KYMCO 2006 MXU 500 Off-Road Owner's Manual

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OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

MXU 500

OFF-ROAD

Issued: 03.09.2006

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Page 1 OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. MXU 500 OFF-ROAD Issued: 03.09.2006...
Page 3: Important Notices
IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle. AGE RECOMMENDATION The minimum recommended age for this ATV model is 16. Children under age 16 should never operate this vehicle.
Page 4 SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol . Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.
Page 5 PREFACE Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service. For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.
Page 6: Table Of Contents
CONTENTS Page Page LOCATION OF THE WARNING AND CONTROL FUNCTIONS ....16 SPECIFICATION LABELS IGNITION SWITCH......16 ....1 INSTRUMENTS AND INDICATOR..17 Multi-function display.......19 HANDLEBAR SWITCHES....26 SAFETY INFORMATION ......4 Headlight dimmer switch....26 Start button........26 Engine stop switch......27 Passing signal switch.......27 DESCRIPTION AND MACHINE RIGHT HANDLEBAR SWITCH...28 IDENTIFICATION ........9...
Page 7 Page Page FRONT BRAKE LEVER.......32 PRE-OPERATION CHECKS.....43 DRIVE SELECT LEVER ......44 REAR BRAKE LEVER......32 Drive select lever adjustment....46 BRAKE PEDAL........32 FRONT AND REAR BRAKES....48 PARKING BRAKE.......33 FUEL..........49 DRIVE SELECT LEVER.......34 DRIVE SHAFT BOOTS......50 FUEL TANK CAP ........35 ENGINE OIL ........51 FINAL GEAR OIL........52 FUEL VALVE........35 DIFFERENTIAL GEAR OIL....52...
Page 8 Page Page OPERATION RIDING YOUR ATV ........58 ......71 STARTING A COLD ENGINE....58 GETTING TO KNOW YOUR ATV ..72 Using the recoil starter......61 RIDE WITH CARE AND GOOD STARTING A WARM ENGINE....62 JUDGEMENT........73 WARMING UP........62 APPAREL...........75 DRIVE SELECT LEVER OPERATION PRE-OPERATION CHECKS....79 AND REVERSE DRIVING ....63 Speed limiter........80 Shifting: neutral to high...
Page 9 Page Page RIDING DOWNHILL.......104 PERIODIC MAINTENANCE AND ADJUSTMENT CROSSING A SLOPE......106 ........113 TOOL KIT/ RIDING OVER ROUGH TERRAIN..108 TOOL KIT COMPARTMENT....113 CROSSING THROUGH SHALLOW PERIODIC MAINTENANCE/ WATER........109 LUBRICATION........115 PA R K I N G ........11 0 ENGINE OIL ........118 WHAT TO DO IF........111...
Page 10 Page Page COOLING SYSTEM INSPECTION..141 CLEANING AND STORAGE ...153 Engine overheating......143 A. CLEANING ........153 WHEEL REMOVAL......144 B. STORAGE ........155 WHEEL INSTALLATION.....144 BATTERY..........146 SPECIFICATIONS........157 Battery remove......147 Battery installation......147 NOISE REGULATION......161 FUSE REPLACEMENT......148 MAINTENANCE RECORD.......162 HEADLIGHT BEAM ADJUSTMENT..149 DRIVE SHAFT BOOTS.......149 INDEX...........163 CABLE INSPECTION AND LUBRICATION........150 TROUBLESHOOTING .......151...
Page 11: Location Of The Warning And Specification Labels
ATV. The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements. (A) (USA only)
Page 12 WARNING Never carry passenger WARNING This carrier. ： Maximum load 45 Kg (100 lbs) WARNING Operating this ATV if you are under NEVER ride as a the age of 16 increases your changes passenger. of severe injury or death. Passengers can cause a NEVER operate this ATV if you are loss of control, resulting...
Page 13 WARNING WARNING Improper ATV use can result in SEVERE IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. INJURY or DEATH. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE : Set with tires cold Recommended : FRONT : 25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi ALWAYS USE AN...
Page 14: Safety Information
SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. An accident can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre- cautions.
Page 15 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
Page 16 Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed.
Page 17 WARNING POTENTIAL HAZARD WHAT CAN HAPPEN Improper handling of gasoline. Gasoline is poisonous and can cause injuries. WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Gasoline can catch fire and you could be If you should swallow some gasoline or inhale burned.
Page 18 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation.
Page 19: Description And Machine Identification
DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION NUMBER RECORDS KEY IDENTIFICATION NUMBER Record the key identification number, frame The key identification number is stamped on serial number, engine serial number and the hang tag as shown in the following model code information for assistance when illustration.
Page 20: Frame Serial Number
FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the The engine serial number is stamped on the left front and rear of the frame. crankcase. (1) Frame serial number (1) Engine serial number...
Page 21: Parts Location
PARTS LOCATION (03) (02) (02) (01) (01) Rear brake lever (02) Headlights/Position lights (03) Front brake lever...
Page 22 (04) (07) (06) (05) (04) (04) Taillights/Brake lights (05) 2WD/4WD select switch (06) Instrument and indicators (07) Headlight dimmer switch Starter button Engine Stop Switch (08) Spark arrester (09) Trailer hitch (10) Throttle lever (08) (09) (10)
Page 23 (15) (14) (13) (12) (11) (11) Reservoir water tank (12) Front brake fluid reservoir (13) Fuel valve (14) Recoil starter (15) Seat (16) Brake pedal fluid reservoir (17) Seat lock lever (18) Oil level inspection window (16) (17) (18)
Page 24 (23) (22) (21) (20) (19) (19) Exhaust system ) Battery/Fuse (21) Tool kit (22) Accelerating pump lever (23) Rear brake fluid reservoir (24) Accessory socket seat (25) Drive select lever (24) (25)
Page 25 (30) (29) (28) (27) (26) (26 Right footpeg (27) Owner’s manual storage (28) Front cargo rack (29) Ignition switch (30) Left footpeg (31) Rear cargo rack (32) Fuel fill cap (33) Choke knob (34) Rear brake pedal (35) Flag pole bracket NOTE: The machine you have purchased may differ slightly from those shown in the figures of this...
