTION INSTALLAT...

Page 248: ...13 DRIVE TRAIN 13 1 UXU 500 FRONT DRIVE REAR DRIVE...

Page 249: ...bolt M8 2 3 kgf m 23 N m 16 5 lbf ft Apply threebond 1215 2WD 4WD shift motor mounting bolt M6 1 2 kgf m 12 N m 8 5 lbf ft Rear drive gear case mounting nut 5 5 kgf m 55 Nm 40 lbf ft Rear drive gear...

Page 250: ...nt cvj assy from front assy gearcase SIEP 1 Drain gear oil SIEP 2 Pushing and pulling the front assy cvj from front assy gearcase INSPECTION Inspect the boots circlip and boot bands for wear or damage...

Page 251: ...l a new circlip into its groove in the splines Apply lightweight lithium soap base grease to the splines of the drive shafts and install the cvj to the front assy gearcase Case Side Joint Circlip Be c...

Page 252: ...BLY DISASSEMBLY Remove the front drive axle Remove the boot band of the case side joint Slide the boot toward the center of the front cvj assy and remove the circlip from the case side joint Separate...

Page 253: ...irclip and snap ring for wear or damage If any damages are found replace them with new ones Inspect the cage and inner surface of case side joint for pitting wear or damage If any damages are found re...

Page 254: ...LY Do not attempt to straighten a bent shaft this may dangerously weaken the shaft Circlip Case Side Joint Snap Ring Cage Circlip Band Boot Band Band Boot Band Front Drive Shaft Wash all parts except...

Page 255: ...small diameter side of the boot to the shaft groove fix its end with a new band Install the cage on the shaft Install the snap ring to the groove on the drive shaft Band Snap Ring Large Diameter Side...

Page 256: ...e case side joint and fit a circlip in the groove of the case side joint Circlip Position Grease Case side joint Wheel side joint Quantity 85 g 2 8 oz 45 g 1 5 oz The tube of joint molybdenum disulfid...

Page 257: ...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 Fix the boot on the case side joint with a new boot band taking c...

Page 258: ...teering knuckle refer to the STEERING KNUCKLE REMOVAL INSPECTION INSTALLATION section in the chapter 14 Remove the front upper arms and front lower arms refer to the FRONT ARMS INSPECTION REMOVAL INST...

Page 259: ...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 Also check that the joi...

Page 260: ...tall 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 Connect all wire conn...

Page 261: ...sembly 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 Remove the differential lock lever wire F...

Page 262: ...ine 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 Remove the shim from right gear case Remove the 8 bolts...

Page 263: ...13 DRIVE TRAIN 13 16 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...

Page 264: ...nd hammer screwdriver Remove the pinion gear from the gear case housing Secure the pinion gear in a bearing puller Then remove the pinion bearing using a press Account for a collar and a bearing SPECI...

Page 265: ...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 beari...

Page 266: ...VAL 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 Suit...

Page 267: ...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 cali...

Page 268: ...13 DRIVE TRAIN 13 21 UXU 500 Remove 7 bolts from R side case rear final then remove R side case rear final Shim Ring Gear Gear Ring L side case rear...

Page 269: ...TRAIN 13 22 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 housin...

Page 270: ...13 DRIVE TRAIN 13 23 UXU 500 SPECIAL TOOL A120F00026 5 6...

Page 271: ...Secure the pinion gear in a bearing puller Then remove the pinion bearing using a press Account for a collar and a bearing Remove the needle bearing by using the special tools Special tool Bearing pul...

Page 272: ......

Page 273: ...__________________________________________________________________________________ SERVICE INFORMATION 14 2 TROUBLESHOOTING 14 3 FRONT WHEEL REMOVAL INSPECTION INSTALLATION 14 4 FRONT WHEEL HUB REMOV...

Page 274: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 1 UXV 500...

Page 275: ...25 15 19 0 01 Rod end tie rod angle 180 TORQUE VALUES Front swing arm nut 4 8 kgf m 48N m 34 8lbf ft Front wheel nut 5 5 kgf m 55 N m 40 lbf ft Front wheel hub nut 20kgf m 200 N m 145 lbf ft Castle n...

