KYMCO 2006 MXU 500 Off-Road Manuals

KYMCO 2006 MXU 500 Off-Road Manuals

Manuals and User Guides for KYMCO 2006 MXU 500 Off-Road. We have 1 KYMCO 2006 MXU 500 Off-Road manual available for free PDF download: Owner's Manual

KYMCO 2006 MXU 500 Off-Road Owner's Manual

KYMCO 2006 MXU 500 Off-Road Owner's Manual (677 pages)

Brand: KYMCO | Category: Offroad Vehicle | Size: 40.16 MB

Table of Contents

Table of Contents

6
- 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
    20
  - Parts Location
    21
    
    Control Functions
    26
- Control Functions Ignition Switch
  
  26
  - Instruments and Indicator
    27
    
    Multi-Function Display
    29
  - Handlebar Switches
    36
    
    Headlight Dimmer Switch
    36
    
    Start Button
    36
    
    Engine Stop Switch
    37
    
    Passing Signal Switch
    37
  - Right Handlebar Switch
    38
    
    2WD/4WD Select Switch
    38
  - Recoil Starter
    39
  - Throttle Lever
    40
  - Speed Limiter
    41
  - Front Brake Lever
    42
  - Rear Brake Lever
    42
  - Brake Pedal
    42
  - Parking Brake
    43
  - Drive Select Lever
    44
  - Fuel Tank Cap
    45
  - Fuel Valve
    45
  - Choke Knob
    47
  - Accelerating Pump Lever
    48
  - Seat
    49
  - Flag Pole Bracket
    50
  - Trailer Hitch
    50
  - Owner's Manual Storage Compartment
    51
  - Accessory Socket
    52
- Pre-Operation Checks
  
  53
  - Drive Select Lever
    54
    
    Drive Select Lever Adjustment
    56
  - Front and Rear Brakes
    58
  - Fuel
    59
  - Drive Shaft Boots
    60
  - Engine Oil
    61
  - Final Gear Oil
    62
  - Differential Gear Oil
    62
  - Throttle Lever
    63
  - Fittings and Fasteners
    63
  - Lights
    63
  - Switches
    63
  - Tires
    64
  - How to Measure Tire Pressure
    65
  - Tire Wear Limit
    66
  - Coolant
    66
- Operation
  
  68
  - Starting a Cold Engine
    68
    
    Using the Recoil Starter
    71
  - Starting a Warm Engine
    72
  - Warming up
    72
  - Drive Select Lever Operation and Reverse Driving
    73
    
    Shifting: Neutral to High and High to Low
    73
    
    Shifting: Neutral to Reverse and Reverse to Park
    74
  - Engine Break-In
    75
  - Parking
    76
    
    Parking on a Slope
    77
  - Accessories
    78
  - Loading
    79
- Riding Your Atv
  
  81
  - Getting to Know Your Atv
    82
  - Ride with Care and Good Judgement
    83
  - Apparel
    85
  - Pre-Operation Checks
    89
    
    Speed Limiter
    90
  - Loading and Accessories
    91
    
    Load Limits
    91
    
    Loading and Operational Guidelines
    91
    
    Accessories
    92
  - Modifications
    93
    
    No Modifications
    93
  - Exhaust System
    94
  - Be Careful Where You Ride
    95
  - For Off-Road Use Only
    100
  - During Operation
    102
  - Turning Your Atv
    104
  - Sliding and Skidding
    106
  - Climbing Uphill
    108
  - Riding Downhill
    114
  - Crossing a Slope
    116
  - Riding over Rough Terrain
    118
  - Crossing through Shallow Water
    119
  - Pa R K I N
    120
  - What to Do if
    121
  - What to Do
    121
- Periodic Maintenance and Adjustment
  
  123
  - Tool Kit Compartment
    123
  - Periodic Maintenance/Lubrication
    125
  - Engine Oil
    128
  - Final Gear Oil
    135
  - Differential Gear Oil
    137
  - Spark Plug Inspection
    139
  - Spark Arrester
    140
  - Air Filter Cleaning
    142
  - Air Cleaner Housing Drain Tube
    145
  - Idle Speed Adjustment
    146
  - Throttle Lever Adjustment
    147
  - Valve Clearance Adjustment
    148
  - Front Brake Pads Inspection
    148
  - Rear Brake Pads Inspection
    149
  - Brake Fluid Inspection
    149
  - Cooling System Inspection
    151
    
    Engine Overheating
    153
  - Wheel Removal
    154
  - Wheel Installation
    154
  - Battery
    156
    
