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Messages - CThacker

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Technical | How To / Re: Kymco UXV 500 Replacement CDI Box 30400-LEE8-900
« on: June 14, 2023, 08:35:37 PM »
With my oversized jump pack, it can start so yea maybe it is just a crap design on the battery and ECU....
I think a Master switch may be the best option.  A buddy of mine actually suggested that as well. Kind of like some boats.
I might be able to put multiple batteries (I have spare small ones) in there instead of buying a new larger one.

Heck honestly, I want to sell it and get something better, but who's going to really buy it until I figure this out.  LOL
Thanks for the advice CROSSBOLT and Ruffus!!! I will give it a go and clean the grounds the try the master switch with separate power lines to start it.

Wish me luck!

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Technical | How To / Kymco UXV 500 Replacement CDI Box 30400-LEE8-900
« on: June 14, 2023, 03:03:14 PM »
I am having trouble with my Side x Side starting.
Everything has been updated as far as the Engine, however now something seems to be draining the battery when I try to start it up.
It is pulling so much off the battery that the starter isn't getting enough juice and the battery drains fast.
I have eliminated the accessories like the fan and lights, pulled fuses and disconnected their Relays.  Only thing left I can think of to check is the CDI Box or if there is a voltage regulator somewhere.
The CDI Box is CDI Box 30400-LEE8-900 however I cannot find a replacement.  I am thinking maybe a different model number may work but I cannot find a cross reference sheet anywhere.  The single piston timing is good, new starter, it has good gas, new battery, new cam shafts.

Does anybody here have any experience in the CDI's? Again, this is a Kymco UXV 500 4x4 and I am thinking this may be the problem.

Thanks!

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Side By Side / Re: 2011 Kymco UXV 500 -Replaced Camshaft now it wont fire and wont lose Compression
« on: October 24, 2022, 06:49:18 PM »
Quote from: CROSSBOLT on October 24, 2022, 06:44:37 PM
It will run again if it ran before. When deer season is over, look for some part on thr compression release thingy that can be assembled two ways.....

Just so I understand correctly, it won't start because it stops revolving on the compression stroke, right?

Thats correct once the compression stroke tops out, it just does a hard stop until the buildup of pressure manages to dissipate out (I'm assuming leak by through the exhaust valves).  We did get a small backfire once or twice but no real luck.

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Side By Side / Re: 2011 Kymco UXV 500 -Replaced Camshaft now it wont fire and wont lose Compression
« on: October 24, 2022, 06:23:09 PM »
Yep,
The spark plug shows good spark.  Cams shafts are installed correctly as well with the indicator Dots on Top. 
We manually moved the piston as well and felt it top out from the spark plug hole and it pretty much matched the T mark.

We even tried putting in the old camshaft and it did the same thing.  So, either we broke something or found another underlying problem that already existed and we didn't know about it.

That is an interesting thought about the flywheel keyway being sheared. We may just have to open this thing up and check for sheared components in there.

Either way I am now borrowing a different 4x4 for deer season so this is now not as much of an urgency as before so I can take my time now.
Time will tell I guess.


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Side By Side / Re: 2011 Kymco UXV 500 -Replaced Camshaft now it wont fire and wont lose Compression
« on: October 24, 2022, 03:29:15 PM »
Hey Guys, 
Sorry for the Delay in responding Work has been crazy busy. 
Yea we are able to manually bar the machine over from the nut where the recoil starter cover is, and we found the T and F mark on my 500.   Unfortunately, it still does not want to fire off.  It almost seems that there are not enough amps to crank the machine over and allow the compression to exhaust out (We even tried a Deep Cycle with 600 CCA).   We marked the chain originally and realigned TDC for both Cam Shafts and the Piston with the T mark on the flywheel.  With the spark plug out it purrs Beautifully so we are super confused of what else it may be that is stopping the exhaust of the compression from coming out.

It does not seem that the valves are misaligned, and my buddy is now thinking that there may be something more internal going on Cylinder or Crank damage???...  We might just go ahead and take the Cylinder head apart and inspect the piston etc.....

Here is the manual we have been referencing.
https://www.manualslib.com/manual/2032784/Kymco-Uxv500i.html?page=112#manual

Any other suggestions would be appreciated.  Thanks Guys!!!

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Side By Side / 2011 Kymco UXV 500 -Replaced Camshaft now it wont fire and wont lose Compression
« on: October 18, 2022, 03:53:41 PM »
Looking for some help here.  We recently replaced the exhaust Camshaft due to a broken decompression cam.  We were pretty sure the linkage on the intake cam did not move so the Piston should be exact where we need it.  However when trying to start back up the cams roll over once but then it stops.  Almost like there is too much compression and it is not relieving through the exhaust. 
It has a new starter, spark plug is good, starting fluid doesn't help, Both cams are at TDC.
We even tried removing the exhaust pipe and no change.  When the Spark plug is removed it turns over just fine and never stops as all the pressure is exhausting through the spark plug hole.

Only thing we can think of now is maybe we slipped the chain on the intake Cam gear and didn't notice so now the Piston is NOT at TDC when the Cam shafts ARE at TDC.  I know to check this we need to open the Crank Case up and look at the flywheel.  Can anybody help on the location of this?   Or are there any better ideas????  My buddy has rebuilt machines more complicated than this and is an Ex mechanic and even he is stumped.....

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Side By Side / Re: 2012 uxv 500 i i would like to try and check the timing
« on: October 18, 2022, 02:43:05 PM »
Quote from: ktmurph52@gmail.com on January 30, 2021, 10:14:56 PM
Thank you for your reply, my issue was that the timing chain was not properly timed when the motor was taken apart and put back together by a local dealer when I had them replace the reverse gear. I was able to get it back in time and it ran very well until today now it will run but  has no power (won't fast idle or i should say rev up) so back  to the drawing board.   It may be a water or ice issue now as it is 8 degrees here today      Thanks again.

We just replaced the Exhaust Cam shaft and thought we had the chain secured to not move off the intake.  Now we cant turn it over and think maybe our piston is off of TDC. Camshafts are at TDC however.  The manual says to confirm Piston TDC off the flywheel in the crank case.  Do you happen to have any pictures of yours opened up?  i am not completely sure which cover to open up for this.

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Side By Side / Re: what is the size of the flywheel nut
« on: October 18, 2022, 02:33:30 PM »
Quote from: B3N on December 31, 2020, 12:01:22 AM
I lost my nut  >:( so what is the size of the nut at the end of the crank shaft on the flywheel side uxv 500i 2012 thank you

Where you able to figure out the size?  Send me a picture of your flywheel as I am about to open up the crank case to ensure my piston is at TDC.  I can tell you what the size it after that.

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