KWANG YANG MOTOR CO.,LTD.
Battery & EFI Damage Alert
CELP indication
CELP indication :
If flashing or brightness, it indicates that a fault has
been detected in the vehicle 's EFI or electrical system.
Requires immediate inspection by a KYMCO dealer.
Dear KYMCO UXV 500 i Users:
Thank you for purchasing this KYMCO UXV 500i and welcome to the family
of KYMCO UXV500 i riders. To enjoy safety and more pleasant riding, become
thoroughly familiar with this owner manual before you ride the UXV 500i.
You safety depends not only on your own alertness and familiarity with the
UXV 500i but also the UXV mechanical condition.
A pre-ride inspection before every outing and regular maintenance are
essential. The quality of each KYMCO UXV 500 i is guaranteed.
Note: 1. The information and specifications stated in this manual are for
reference only and subject to change without notice.
2.When starting the engine, the battery must be installed to facilitate
starting and increase the engine performance.
TABLE OF CONTENTS
A
Auxiliary Outlet
Air Cleaner
D
39
74-76
B
Battery Remove
Brake Fluid Inspection
Back Mirrors
Brake Pedal
77
73
49
50
C
Cargo Bed
Crossing Water
Cooling System Inspection
Changing the rear gear box oil
Changing the front gear box oil
52-54
63
79
71
72
Differential Lock Lever And Indictor
Daily Safety Checks
46
57
Driving Safety
Driving Downhill
Driving Uphill
Driving Reverse
58
61
62
64
E
Emission Control System
Engine Oil
65
67-70
F
Fuel Lever Inspection/Refilling
Fuel Cap key
Fuse Replacement
30
6
76
TABLE OF CONTENTS
H
Horn
Hazarb Warn Flashers
Switch
O
49
48
42
I
Indicator Lights
Ignition Switch
Ignition Switch Key
Periodic Maintenance/Lubrication
Pillows Aduust
Parking Brake Release
Packing
89-91
41
51
61
R
31-32
43
6
Right Glove Compartment Key
44
6-10
Serial Number Locations
Start The Engine
Spark Arrestor
Spark Plug Inspection
L
Light Switch
Location Of Parts
33-38
P
G
Gear Selector
Operation Instruction for
Multi-Meter
6
S
Specifications
Seat Removal
Seat Belts
4-5
59-60
66
82
84-88
40
40
TABLE OF CONTENTS
T
Throttle Pedal
Tool Kit
Turn Signal Lights Switch
50
83
47
U
Under-Hood
55-56
W
2WD/4WD Switch
Warning Labels Locaton
Warning Labels (English)
Warning Labels (French)
45
11-13
14-21
22-29
Wheel Removal
80-81
This vehicle can be dangerous to operate.
A impact or rollover can occur quickly. even during routine maneuvers such
as turning and driving on hills or over obstacles, if you fail to take proper
precautions.
For your safety, understand and follow all the warnings contained in this
Owner’s Manual and labels on this vehicle.
Keep this Owner’s Manual with this vehicle at all times.
Failure to follow the warnings contained in this manual
can result in serious injury or death.
Particularly important information is distinguished in this manual by the
Following notations:
Indicates a strong possibility that serious injury or death may
WARNING
!
Result if instructions are not followed.
!
CAUTION
●Note:
Indicates a possibility that equipment or property damage
could result if instructions are not followed.
Gives helpful information
1
This vehicle is not a toy and can be dangerous to operate.
●Always go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating this vehicle.
●Never operate on too rough, slippery, or loose terrain.
●Always follow proper procedures for turning as represent in this manual.
Institution turning at slow speeds before attempting to turn at faster speeds.
Do not turn at intemperate speed.
WARNING
●Never operate on hills too steep for your abilities and cross the side of a hill,
Practice on smaller hills before attempting larger hills .
●Always use proper procedures if you stall or roll backward when climbing a hill.
To avoid maintain a steady speed when climbing a hill. IN case of you stall or
roll return,follow the procedure for braking described in this manual.
●Operation of this vehicle is restricted to people 16 years of age and older who
possess a valid operator’s license. Usually, no person under the age Of 6
may ride as a passenger on this vehicle.
