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KYMCO
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MXU400
KYMCO MXU400 User Manual
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9-1
9
SECTION 9 - CONTR
OLS/INDICA
T
ORS
TABLE OF
CONTENTS
Hand Brake Lev
er/
Master Cylinder
Assembly
.........
9-2
Throttle Contro
l
...............
................
................
........
9-2
LCD Gauge
.....................
................
...................
.....
9
-3
144
146
Table of Contents
1 Section 1 - General Information/ Specifications
5
Table of Contents
5
General Specifications
6
Torque Conversions (Ft-Lb/N-M)
7
Tightening Torque (General Bolts)
7
Break-In Procedure
8
Gasoline - Oil - Lubricant
8
Genuine Parts
9
Preparation for Storage
9
Preparation after Storage
9
Section 2 - Periodic Maintenance
11
Periodic Maintenance Chart
12
Battery
13
Torque Specifications
13
Lubrication Points
13
Periodic Maintenance
13
Air Filter
14
Fuses
14
Valve/Tappet Clearance (Feeler Gauge Procedure)
16
Valve/Tappet Clearance (Valve Adjuster Procedure)
16
Testing Engine Compression
17
Muffler/Spark Arrester
18
Spark Plug
18
Adjusting Engine RPM (Idle)
19
Adjusting Throttle Cable
19
Engine/Transmission Oil - Filter - Strainer
19
Front Differential/Rear Drive Lubricant
21
Driveshaft/Coupling
22
Ignition Timing
22
Nuts/Bolts/Cap Screws
22
Steering Components
22
Suspension/Shock Absorbers/Bushings
22
Tires
22
Lights
23
Electrical Connections
25
Frame/Welds/Racks
25
Hydraulic Brake Systems
25
Shift Lever
25
Burnishing Brake Pads
27
Checking/Replacing V-Belt
27
Table of Contents
37
Removing Top-Side Components
39
Top-Side Components
39
Servicing Top-Side Components
43
Installing Top-Side Components
51
Left-Side Components
55
Removing Left-Side Components
56
Installing Left-Side Components
58
Removing Right-Side Components
59
Right-Side Components
59
Installing Right-Side Components
63
Driven Pulley Assembly
63
Servicing Right-Side Components
63
Center Crankcase Components
66
Disassembling Crankcase Half
67
Separating Crankcase Halves
67
Servicing Center Crankcase Components
69
Crankshaft Assembly
70
Assembling Crankcase Half
72
Installing Engine/Transmission
74
Joining Crankcase Halves
74
Section 4 - Fuel/Lubrication/Cooling
79
Fuel/Lubrication/Cooling
79
Carburetor
80
Carburetor Schematic
80
Carburetor Specifications
80
Engine RPM (Idle)
86
Gas Tank
86
Throttle Cable Free-Play
86
Oil Filter/Oil Pump
88
Testing Oil Pump Pressure
88
Oil Cooler
89
Troubleshooting
90
Section 5 - Electrical System
91
Electrical System
91
Accessory Receptacle/Connector
92
Battery
92
RPM Limiter
92
Specifications
92
Testing Electrical Components
92
Brakelight Switch (Pressure)
93
Oil Temperature and Cooling Fan Switches
93
Fan Motor
94
Fuses
95
Ignition Coil
95
Ignition Switch
96
Speed Sensor
96
Front Drive Selector Switch
97
Handlebar Control Switches
97
Front Drive Selector Actuator
98
Gear Shift Position Switch
98
Starter Relay
99
Stator Coil
99
CDI Unit
100
Starter Motor
100
Headlights
101
Neutral Start/Front Drive Actuator/Start-In-Gear/ 2WD Relays
101
Regulator/Rectifier
101
Taillights - Brakelights
101
Back-Up Lights
102
Running Lights
102
Ignition Timing
103
Troubleshooting
103
Section 6 - Drive System
105
Drive System
106
Front Drive Actuator
106
Suspension
106
Front Differential
107
Drive Axles
118
Rear Gear Case
122
Hub
123
Hydraulic Brake Caliper
124
Troubleshooting Brake System
126
Troubleshooting Drive System
126
Section 7 - Suspension
127
Front A-Arms
128
Shock Absorbers
128
Suspension
128
Rear A-Arms
129
Wheels and Tires
130
Troubleshooting
132
Section 8 - Steering/Frame
133
Steering Post/Tie Rods
134
Steering/Frame
134
Handlebar Grip
135
Steering Knuckles
136
Measuring/Adjusting Toe-In
137
Front Bumper Assembly
138
Front Rack
138
Front Body Panel/Fender
139
Exhaust System
140
Rear Body Panel/Rack
141
Troubleshooting
143
Controls/Indicators
145
Throttle Control
146
Lcd Gauge
147
5
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KYMCO MXU400 Specifications
General
Brand
KYMCO
Model
MXU400
Category
Offroad Vehicle
Language
English
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