Page 276: ...m Excessive wheel bearing play Bent spoke plate Faulty tire Steers to one side or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent fron...

Page 277: ...el hub nut cap together INSPECTION Measure the wheel run out Replace wheel or check bearing play if out of specification Rim run out limits Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in INSTALLATION When...

Page 278: ...VAL INSPECTION INSTALLATION section in this chapter Elevate the front wheels by placing a suitable stand under the frame Remove the cotter pin Apply the front brake and then remove nut washer and fron...

Page 279: ...gf m 200 N m 145 lbf ft Install the cotter pin and band ends of cotter pin Apply grease onto the wheel hub splines Always use a new cotter pin Do not apply oil to the seat of the nut Do not loosen the...

Page 280: ...embly Inspect the shock absorber Oil leaks Replace the shock absorber assembly Inspect the spring of the shock absorber by move the spring up and down Fatigue Replace the shock absorber assembly Inspe...

Page 281: ...L Elevate the front wheels by placing a suitable stand under the frame Remove the front wheel hub Remove the three bolts and brake disc protection plate Remove the cotter pin and nut from the tie rod...

Page 282: ...ION STEERING SYSTEM 14 9 UXV 500 Release the tie rod ball joint upper arm ball joint off the knuckle Apply grease to the ball joint remover at the point shown Remove the knuckle from the upper and low...

Page 283: ...mages are found replace the knuckle end with a new one Inspect the brake disc protection plate for damage If any damages are found replace the brake disc protection plate with a new one Inspect the du...

Page 284: ...d torque Torque 3 5 kgf m 35 N m 25 lbf ft Install the cotter pins and band ends of cotter pins Install the tie rod onto the steering knuckle and tighten the nut to the specified torque Torque 4 8kgf...

Page 285: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 12 UXV 500 Install the brake disc protection plate and then tighten the three bolts securely Plate...

Page 286: ...ay 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 If there is anything unusual replace the bearing with a ne...

Page 287: ...using the special tool Special tool Oil seal and bearing driver A120E00014 Install the spacer into the steering knuckle Install the new outer bearing by using the special tool Special tool Oil seal an...

Page 288: ...HEEL FRONT SUSPENSION STEERING SYSTEM 14 15 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 whee...

Page 289: ...ch 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 ST...

Page 290: ......

Page 291: ...______________________________________________________________ __________________________________________________________________________________ REAR WHEEL SHOCK ABSORBER SWING ARM __________________...

Page 292: ...15 REAR WHEEL SHOCK ABSORBER SWING ARM 15 1 UXV 500...

Page 293: ...absorber upper mount bolt 4 5 kgf m 45 N m 32 lbf ft Rear shock absorber lower mount bolt 4 5kgf m 45 N m 32 lbf ft Rear wheel hub nut 20 kgf m 200 N m 145 lbf ft Right pivot bolt 11 8 kgf m 118 N m...

Page 294: ...d wheel hub nut cap together INSPECTION Measure the wheel run out Replace wheel or check bearing play if out of specification Rim run out limits Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in INSTALLATION...

Page 295: ...heel Elevate the rear wheels by placing a suitable stand under the frame Remove the cotter pin Apply the rear brake and then remove nut and rear wheel hub INSPECTION Check the wheel hub for cracks or...

Page 296: ...otter pin Apply lightweight lithium soap base grease onto the wheel hub splines rear axle splines and dust seal lips of the axle housing Apply grease Apply grease Always use a new cotter pin Do not ap...

Page 297: ...leaks Replace the shock absorber assembly Inspect the spring of the shock absorber by move the spring up and down Fatigue Replace the shock absorber assembly Inspect bushes collar and dust seals Wear...

Page 298: ...Elevate the rear wheels by placing a suitable stand under the frame Remove the rear wheel hub Remove the cotter pin and nut from the tie rod end Remove the 2 bolts Remove the knuckle from the upper an...

