KYMCO Kymco UXV 500i User manual

Service Manual
englisch
UXV 500i
AMSLER & CO. AG
8245 FEUERTHALEN ZH
fon 052 647 36 36
fax [phone]
[email protected]
www.amsler.ch

1. GENERAL INFORMATION
1-0
UXV 500
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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
1

1. GENERAL INFORMATION
1-1
UXV 500
SERIAL NUMBER
(1) Location of Engine Serial Numbe
r
(1) Location of Frame Serial Numbe
r

1. GENERAL INFORMATION
1-2
UXV 500
SPECIFICATIONS
Model No. UAA0
Name & Type UXV 500
Overall length 2870 mm
Overall width 1500 mm
Overall height 1850 mm
Wheel base 1910 mm
Engine type D.O.H.C.
Displacement 498.5 CC
Fuel used Nonleaded Gasoline
Front wheel 228 kg
Rear wheel 297kg
Dry weight Total 525kg
Front wheel 243 kg
Rear wheel 317 kg
Curb weight Total 560 kg
Front wheel 25X8R-12
Tires Rear wheel 25X10R-12
Ground clearance 310 mm (12.2 in)
Min. turning radius 4350 mm (170 in)
Starting system Electric/Recoil
starter
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke 92X75 mm
(3.68X3 in)
Compression ratio 10.5:1
Compression pressure 15 kgf/cm²
(1500kPa, 213 psi)
Opens 5°BTDCIntake valve
(at 1mm lift) Closes 45°ABDC
Opens 45°BBDCExhaust valve
(at 1mm lift) Closes 5°ATDC
Intake 0.1 mm (0.004 in)Valve clearance
(cold) Exhaust 0.1 mm (0.004 in)
Idle speed (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 draining and oil
filter cartridge change 3.2 L
Air cleaner type & No Wet type element
Fuel capacity 32 L
Type CVK
ON ROAD #122Main
jet OFF ROAD #130
Slow jet #40
Choke jet #90
Type Full transistor digital
ignition
Ignition timing 5°/1500 rpm
Spark plug CR7E (NGK)
Spark plug gap 0.6~0.7mm
Battery Capacity 12V18AH
Clutch type Wet, centrifugal
automatic
Clutch operation system Automatic (V-belt)
Primary reduction system V-belt
Secondary reduction
system Shaft drive
High reduction ratio 3.48
Low reduction ratio 6.464
Reverse ratio 5.31
FR/RR tire rolling
circumference 1995/1995 mm
(79.8/79.8 in)
Front
Tire pressure
(1person 75kg) Rear 0.7/0.98 kgf/cm²
(10/14 psi)(FR/RR)
Left 38.8°
Turning angle Right 38.8°
Front Disk brake
Brake system type Rear Disk brake
Front Double A-arm
Suspension type Rear Double A-arm
Frame type Double cradle
Engine
Ignition System
Drive Train Moving Device
Lubrication System Fuel System
Carburetor
Electrical Equipment

1. GENERAL INFORMATION
1-3
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.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-4
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.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive (+)
terminal must be connected first.
After connection, apply grease to the battery
terminals.
Terminal caps shall be installed securely.
(-)
(+)

1. GENERAL INFORMATION
1-5
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.
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 connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confir
m
Capacity

1. GENERAL INFORMATION
1-6
UXV 500
The connector shall be inserted
completely.
If the double connector has a lock, lock it
at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged 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 make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the designated
locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!

1. GENERAL INFORMATION
1-7
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.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !

1. GENERAL INFORMATION
1-8
UXV 500
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
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 sheath,
repair by wrapping it with protective tape or
replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight!
Do not press or
squeeze the wire
.

1. GENERAL INFORMATION
1-9
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
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do you understand
the instrument? Is the
instrument set
correctly?
Remove Rust !