Page 26: Control Functions
CONTROL FUNCTIONS IGNITION SWITCH Functions of the respective switch positions are as follows: OFF: All electrical circuits are switched off . The key can be removed in this position. ON : All electrical circuits are switched on. The engine can be started. The key can not be removed.
Page 27: Instruments And Indicator
INSTRUMENTS AND INDICATOR (1) Multi-function display The display includes the following functions: Speedometer Odometer/Tripmeter Digital clock 2WD/4WD indicator TRIP mile Fuel gauge MODE P R N H L (2) High beam indicator The ignition switch is at the " " position, the (10) high beam indicator will light when the headlight (6) (5)
Page 28 (3) Coolant temperature warning indicator (8) Reverse indicator light “R” When the coolant temperature reaches a This indicator light comes on when the drive specified level, this indicator comes on to select lever is in the “R” position. warn that the coolant temperature is too hot. If the indicator comes on during operation, (9) Park indicator light “P”...
Page 29: Multi-Function Display
Multi-function display (1) Speedometer Shows riding speed in km/h or mph. Press and hold MODE button for more than 2 seconds to select mph or km/h. TRIP mile TRIP mile MODE (1) Speedometer P R N H L (2) 2WD/4WD indicator (3) Fuel gauge (4) Odometer/Tripmeter (5) Digital clock...
Page 30 (2) 2WD/4WD indicator (3) Fuel gauge Shows the drive mode is in the 2WD or 4WD. The fuel gauge shows the approximate fuel supply available in a graduated display. The normal operating fuel range is with the section between the segment F and segment E.
Page 31 (4) Odometer/Tripmeter The odometer shows the total mileage in Km or in miles. The tripmeter shows the trip distance in Km or in miles. There are two tripmeters, tripmerer A and tripmeter B Press and hold SET button for more than 2 seconds to select ODO, TRIP A or TRIP B. Press and hold MODE button for more than 2 seconds to select mph or km/h.
Page 32 To reset tripmeter: 1. Press and hold SET button for more than 2 2. Press and hold both the MODE button and seconds to select tripmeter A or tripmeter SET button in the same time until the tripmeter is reset. TRIP TRIP mile...
Page 33 (5) Digital clock Show the time (hours and minutes) while the ignition is ON. To adjust the time manually, proceed as follows: 1. Turn the ignition switch ON. 2. Press and hold SET button for more than 2 mile seconds to select ODO mode. MODE 3.
Page 34 4. To set the hour, press the SET button until the 5. Press the MODE button, the minute display will desired hour. start flashing. mile mile MODE MODE P R N H L P R N H L...
Page 35 6. To set minute, press the SET button until the 7. To end the adjustment, Press both the MODE desired minute. button and SET button in the same time. mile mile MODE MODE P R N H L P R N H L...
Page 36: Handlebar Switches
HANDLEBAR SWITCHES (1) Headlight switch (2) Starter button Stater button Headlight dimmer switch To starter the engine, press the starter button, Turn the switch to the " " position to switch on with the transmission in neutral, the ignition the low beam. switch ON and the engine stop switch Turn the switch to the "...
Page 37: Engine Stop Switch
(3)Engine stop switch (4) Passing signal switch Engine stop switch Passing signal switch When the switch is in the RUN ( ) position, the When passing, if there are cars coming from the engine will operate. When the switch is in OFF opposite direction, press and release the ) position, the engine will not operate.
Page 38: Right Handlebar Switch
RIGHT HANDLEBAR SWITCH 2WD/4WD select switch This ATV is equipped with a 2WD/4WD select switch, which permits a choice between the “2WD” and “4WD” drive modes. Select a drive mode that is suitable for your riding. The 2WD/4WD select switch is located above the throttle lever.
Page 39: Recoil Starter
RECOIL STARTER The recoil starter is on the right side of the ATV. It is used to start the engine when the battery is low. See using the recoil starter (page 61) 1. Pull the grip up briskly and fully. 2.After the engine starts, put the grip back to original position and seal the hole.
Page 40: Throttle Lever
Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. (1) Throttle lever Consult a KYMCO dealer if you can't find or solve the problem yourself.
Page 41: Speed Limiter
SPEED LIMITER The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed WARNING to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle.
Page 42: Front Brake Lever
FRONT BRAKE LEVER BRAKE PEDAL The front brake lever is next to the right Operating the brake pedal applies the rear handgrip. brake. The front brakes are operated by squeezing the front brake lever. REAR BRAKE LEVER The rear brake is operated by squeezing the rear brake lever, near left handgrip.
Page 43: Parking Brake
PARKING BRAKE WARNING To set the parking brake, squeeze the front POTENTIAL HAZARD brake lever and lock it with the lock lever. Always set the parking brake when parking and before Improper use of the parking brake. starting the engine. To unlock the parking brake, squeeze the front WHAT CAN HAPPEN brake lever until the lock lever releases.
Page 44: Drive Select Lever
DRIVE SELECT LEVER The drive select lever is used to shift your ATV into the low, high, neutral, reverse and park positions. Refer to page 46 ~ 47 for drive select lever adjustment and operation. NOTE: Apply the rear brake and shift the shift lever into P position before turning off the engine when parking the vehicle on an incline if you park on an incline with shift lever in H, L or R...
Page 45: Fuel Tank Cap
FUEL TANK CAP FUEL VALVE After refueling, be sure to tighten the fuel tank The fuel valve supplies fuel from the fuel tank to cap until it clicks. the carburetor. The fuel valve has three positions. Insert the breather tube into the meter cover hole.
Page 46 OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever " " mark in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
Page 47: Choke Knob
CHOKE KNOB CAUTION: Starting a cold engine requires a richer air-fuel Extended use of the choke may impair piston mixture. A separate starter circuit supplies this and cylinder wall lubrication and shorten the mixture. life of the engine. Pushing the choke knob too hard to the OFF Move in direction (A) to turn on the choke knob.