2
Safety Watchful
●Always read the owner’s manual carefully and follow the operating
procedures described. Pay special attention to the warnings contained
In the manual and on all labels.
●Never operate this vehicle with the canopy frame removed.
WARNING
●Always wear the seat belt when driving.
●Always follow this age prescription:
Operation of this vehicle is restricted to people 16 years of age and older who
possess a valid operator’s license. Usually, no person under the age
Of 6 may ride as a passenger on this vehicle.
3
Serial Number Locations
This vehicle has 2 serial numbers:The frame number and Engine serial number.
The frame number is located on the frame near right front wheel place.
Frame Number
4
Serial Number Locations
The engine serial number is located on the right side of the engine crankcase.
Engine Serial Number
5
Ignition Switch Key/Fuel Cap Key
Right Glove Compartment Key
Fore keys come with this vehicle. Keep the spare in the safe place.
Fuel Cap Key
Right Glove Compartment
Key →2PCS
Ignition Switch Key→2PCS
6
Location Of Parts (1)
4
1
5
2
6
3
1.Right Head Pillow 2.Right Seat 3.Right Tail /Brake/Turn Light
4.Left Head Pillow 5. Left Seat
7
6.Left Tail /Brake /Turn Light
Location Of Parts(2)
8
07.Seat Belts
16
08.Cargo Bed
09.Back mirrors
10.Headlights
14
11.Front Turn Lights
12.Battery
13.Steering Wheel
7
14.Cab Frame
15.hands Bars
15
16.Tool or Parts Box
9
(Under the operator’s seat)
13
12
11
8
10
Location Of Parts(3)
17.Under-Hood
17
23
18.Bumper
18
19.Hands Bars
20.Seat Belts
21.Fuel Tank Cap
22.Muffler&
Spark Arrester
23.Latch Handles
23
22
21
19
20
9
Location Of Parts(4)
29
30
24
31
25
26
27
32
28
33
24.Right Glove Compartment 25. Auxiliary Outlet 26.Speedometer
27. Center Glove Compartment 28.Shifting The Automatic Transaxle
29. Ignition Switch 30.Horn31. Steering Wheel 32. Brake Pedal
33.Throttle Pedal
10
Warning Labels Location
4
3
1
2
5
6
11
Warning Labels Location
7
8
12
Warning Labels Location
9
10
13
Warning Labels (English)
14
1
Warning Labels (English)
15
1
Warning Labels (English)
16
1
Warning Labels (English)
17
2
Warning Labels (English)
3
4
5
18
9
10
Warning Labels (English)
19
6
Warning Labels (English)
20
7
Warning Labels (English)
21
8
Warning Labels (French)
22
1
Warning Labels (French)
23
1
Warning Labels (French)
24
1
Warning Labels (French)
25
2
Warning Labels (French)
3
4
5
26
9
10
Warning Labels (French)
27
6
Warning Labels (French)
28
7
Warning Labels (French)
29
8
Features And Controls
Fuel Lever Inspection/Refilling
Check if fuel is sufficient.
If the fuel gauge pointer is E(flash).refill
nonleaded gasoline as soon as possible.
(Refilling Method)
1.Turn the tank cap counterclockwise with
hand to open the cap.
2.Use only nonleaded gasoline.
3.Turn the fuel tank cap clockwise to tighten
it.
4.Close the fuel tank cap in the reverse
order of opening.
!
OPEN
CLOSE
CAUTION
Be sure to stop the engine before refilling.The gasoline level shall not
exceed the reference plate;otherwise the fuel will penetrate out.
30
Features And Controls
Indicator Lights
The indicator lights on the console display:
1. Lower Gear 2. High Gear 3.Neutral Gear 4.Reverse Gear 5. Parking Gear
6. Right Turn Signal Indicator Light and Left Turn Signal Indicator Light
7. High Beam Indicator Light 8. FI System Indicator Light 9.Lock:( Differential
Lock Indicator Light )10.Battery Low Voltage Indicator Light 11. High Coolant
Temperature Indicator Light 12. Parking Brake
10
6
9
7
12
11
8
5
4
3
31
2
1
Features And Controls
Instruments and Indicators
1.Speedometer 2. Km/h or Mph 3. Clock 4. 4WD 5.Fuel Gauge 6.ODO Meter
7. Adjust Button 8.Engine Tachometer
4
5
8
2
3
1
6
7
32
Features And Controls
Operation Instruction for Multi-meter
Button A (MODE)
Button B (SET)
33
Features And Controls
Operation Instruction for Multi-meter
Press and hold button A until 2
seconds over.
