1. GENERAL INFORMATION

1-0

UXV 500

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GENERAL INFORMATION__________________________________________________________________________________

SERIAL NUMBER---------------------------------------------------------- 1- 1SPECIFICATIONS ---------------------------------------------------------- 1- 2SERVICE PRECAUTIONS ------------------------------------------------ 1- 3TORQUE VALUES --------------------------------------------------------- 1-11SPECIAL TOOLS ----------------------------------------------------------- 1-15LUBRICATION POINTS -------------------------------------------------- 1-18

1

1. GENERAL INFORMATION

1-1

UXV 500

SERIAL NUMBER

(1) Location of Engine Serial Number

(1) Location of Frame Serial Number

1. GENERAL INFORMATION

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UXV 500

SPECIFICATIONS

Model No. UAA0 seriesName & Type UXV 500Overall length 2870 mmOverall width 1500 mmOverall height 1850 mmWheel base 1910 mmEngine type D.O.H.C.Displacement 498.5 CCFuel used Nonleaded Gasoline

Front wheel 228 kgRear wheel 297kgDry weightTotal 525kgFront wheel 243 kgRear wheel 317 kgCurb weightTotal 560 kgFront wheel 25X8R-12TiresRear wheel 25X10R-12

Ground clearance 310 mm (12.2 in)Min. turning radius 4350 mm (170 in)

Starting systemElectric/Recoilstarter

Type Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C., chain drive

Bore x stroke92X75 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 rpmCooling type Liquid cooled

Lubrication type Forced pressure &Wet sump

Oil pump type TrochoidOil filter type Full-flow filtration

Oil capacity 3.6 L

Oil exchanging capacity 3 L

After draining and oilfilter cartridge change

3.2 L

Air cleaner type & No Wet type element

Fuel capacity 32 L

Type CVKON ROAD #124Main

jet OFF ROAD #122Slow jet #40Choke jet #90

Type Full transistor digitalignition

Ignition timing 5°/1500 rpmSpark plug CR7E (NGK)

Spark plug gap 0.6~0.7mm

Battery Capacity 12V18AH

Clutch type Wet, centrifugalautomatic

Clutch operation system Automatic (V-belt)Primary reduction system V-beltSecondary reductionsystem Shaft drive

High reduction ratio 3.48Low reduction ratio 6.464Reverse ratio 5.31FR/RR tire rollingcircumference

1995/1995 mm(79.8/79.8 in)

FrontTire pressure

(1person 75kg)Rear

0.7/0.98 kgf/cm²(10/14 psi)(FR/RR)

Left 38.8°Turning angleRight 38.8°

Front Disk brakeBrake system typeRear Disk brakeFront Double A-armSuspension typeRear Double A-arm

Frame type Double cradle

Engine

Ignition System

Drive Train

Moving D

eviceLubrication System

Fuel System

Carbureto r

Electrical Equipment

1. GENERAL INFORMATION

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UXV 500

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. when reassembling.

When tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure touse special tools for removal andinstallation.

After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.

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UXV 500

Apply or add designated greases andlubricants to the specified lubricationpoints.

After reassembly, check all parts for propertightening and operation.

When two persons work together, payattention to the mutual working safety.

Disconnect the battery negative (-) terminalbefore operation.When using a spanner or other tools, makesure not to damage the motorcycle surface.

After operation, check all connecting points,fasteners, and lines for proper connectionand installation.When connecting the battery, the positive (+)terminal must be connected first.After connection, apply grease to the batteryterminals.Terminal caps shall be installed securely.

(-)

(+)

1. GENERAL INFORMATION

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UXV 500

If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

After operation, terminal caps shall beinstalled securely.

When taking out the connector, the lock onthe connector shall be released beforeoperation.

Hold the connector body when connectingor disconnecting it.Do not pull the connector wire.

Check if any connector terminal is bending,protruding or loose.

ConfirmCapacity

1. GENERAL INFORMATION

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UXV 500

The connector shall be insertedcompletely.If the double connector has a lock, lock itat the correct position.Check if there is any loose wire.

Before connecting a terminal, check fordamaged terminal cover or loosenegative terminal.

Check the double connector cover forproper coverage and installation.

Insert the terminal completely.Check the terminal cover for propercoverage.Do not make the terminal cover openingface up.