Page 299: ...R WHEEL SHOCK ABSORBER SWING ARM 15 8 UXV 500 INSPECTION Inspect the knuckle end boot for wear or damage If any damages are found replace the knuckle end with a new one Knuckle End Boot Dust Seal Dust...

Page 300: ...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 Do not loosen the nuts after torque tightening If the nuts groove i...

Page 301: ...e 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 If there is anything unusual replace the bearing with...

Page 302: ...sing the special tool Special tool Oil seal and bearing driver A120E00014 Install the spacer into the steering knuckle Install the new outer bearing by using the special tool Special tool Oil seal and...

Page 303: ..._____________________ 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 1...

Page 304: ...fluid use shop towels to cover and protect painted rubber and plastic parts Wipe off any splash of brake fluid with a clean towel Do not wipe the machine with a towel contaminated by brake fluid Make...

Page 305: ...pad Poor brake performance Brake noise Air in brake system Contaminated brake pad surface Deteriorated brake fluid Excessive brake disk run out Contaminated brake pads and brake disk Incorrectly insta...

Page 306: ...n 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 Compress the brake caliper holder and remove brake...

Page 307: ...or Install the new brake pads Install the brake pad mounting pins Install the brake caliper mounting bolts to the specified torque Torque 2 7 kgf m 27 Nm 19 5 lbf ft Tighten the brake pad mounting pin...

Page 308: ...e same Rear brake combined Remove the rear wheel refer to the REAR WHEEL REMOVAL INSPECTION INSTALLATION section in the chapter 15 Remove the two brake pad pins from the brake caliper Remove the two m...

Page 309: ...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 pa...

Page 310: ...16 BRAKE SYSTEM 16 7 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...

Page 311: ...section in the chapter 14 Remove the four bolts and then remove the brake disc INSPECTION Measure the brake disc thickness Service Limit 3 mm 0 12 in Measure the brake disk run out Service Limit 0 3 m...

Page 312: ...der disk rear brake Remove the rear drive Remove the 5 bolts and then remove the brake disc Use the impact driver remove it INSPECTION Measure the brake disc thickness Service Limit 4 mm 0 16 in Measu...

Page 313: ...nnect a transparent hose to the brake caliper bleed valve right and calipers and then loosen the bleed valve nuts Use a syringe to draw the brake fluid out through the hose Then tighten the bleed valv...

Page 314: ...kgf m 6 Nm 4 32 lbf ft Connect a transparent hose to the left 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...

Page 315: ...e right caliper bleed valve nut to bleed air from the brake system 3 Fully apply the brake pedal after continuously to tread it several times Then loosen the left caliper bleed valve nut to bleed air...

Page 316: ...d 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 Then tighten the bleed valve nut...

Page 317: ...em 3 Repeat these steps until the brake system is free of air BRAKE PEDAL Brake fluid change Place the machine on the level ground and set the handlebar upright Remove the brake fluid reservoir cap Wh...

Page 318: ...ommended Brake Fluid DOT 4 Brake system bleeding 1 Connect a transparent hose to the bleed valve 2 Fully apply the brake pedal after continuously depress it several times Then loosen the caliper bleed...

Page 319: ...ke pads refer to the BRAKE PADS REPLACEMENT section in this chapter Remove the brake caliper INSTALLATION Install the brake fluid hose with the attaching bolt and two new sealing washers then tighten...

Page 320: ...L INSTALLATION section or REAR BRAKE CALIPERS REMOVAL INSTALLATION section in this chapter Remove the brake pad spring plate Remove the piston from the brake caliper If necessary use compressed air to...

Page 321: ...the caliper bracket INSPECTION Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages If any abnormal condition is noted replace the caliper Inspect the dust boot...

Page 322: ...ke 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 Never use different types of fluid or...

Page 323: ...is chapter Remove the brake pad 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 t...

Page 324: ...em with a new ones Remove the caliper bracket Remove the dust boot Remove the dust seal and piston seal Loosen the lock nut while hold the adjusting bolt Remove the adjusting bolt Remove the parking b...