Page 48: Accelerating Pump Lever
ACCELERATING PUMP LEVER The accelerating pump lever is on the carburetor right side under the seat. Starting a cold engine start-ambient temperature below -15 C (0 F) requires a richer air-fuel mixture. When the pump lever is pressed, the pump send the necessary amount of fuel to the fuel pipe for correcting fuel.
Page 49: Seat
To install the seat, align the tabs on the seat with SEAT the grommets on the frame and press the seat To remove the seat, pull the seat lock lever down until it locks. upward and pull up the seat at the rear. NOTE: Make sure that the seat is securely fitted.
Page 50: Flag Pole Bracket
Flag poles are optional equipment available The trailer hitch is located on the rear axle from your KYMCO dealer. To mount a flag pole housing. To use the hitch, you will need proper in the bracket to make you more visible.
Page 51: Owner's Manual Storage Compartment
OWNER’S MANUAL STORAGE COMPARTMENT Your ATV provides storage for the owner’s To open the compartment, remove the lid (3). manual so you’ll have it with you for easy The owner’s manual should be stored in the reference. Store your owner’s manual (1) in the plastic bag.
Page 52: Accessory Socket
ACCESSORY SOCKET The accessory socket (1) is attached to the left Be sure the engine is on and the headlights are side of the meter cover. You can use the turned off before using the accessory socket, accessory socket to power a trouble light, otherwise you may drain the battery.
Page 53: Pre-Operation Checks
PRE-OPERATION CHECKS Before using this machine, check the following points: ROUTINE PAGE ITEM ～ Check the lever for proper operation. 44 47 DRIVE SELECT LEVER Check operation, condition, and brake fluid level. ～ 48, 138 140 BRAKE Fill with DOT 4 brake fluid if necessary. Check fuel level.
Page 54: Drive Select Lever
DRIVE SELECT LEVER WARNING CAUTION: POTENTIAL HAZARD Before shifting, you must stop the machine Failure to inspect the ATV before operating. and return the throttle lever to its closed position until the engine speed to the Failure to properly maintain the ATV. specified idling speed.
Page 55 WARNING POTENTIAL HAZARD Operating with improperly adjusted drive select lever. WHAT CAN HAPPEN You may lose control of the gear shifting, which lead to accident. HOW TO AVOID THE HAZARD Make sure moving the shift lever into the "N" position and neutral indicator lamp comes on before start the engine.
Page 56: Drive Select Lever Adjustment
Drive select lever adjustment 1. Turn the ignition switch is ON and make sure 3. Loosen the locknuts (3) of rod (4). Shift the the engine stop. gear to neutral by moving the shift lever and/or turn the rod. (The neutral indicator 2.
Page 57 4.Turn the rod clockwise or counterclockwise until the drive select lever (5) into the "N" position of the shift guide and tighten the locknuts. (5) Drive select lever (N) Neutral...
Page 58: Front And Rear Brakes
If a problem performance, inspect the brakes for wear. cannot be corrected by the adjustment (See page 138~140.) procedures provided in this manual, have the ATV inspected by a KYMCO dealer.
Page 59: Fuel
FUEL Fill the fuel tank when necessary and make sure Your KYMCO engine has been designed to use there is sufficient gasoline in the tank. regular unleaded gasoline with a pump octane Check for leaks. number of 86 or higher, or research octane number of 91 or higher.
Page 60: Drive Shaft Boots
DRIVE SHAFT BOOTS Check the rubber drive shaft boots for damage or leaking grease. If necessary, have your KYMCO WARNING dealer replace them. POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.
Page 61: Engine Oil
ENGINE OIL CAUTION: Make sure the engine oil at the specified level. Be sure to use motor oils that do not contain Add oil as necessary. (See page 118~124.) anti-friction modifiers. Passenger car motor Check for leaks. oils (often labeled "Energy Conserving") contain anti-friction additives which will cause starter clutch slippage, resulting in reduced component life and poor engine...
Page 62: Final Gear Oil
FINAL GEAR OIL DIFFERENTIAL GEAR OIL Make sure the final gear oil at the specified Make sure the differential gear oil at the level. Add oil as necessary. (See page specified level. Add oil as necessary. (See page 125~126.) 127~128.) Check for leaks.
Page 63: Throttle Lever
Always check the tightness of chassis fittings engine stop switch and any other switches. and fasteners before a ride. Take the machine to Repair as necessary for proper operation. a KYMCO dealer or refer to the Service Manual for correct tightening torque.
Page 64: Tires
TIRES WARNING 2.The tires should be set to the POTENTIAL HAZARD recommended pressure: Operating this ATV with improper tires, or Recommended tire pressure with improper or uneven tire pressure. Front: 25~32 kpa (0.25~0.32 kgf/cm , WHAT CAN HAPPEN 3.5~4.5 psi) Use of improper tires on this ATV, or Rear: 25~32 kpa (0.25~0.32 kgf/cm ,...
Page 65: How To Measure Tire Pressure
How to measure tire pressure Use the low-pressure tire gauge. (Tool kit) 4.Higher pressures may cause the tire to NOTE: burst. Inflate the tires very slowly and The low-pressure tire gauge is included as carefully. Fast inflation could cause the standard equipment.
Page 66: Tire Wear Limit
COOLANT Check the coolant level in the reservoir tank Tire wear limit when the engine is cold. (The coolant level will When the tire groove decreases to 4 mm (0.16 vary with engine temperature.) The coolant in) due to wear, replace the tire. level is satisfactory if it is between the "FULL"...
Page 67 (2) Maximum level mark the radiator cap. Always use a thick rag (3) Minimum level mark over the cap. Allow any remaining pressure to escape before completely removing the cap. Should be serviced by your authorized KYMCO dealer when changing the coolant.