Shift the unit mph or km/h
Button A (MODE)
34
Features And Controls
Operation Instruction for Multi-meter
Button A (SET)
35
Press and hold button B until 2
seconds over.
Shift function to ODO or TRIP
Features And Controls
Operation Instruction for Multi-meter
Press and hold button A and B
until 2 seconds over.
Simultaneously to reset to zero
when at TRIP function.
Button A (MODE)
Button B (SET)
36
Features And Controls
Operation Instruction for Multi-meter
Press and hold button A and B
until 5 seconds over . when at
ODO function then you can see
clock position is flash word .
Button A (MODE)
Button B (SET)
37
Features And Controls
Operation Instruction for Multi-meter
When you seeing clock position is
flash word . You can start setting
hour item. Press button B adjust
correct hours then Press button A
you can see minute position is
flash. adjust correct minute.
Waiting for 2second .finish times
setting.
Button A (MODE)
Button B (SET)
38
Features And Controls
Auxiliary Outlet
The 12-volt receptacle has spade
connections on the back that may be used to
power an auxiliary light or other optional
accessories or lights. The connections are
behind the console,under the hood.
Auxiliary Outlet
39
Features And Controls
Seat Removal
• Pull up on front of seat it toward the
front of vehicle.
• Install the seat by sliding the tabs into
the rear of the seat base.
• Push down firmly on the front of the
pins are fully seated into the grommets.
Seat Belts
The UXV500i is equipped with lapshoulder seat belts for the operator
and passenger.
operator
40
passenger
Features And Controls
Pillows adjust
If you want to adjusting your pillows.
Remove 3 bolts then adjusting you need pillow position install 3 bolts.
41
Features And Controls
Gear Selector
Maintaining shift linkage adjustment is
important to assure proper
transmission function .
See your dealer if you experience any
shifting problems.
1.Lower Gear
2.High Gear
3.Neutral Gear
4.Reverse Gear
5.Parking Gear
To change gears,stop the vehicle and
with the engine idling, move the lever
to the desired gear.
Do not attempt to shift gears with
engine speed above idle or while the
vehicle is moving.
Always place the transmission in gear
with the parking brake locked
whenever the vehicle is left
unattended.
.
42
Features And Controls
Switches
Ignition Switch
The ignition switch is a three-position,keyoperated switch, The key can be removed
from the switch when it is in the OFF
position.
ON:
Electrical circuits are on
Electrical equipment can be used.
OFF:
Engine off .All electrical circuits are
off except Acc.12V
START: Electrical starter is engaged by
holding ignition switch key in this
position. Upon release ,the key will
return to the ON position.
43
Features And Controls
Switches
Light Switch
• The ignition switch key must be in the ON
position to operate the headlights.
• The switch has 4 positions.
1:Light off -At this position , light is turn off.
2: Position light - At this position , light is
turn off
3.LO Headlight Beam- When you select
this position . low beam will illuminate.
4.Hi Headlight Beam- When you select this
position .high beam will illuminate .High
beam indicator light will turn on.
44
1
2
3
4
Features And Controls
Switches
Drive Select Switch
The 2WD/4WD allows the operator to operate
the vehicle in either two-wheel drive
(rear wheel) or four wheel drive(all wheels)
For normal riding on flat,dry,hard surfaces,
two-wheels drive should be sufficient.
In situations when additional traction is
necessary,for-wheel drive would be the
desired choice.
To either engage or disengage the front
wheels move the switch to the 4WD position
or the 2WD position.
Drive Select Indicator
Displays 4WD when selected by the 4WD
drive selector switch.
45
Features And Controls
Differential Lock lever and
indicator
The front axle is equipped with a
lockable differential that allows the
operator to choose between an open
differential or a closed differential in
low traction situations.
Pulling the lock lever up.
To lock the differential on the 4WD,
move the 4WD differential Button.