1. GENERAL INFORMATION
1-10
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.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Caution
: Warning
En
g
ine Oil
Grease
Gear Oil

1. GENERAL INFORMATION
1-11
UXV 500
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque
kgf-m (N-m) Item Torque
kgf-m (N-m)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
0.45-0.6 (4.5-6)
0.8-1.2 (8-12)
1.8- 2.5(18-25)
3-4 (30-40)
5-6 (50- 60)
6-8(60-80)
4mm screw(Round)
4mm screw(Sharp)
5mm screw(Round)
5mm screw(Sharp)
6mm screw, flange SH bolt
6mm bolt and nut
8mm flange 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 important fasteners.
ENGINE
Item Thread dia.
(mm) Torque kgf-m (N-m) Remarks
MAINTENANCE:
Spark plug
Tappet ADJ nut
Engine oil filter cap
Engine oil filter cartridge
Engine drain plug
LUBRICATION SYSTEM:
Oil pump screw
Oil pipe bolt
COOLING SYSTEM:
Water pump bolt
Fan motor bolt
Fan motor switch
10
5
30
20
12
4
16
6
5
16
1.2 (12)
0.9 (9)
1.5 (15)
1 (10)
2.5 (25)
0.3 (3)
3.5 (35)
1.3 (13)
0.53 (5)
1.8 (17)
Apply oil
Apply oil
Apply oil
(Cont’d)

1. GENERAL INFORMATION
1-12
UXV 500
Item Thread dia.
(mm) Torque kgf-m (N-m) Remarks
CYLINDER HEAD:
Cylinder head bolt
Cylinder head bolt
Cylinder head nut
Cylinder head cover
Breather separator bolt
Cam chain tensioner bolt
Tensioner sealing bolt
Rocker arm shaft
Chain guide pivot bolt
Water joint bolt
CYLINDER:
Cylinder bolt
DRIVE/DRIVEN PULLEY:
Drive pulley nut
Wet clutch nut
Driven 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 bearing nut
Drive shaft bearing bolt
STARTER SYSTEM:
Starter pulley nut
10
8
6
6
6
6
10
18
8
6
6
20
25
16
36
6
20
20
8
12
20
85
8
14
4.8 (48)
2.3 (23)
1 (10)
1 (10)
1.3 (13)
1.2 (12)
1 (10)
4.5 (45)
2 (20)
1.2 (12)
1 (10)
14 (140)
14 (140)
10 (100)
7.5 (75)
1.2 (12)
14 (140)
14 (140)
2.5 (25)
3 (30)
4.8 (48)
11 (110)
3 (30)
5.5 (55)
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil

1. GENERAL INFORMATION
1-13
UXV 500
FRAME
Item Q‘ty Thread
dia.
(mm)
Torque
Kgf-m (N-m,
lbf-ft)
Remarks
STEERING:
Steering column and intermediate shaft
Steering assembly and intermediate shaft
Steering assembly and frame
Steering column assembly and frame
Steering wheel and steering column
Front knuckle and front upper arm
Front knuckle and front lower arm
Tie-rod lock nut
Front knuckle and Tie-rod
WHEEL:
Front wheel and front wheel hub
Rear wheel and rear wheel hub
Front wheel hub and cvj
Rear wheel hub and cvj
FR SUSPENSION:
Front upper arm 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 arm
Rear knuckle and rear lower arm
Rear shock cushion and frame
Rear shock cushion and rear lower arm
Stabilizer and frame
Stabilizer joint and stabilizer
Stabilizer joint and rear lower arm
8
8
10
10
12
10
10
12
10
10
10
18
18
10
10
10
10
10
10
10
10
10
10
10
10
10
2.7 (27, 15)
2.7 (27,15)
4.8 (48, 34)
3.2 (32, 23)
3.5 (35 25.)
4.8 (48 ,34)
4.8 (48 ,34)
4.0 (40, 28)
3.5 (35, 25)
5.5 (55, 39)
5.5 (55, 39)
20 (200, 160)
20(200,160)
4.8(48,34)
4.8(48,34)
4.5(45,32.4)
4.5 (45, 32.4)
4.8 (48, 34)
4.8 (48, 34)
4.8 (48, 34)
4.8 (48, 34)
4.5 (45, 32)
4.5 (45, 32)
3.2(32, 23)
5.5(55,39)
5.5(55,39)
(Cont’d)