Page 325: ...ion or damage If any damage is found replace it with a new one Remove the drive bolt and dust boot Inspect the drive shaft and shaft guide for wear or damage Remove the two bolts and parking brake cas...

Page 326: ...23 UXV 500 Remove the O ring Inspect the O ring for wear or damage If any damages are found replace it with a new one INSTALLATION Apply silicone grease to the new O ring then install the new O ring O...

Page 327: ...securely Apply silicone grease to the new piston seal and new dust seal then install them Install the piston Apply silicone grease to the brake shaft then install it Apply silicone grease to the dust...

Page 328: ...s not touch piston Install the parking brake arm and spring Install the adjusting bolt and lock nut Dust Boot Piston Adjusting Bolt Lock Nut Parking Brake Arm Spring Brake Fluid Inlet hole Align the p...

Page 329: ...stall it Install the spring plate Install the parking brake caliper refer to the REAR BRAKE PARKING BRAKE CALIPER EMOVAL INSTALLATION ON ROAD section in this chapter Adjust the parking brake refer to...

Page 330: ...olt two washers and then disconnect the fluid hose Remove the two master cylinder holder bolts and rear stop switch spring remove the master cylinder Do not splash brake fluid onto any rubber plastic...

Page 331: ...and rin comp brake rod then remove the master cylinder 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 co...

Page 332: ...00 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...

Page 333: ...XV 500 REAR BRAKE DISK REMOVAL Remove the two bolts attaching the skid plate Remove the skid plate Drain out the rear gear box oil as picture Remove the three bolts attaching the muffler Remove the mu...

Page 334: ...BRAKE SYSTEM 16 31 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 Nut Cotter Pin Hub Hub Nut Cotter P...

Page 335: ...6 BRAKE SYSTEM 16 32 UXV 500 Remove the bolts nut Remove the knuckle attaching the upper arm as picture Remove the CVJ ASSY attaching the rear gear box assembly Bolt nut knuckle Rear Gear Box CVJ ASSY...

Page 336: ...16 BRAKE SYSTEM 16 33 UXV 500 Remove the two bolts attaching the rear gear box Remove the caliper from rear gear box Remove the boot attaching the transmission out shaft Caliper...

Page 337: ...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 br...

Page 338: ......

Page 339: ...___________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM _________________________...

Page 340: ...17 BATTERY CHARGING SYSTEM 17 1 UXV 500 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT Battery Regulator Rectifier ACG...

Page 341: ...one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte level goes down quickly...

Page 342: ...seals again For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery SPECIFICATIONS ITEM...

Page 343: ...all the battery Check the battery current leakage Specified current leakage 0 5 Ma max Check the alternator charging coil Standard 0 1 0 3 20 C 68 F Measure and record the battery voltage using a digi...

Page 344: ...ery first then disconnect the positive terminal lead 3 5 Remove the battery Battery installation 1 Install in the reverse order of removal 2 After installing the battery check to see if the battery ca...

Page 345: ...on switch OFF disconnect the negative cable from the battery Connect the ammeter probe to the negative cable and the ammeter probe to the battery terminal With the ignition switch OFF check for curren...

Page 346: ...ve and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multi meter when the engine runs at 5000 min 1 rpm Standard...

Page 347: ...if any wire has continuity to ground REGULATOR RECTIFIER WIRE HARNESS INSPECTION Disconnect the regulator rectifier connectors Check the connectors for loose contacts of corroded terminals Battery li...

Page 348: ...en 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 20 C 68 F Check for continui...

Page 349: ...UXV 500 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 Rectif...

Page 350: ...section in the chapter 3 Disconnect the alternator stator connectors Remove the starter pulley refer to the STARTER PULLEY REMOVAL INSPECTION INSTALLATI ON section in the chapter 19 Remove the oil fil...

Page 351: ...the two dowel pins and gasket Remove the two pulse coil mount bolts Remove the three stator mount bolts grommet and the stator from the right crankcase cover INSPECTION Check the stator and pulse coil...

Page 352: ...y Install the pulse coil and tighten mount bolts to the specified torque Torque 1 2 kgf m 12 N m 9 lbf ft Clean the mating surfaces of the right crankcase and cover Install the dowel pins and gasket I...