46
Features And Controls
Switches
Turn Signal Lights Switch
When you want direction change just raise
or lower the lever the lever until the green
arrow starts to flash.hold it there until you
complete your direction change .
A green arrow on the instrument panel
will flash in the direction of the turn or
lane change.
When you returned to center position turn
signal lights will not flash.
1.Right turn- raise the lever will flash
arrow .
2.Left turn- --lower the lever will flash
arrow .
47
Features And Controls
Switches
Hazard Warn Flashers Switch
Your hazard warn flashers let you warn
others.They also let police know you
have a problem.
Your front and rear turn signal lights will
flash on and off.
Pressing the switch .Turn signal lights
will flash on the meter.
When the hazard warn flashers are ON
your turn signal lights won’t work.
48
Features And Controls
Switches
Back Mirrors
Horn
You can sound born by pressing the
born symbols on your steering wheel
Your back mirrors is convex.A convex
mirror’s surface is curved so you can see
more from the seat.
Horn
49
Back Mirrors
Features And Controls
Brake Pedal(1)
Depress the brake pedal to slow or stop or
stop the vehicle.
Throttle Pedal(2)
Push the pedal down to increase engine
speed .Spring pressure returns the pedal to
the rest position when released.
Always check that the throttle pedal returns
normally before starting the engine. Make
(1)
sure there’s adequate throttle pedal free
play.
50
(2)
Features And Controls
Parking Brake Release(3)
To release the parking brake, pull the
release handle Spring pressure helps return
the lever to the released position .make sure
the parking brake lever is functioning
properly before each operation.
(3)
51
Features And Controls
Cargo Bed (Lift and lower the cargo bed)
To lift
Push the cargo bed release
lever to right side, then
slowly lift up cargo bed until
it stop.
To lower
Lower the cargo bed slowly
to its original position and
be sure the it is locked into
place.
Maximum load in cargo bed:200 kg
Cargo Bed Lever
52
Features And Controls
Cargo Bed(Open and close the tailgate 1)
To open---(1)
Unlock the latches,and then lower
the tailgate.
(1)
Latch(x2)
Pull
53
Features And Controls
Cargo Bed(Open and close the tailgate 2)
To close
Place the tailgate in the
original position ,and then
hook the latches.
54
Features And Controls
Under-Hood (To Open)
Unhook the hood latches and then slowly tilt the hood up until it stop.
Latch x2
55
Features And Controls
Under-Hood (To Close)
Lower the hood slowly to its original position and then hook the hood latches .
Latch x2
56
How to operate
Daily Safety Checks
Check the following items each day before operation.
01.Fuel---------------------Enough fuel in tank,no leaks.
02.Engine Oil-------------Oil lever between lever holes(when engine is cold),no
leaks.
03.Air Cleaner------------Check the restriction gauge.
04.Tires --------------------Air pressure(when cold)and check tires cracks, damage or
abnormal wear.Check for any imbedded stones or other
foreign particles in tread.
05.Front wheel Air pressure :0.7kgf/cm²;10psi
06.Rear wheel Air pressure :0.98kgf/cm²;14psi
07.Headlight & other indicate light ----- Check the operate is normal.
08.Brake/Brake oil lever ----- Check the operate and oil lever is normal.
09.Coolant ------Coolant lever between lever lines(when engine is cold),no leaks.
10.Front final gear case & transmission case ----No oil leaks
11.EFI system ------ Engine check lamp hasn’t bright or flashes.
57
How to operate
Driving Safely(Driving procedures)
1.Sit in the driver’s seat and fasten the seat belt.
2.After staring the engine and allowing it to warm up,shift the transmission
into gear.
3.Check your surroundings and determine your path of travel.
4.Release the parking brake.
5.Keeping both hands on the steering wheel, slowly depress the throttle with
your right foot and begin driving.Vehicle speed is controlled by the amount of
throttle opening & transmission shifting is automatic.
6.Drive slowly . Practice maneuvering and using the throttle and brakes on
level surfaces.
58
How to operate
Start the Engine
!
WARNING
Never run the vehicle in a closed area, such as a
garage Exhaust gases contain carbon monoxide,
a colorless, odorless, poisonous gas.
Breathing exhaust gas leads to carbon monoxide
poisoning, asphyxiation, and death.