Page 68: Operation
When riding in cold weather, always make is a control or function you do not sure all control cables work smoothly understand, ask your KYMCO dealer. before you begin riding. 1. Set the parking brake . 2. Turn the fuel valve to "ON".
Page 69 5. Use the accelerating pump if the cold engine start-ambient temperature below -15 C (0 F). Using the accelerating pump: Remove the seat (page 39) , then press the accelerating pump lever twice. (1) Accelerating pump...
Page 70 When the select lever is in the neutral or park position, if either indicator light does not come on, ask a KYMCO dealer to inspect its electric circuit. 6. Use the choke knob in reference to the figure: 1.
Page 71: Using The Recoil Starter
NOTE: Using the recoil starter If the engine fails to start, release the start The recoil starter is used to start the engine switch, then push the start switch again. when the battery is low. Each cranking should be as short as possible to preserve battery energy.
Page 72: Starting A Warm Engine
CAUTION: To start the engine without the electric starter: See the "engine break-in" section prior to operating engine for the first time. 1. Follow steps 1 through 6. 2. With the throttle closed, grasp the starter grip firmly, then pull it out slowly until it seats STARTING A WARM ENGINE lightly.
Page 73: Drive Select Lever Operation And Reverse Driving
DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING CAUTION: Before shifting, you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed. Otherwise, the transmission may be damaged. NOTE: (1) Drive select lever (L) Low Apply the rear brake and shift the shift lever...
Page 74: Shifting: Neutral To Reverse And Reverse To Park
NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a KYMCO dealer to inspect the machine. WARNING POTENTIAL HAZARD 4. Check behind for people or obstacles, then Improperly operation in reverse.
Page 75: Engine Break-In
If any abnormality is noticed during this period, consult a KYMCO dealer.
Page 76: Parking
PARKING When parking, stop the engine and shift into the park position. Turn the fuel valve to "OFF" and apply the parking brake. The front brake lever has three locked position that allow it to be used as a parking brake. To set the parking brake, see page 33 (1) Locked position...
Page 77: Parking On A Slope
Parking on a slope 1. Bring the machine to a stop by applying the brakes. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the brake applied, shift the drive select lever into the park position Parking on a hill or other incline. 4.
Page 78: Accessories
Choose only accessories designed for your difficult, an accessory that limits your ability ATV. Your KYMCO dealer has a variety of to move around on the seat, or one that limits genuine KYMCO accessories. Other your view.
Page 79: Loading
LOADING As originally equipped, this ATV can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: Never exceed the weight limit shown. An overloaded ATV can be unstable. Maximum load Rear cargo rack: 85 kg (187 lbs) Front cargo rack: 45 kg (100 lbs) Trailer...
Page 80 Load cargo on the cargo racks as close to the WARNING center of the vehicle as possible. Put cargo at POTENTIAL HAZARD the rear of the front cargo rack and at the front Overloading this ATV or carrying or towing of the rear cargo rack .
Page 81: Riding Your Atv
Riding Your ATV...
Page 82: Getting To Know Your Atv
WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This Before you begin to ride, be sure you have read section, riding your ATV, provides general ATV this Owner's manual completely and understand riding instructions for recreational riding.
Page 83: Ride With Care And Good Judgement
RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners and inexperienced riders should get proper instruction on how to operate this ATV. WARNING POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without proper Become familiar with this ATV at slow instruction.
Page 84 Not recommended for children under 16 year of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
Page 85: Apparel
APPAREL WARNING POTENTIAL HAZARD Operating without protective clothing Operating this ATV without wearing an increases your chances of severe injury in approved motorcycle helmet, eye the event of an accident. protection and protective clothing. HOW TO AVOID THE HAZARD WHAT CAN HAPPEN Always wear an approved motorcycle Operating without an helmet that fits properly.
Page 86 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator's performance capability is reduced by Operating this ATV after consuming the influence of alcohol or drugs. alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.
Page 87 This machine is designed to carry operator only-passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.
Page 88 Never carry passenger on the cargo racks WARNING POTENTIAL HAZARD Carrying a passenger on the cargo racks WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.
Page 89: Pre-Operation Checks
PRE-OPERATION CHECKS Always perform the pre-operation checks listed page 43 before riding for safety and proper WARNING care of the machine. POTENTIAL HAZARD Operating this ATV with improper tires, or WARNING with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before operating.
Page 90: Speed Limiter
Do not operate at speeds too fast your skills Speed limiter or the conditions. For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits WARNING the power and top speed of the machine. POTENTIAL HAZARD Turning the screw in decreases top speed, and Operating this ATV at speeds too fast for...
Page 91: Loading And Accessories
LOADING AND ACCESSORIES Loading and Operational Guidelines Load Limits This ATV is not designed to carry or tow a trailer. There are limits to how much weight can be If you decide to add accessories to allow you to carried on your ATV. carry cargo or tow a trailer, use common sense.
Page 92: Accessories
WARNING Genuine KYMCO accessories have been specifically designed for and tested on this POTENTIAL HAZARD vehicle. Because KYMCO cannot test all other Overloading this ATV or carrying or towing accessories, you are personally responsible for cargo improperly. properly selecting, installing, and using non- KYMCO accessories.
Page 93: Modifications
Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction. If you have question, consult...
Page 94: Exhaust System
EXHAUST SYSTEM The exhaust on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system...
Page 95: Be Careful Where You Ride
BE CAREFUL WHERE YOU RIDE This machine is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATV are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
Page 96 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
Page 97 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the machine to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
Page 98 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary...
Page 99 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the machine. DO NOT use the flag pole bracket as a trailer hitch. WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles.
Page 100: For Off-Road Use Only
FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. Do not ride in areas posted "no trespassing". Do not ride on private property without getting permission.
Page 101 Select a large, flat area off-road to become With the engine idling, return the starter knob to familiar with your ATV. Make sure that this area the closed position and shift the drive select is free of obstacles and other riders. You should lever into the forward position.
Page 102: During Operation
DURING OPERATION WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the Removing hands from handlebars or feet rear wheels. from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg, your foot or leg may come...