Page 353: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGN...

Page 354: ...18 IGNITION SYSTEM 18 1 UXV 500 IGNITION SYSTEM LAYOUT Fuse CDI Spark Plug Ignition Coil...

Page 355: ...18 IGNITION SYSTEM 18 2 UXV 500 IGNITION CIRCUIT...

Page 356: ...f the ignition switch before servicing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the sta...

Page 357: ...TAGE Short circuit in engine stop switch or ignition switch wire Faulty engine stop switch or ignition switch Loose or poorly connected ignition control module connectors Open circuit or poor connecti...

Page 358: ...rk plug cap and ground the spark plugs to the cylinder as done in the spark test Turn the ignition switch to ON and engine stop switch ON Turn the engine stop switch in RUN OFF ROAD Connect the multi...

Page 359: ...8 F IGNITION COIL REMOVAL INSTALLATION Disconnect the spark plug cap from the spark plug page 18 4 Disconnect the ignition coil primary connectors Remove the two bolts and the ignition coil Installati...

Page 360: ...W G GR L Y G W B Y G B W G GR 6 7 M 6 7 M 6 7 M L Y 0 785 K Continue G W 0 778 K 0 785 k B Y G Continue 0 785 K Due to the semiconductor in circuit it is necessary to use a specified tester for accur...

Page 361: ..._______________ __________________________________________________________________________________ __________________________________________________________________________________ STARTER SYSTEM ___...

Page 362: ...19 STARTER SYSTEM 19 1 UXV 500 STARTING SYSTEM LAYOUT Start Motor Battery Start Relay Start MAG...

Page 363: ...19 STARTER SYSTEM 19 2 UXV 500 STARTING CIRCUIT...

Page 364: ...follow the steps in the troubleshooting flow chart page 19 2 A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current If the current is kept flowing t...

Page 365: ...ignition switch turned to OFF Remove the two mounting bolts and starter motor Release the rubber cap and remove the terminal nut to disconnect the starter motor cable from the starter motor INSTALLATI...

Page 366: ...relay switch and starter MAG using the procedure below GROUND LINE INSPECTION Disconnect the starter relay switch connector Check for continuity between the Green wire terminal and ground There should...

Page 367: ...bles 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 te...

Page 368: ...NSTALLATION REMVOAL Remove the right crankcase cover Remove the flywheel driven gear by using the special tool Special tool Flywheel puller A120E00060 Remove the woodruff key Remove the reduction gear...

Page 369: ...ear should not turn counterclockwise Remove the starter driven gear by turning the driven gear Check the starter driven gear teeth for wear or damage Measure the starter driven gear boss O D Service l...

Page 370: ...gear Install the starter reduction gear to the right crankcase Install the woodruff key in the crankshaft key groove Apply molybdenum oil solution to the starter driven gear bushing Install the starte...

Page 371: ...SYSTEM 19 10 UXV 500 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 Reduction Gear Dr...

Page 372: ......

Page 373: ...__________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS SWITHCES...

Page 374: ...g 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...

Page 375: ...d replace with a new one Install the bulb aligning the bulb socket groove with the bulb tab and set the lock clip Connect headlight wire connector Install the rubber boot Install the front fender in t...

Page 376: ...ulb 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 Remove...

Page 377: ...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 s...

Page 378: ...tween 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 ign...

Page 379: ...ight switch connector Remove the bolt then remove the gear indicator light switch and washer Install the washer and a new switch with a new O ring apply engine oil to O ring Shift the drive select lev...

Page 380: ...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 If the speedom...

Page 381: ...elect the 4WD position on the front drive selector switch then connect the red tester lead to the white blue wire in the supply harness The meter must show 0DC volts 6 Connect the red tester lead to t...

Page 382: ...PECTION 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 3 Float at empty position 100 3 INSTALLATI...

Page 383: ...21 WIRING DIAGRAMS 21 0 UXV 500 21 21...

