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MXU 500
KYMCO MXU 500 User Manual
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4
. LUBRICATION SYSTEM
4-16
MXU 500
Apply clean engine oil to the bolts, then
install the outer washers and two bolts.
Tighten the two bolts to the specified torque.
Torque:
3.5 kgf-m (35 N-m, 25.2 lbf•
ft)
Oil
Pipe/Washers
(under
oil
pipe)
Bolts/Washers
(on
the
oil
pipe)
276
278
Table of Contents
Table of Contents
6
Default Chapter
3
Important Notices
3
Location of the Warning and Specification Labels
11
Safety Information
14
Description and Machine Identification
19
Identification Number Records
19
Key Identification Number
19
Frame Serial Number
20
Engine Serial Number
21
Parts Location
22
Control Functions
27
Control Functions Ignition Switch
27
Instruments and Indicator
28
Multi-Function Display
30
Left Handlebar Switches
37
Horn Button
37
Turn Signal Switch
37
Headlight Dimmer Switch
38
Hazard Switch
39
Start Switch
40
Right Handlebar Switch
41
2WD/4WD Select Switch
41
Recoil Starter
42
Throttle Lever
43
Speed Limiter
44
Front Brake Lever
45
Rear Brake Lever
45
Brake Pedal
45
Parking Brake
46
Locking Steering
47
Drive Select Lever
48
Fuel Tank Cap
49
Fuel Valve
49
Choke Knob
51
Accelerating Pump Lever
52
Seat
53
Flag Pole Bracket
54
Trailer Hitch
54
Owner's Manual Storage Compartment
55
Accessory Socket
56
Pre-Operation Checks
57
Drive Select Lever
58
Drive Select Lever Adjustment
60
Front and Rear Brakes
62
Fuel
63
Drive Shaft Boots
64
Engine Oil
65
Final Gear Oil
66
Differential Gear Oil
66
Throttle Lever
67
Fittings and Fasteners
67
Lights
67
Switches
67
Tires
68
How to Measure Tire Pressure
69
Tire Wear Limit
70
Coolant
70
Operation
72
Using the Recoil Starter
75
Starting a Warm Engine
76
Drive Select Lever Operation and Reverse Driving
77
Engine Break-In
79
Parking
80
Parking on a Slope
81
Accessories
82
Loading
83
Riding Your Atv
85
Getting to Know Your Atv
86
Ride with Care and Good Judgement
87
Apparel
90
Pre-Operation Checks
92
Loading and Accessories
94
Accessories
95
Modifications
96
During Operation
97
Exhaust System
99
Practicing
100
Turning Your Atv
101
Climbing up Slope
102
Riding down Slope
108
Parking
109
Adjustment
111
Periodic Maintenance Lubrication
113
Engine Oil
116
Final Gear Oil
123
Differential Gear Oil
125
Spark Plug Inspection
127
Spark Arrester
128
Air Filter Cleaning
130
Air Cleaner Housing Drain Tube
133
Idle Speed Adjustment
134
Throttle Lever Adjustment
135
Valve Clearance Adjustment
136
Rear Brake Pads Inspection
137
Cooling System Inspection
139
Engine Overheating
141
Wheel Removal
142
Battery
144
Battery Remove
145
Fuse Replacement
146
Headlight Beam Adjustment
147
Cable Inspection and Lubrication
148
Troubleshooting
149
Troubleshooting Chart
150
Cleaning and Storage
151
B. Storage
153
Specifications
155
Noise Regulation
159
Maintenance Record
160
Index
161
General Information
170
Serial Number
171
Specifications
172
General Information
172
Service Precautions
173
Torque Values
181
Special Tools
185
Lubrication Points
189
Cable & Harness Routing
191
Troubleshooting
205
2. Frame Covers/Exhaust Muffler
211
Service Information
213
Troubleshooting
213
Fastener Removal and Reinstallation
214
Frame Covers
215
Exhaust Muffler
224
3. Inspection/Adjustment
226
Service Information
227
Maintenance Schedule
229
Fuel Line/Throttle Operation
230
Speed Limiter/Air Cleaner
231
Air Filter for Drive Belt
233
Secondary Air Supply System
234
Spark Plug
235
Valve Clearance
237
Carburetor Idle Speed
238
Clinder Compression/Engine Oil
239
Rear Drive Gear Oil
243
Front Drive Gear Oil
244
Spark Arrester
245
Drive Belt/Brake Pads Inspection
247
Brake Fluid Inspection/Headlight Aim
248
Steering System Inspection
249
Toe-In Adjustment
250
Wheels/Tires
251
Cable Inspection and Lubrication/Adjusting the Rear Brake Light Switch (Brake Pedal)
255
Cooling System
256
Parking Brake Adjustment (on Road)
258
4. Lubrication System
261
Lubrication System Diagram
262
Service Information
263
Troubleshooting
264
Lubrication Check Hole
265
Oil Pump Removal/Inspection/Installation
266
Oil Pump Disassembly/Inspection/Assembly
270
Right Crankcase Cover Disassembly/Assembly
273
Oil Pressure Relief Valve
275
Oil Pipe Removal/Installation
276
5. Fuel System 5
278
Service Information
280
Fuel System
280
Troubleshooting
281
Fuel Tank
282
Fuel Valve
282
Carburetor Removal/Choke Inspection/Installation
285
Carburetor Disassembly/Inspection/Assembly
287
Air Cleaner Housing
297
Pair Solenoid Valve
298
6 Cooling System
299
System Flow Pattern
300
Service Information
301
Troubleshooting
303
Coolant Replacement
304
Cooling System Testing
304
Thermostat
307
Water Pump
310
Radiator
313
Fan Motor Switch
314
Fan Motor
315
Water Temperature Sensor
316
Raidator Reserve Tank
317
Engine Removal
318
Cylinder Head/Valves