Page 103 Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.
Page 104: Turning Your Atv
TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner's on one axle and turn together at the same Manual.
Page 105 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
Page 106: Sliding And Skidding
SLIDING AND SKIDDING If the rear wheels of your ATV start to slide sideways, control can usually be regained (if Care should be used when riding on loose or there is room to do so) by steering in the slippery surfaces since the ATV may slide. If direction of the slide.
Page 107 With practice, over a period of time, skill at WARNING controlled sliding can be developed. The terrain POTENTIAL HAZARD should be chosen carefully before attempting Skidding or sliding improperly. such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on WHAT CAN HAPPEN extremely slippery surfaces such as ice, since...
Page 108: Climbing Uphill
CLIMBING UPHILL WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on hills. Be sure that you can Operating on excessively steep hills. maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
Page 109 An obstacle, a sharp drop, or another WARNING vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual.
Page 110 If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make it Always follow proper procedures as to the top, you should turn the ATV around while described in the Owner's Manual.
Page 111 If your ATV has stalled or stopped and you WARNING believe you can continue up the hill, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improperly wheels which could cause you to lose control. If dismounting while climbing a hill.
Page 112 If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD: Apply both front and rear brakes gradually. When fully stopped, shift to the parking position “P”. Dismount on uphill side or to a side if pointed straight uphill.
Page 113 If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV . If you decide you can walk the ATV safely: 1.
Page 114: Riding Downhill
RIDING DOWNHILL When riding your ATV downhill, shift your weight When this ATV is in 4WD, all wheels (front and as far to the rear and uphill side of the ATV as rear) are interconnected by the drive train. This possible.
Page 115 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner's Manual. Note: a special technique is required when braking as you go down a hill.
Page 116: Crossing A Slope
CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV POTENTIAL HAZARD requires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you have hills. learned the basic riding skills on flat ground before attempting to cross a sloping surface.
Page 117 Shift your weight to the uphill side of the ATV.
Page 118: Riding Over Rough Terrain
RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet WHAT CAN HAPPEN firmly mounted on the footboards at all time.
Page 119: Crossing Through Shallow Water
CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have The ATV can be used to cross slow moving, reduced stopping ability. Test your brakes shallow water of up to a maximum of 20 cm (7.9 after leaving water. If necessary, apply inches) in depth.
Page 120: Pa R K I N
Test your brakes after leaving the water. Do not PARKING continue to ride your ATV without verifying that Always choose a level place to park. After you have regained proper braking ability. bringing your ATV to a stop, hold the brakes while you shift into neutral.
Page 121: What To Do If
WHAT TO DO IF If your ATV starts to slide sideways: This section is designed to be a reference guide Steer in the direction of the slide if you have the only. Be sure to read each section on riding room.
Page 122 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.
Page 123: Periodic Maintenance And Adjustment
Have KYMCO dealer perform service if you PERIODIC MAINTENANCE AND are not familiar with machine service. ADJUSTMENT Periodic inspection, adjustment and lubrication TOOL KIT/TOOL KIT COMPARTMENT will keep your machine in the safest and most The tool kit is stored in the tool kit compartment efficient condition possible.
Page 124 The tools in the kit are sufficient to perform WARNING routine maintenance and simple repairs. Any POTENTIAL HAZARD extensive work requiring additional tools should be performed by your authorized KYMCO Operating this ATV with improper dealer. modifications. The tool kit includes the following items:...
Page 125: Periodic Maintenance/Lubrication
PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH ! Replace (Warm engine before draining). Engine oil Clean. *Oil strainer Replace if necessary. Engine oil filter cartridge ! Replace Check oil level/oil leakage Final gear oil Replace every 12 months.
Page 126 INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH Check operation and brake fluid. *Brake Replace brake pad if necessary. Check coolant leakage. Replace if necessary. *Coolant Replace coolant every 24 months. Check operation. *V-belt Replace if damage or excessive wear. Check leakage.
Page 127 *Knuckle shafts/ ! Lubricate every 6 months. Steering shaft Check all chassis fittings and fasteners. *Fittings and Fasteners Correct if necessary. : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.
Page 128: Engine Oil
ENGINE OIL 1.Engine oil level measurement A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Check the oil level through the inspection window. D. The oil level should be between the maximum (H) and minimum (L) marks.
Page 129 2-1. Engine oil replacement and oil filter cleaning A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil fill cap (1) and oil filter cap (2) to drain the oil.
Page 130 H. Fill the engine with oil and install the oil fill E. Clean the oil strainer with solvent. cap. F. Inspect the O-ring and replace if damaged. G. Reinstall the O-ring, oil strainer, compression Recommended oil: see page 158 spring and oil filter cap. Tighten the oil filter Oil quantity: cap to specification.
Page 131 2-2. Engine oil replacement (with or without oil filter cartridge replacement) A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil fill cap (1) and drain plug (2) to drain the oil.
Page 132 NOTE: Skip steps E to I if the oil filter cartridge is not being replaced. E. Remove the three fasteners (3) and then remove right side cover (4). F. Remove the oil filter cartridge (5) with an oil cartridge wrench. (3) Fasteners (4) Right side cover (5) Oil filter cartridge...
Page 133 G. Apply a light coat of clean engine oil to the O-ring (6) of the new oil filter cartridge. NOTE: An oil cartridge wrench is available at a nearby KYMCO dealer NOTE: Make sure the O-ring is seated properly. H. Install the new oil filter cartridge with an oil...
Page 134 I. Install right side cover. L. Start the engine and warm it up for several minutes. While warming up, check for oil J. Reinstall the drain plug and tighten the leakage. If oil leakage is found, turn the drain plug to specification. engine off immediately and check for the cause.
Page 135: Final Gear Oil
FINAL GEAR OIL Change the oil in the final gear case when specified by the Maintenance Schedule. Change the oil with the final gear case warm, and the ATV on level ground to assure complete and rapid draining. Final gear oil replacement 1.
