Rear Gear Case - KYMCO MXU 450i Service Manual

8. Inspect the axle components for correct position-
ing of the four clamps. Also, inspect the boots for
being correctly positioned on the shaft.
INSTALLING REAR DRIVE AXLE
1. Slide the drive axle into place in the gear case.
NOTE: To assure proper seating of the axle, give
it a light pull; the axle should remain "clipped" in
place.
2. Swing the knuckle up and onto the drive axle; then
place the knuckle into place in the upper A-arm.
Secure the knuckle to the A-arm with a cap screw
and a new lock nut. Tighten to 35 ft-lb.
3. Place the hub into position on the axle followed by
a hex nut. Tighten the hex nut finger-tight at this
time.
4. If the brake caliper was removed, position it on the
knuckle and secure with existing cap screws.
Tighten the brake caliper cap screws to 20 ft-lb.
5. Pump up the hand brake lever; then engage the
brake lever lock.
6. Tighten the hub hex nut (from step 3) to 200 ft-lb;
then install and spread a new cotter pin making
sure each side of the pin is flush to the hub nut.
7. Install the wheel. Tighten to 40 ft-lb.
8. Remove the ATV from the support stand and
release the brake lever lock.
INSTALLING FRONT DRIVE AXLE
1. Position the drive axle in the gear case and steer-
ing knuckle; then insert the upper A-arm ball joint
into the steering knuckle. Secure with a cap screw
tightened to 35 ft-lb.
2. Slide the hub w/brake disc into position in the
steering knuckle followed by a washer and hex
nut. Tighten finger-tight at this time.
3. Install the brake caliper on the steering knuckle.
Tighten to 20 ft-lb; then pump up the hand brake
lever and engage the brake lever lock.
6-18
4. Tighten the hub hex nut (from step 2) to 200 ft-lb;
then install and spread a new cotter pin making
sure each side of the pin is flush to the hub nut.
CD024
5. Install the wheel and tighten to 40 ft-lb.
6. Remove the ATV from the support stand and
release the brake lever lock.
7. Check the front differential oil level and add oil as
necessary.

Rear Gear Case

REMOVING
1. Remove both of the rear drive axles (see Drive
Axles in this section).
2. Remove the four cap screws securing the engine
output shaft to the rear gear case input flange.
KC305
CF113A