1.Wear the seat belts(both operator and passenger)
2.Set the parking brake.
3.Put the gear shift lever in the “N(neutral) position.
4.Turn the ignition switch clock wise to the START position; then when the engine
starts, release to the RUN position.
59
How to operate
Start the Engine
!
CAUTION
Do not run the starting attempt. The starter motor may
overheat causing severe starter motor damage. Allow
15 seconds between starting attempts to allow the
starter motor to cool.
Braking/Stopping
Always allow plenty of room and time to stop smoothly. Sometimes quick stops
are inevitable’ so always be prepared.Whether you’re stopping quickly’ do this:
1.Release the accelerator;then press the foot brake pedal to apply the brake.
2.If the wheels lock,release them for a second;then apply them again .On
surfaces such as ice,mud ,or loose gravel’ pump the brake pedal rapidly.
3.Never ride the brake .Even maintaining minimal pressure on the brake pedal
will cause the brake pads drag on the disc and may overheat the brake fluid.
60
How to operate
Parking
Parking involves flowing the previous rules for braking;then :
1.After the vehicle stops,shift into neutral gear.
2.Set the parking brake.
3.Turn off the ignition key.
4.If you have to park on the hill,shift to low range,set the parking brake,and
block the wheel on the downhill side.
Driving Downhill
Always drive straight down the hill and always avoid hills sleeper than 15°.
1.Keep both hands on the wheel.
2.Prior to descending the hill,shift into range and release the accelerator to
allow maximum engine brake.Do not use 4 wheel drive when descending
a hill.Engine braking can cause the front wheels to slide reducing steering
control.
61
How to operate
Driving Uphill
whenever travel straight uphill, follow these precautions:
1.Always travel straight uphill.
2.Avoid steep hills(15° maximum)
3.Keep both feet on the floor.
4.Proceed at a steady rate of speed and throttle opening.
NEVER OPERATE UP OR
DOWN HILLS STEEPER
THAN 15°
15° maximum
62
How to operate
Crossing Water
UXV500i can only operate in water up to its floorboard.Stay away from fast
moving rivers. This vehicle’s tires can be buoyant.In deep water,the vehicle
may lose traction due to floating.
1.Physically check the depth and current of the water, especially if you can not
see the bottom.Also,check for boulders,logs,or any other hidden obstacles.
2.Keep speed slow while maintaining momentum.
3.Make sure you have a way out on the other side of the water.
4.Once you have cleared the water,briefly apply the brakes to make sure they
work.
63
How to operate
Driving in Reverse
Follow these guidelines when operating in reverse:
1.Back slowly.
2.Apply the brakes lightly for stopping.
3.Avoid turning at sharp angles.
4.Always avoid backing downhill.
5.Never open the throttle suddenly while backing.
6. Always inspect left and right fields of vision before backing.
64
Emission Control System
Crankcase Emission Control System
This engine is equipped with a closed crankcase system .
Blow-by gases forced back to the combustion chamber by the intake system.
The system does not allow the blow-by gases to enter the atmosphere.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design,including factory-set fuel delivery and ignition.KYMCO Exhaust
Emission Control System including catalytic converter system.please do not
change any kymco design.
Noise Exhaust Emission Control System
Do not modify the engine ,intake or exhaust components, as doing so may
affect compliance with state and local noise level requirements.
65
Emission Control System
Spark Arrester
Your UXV 500i has a spark arrester.
The spark arrester be installed and functional when the vehicle operated on
public lands.
Clean method
Remove method
Use the iron brush cleaning
carbon on the spark arrester
remove 3 bolts
66
Maintenance And Lubrication
Engine Oil
Always check and change the oil at the OWNER MANUAL standard intervals.
The oil tank is located under the seat.
10
30
50
70
90
110
1.Position the vehicle on the surface.
2.Start the engine and let it idle for 20~30seconds.
SAE 5W
3.Stop the engine and remove the seat.
4.Add fresh oil into the oil tank .
SAE 10W-30
0
0
Make sure the engine oil at the specified level.
Add oil as necessary. Check for leaks.