Page 136 3. Remove the oil filler cap (5), then remove 7. Install the skid plate. the drain plug/washer. 4. After the oil has completely drained, reinstall the drain plug/washer. CAUTION: Tightening torque Drain plug: 20 N-m (2 kgf-m, 15 lbf-ft) Be sure no foreign material enters the gear case.
Page 137: Differential Gear Oil
DIFFERENTIAL GEAR OIL Change the oil in the differential gear case when specified by the Maintenance Schedule. Change the oil with the differential gear case warm, and the ATV on level ground to assure complete and rapid draining. Differential gear oil replacement 1.
Page 138 3. Remove the drain plug. 4. After the oil has completely drained, reinstall the drain plug/washer. Tightening torque Drain plug: 32 N-m (3.2 kgf-m, 23 lbf-ft) 5. Fill the gear case with the recommended oil. CAUTION: Recommended oil : SAE 90 Be sure no foreign material enters the gear Oil quantity : case.
Page 139: Spark Plug Inspection
Do not attempt to diagnose such problems yourself. Instead, take the machine to a KYMCO dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
Page 140: Spark Arrester
SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the three bolts (1), the spark arrester (2) and the gasket (3) from the muffler. (1) Bolts (2) Spark arrester (3) Gasket...
Page 141 WARNING 3. Use a brush to remove carbon deposits from POTENTIAL HAZARD the spark arrester screen. Be careful to avoid Improper cleaning of the spark arrester. damaging the spark arrester screen. The Hot exhaust system. spark arrester must be free of breaks and holes.
Page 142: Air Filter Cleaning
AIR FILTER CLEANING The air cleaner accumulates dust and must be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule. If the ATV is submerged in water, the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine.
Page 143 (10) (11) 5. Remove the outer air cleaner (7). 6. Remove the screw/washers (6) and remove the air cleaner assembly from the air cleaner holder (8). 7. Remove the inner air cleaner (9) and air cleaner screen (10) from the air cleaner guide (11).
Page 144 9. Gently wash the air cleaner in clean, non- 10. Soak the air cleaner an equivalent (gear oil: flammable (high flash point) solvent such as SAE 80 - 90) until saturated, then squeeze out ─ kerosene not gasoline. Allow the air cleaner the excess oil.
Page 145: Air Cleaner Housing Drain Tube
AIR CLEANER HOUSING DRAIN TUBE The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle.
Page 146: Idle Speed Adjustment
IDLE SPEED ADJUSTMENT NOTE: A diagnostic tachometer must be used for this procedure. 1. Remove the seat (see page 39) 2. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min.
Page 147: Throttle Lever Adjustment
THROTTLE LEVER ADJUSTMENT NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. To adjust throttle free play: 1. Slide the rubber sleeve (1) back to expose the throttle cable adjuster (2). 2. Loosen the lock nut (3), then turn the adjuster to obtain the correct free play.
Page 148: Valve Clearance Adjustment
If the be adjusted regularly. This adjustment however, indicator reaches the wear limit line, ask a should be left to a professional KYMCO service KYMCO dealer to replace the pads. technician. (1) Wear indicator...
Page 149: Rear Brake Pads Inspection
If the indicator reaches the wear limit line, ask a WARNING KYMCO dealer to replace the pads. POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation.
Page 150 (1) Lower level mark (Foot brake pedal) (1) Lower level mark (Hand brake lever) (2) Upper level mark (Foot brake pedal)
Page 151: Cooling System Inspection
(page 138~139) , There is probably air in the brake system and it must be bled. See your authorized KYMCO dealer for this service. CAUTION: To prevent damage to the brake system, use (1) Fasteners only fluid from a sealed container.
Page 152 You may use distilled water if rou NOTE: can not get soft water. 1. If water is added, have a KYMCO dealer check the antifreeze content of the coolant as soon as possible. 2. The radiator fan operation is completely automatic.
Page 153: Engine Overheating
Should be serviced by your authorized KYMCO dealer when changing the coolant. Restart the engine. If the engine overheats again, ask a KYMCO dealer to inspect and/or repair the cooling system NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it...
Page 154: Wheel Removal
WHEEL REMOVAL WHEEL INSTALLATION 1. Elevate the wheel by placing a suitable stand When reinstalling a wheel, tighten the wheel under the frame. nuts in a crisscross (rather than a circular) 2. Remove the nuts from the wheel. pattern. Be sure the tapered side of the wheel 3.
Page 155 NOTE: WARNING The arrow mark on the tire must point POTENTIAL HAZARD toward the rotating direction of the wheel. Installing wheels improperly. WHAT CAN HAPPEN A wheel may come loose, possibly leading to an accident. HOW TO AVOID THE HAZARD Carefully follow the instructions in this Owner's Manual when installing.
Page 156: Battery
If battery. the battery seems weak, see your authorized KYMCO dealer for information on recharging or WHAT CAN HAPPEN Gases may explode and possibly cause replacement. If you replace the battery, choose one injury.
Page 157: Battery Remove
Battery remove 1. Make sure the ignition switch is OFF. 2. Remove the seat (page 39) 3. Release the rings and remove the rubber band (1). 4. Disconnect the negative (-) terminal lead (2) from the battery first, then disconnect the positive (+) terminal lead (3).
Page 158: Fuse Replacement
FUSE REPLACEMENT 2. Remove the seat (page 39) The fuse box (1) stored in the battery 3. Open the fuse box cap (2). compartment under the seat. 4. Pull the old fuse out of the fuse holder. To replace a fuse: 5.
Page 159: Headlight Beam Adjustment
DRIVE SHAFT BOOTS Check the protective boots for holes or tears. CAUTION: If any damage is found, have them replaced by a It is advisable to have a KYMCO dealer make KYMCO dealer this adjustment. To adjust: Turn the ignition switch at "...
Page 160: Cable Inspection And Lubrication
Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a KYMCO dealer to replace them. Recommended lubricant: KYMCO chain and cable lube or SAE 10W40 motor oil...