Secure wire harnesses to the frame withtheir respective wire bands at the designatedlocations.Tighten the bands so that only the insulatedsurfaces contact the wire harnesses.

Snapping!

1. GENERAL INFORMATION

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UXV 500

After clamping, check each wire to makesure it is secure.

Do not squeeze wires against the weld or itsclamp.

After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts.

When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.Route wire harnesses passing through theside of bolts and screws. Avoid theprojected ends of bolts and screws.

No Contact !

1. GENERAL INFORMATION

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UXV 500

Route harnesses so they are neitherpulled tight nor have excessive slack.

Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.

When rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled 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 orreplace it.

When installing other parts, do not press orsqueeze the wires.

Do not pulltoo tight!

Do not press orsqueeze the wire.

1. GENERAL INFORMATION

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UXV 500

After routing, check that the wire harnessesare not twisted or kinked.

Wire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.

When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.

Do you understandthe instrument? Is theinstrument setcorrectly?

Remove Rust !

1. GENERAL INFORMATION

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UXV 500

Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Caution

: Warning

Engine 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 nut6mm bolt and nut8mm bolt and nut

10mm bolt and nut12mm bolt and nut14mm 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 bolt6mm bolt and nut8mm flange bolt and nut10mm 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 plugTappet ADJ nutEngine oil filter capEngine oil filter cartridgeEngine drain plug

LUBRICATION SYSTEM:Oil pump screwOil pipe bolt

COOLING SYSTEM:Water pump boltFan motor boltFan motor switch

105

302012

416

65

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 oilApply oil

Apply oil

(Cont’d)

1. GENERAL INFORMATION

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UXV 500

Item Thread dia.(mm)

Torque kgf-m (N-m)

Remarks

CYLINDER HEAD:Cylinder head boltCylinder head boltCylinder head nutCylinder head coverBreather separator boltCam chain tensioner boltTensioner sealing boltRocker arm shaftChain guide pivot boltWater joint bolt

CYLINDER:Cylinder bolt

DRIVE/DRIVEN PULLEY:Drive pulley nutWet clutch nutDriven pulley nutDriven pulley assembly plate nut

TRANSMISSION:Crankcase boltDrive bevel gear nutDriven bevel gear nutStopper lever boltStopper lever boss nutShift came stopper plugOutput shaft bearing nutDrive shaft bearing bolt

STARTER SYSTEM:Starter pulley nut

1086666

101886

6

20251636

620208

1220858

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 oilApply oil

Apply oil

Apply oil

Apply oil

Apply oilApply oilApply oil

Apply oil

1. GENERAL INFORMATION

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UXV 500

FRAME

Item Q‘ty Threaddia.

(mm)

Torque Kgf-m (N-m,

lbf-ft)Remarks

STEERING:Steering column and intermediate shaftSteering assembly and intermediate shaftSteering assembly and frameSteering column assembly and frameSteering wheel and steering columnFront knuckle and front upper armFront knuckle and front lower armTie-rod lock nutFront knuckle and Tie-rod

WHEEL:Front wheel and front wheel hubRear wheel and rear wheel hubFront wheel hub and cvjRear wheel hub and cvj

FR SUSPENSION:Front upper arm and frameFront lower arm and frameFront shock absorber and frameFront shock absorber and front upper armRR SUSPENSION:Rear upper arm and frameRear lower arm and frameRear knuckle and rear upper armRear knuckle and rear lower armRear shock cushion and frameRear shock cushion and rear lower armStabilizer and frameStabilizer joint and stabilizerStabilizer joint and rear lower arm

88

10101210101210

10101818

10101010

101010101010101010

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

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UXV 500

Item Q‘ty Threaddia.

(mm)

TorqueKgf-m (N-m,

lbf-ft)Remarks

BRAKE:Front caliper bracket mounting boltRear caliper bracket mounting boltFront brake disc and wheel hubFR/RR brake caliper bleed screwBrake hose oil boltBrake master cylinder and frameRear disc holder and gear boxRear disc mounting bolt3-way junction nut

FRAME:FR/RR hanger and damperEngine damper and frameDifferential gear caseDifferential gear stay and frameFinal drive gear caseFuel tank stay and frameGas DamperFR bumper and frameR/L roof and frameCross pipe, roofShifterPedal assy .stay and frameSeat belt and frameShifter rod assy

ENGINE:Rear gear box and caliper bracketAir cleaner and frameExhaust pipe and engine headMuffler stay and frame

8888

108

1088

108

108

1088

1010888

7/16-20unf8

8108

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

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UXV 500

SPECIAL TOOLS

Tool Name Tool No.