Page 384: ...21 WIRING DIAGRAMS 21 1 UXV 500...

Page 385: ...ATIONS 22 2 INJECTION SYSTEM DIAGRAM 22 3 PARTS LOCATION 22 4 TROUBLESHOOTING 22 8 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL 22 7 EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES 22 9...

Page 386: ...e throttle and idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has b...

Page 387: ...e at 20 C 68 F Float at empty position About 3 Fuel pump standard pressure at 80 L Hr 300 10 kPa 3 Bar At 20 C 4 F 28 6 K At 40 C 104 F 20 C 1 46 K 3 51 K 10 Water temperature sensor resistance At 100...

Page 388: ...TION SYSTEM 22 3 UXV500i INJECTION SYSTEM DIAGRAM ECU FUEL PUMP T MAP SENSOR CPS WTS VOLTAGE TPS Fuel Injector ISC Inductive Ignition Coil END KEY OFF No YES Output Signal By ECU Input Signal To ECU K...

Page 389: ...22 FUEL INJECTION SYSTEM 22 4 UXV 500i PARTS LOCATION ECU ISC ECU Connector Throttle Body T MAP Sensor TPS Fuel Injector Inlet Pipe...

Page 390: ...22 FUEL INJECTION SYSTEM 22 5 UXV500i Air C Fuel Hose Fuel Hose Fuel Pump Fuel Pump Coupler Connector Fuel Pump Inductive ignition coil WTS...

Page 391: ...22 FUEL INJECTION SYSTEM 22 6 UXV 500i WTS Inductive Ignition Coil Hi Beam Relay Start Relay Battery Lo Beam Relay...

Page 392: ...22 FUEL INJECTION SYSTEM 22 7 UXV500i Fuel Pump Relay Switch Power Relay Roll Sensor Winker Relay REG REC Hazard Control...

Page 393: ...ged fuel hose Poor performance drive ability and poor Faulty fuel pump operating system fuel economy Pinched or clogged fuel hose Clogged fuel injector Faulty fuel injector Faulty spark plug or wrong...

Page 394: ...uble z There are 3 kinds of priority grade let user to know what kind of trouble was happened z Priority grade 1 CELP blinks continuously This is the most emergent situation like engine over heat User...

Page 395: ...hen show the other higher number one after four seconds All the failure codes would be shown repeatedly How To Reset Failure Code z After repairing the trouble you should clear the failure code or it...

Page 396: ...cuit malfunction 2 1 Check if the connector of crankshaft position sensor is loosen 2 Check if the Rotor is align with Crankshaft position sensor during the crankshaft running 3 P1120 Throttle positio...

Page 397: ...f the charge system is malfunction 7 P0110 Intake air temperature circuit malfunction 2 Inlet air temperature sensor or electric circuit malfunction 8 P0410 Idle air valve circuit malfunction 2 1 Chec...

Page 398: ...elay resistance 13 P0219 Engine speed is over than top speed 2 Check if the belt of CVT is broken 14 P1560 Sensor don t receive power source from ECU 2 Check if ECU output DC5V to sensor 2 Check if th...

Page 399: ...res of CELP is broken 21 P0105 Atmospheric Pressure Sensor Circuit Malfunction 2 1 Check if the connector of sensor is loosen 2 Check if ECU pin is broken 3 Check if voltage of sensor is fit in specif...

Page 400: ...ve to obtain smooth idling speed The ECU may record the incorrect ISC position during the engine speed isn t working when the ECU or the throttle body has been reinstalled It can cause engine stop har...

Page 401: ...It should be shown the current battery voltage for a few seconds If there is still battery voltage replace the fuel pump If there is not any battery voltage inspect the following Fuse Fuel pump relay...

Page 402: ...the connector rearward carefully Torque 0 35 kgf m 3 5 N m 2 5 lbf ft FUEL OUTPUT PRESSURE INSPECTIION Turn the key to the OFF position Use the fuel hose clamp Disconnect the fuel hose from the fuel i...

Page 403: ...Connection R L B R Connect 12 V battery with the fuel pump relay connector Connection R Y O R There should be continuity only when 12 V battery connected If there is not continuity when the 12 V batt...