Page 161: Troubleshooting
The troubleshooting chart describes a WHAT CAN HAPPEN quick, easy procedure for making checks. If your Fuel can ignite or explode, causing severe machine requires any repair, take it to a KYMCO dealer. injury or property damage. HOW TO AVOID THE HAZARD...
Page 162: Troubleshooting Chart
Check fluid, recharge, check connections. over slowly. Use electric starter. Engine turns Battery good. over quickly. Ask a KYMCO dealer to inspect. 3. Ignition Wipe clean with dry Adjust plug gap or cloth. Remove plug and No spark. replace plug.
Page 163: Cleaning And Storage
CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend the bills have resulted from improper high useful life of many components.
Page 164 7. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after washing. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid WHAT CAN HAPPEN combination cleaner-waxes.
Page 165: Storage
B. STORAGE WARNING Before storing your ATV for an extended time, be POTENTIAL HAZARD sure you thoroughly check the vehicle for Refueling this ATV or handling fuel needed repairs and have them corrected. improperly. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage.
Page 166 4. Remove the battery (page 147) And store it in WARNING an area protected from freezing temperatures POTENTIAL HAZARD and direct sunlight and out of the reach of Prolonged contact of fuel with the skin. children, slow charge the battery once a Breathing fuel vapor.
Page 167: Specifications
SPECIFICATIONS MXU 500 Model Dimension: Overall length 2203 mm (88.12 in) Overall width 1223 mm (48.92 in) Overall height 1240 mm (49.6 in) Seat height 857 mm (34.28 in) Wheel base 1293 mm (51.72 in) Minimum ground clearance 235 mm (9.4 in) Minimum turning radius 3350 mm (134 in) Basic weight:...
Page 168 MXU 500 Model 110 F Engine oil/transmission oil/ rear final gear case oil: SAE 5W － SAE 10W 30 Type － SAE 10W 40 Engine oil classification: － SAE 20W 40 － SAE 20W 50 -1 0 40 C API Service SJ type or higher SEA#80 Final gear oil classification: SAE #90...
Page 169 MXU 500 Model Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED FUEL Tank capacity 17 L (3.57 lmp gal, 4.42 US gal) Reserve amount 2.3 L (0.48 lmp gal, 0.6 US gal) Carburetor: Type Spark plug:...
Page 170 MXU 500 Model Suspension: Front Double wishbone Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system A.C. magneto Battery type 12V, 18AH Tire: Type Tubeless Size: Front 25X8-12 Rear 25X10-12 Bulb voltage, wattage*quantity: Headlight 12V35W/35W X2...
Page 171: Noise Regulation
NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Some local laws and regulations prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Page 172: Maintenance Record
MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
Page 173: Index
INDEX Page Page ACCELERATING PUMP LEVER....38 CABLE INSPECTION AND ACCESSORIES......68, 81, 82 LUBRICATION........150 ACCESSORY SOCKET......42 CHOKE KNOB.........37 AGE RECOMMENDATION......A CLEANING..........153 AIR CLEANER HOUSING DRAIN CLIMBING UPHILL........98 TUBE............135 CONTENTS..........D AIR FILTER CLEANING ......132 CONTROL FUNCTIONS......16 APPAREL..........75 COOLANT..........56 Coolant temperature warning indicator..18 COOLING SYSTEM INSPECTION..141 BATTERY..........146...
Page 174 Page Page ENGINE BREAK-IN........65 IDLE SPEED ADJUSTMENT ....136 ENGINE OIL........51,118 IGNITION SWITCH........16 ENGINE OVERHEATING......143 IMPORTANT NOTICES......A ENGINE SERIAL NUMBER...... 10 INSTRUMENTS AND INDICATOR....17 ENGINE STOP SWITCH......27 EXHAUST SYSTEM.........84 HANDLEBAR SWITCHES.....26, 31 HEADLIGHT BEAM ADJUSTMENT ..149 Headlight dimmer switch......26 FINAL GEAR OIL........52, 125 High beam indicator.........
Page 175 Page Page KEY IDENTIFICATION NUMBER..... 9 Odometer ..........21 OPERATION ........... 58 OWNER’S MANUAL LIGHTS...........53 .... 4 1 STORAGE COMPARTMENT LOADING........... 69, 81 Low-range indicator light......18 LUBRICATION ........115, 150 Park indicator light........18 PARKING ......... 66, 110 PARKING BRAKE........33 MAINTENANCE RECORD......83 Parking on a slope ........
Page 176 Page Page THROTTLE LEVER......30, 53 RECOIL STARTER......29, 61 THROTTLE LEVER ADJUSTMENT..137 Reverse indicator light.......18 TIRES.............54 RIDING DOWNHILL........104 Tire wear limit.......... 56 RIDING YOUR ATV........71 RIGHT HANDLEBAR SWITCH....28 TOOL KIT..........113 2WD/4WD select switch......28 TRAILER HITCH........40 Tripmeter..........21 TROUBLESHOOTING ......151 Troubleshooting chart ......152 SAFETY INFORMATION......4 TURNING YOUR ATV........94 SEAT............
Page 177 KWANG YANG MOTOR CO.,LTD. NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. First Edition, Mar 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.
Page 180 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN NEVER USE NEVER CARRY NEVER USE APPROVED HELMET ON PUBLIC PASSENGERS WITH DRUGS AND PROTECTIVE ROADS OR ALCOHOL GEAR NEVER operate : Without proper training or instruction. At speeds too fast for your skills or the conditions.
Page 181 MXU 500 By KWANG YANG Motor Co., Ltd. First Edition, May 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100LAA001...
Page 182 The information and contents included in this manual may be different from the WIRING DIAGRAMS vehicle in case specifications are changed. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation. KWANG YANG MOTOR CO., LTD.