Illustration(Note: the special tools may differ

slightly from those shown in thefigure of this manual.)

Oil seal and bearinginstaller A120E00014

Valve adjuster

(Refer to the “VALVECLEARANCE” section in thechapter 3.)

A120E00036

Bearing puller A120E00037

Valve spring compressor

(Refer to the “CYLINDER HEADDISASSEMBLY/INSPECTION/ASSEMBLY” section in thechapter 8.)

A120E00040

Universal holder

(Refer to the “DRIVE PULLEY,DRIVE V-BELT AND DRIVENPULLEYREMOVAL/INSPECTION/INSTALLATION” section and“CLUTCH REMOVAL/INSTALLATION” section in thechapter 10.)

A120E00056

Drive pulley holder

(Refer to the “DRIVE PULLEY,DRIVE V-BELT AND DRIVENPULLEYREMOVAL/INSPECTION/INSTALLATION” section in thechapter 10.)

A120E00058

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UXV 500

Tool Name Tool No.

Illustration(Note: the special tools may differ

slightly from those shown in thefigure of this manual.)

Driven pulley holder

(Refer to the “DRIVEN PULLEYDISASSEMBLY/INSPECTION/ASSEMBLY” section in the chapter10.)

A120E00059

Flywheel puller

(Refer to the “STARTERCLUTCH REMOVAL/INSPECTION/INSTALLATION” section in thechapter 19.)

A120E00060

Oil filter cartridge wrench

(Refer to the “(Refer to the“ENGINE OIL” section in thechapter 3.)

A120E00061

Output shaft bearing nutwrench

(Refer to the “(Refer to the“BEARING REPLACEMENTIN THE RIGHTCRANKCASE” section in thechapter 11.)

A120E00066

(Cont’d)

1. GENERAL INFORMATION

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UXV 500

Tool Name Tool No.

Illustration(Note: the special tools may differ

slightly from those shown in thefigure of this manual.)

Crankshaft bearing puller A120E00068

Ball joint remover

(Refer to the “STEERINGKNUCKLE REMOVAL/INSPECTION/INSTALLATION” section in thechapter 15)

A120F00012

Left pivot lock nut wrench

(Refer to the “REAR SWINGARM REMOVAL/INSTALLATION” section in thechapter 15)

A120F00013

Joint yoke puller

(Refer to the “FRONT DRIVEDISASSEMBLY/INSPECTION/ASSEMBLY” section in thechapter 13)

A120F00016

Drive shaft puller

(Refer to the “FRONT DRIVESHAFT REOMVAL/INSPECTION/INSTALLATION” section in thechapter 13)

A120F00017

Yoke bearing puller

(Refer to the “FRONT DRIVEDISASSEMBLY/INSPECTION/ASSEMBLY” section in thechapter 13)

A120F00018

(Cont’d)

1. GENERAL INFORMATION

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UXV 500

Tool Name Tool No.

Illustration(Note: the special tools may differ

slightly from those shown in thefigure of this manual.)

Pinion bearing lock nutwrench

(Refer to the “REAR DRIVEDISASSEMBLY/INSPECTION/ASSEMBLY” section in the chapter13.)

A120F00020

Pinion puller

(Refer to the “REAR DRIVEDISASSEMBLY/INSPECTION/ASSEMBLY” section in the chapter13.)

A120F00021

C-ring remover

(Refer to the “FRONT DRIVEDISASSEMBLY/INSPECTION/ASSEMBLY” section in thechapter 13)

A120F00022

Carburetor adjustmentAdjust pilot screw position

A120E00076

1. GENERAL INFORMATION

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UXV 500

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant Valve guide/valve stem movable part Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt Piston surroundings and piston ring grooves Piston pin surroundings Cylinder 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 gear Starter one-way clutch O-ring face Oil seal lip Output shaft Bevel gear Drive shaft Countershaft Main shaft Transmission gear shaft bearing part

•Genuine KYMCO Engine Oil (SAE10W-30) •API SJ Engine Oil

Front drive gear and bearing part Gear oil: SAE 80-90#Rear drive gear and bearing part Gear oil: SAE 80-90#