0
0
0
0
F
SAE 10W-40
SAE 20W-40
Oil quantity:
Engine oil:
Periodic oil change:
3 L (2.64 Imp qt, 3.18 US qt)
Total amount:
3.6 L (3.17 Imp qt, 3.82 US qt)
SAE 20W-50
0
-1 0
0
0
0
10
0
20
0
30
0
40 C
Recommended engine oil classification: API
Service SJ type or higher
67
Maintenance And Lubrication
Engine Oil
1.Engine oil level measurement
A. Place the machine on a level place.
B. Warm up the engine for several minutes and stop it.
C. Check the oil level through the inspection window.
D. The oil level should be between the maximum (H) and minimum (L) marks.
If the level is low, add oil to raise it to the proper level.
NOTE:
Wait a few minutes until the oil level settles
before checking.
H
L
68
Maintenance And Lubrication
Engine oil replacement and oil filter cleaning
1. Place the machine on a level place.
2. Warm up the engine for several minutes and stop it.
3. Place a container under the engine.
4. Remove the oil fill cap (1) and oil drain bolt (2)
to drain the oil.
(2) oil drain bolt
CAUTION:
Be sure no foreign material enters the
crankcase.
CAUTION:
When removing the oil filter cap, the
compression spring, oil strainer and O-ring
will fall out. Take care not to lose these
parts.
(1) oil fill cap
69
Maintenance And Lubrication
NOTE:
Skip steps E to I if the oil filter cartridge is not
being replaced.
Remove the oil filter cartridge with an oil cartridge wrench.
oil filter cartridge
remove
70
lock
Maintenance And Lubrication
Changing the rear gear box oil
1. Place the vehicle on the a level surface.
2. Place a container under the rear gear box
to collect the used oil.
3.Remove the rear gear box oil drain bolt(1)
and rear gear box oil filler cap (2).
4.Install the rear gear box oil drain bolt(1) and
then tighten it to the specified torque.
5.Fill the rear gear box oil with recommended oil.
6.Install the rear gear box oil filler cap(2) and then
tighten it to the specified torque.
Recommended oil : SAE 80
Oil quantity :
Periodic oil change
0.25ML
(2)
Tightening torque
Drain bolt : 20 N-m (2 kgf-m)
Oil filler cap : 14.7 N-m (1.5 kgf-m)
(1)
71
Maintenance And Lubrication
Changing the front gear box oil
1. Place the vehicle on the a level surface.
2. Place a container under the front gear box
to collect the used oil.
3.Remove the front gear box oil drain bolt(1)
and front gear box oil filler bolt (2).
4.Install the front gear box oil drain bolt(1) and
then tighten it to the specified torque.
5.Fill the front gear box oil with recommended oil.
6.Install the front gear box oil filler bolt(2) and then
tighten it to the specified torque.
Tightening torque
Drain bolt : 32 N-m (3.2 kgf-m)
Oil filler bolt : 35 N-m (3.5 kgf-m)
Recommended oil : SAE 80
Oil quantity :
Periodic oil change
0.27ML
(2)
72
(1)
Maintenance And Lubrication
BRAKE FLUID INSPECTION
Check if the fluid level is below the lower level
mark through the inspection window.
WARNING
POTENTIAL HAZARD
Brake fluid contacting the skink or eyes.
WHAT CAN HAPPEN
May cause irritation.
HOW TO AVOID THE HAZARD
Avoid contacting brake fluid with the skin
or eyes. In case of contact, flush thoroughly
with water and call a doctor if your eyes
were exposed.
73
(1) Lower level mark
(2) Upper level mark
Maintenance And Lubrication
Air Cleaner
Remove the center cover screws.
Remove gear selector bolt and center cover.
74
Maintenance And Lubrication
Air Cleaner
Remove air cleaner cover screws and air filter element fixed bolt .
Remove air filter element.
75
Maintenance And Lubrication
Air Cleaner
Using high pressure air to clean air filter element .
Inspect the air filter element and replace it if damaged.
76
Maintenance And Lubrication
Battery Remove
1. Make sure the ignition switch is OFF.
2. Remove the under-hood hook& pu bolts.
3. Remove the battery cover screws.
4. Disconnect the negative (-) terminal lead
(1) from the battery first, then disconnect
the positive (+) terminal lead (2).
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 cables are routed correctly.
NOTE:
First connect the positive (+) cable and then
negative (-) cable to avoid short circuit.