1. GENERAL INFORMATION
1-14
UXV 500
Item Q‘ty Thread
dia.
(mm)
Torque
K
g
f-
m
(
N-m,
lbf-ft)
Remarks
BRAKE:
Front caliper bracket mounting bolt
Rear caliper bracket mounting bolt
Front brake disc and wheel hub
FR/RR brake caliper bleed screw
Brake hose oil bolt
Brake master cylinder and frame
Rear disc holder and gear box
Rear disc mounting bolt
3-way junction nut
FRAME:
FR/RR hanger and damper
Engine damper and frame
Differential gear case
Differential gear stay and frame
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 gear box and caliper bracket
Air cleaner and frame
Exhaust pipe and engine head
Muffler stay and frame
8
8
8
8
10
8
10
8
8
10
8
10
8
10
8
8
10
10
8
8
8
7/16-20unf
8
8
10
8
10
2.7 (27, 19)
2.7 (27, 19)
3.5 (35, 25)
0.6 (6, 4)
3.5(35,25)
2.2(22,15.6)
4.5 (45, 32)
3.5 (35, 25)
2.5(25,18)
5.5(55, 39)
2.7(27, 19)
5.5(55, 39))
3.2(32,22.7)
5.5(55, 39)
2.7 (27, 19)
2.2 (22, 15.6)
3.2 (32, 22.7)
6.4(64, 45)
3.2(32, 22.7)
2.2 (22, 15.6)
2.2 (22, 15.6)
5.9 (59, 42)
2.2 (22, 15.6)
3.2(32, 22.7)
1.6 (16, 11.7)
2.0 (20, 15)
3.5 (35, 25)

1. GENERAL INFORMATION
1-15
UXV 500
SPECIAL TOOLS
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Oil seal and bearing
installer
A120E00014
Valve adjuster
(Refer to the “VALVE
CLEARANCE” section in the
chapter 3.)
A120E00036
Bearing puller A120E00037
Valve spring compressor
(Refer to the “CYLINDER HEAD
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the
cha
p
ter 8.
)
A120E00040
Universal holder
(Refer to the “DRIVE PULLEY,
DRIVE V-BELT AND DRIVEN
PULLEYREMOVAL/
INSPECTION/
INSTALLATION” section and
“CLUTCH REMOVAL/
INSTALLATION” section in the
chapter 10.)
A120E00056
Drive pulley holder
(Refer to the “DRIVE PULLEY,
DRIVE V-BELT AND DRIVEN
PULLEYREMOVAL/
INSPECTION/
INSTALLATION” section in the
chapter 10.)
A120E00058

1. 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)

1. GENERAL INFORMATION
1-17
UXV 500
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Crankshaft bearing puller A120E00068
Ball joint remover
(Refer to the “STEERING
KNUCKLE REMOVAL/
INSPECTION/
INSTALLATION” section in the
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/INSPECTION/
ASSEMBLY” section in the
chapter 13)
A120F00016
Drive shaft puller
(Refer to the “FRONT DRIVE
SHAFT REOMVAL/
INSPECTION/
INSTALLATION” section in the
chapter 13)
A120F00017
Yoke bearing puller
(Refer to the “FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the
chapter 13)
A120F00018
(Cont’d)

1. GENERAL INFORMATION
1-18
UXV 500
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Pinion bearing lock nut
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.)
A120F00021
C-ring remover
(Refer to the “FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the
chapter 13)
A120F00022
Carburetor adjustment
Adjust pilot screw position
A120E00076