2008 Kymco UXV 500 Repair Manual (P/N T100-UAA0AA-US)

Published by Kwang Yang Motor Co., Ltd. as the First Edition dated February 2008, this 368-page PDF covers the carbureted Kymco UXV 500, model UAA0, identified on the cover by document code T100-UAA0AA-US. The specifications describe a liquid-cooled 498.5 cc DOHC single-cylinder engine with a CVK carburetor. It is not the service manual for the fuel-injected UXV 500i.

Before starting engine, driveline, brake, or fuel-system work, secure the vehicle on a stable surface, support heavy assemblies correctly, isolate the electrical system where required, and wear appropriate personal protective equipment. Keep fuel-system work away from ignition sources, ventilate the area before running the engine, let the cooling system depressurize, and protect painted or plastic parts from brake fluid.

Core Manual Contents

• Engine and top-end repair: Covers engine removal and installation, compression testing, cylinder-head cover service, camshaft and rocker-arm inspection, cylinder-head and valve disassembly, cam-chain work, and cylinder/piston removal, measurement, and reassembly.
• Lubrication, fuel, and cooling systems: Details oil-pump removal and overhaul, oil-pressure relief-valve and oil-pipe service, CVK carburetor and choke repair, fuel tank/filter/pump inspection, secondary-air components, cooling-system testing, coolant replacement, thermostat, water pump, radiator, fan controls, temperature sensor, reserve tank, and oil cooler.
• CVT and internal transmission work: Includes the drive pulley, driven pulley, V-belt, centrifugal clutch, final-reduction bevel gears, transmission shafts and shift forks, plus crankshaft and balance-shaft service. Separate clutch-housing procedures distinguish USA-type and non-USA-type construction.
• 4WD driveline and chassis coverage: Provides front CV-joint and front gear-case removal, disassembly, inspection, and assembly, followed by the included initial rear gear-case teardown pages. Frame-cover and exhaust-muffler removal, wheel and hub service, shocks, steering knuckles, brake discs, calipers, master cylinders, hydraulic bleeding, the brake pedal, and the parking brake are also covered.
• Electrical diagnosis and component testing: Covers battery and charging tests, alternator stator, regulator/rectifier, ignition coil and control module, starter motor, starter relay, starter clutch, bulbs, switches, gear indicator, speed sensor, 2WD/4WD selector actuator, fuel-level unit, and system-specific voltage, resistance, and continuity checks.
• Factory reference data: Provides one periodic maintenance schedule, component-specific torque tables, fluid-capacity and lubricant data, wear limits, clearances, inspection specifications, troubleshooting sections, and a special-tool list with KYMCO tool numbers.

Variant-Specific Coverage, Diagrams, and Tools

The manual distinguishes on-road and off-road carburetor main-jet specifications and identifies horn and turn-signal service as on-road equipment. Its final electrical section contains two full-page schematics: “UXV 500 Wiring Diagram (ON ROAD)” marked ERU and “UXV 500 Wiring Diagram (OFF ROAD)” marked US. Other useful visual references include the Lubrication System Diagram, Cooling System Flow Pattern, Cylinder Head/Valves Schematic Drawing, and Drive Pulley/Driven Pulley/Clutch Schematic Drawing.

The special-tool chart identifies factory tools used for engine, CVT, and driveline repair, including the valve spring compressor A120E00040, universal holder A120E00056, flywheel puller A120E00060, and pinion-bearing lock-nut wrench A120F00020. These references let a technician or experienced owner verify tool availability before disassembly.

Two manual-specific repair traps deserve attention. The piston section warns against confusing the top and second rings or forcing the cylinder over them, since the rings and cylinder wall can be damaged. The driveline section warns that insufficient gear backlash is destructive to the gear teeth and instructs the operator to stop riding immediately if that condition appears after reassembly.

Important PDF Scope Limit

This 368-page edition does not contain every page listed in its own chapter contents. The Drive Train chapter ends at printed page 13-24, although its contents page lists rear-drive disassembly, rear-drive shim adjustment, and front/rear propeller-shaft procedures through 13-61. The Front Wheel/Front Suspension/Steering System chapter ends at 14-16, while its contents page continues through 14-30; the file breaks off during steering-wheel/shaft removal, before the listed front-arm, tie-rod, handlebar, and steering-column sections. The Rear Wheel/Shock Absorber/Swing Arm chapter also has no dedicated swing-arm removal procedure despite the chapter title and special-tool cross-reference. Buyers who need those specific repair procedures will require the missing factory pages or another demonstrably complete edition.