Page 404: ...itch 65 10 degrees to the left or right with the ignition switch turned to ON Measure the voltage between the following terminals of the tilt switch connector with the connector connected Terminal Nor...

Page 405: ...er of the removal ECU connector remove procedure Same as DOWNTOWN 125i ECU connector install procedure Same as DOWNTOWN 125i Do not disconnect or connect the ECU connector during the ignition switch O...

Page 406: ...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 wir...

Page 407: ...ct the connector from the fuel injector Remove the bolts of the fuel injector Take out of the fuel pipe and fuel injector from the Inlet pipe Remove the fuel injector from the fuel pipe Connector Bolt...

Page 408: ...PROBLEM 1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard See the KYMCO Diagnostic report ANALYSIS Injector block With some carbons TROUBLESHOOTING...

Page 409: ...S sensor and O ring Install a new O ring and WTS sensor Tighten the WTS sensor to the specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Connect the WTS sensor connector Fill the cooling system with...

Page 410: ...ry do not disassemble it by a wrong way Do not loosen or tighten the painted bolts and screws for the throttle body Loosen or tighten them can cause the throttle and idle valve to synchronization fail...

Page 411: ...Throttle position sensor TPS resistance at 20 C 68 F 3500 6500 REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from throttle seat Disconnect the TPS ISC...

Page 412: ...PS ASSEMBLY Apply oil onto a new O ring When install the TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely TPS Screw ISC TPS T MAP sensor The thr...

Page 413: ...ing DIAGNOSTIC TOOL CONNECTOR INSPECTION Unhook the hood and then slowly tilt hood up until it Make sure moving the shift lever into the N or P position Remove diagnostic tool connector protect sheath...

Page 414: ...IDLE rpm 1400 100 rpm MAPSample kPa 30 40kpa Injection duration ms 2 6 3 8ms Ign Advance 12 16 BTDC Ign Dwell duration ms Air Temp C 45 C Engine Temp C 80 C O2 sensor voltage V O2 sensor heater Yes no...

Page 415: ...22 FUELINJECTION SYSTEM 22 30 UXV 500i UXV500 i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 E00 ENGLISH VERSION version V1 0 7...

Page 416: ...ed with 12V battery z For connection please connect this tool with the connector of ECU It s available when turning on the ignition switch z The function includes ECU version model name data analysis...

Page 417: ...ON PROCEDURE Showing four functions on the screen when switching on power A ECU version Including of model name ECU number identifications number and software version Press the Enter button Press the...

Page 418: ...22 FUELINJECTION SYSTEM 33 22 33 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...

Page 419: ...22 FUELINJECTION SYSTEM 22 34 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 FUELINJECTION SYSTEM 22 35 UXV 500i G Press the UP button H Press the Enter button and then turn to the previous page I Press the UP button...

Page 421: ...22 FUELINJECTION SYSTEM 22 36 UXV 500i J Press the Enter button and then turn to the first page...

Page 422: ...22 FUELINJECTION SYSTEM 22 37 UXV 500i 3 DTC CLEAR PROCEDURE A Check the DTC B Press the Enter button C Choose DTC Load Press the Down button...

Page 423: ...22 FUELINJECTION SYSTEM 22 38 UXV 500i D Press the Enter button and the indicator is lighting E Clearing DTC completed if the indicator is off...

Page 424: ...DATAANALYSIS PROCEDURE A Press the Down twice B Choose Data Analyze Press the Enter button to enter page 01 C Down page 01 The measure figures including of Engine speed Battery voltage and Engine spee...

Page 425: ...ress the Down button to enter page 03 E Down page 03 The measure figures including of engine temperature air temperature and intake pressure Press the Down button to enter page 04 F Down page 04 The m...

Page 426: ...ition and gear ratio Press the Down button to enter page 06 H Down page 06 The measure figures including of rollover voltage The function setting is not allowed Press the Down button to enter page 07...

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KYMCO Kymco UXV 500i, Service Manual

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