    Battery Remove
    157
    
    Battery Installation
    157
  - Fuse Replacement
    158
  - Headlight Beam Adjustment
    159
  - Drive Shaft Boots
    159
  - Cable Inspection and Lubrication
    160
  - Troubleshooting
    161
    
    Troubleshooting Chart
    162
- Cleaning and Storage
  
  163
  - Cleaning
    163
  - Storage
    165
  - Specifications
    167
  - Noise Regulation
    171
  - Maintenance Record
    172
  - Index
    173
General Information

183
- Serial Number
  184
- Specifications
  185
- Service Precautions
  186
- Torque Values
  194
- Special Tools
  198
- Lubrication Points
  202
- Cable & Harness Routing
  204
- Troubleshooting
  218
2. Frame Covers/Exhaust Muffler

224
- Service Information
  226
- Troubleshooting
  226
- Fastener Removal and Reinstallation
  227
- Frame Covers
  228
- Exhaust Muffler
  237
3. Inspection/Adjustment

239
- Service Information
  240
- Maintenance Schedule
  242
- Fuel Line/Throttle Operation
  243
- Speed Limiter/Air Cleaner
  244
- Air Filter for Drive Belt
  246
- Secondary Air Supply System
  247
- Spark Plug
  248
- Valve Clearance
  250
- Carburetor Idle Speed
  251
- Clinder Compression/Engine Oil
  252
- Rear Drive Gear Oil
  256
- Front Drive Gear Oil
  257
- Spark Arrester
  258
- Drive Shaft Boots
  259
- Drive Belt/Brake Pads Inspection
  260
- Brake Fluid Inspection/Headlight Aim
  261
- Steering System Inspection
  262
- Toe-In Adjustment
  263
- Wheels/Tires
  264
- Cable Inspection and Lubrication/Adjusting the Rear Brake Light Switch (Brake Pedal)
  268
- Cooling System
  269
- Parking Brake Adjustment (on Road)
  271
4. Lubrication System

274
- Lubrication System Diagram
  275
- Service Information
  276
- Troubleshooting
  277
- Lubrication Check Hole
  278
- Oil Pump Removal/Inspection/Installation
  279
- Oil Pump Disassembly/Inspection/Assembly
  283
- Right Crankcase Cover Disassembly/Assembly
  286
- Oil Pressure Relief Valve
  288
- Oil Pipe Removal/Installation
  289
5. Fuel System 5

291
- Service Information
  293
- Troubleshooting
  294
- Fuel Tank
  295
- Fuel Valve
  295
- Carburetor Removal/Choke Inspection/Installation
  298
- Carburetor Disassembly/Inspection/Assembly
  300
- Air Cleaner Housing
  310
- Pair Solenoid Valve
  311
6 Cooling System

312
- System Flow Pattern
  313
- Service Information
  314
- Troubleshooting
  316
- Coolant Replacement
  317
- Cooling System Testing
  317
- Thermostat
  320
- Water Pump
  323
- Radiator
  326
- Fan Motor Switch
  327
- Fan Motor
  328
- Water Temperature Sensor
  329
- Raidator Reserve Tank
  330
Cylinder Head/Valves

343
- Schematic Drawing
  344
- Service Information
  345
- Troubleshooting
  346
- Cylinder Compression Test
  347
- Cylinder Head Cover Removal/Installation
  348
- Cylinder Head Cover Disassembly/Assembly
  349
- Camshaft Removal/Inspection/Installation
  350
- Rocker Arms Removal/Inspection/Installation
  358
- Cylinder Head Removal/Installation
  360
- Cylinder Head Disassembly/Inspection/Assembly
  367
- Cam Chain Removal/Inspection/Installation
  371
Cylinder/Piston

373
- Schematic Drawing
  374
- Service Information
  375
- Troubleshooting
  375
- Cylinder and Piston Removal/Inspection/ Installation
  376
Drive Pulley/Driven Pulley/Clutch

383
- Schematic Drawing
  384
- Service Information
  385
- Troubleshooting
  385
- Left Crankcase Cover Removal/Installation
  386
- Drive Pulley, Drive V-Belt and Driven Pulley
  388
- Removal/Inspection/ Installation
  388
- Drive Pulley Disassembly/Inspection/Assembly
  392
- Driven Pulley Disassembly/Inspection/Assembly
  396
Transmission System 11

410
Left Crankcase/Crankshaft/ Balance Shaft

439
- Service Information
  441
- Troubleshooting
  441
- Crankshaft and Balance Shaft
  442
- Removal/Inspection/Installation
  442
- Bearing/Oil Seal Replacement in the Left Crankcase
  445
Drive Train