77
(2)
(1)
Maintenance And Lubrication
Fuse Replacement
(1) (2) (3) (4) (5) (6)
The fuse box stored in the battery
compartment.
To replace a fuse:
1. Make sure the ignition switch is OFF.
2. Remove the under-hood hook& pu bolts.
3. Open the fuse box cap.
4. Pull the old fuse out of the fuse holder.
5. Push the new fuse in to the fuse holder.
6. Close the fuse box cap and install seat.
(6)FAN MOTER---------15A
(5)IGNITION--------------15A
CAUTION:
(4)LIGHT------------------15A
To prevent accidental short-circuiting, turn
off the main switch when checking or
replacing a fuse.
(3)DC12VPOWER------15A
(2)SPARE-----------------15A
(1)SPARE-----------------30A
78
Maintenance And Lubrication
Cooling System Inspection
NOTE:
A permanent type of antifreeze is installed in the
cooling system when shipped.It is colored green
and contains ethylene glycol.It is mixed.It is mixed
at 50% with water and has a freezing point of
-35 °C(-31 °F)
1. Remove the under-hood hook& pu bolts.
2. Check the coolant level in the coolant
reservoir when the engine is cold as the
coolant level will vary with engine
temperature.
The coolant level should be between the
maximum and minimum marks.
3. If the level is low, remove the coolant
reservoir cap, and then add coolant or
distilled water to raise it to the specified
level.
Recommended Coolant Solution
FULL
Coolant Mixture Ratio:
Water 50%:Antifreeze 50%(1:1)
LOW
79
Maintenance And Lubrication
Wheel Removal
Wheel Installation
1.Elevate the wheel by placing a suitable
When reinstalling a wheel, tighten the wheel nuts in
a crisscross(rather than a circular)pattern.
stand under the frame.
2.Remove the nuts from the wheel.
Be sure the tapered a side of the wheel nuts(1)face
the wheel rim(2).
3.Remove the wheel assembly.
Wheel nut torque:
Front:61 N-m(6.1 kgf-m,44 lbf-ft)
Rear:61 N-m(6.1 kgf-m,44 lbf-ft)
Be sure the tapered side of the wheel nuts(1) face
the wheel rim(2).
OK
(2)
80
(1)
Maintenance And Lubrication
NOTE:
WARNING
The arrow mark
on the tire must point
toward the rotating direction of the wheel.
POTENTIAL HAZARD
Installing wheels improperly.
WHAT CAN HAPPEN
A wheel may come loose, possibly leading
to an accident.
HOW TO AVOID THE HAZARD
Carefully follow the instructions in this
Owner's Manual when installing.
(1)
(1) Arrow mark
81
Maintenance And Lubrication
Spark Plug Inspection
Before installing the spark plug, measure the
The spark plug is an important engine
electrode gap with a feeler gauge and adjust to
component and is easy to inspect.
The condition of the spark plug can indicate the specification.
condition of the engine.
Spark plug gap:
For example, a very white center electrode
0.6~0.7 mm (0.024~0.028 in)
porcelain color could indicate an intake air leak
or carburet problem for that cylinder.
Do not attempt to diagnose such problems
yourself.
Instead, take the machine to a KYMCO dealer.
You should periodically remove and inspect the
spark plug because heat and deposits will cause
the spark plug to slowly break down and erode.
(A)
If electrode erosion becomes excessive, you
should replace the spark plug with one of the
proper type.
(A) Spark plug gap
Standard spark plug (NGK): CR7E
82
Maintenance And Lubrication
Tool Kit
The tool kit put down location at Right Glove Compartment .
