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KYMCO
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MXU 300
KYMCO MXU 300 User Manual
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6. ENGINE REMOVAL/INSTALLATION
6-1
MXU
300/250
SERVICE INFORMATION
GENERAL INSTRUCTIONS
•
A floor jack or other adjustable support is required to support and maneuver the engine.
Be careful not to damage the machine body, cables and wires during engine rem
oval.
•
Use shop towels to protect the machine body during engine removal.
•
Parts requiring engine removal for servicing:
⎯
Crankcase
⎯
Crankshaft
98
100
Table of Contents
Preface
2
Table of Contents
2
General Information
3
Serial Number
4
Specifications
5
Service Precautions
7
Torque Values
15
Special Tools
17
Lubrication Points
18
Cable & Harness Routing
21
Troubleshooting
29
2. Frame Covers/Exhaust Muffler
35
Frame Covers/Exhaust Muffler
35
Frame Covers/Exhaust Muffler
37
Service Information
37
Troubleshooting
37
Frame Covers
38
Exhaust Muffler
46
3. Inspection/Adjustment
47
Inspection/Adjustment
47
Service Information
48
Maintenance Schedule
50
Fuel Line/Throttle Operation/Air Cleaner
51
Air Filter for Drive Belt
53
Secondary Aur Supply System/Spark Plug
54
Valve Clearance
55
Carburetor Idle Speed/Ignition Timing
56
Cylinder Compression/ Engine Oil
57
Transmission Oil Replacement
59
Rear Final Gear Case Oil Replacement (Mxu 300)
61
Drive Belt/Brake Pads Inspection
62
Brake Fluid Inspection/ Headlight Aim
63
Steering System Inspection
64
Toe-In Adjustment
65
Wheels/Tires
66
Drive Chain Slack Adjustment (Mxu 250)
68
Drive Select Lever Adjustment
70
Cable Inspection and Lubrication
71
Rear Suspension Lubrication (Mxu 250)
71
Cooling System
72
Spark Arrester Cleaning (off Road)
73
4. Lubrication System
74
Lubrication System
74
Lubrication System
76
Service Information
76
Troubleshooting
76
Engine Oil/Oil Filter
77
Oil Pump
77
5 Fuel System
81
Fuel System
83
Service Information
83
Troubleshooting
84
Fuel Tank
85
Fuel Valve
85
Throttle Valve
88
Carburetor
90
Air Cleaner Housing
96
Pair Solenoid Valve
97
6 Engine Removal
98
Engine Removal
99
Service Information
99
Engine Removal (Mxu 250)
102
Engine Installation (Mxu 250)
105
Engine Removal (Mxu 300)
108
Engine Installation (Mxu 300)
115
Cylinder Head/Valves 7
117
Cylinder Head/Valves
119
Service Information
119
Troubleshooting
120
Camshaft/Camshaft Holder
121
Cylinder Head Cover
121
Cylinder Head
127
Cylinder/Piston
131
9.Drive and Driven Pulleys
141
Drive and Driven Pulleys
141
Service Information
143
Troubleshooting
143
Left Crankcase Cover
144
Drive Pulley/Driven Pulley
145
Transmission System 10
157
Final Reduction/Transmission System
160
Service Information
160
Troubleshooting
160
Transmission Case Cover (Mxu 250)
161
Transmission (Mxu 250)
163
Speedometer Gear
173
Transmission Case Cover/Secondary Driven Bevel Gear Assembly (Mxu 300)
175
Transmission (Mxu 300)
186
Secondary Gear Shims (Mxu 300)
196
Crankcase/Crankshaft/Balance Shaft
199
Balance Shaft
201
Cooling System
206
Cooling System
207
Service Information
207
Cooling System Testing
209
Radiator
210
Coolant Replacement
213
Water Pump
215
Thermosensor
219
Thermostat
220
13. Brake System
222
Brake System
222
Brake System
224
Service Information
224
Front Hydraulic Brake
225
Front Brake Fluid Change/Air Bleed
226
Brake Master Cylinder
228
Front Brake Caliper
231
Rear Hydraulic Brake
234
Rear Brake Master Cylinder (Rear Brake Pedal)
238
Rear Brake Caliper
241
Front Wheel/Front Suspension/Steering System
246
Front Suspension
253
Rear Wheel/Axle/Suspension/ Driving Mechanism
269
Service Information
272
Troubleshooting
272
Right Pivot Bolt (MXU
272
Rear Wheel/Rear Wheel Hub
273
Rear Axle/Axle Hub (Mxu 250)
275
Rear Shock Absorber
284
Swingarm (Mxu 250)
285
Rear Driving Mechanism (Mxu 300) Removal and Inspection
290
Case (Mxu 300) Disassembly
295
Final Drive Shim (Mxu 300) Adjustment/Final Gear
295
Final Gear Case (Mxu 300) Assembly
305
Swingaem (Mxu300)
307
Rear Driving Mechanism (Mxu 300) Installation
309
A.C. Generator
314
Charging System
321
Ignition System
330
Starting System
333
Starting System
335
Service Information
335
Troubleshooting
335
Starter Motor
336
Starter Relay
340
Starter Clutch
341
Recoil Starter
343
Lights/Switches
345
Service Information
346
Bulbs Removal
347
Horn (on Road)
349
Ignition Switch
350
Handlebar Switch
350
Other manuals for KYMCO MXU 300
Owner's Manual
164 pages
Parts Manual
140 pages
5
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KYMCO MXU 300 Specifications
General
Brand
KYMCO
Model
MXU 300
Category
Offroad Vehicle
Language
English
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