330
Schematic Drawing
331
Service Information
332
Troubleshooting
333
Cylinder Compression Test
334
Cylinder Head Cover Removal/Installation
335
Cylinder Head Cover Disassembly/Assembly
336
Camshaft Removal/Inspection/Installation
337
Rocker Arms Removal/Inspection/Installation
345
Cylinder Head Removal/Installation
347
Cylinder Head Disassembly/Inspection/Assembly
354
Cam Chain Removal/Inspection/Installation
358
Cylinder/Piston
360
Schematic Drawing
361
Service Information
362
Troubleshooting
362
Cylinder and Piston Removal/Inspection/ Installation
363
Drive Pulley/Driven Pulley/Clutch
370
Schematic Drawing
371
Service Information
372
Troubleshooting
372
Left Crankcase Cover Removal/Installation
373
Drive Pulley, Drive V-Belt and Driven Pulley
375
Removal/Inspection/ Installation
375
Drive Pulley Disassembly/Inspection/Assembly
379
Driven Pulley Disassembly/Inspection/Assembly
383
Transmission System 11
397
Final Reduction/Transmission System
399
Service Information
399
Troubleshooting
399
Secondary Drive/Driven Bevel Gear
400
Removal/Inspection/Installation
407
Right Crankcase Removal/Installation
407
Bearing Replacement in the Right Crankcase
409
Transmission Removal/Inspection/Installation
414
Upper Shift Fork Disassembly/Assembly
422
Drive Shaft Disassembly/Assembly/Inspection
423
Countershaft Disassembly/Assembly/Inspection
424
Left Crankcase/Crankshaft/ Balance Shaft
426
Service Information
428
Troubleshooting
428
Balance Shaft
428
Crankshaft and Balance Shaft
429
Removal/Inspection/Installation
429
Bearing/Oil Seal Replacement in the Left
432
Crankcase
432
Drive Train
433
Service Information
435
Troubleshooting
435
Installation
436
Assembly
438
Front Drive Shaft Disassembly/Inspection
438
Front Drive Removal/Inspection/Installation
444
Front Drive Disassembly/Inspection/Assembly
447
Front Drive Shim Asjustment
465
Rear Drive Removal/Inspection/Installation
469
Rear Drive Disassembly/Inspection/Assembly
473
Rear Drive Shim Adjustment
484
Front Propeller Shaft Disassembly/Inspection/ Assembly
489
Rear Propeller Shaft Disassembly/Inspection/ Assembly
494
Front Wheel/Front Suspension Steering System
498
Steering System
500
Troubleshooting
501
Front Wheel Removal/Inspection/Installation
502
Front Wheel Hub Removal/Inspection
506
Installation
506
Installation
509
Installation
511
Steering Knuckle Disassembly/Assembly
511
Steering Knuckle Removal/Inspection
511
Front Arms Inspection/Removal/Installation
515
Front Arms Disassembly/Inspection/Assembly
518
Handlebar Removal/Inspection/Installation
524
Removal/Inspection/Installation
528
Steering Column
528
15. Rear Wheel/Axle/Shock Absorber/Swing Arm
532
Service Information
534
Troubleshooting
534
Installation
535
Rear Wheel Removal/Inspection/Installation
535
Rear Shock Absorber Removal/Inspection/ Installation
538
Rear Axle Removal/Inspection/Installation
539
Rear Axle Housing
540
Removal/Inspection/Installation
540
Rear Axle Housing Disassemblt/Assembly
543
Rear Swing Arm Removal/Installation
547
Assembly
549
16 Brake System
552
Service Information
554
Troubleshooting
555
Brake Pads Replacement
556
Front Brake Discs Removal/Inspection/ Installation
561
Rear Brake Disc Removal/Inspection/ Installation
562
Front Brake Fluid Change/Air Bleed (off Road)
563
Rear Brake Fluid Chang/Air Bleed
566
Combination Brake Fluid Chang
569
Brake Master Cylinders Removal/Inspection/ Installation
575
Brake Master Cylinder Disassembly/Inspection
580
Assembly
582
Front Brake Calipers Removal/Inspection/ Installation
586
Rear Brake Calipers Removal/Inspection/ Installation
587
Rear Brake/Parking Brake Caliper Removal
588
Brake Caliper Disassembly/Inspection/Assembly
589
Rear Brake/Parking Brake Caliper
592
Troubleshooting
603
Battery
604
Charging System Inspection
605
Alternator Charging Coil
606
Regulator/Rectifier
607
Alternator Stator Removal/Inspection/ Installation
610
Ignition System Layout
616
Service Information
616
Troubleshooting
617
Ignition Coil Inspection
618
Ignition Control Module
619
Starting System Layout
622
Starting Circuit
623
Service Information
624
Troubleshooting
624
Starter System
625
Starter Motor
627
Starter Relay Switch/Starter Mag
628
Recoil Starter Removal/Inspection/ Installation
630
Recoil Starter Handle Replace
632
Recoil Starter Disassembly/Inspection/ Assembly
633
Starter Pulley Removal/Inspection/ Installation
639
Starter Clutch Removal/Inspection/ Installation
641
Bulbs Removal
647
Horn (on Road)
649
Ignition Switch
650
Handlebar Switch
650
Speed Sensor
654
2Wd/4Wd Selecting System
655
Fuel Unit
658
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User Manual
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KYMCO MXU 500 Specifications
General
Brand
KYMCO
Model
MXU 500
Category
Offroad Vehicle
Language
English
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