446
- Service Information
  448
- Troubleshooting
  448
- Installation
  449
- Front Drive Shaft Disassembly/Inspection/ Assembly
  451
- Front Drive Removal/Inspection/Installation
  457
- Front Drive Disassembly/Inspection/Assembly
  460
- Front Drive Shim Asjustment
  478
- Rear Drive Removal/Inspection/Installation
  482
- Rear Drive Disassembly/Inspection/Assembly
  486
- Rear Drive Shim Adjustment
  497
- Assembly
  502
- Front Propeller Shaft Disassembly/Inspection
  502
- Assembly
  507
- Rear Propeller Shaft Disassembly/Inspection
  507
Front Wheel/Front Suspension Steering System

511
- Service Information
  513
- Troubleshooting
  514
- Front Wheel Removal/Inspection/Installation
  515
- Front Wheel Hub Removal/Inspection
  519
- Installation
  519
- Installation
  522
- Installation
  524
- Steering Knuckle Disassembly/Assembly
  524
- Steering Knuckle Removal/Inspection
  524
- Front Arms Inspection/Removal/Installation
  528
- Front Arms Disassembly/Inspection/Assembly
  531
- Tie-Rod Removal/Inspection/Installation
  534
- Handlebar Removal/Inspection/Installation
  537
- Removal/Inspection/Installation
  541
- Steering Column
  541
15. Rear Wheel/Axle/Shock Absorber/Swing Arm

545
- Service Information
  547
- Troubleshooting
  547
- Installation
  548
- Rear Wheel Removal/Inspection/Installation
  548
- Rear Shock Absorber Removal/Inspection/ Installation
  551
- Rear Axle Removal/Inspection/Installation
  552
- Rear Axle Housing
  553
- Removal/Inspection/Installation
  553
- Rear Axle Housing Disassemblt/Assembly
  556
- Rear Swing Arm Removal/Installation
  560
- Assembly
  562
- Rear Swing Arm Disassembly/Inspection
  562
16 Brake System

565
- Service Information
  567
- Troubleshooting
  568
- Brake Pads Replacement
  569
- Front Brake Discs Removal/Inspection/ Installation
  574
- Rear Brake Disc Removal/Inspection/ Installation
  575
- Front Brake Fluid Change/Air Bleed (off Road)
  576
- Rear Brake Fluid Chang/Air Bleed
  579
- Combination Brake Fluid Chang
  582
- Brake Master Cylinders Removal/Inspection/ Installation
  588
- Brake Master Cylinder Disassembly/Inspection
  593
- Assembly
  595
- Front Brake Calipers Removal/Inspection/ Installation
  599
- Rear Brake Calipers Removal/Inspection/ Installation
  600
- Rear Brake/Parking Brake Caliper Removal
  601
- Brake Caliper Disassembly/Inspection/Assembly
  602
- Rear Brake/Parking Brake Caliper
  605
  - Service Information
    614
  - Troubleshooting
    616
  - Battery
    617
  - Charging System Inspection
    618
  - Alternator Charging Coil
    619
  - Regulator/Rectifier
    620
  - Alternator Stator Removal/Inspection
    623
  - Installation
    623
  - Ignition System Layout
    627
  - Ignition Circuit
    628
  - Service Information
    629
  - Troubleshooting
    630
  - Ignition Coil Inspection
    631
  - Ignition Control Module
    632
  - Starting System Layout
    635
  - Starting Circuit
    636
  - Service Information
    637
  - Troubleshooting
    637
  - Starter Motor
    640
  - Starter Relay Switch/Starter Mag
    641
  - Recoil Starter Removal/Inspection/ Installation
    643
  - Recoil Starter Handle Replace
    645
  - Recoil Starter Disassembly/Inspection
    646
  - Assembly
    646
  - Starter Pulley Removal/Inspection/ Installation
    652
  - Starter Clutch Removal/Inspection/ Installation
    654
  - Service Information
    659
  - Bulbs Removal
    660
  - Horn (on Road)
    662
  - Ignition Switch
    663
  - Handlebar Switch
    663
  - Gear Indicator Switch
    666
  - Speed Sensor
    667
  - 2Wd/4Wd Selecting System
    668
  - Fuel Unit
    671

Advertisement

Advertisement

Related Products

KYMCO Categories

Scooter Offroad Vehicle Motorcycle Engine Wheelchair

More KYMCO Manuals