The tool kit includes the following items:
(1) Hexagon wrench
(6) (7)
(3)
(2) Spark plug wrench
(3) 8/12;10/14;17/19 mm wrench
(4) Screwdriver
(5) Screwdriver handle
(6) Tool bag
(7)Air pressure gauge
83
(5)(4) (1) (2)
Specifications
MODEL
UXV500 i (ON ROAD)
DIMENSIONS:
OVERALL LENGTH
2870mm
OVERALL WIDTH
1500mm
OVERALL HEIGHT
1850mm
SEAT HEIGHT
805mm
WHEELBASE
1910mm
GROUND CLEARANCE
310mm
MINMUN. TURNING RADIUS
4060mm
BASIC WEIGHT:
WITH OIL AND FULL FUEL TANK
560kg
MAX. CARGO BED LOAD
200kg
DRY WEIGHT
525kg
MAX. WEIGHT CAPACITY
350kg
ENGINE:
ENGINE TYPE
4 -STROKE,DOHC
CYLINDER ARRANGEMENT
SINGLE CYLINDER
BOREx STROKE
92X75mm
ACTUAL DISPLACEMENT
498.5cc
COMPRESSION RATIO
10.5:1
STARING SYSTEM
ELECTRIC STARTER
LUBRICATION SYSTEM
WET SUMP
84
Specifications
MODEL
ENGINE GEAR BOX:
CAPICITY/EXCHANGE/TYPE
FRONT GEAR BOX:
CAPICITY/EXCHANGE/TYPE
REAR GEAR BOX
CAPICITY/EXCHANGE/TYPE
AIR FILTER:
FUEL:
TYPE
FUEL TANK CAPACITY
THROTTLE BODY:
TYPE/MANUFACTURER
SPARK PLUG:
TYPE/MANUFACTURER
SPARK PLUG
CLUTH TYPE:
UXV500 i (ON ROAD)
3.6L/3.0L/5W-30
270ML/270ML/SAE80#
250ML/250ML/SAE80#
SPONGE ELEMENT
UNLEADED GASOLINE
32L
PTA1/KYMCO
CR7E-NGK
0.6~0.7mm
WET CENTRIFUGAL AUTOMATIC
85
Specifications
MODEL
TRANSMISSION:
UXV500 i (ON ROAD)
PRIMARY REDUCTION SYSTEM
V-BELT
SHAFT DRIVE
V-BELT AUTOMATIC
SECONDARY REDUCTION SYSTEM
TRANSMISSION TYPE:
TIRE:
TYPE
SIZE(FRONT)
SIZE(REAR)
WHEEL MATERIAL
PRESSURE FR/RR
BRAKES:
SYSTEM
TYPE(FRONT)
TYPE(REAR)
OPERATION
SUSPENSION:
FRONT SUSPENSION
REAR SUSPENSION
SHOCK ABSORBER:
TUBELESS
25x 8-12
25x10-12
STEEL
0.7/0.98(kgf/cm2) OR 10/14 psi
FRONT AND REAR UNIFIED
DUAL DISC BRAKE
SINGLE DISC BRAKE
FOOT OPERATION
DOUBLE WISHBONE
DOUBLE WISHBONE
COIL SPRING/OIL DAMPER
86
Specifications
UXV500 i ( ON ROAD)
MODEL
WHEEL TRAVEL:
FRONT WHEEL TRAVEL
REAR WHEEL TRAVEL
ELETRICAL:
IGNITION SYSTEM
GENERATOR SYSTEM
BATTERY TYPE
BATTERY CAPACITY
HAEDLIGHT TYPE:
BULB VOLTAGE
WATTAGE X QUANTITY:
HAEDLIGHT:
NO.PLATE LIGHT
REAR LIGHT
INDICATORS FR/RR DIRECTION
BRAKE LIGHT
POSITION LIGHT
190mm
190mm
DC, ECU AUTOMATIC CONTROL
A.C.MAGNETO
MF-VTX20L
12V18AH
HS1
12V35/35W*2
12V5W
12V21/5W*2
12V10W
12V21/5W*2
12V21/5W*2
87
Specifications
MODEL
SPECIFIED FUSES:
MAIN FUSE
FAN MOTER
IGNITION
LIGHT
DC12VPOWER
SPARE
SPARE
UXV500 i (ON ROAD)
30A
15A
15A
15A
15A
15A
30A
88
89
90
91
Maintenance Record
Maintenance Record
Maintenance Record
Maintenance Record
By KWANG YANG Motor Co., Ltd.
First Edition, JUN 2010
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T200 -UBA0AD -IT-A1
KWANG YANG MOTER CO .,LTD
NO.35 Wan Hsing Street,San Min District
Kaohsiung, Taiwan, Republic Of China
Telephone : 886-7-3822526
Fax : 886-7-3950021
Printed in Taiwan
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