Page 183 . GENERAL INFORMATION MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER---------------------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 3 TORQUE VALUES --------------------------------------------------------- 1-11 SPECIAL TOOLS ----------------------------------------------------------- 1-15 LUBRICATION POINTS -------------------------------------------------- 1-19 CABLE & HARNESS ROUTING ---------------------------------------- 1-21 TROUBLESHOOTING----------------------------------------------------- 1-35...
Page 184: Serial Number
. GENERAL INFORMATION MXU 500 SERIAL NUMBER (1) Location of Frame Serial Number (1) Location of Engine Serial Number...
Page 185: Specifications
. GENERAL INFORMATION MXU 500 SPECIFICATIONS Forced pressure & Lubrication type Model No. LAA0 Wet sump Name & Type MXU 500 Oil pump type Trochoid Overall length 2203 mm (88.12 in) Oil filter type Full-flow filtration Overall width 1223 mm (48.92 in) 3.6 L (3.17 lmp qt, Oil capacity Overall height...
Page 186: Service Precautions
. GENERAL INFORMATION MXU 500 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 187 . GENERAL INFORMATION MXU 500 Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
Page 188 . GENERAL INFORMATION MXU 500 If the fuse is burned out, find the cause and Confirm repair it. Replace it with a new one Capacity according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
Page 189 . GENERAL INFORMATION MXU 500 The connector shall be inserted completely. If the double connector has a lock, lock it Snapping! at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 190 . GENERAL INFORMATION MXU 500 After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 191 . GENERAL INFORMATION MXU 500 Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 192 . GENERAL INFORMATION MXU 500 After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the...
Page 193 . GENERAL INFORMATION MXU 500 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Engine Oil : Apply grease for lubrication. Grease : Transmission Gear Oil (90#) Gear Oil...
Page 194: Torque Values
. GENERAL INFORMATION MXU 500 TORQUE VALUES STANDARD TORQUE VALUES Torque Torque Item Item kgf-m (N-m, lbf-ft) kgf-m (N-m, lbf-ft) 5mm bolt and nut 0.5 (5, 3.6) 4mm screw 0.3 (3, 2.2) 6mm bolt and nut 1 (10, 7.2) 0.4 (4, 2.9) 5mm screw 8mm bolt and nut 2.2 (22, 16)
Page 195 . GENERAL INFORMATION MXU 500 Thread dia. Torque Item Q‘ty Remarks (mm) kgf-m (N-m, lbf-ft) CYLINDER HEAD: Cylinder head bolt 4.8 (48, 34.6) Apply oil Cylinder head bolt 2.3 (23, 17) Apply oil Cylinder head nut 1 (10, 7) Cylinder head cover 1 (10, 7) Breather separator bolt 1.3 (13, 9)
Page 196 . GENERAL INFORMATION MXU 500 FRAME Thread Torque Item Q‘ty Remarks dia. Kgf-m (N-m, (mm) lbf-ft) MAINTENANCE: Rear drive gear oil drain bolt 2 (20, 15) Rear drive gear oil filler cap 1.5 (15, 11) Rear drive gear oil level check bolt 2 (20, 15) Front drive gear oil drain bolt 3.2 (32, 23)
Page 197 . GENERAL INFORMATION MXU 500 Thread Torque Item Q‘ty Remarks dia. Kgf-m (N-m, (mm) lbf-ft) STEERING SYSTEM: Handlebar holder bolt 2.5 (25, 18) Steering bracket 2.2 (22, 16) Steering column nut 7 (70, 50) Tie-rod ball joint nut 2.1 (21, 16) Castle nut WHEEL: Front wheel nut...
Page 198: Special Tools
. GENERAL INFORMATION MXU 500 SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Oil seal and bearing A120E00014 installer Valve adjuster A120E00036 (Refer to the “VALVE CLEARANCE”...
Page 199 . GENERAL INFORMATION MXU 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Driven pulley holder (Refer to the “DRIVEN PULLEY A120E00059 DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 10.) Flywheel puller (Refer to the “STARTER...
Page 200 . GENERAL INFORMATION MXU 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) A120E00068 Crankshaft bearing puller Ball joint remover (Refer to the “STEERING KNUCKLE REMOVAL/ A120F00012 INSPECTION/ INSTALLATION”...
Page 201 . GENERAL INFORMATION MXU 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Pinion bearing lock nut wrench (Refer to the “REAR DRIVE A120F00020 DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 13.) Pinion puller (Refer to the “REAR DRIVE...
Page 202: Lubrication Points
MXU 500 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE5W-50) Camshaft protruding surface API SJ Engine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt Piston surroundings and piston ring grooves...
Page 203 . GENERAL INFORMATION MXU 500 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the ATV. Steering Column Upper Throttle Cable Front Swing Arm Bush...
Page 204: Cable & Harness Routing
. GENERAL INFORMATION MXU 500 CABLE & HARNESS ROUTING ＊ Remove the fuel tank and fuel valve together (refer to the “FUEL TANK” section in the chapter 5). ＊ Remove the front cooling duct (refer to the “ENGINE REMOVAL” section in the chapter 7).
Page 205 . GENERAL INFORMATION MXU 500 (1) Throttle cable (7) Brake light switch wire (2) Instrument connector (8) Rear brake hose (Brake lever) (3) Ignition switch wire (9) 2WD/4WD switch wire (4) Accessory socket connectors (10) Choke cable (5) Left handlebar switch (11) Front brake hose (6) Rear parking brake cable (ON ROAD) (12) Brake light switch wire...
Page 206 . GENERAL INFORMATION MXU 500 (1) Fan EMI filter (12) Ignition coil wire (2) Headlight connector (13) 2WD /4WD start switch Right front signal light connectors (ON ROAD) /2WD/4WD motor connectors (3) Harness wire (14) Left handlebar switch connectors (4) Siphon hose (15) Upper radiator hose (5) Over flow hose (Reserve tank) (16) Headlight connector...
Page 207 . GENERAL INFORMATION MXU 500 (1) Fuel tank flow hose (connect the fuel tank cover, Note) (5) Crankcase breather hose (2) Hazard connector (ON ROAD) (6) Over flow (carburetor) (3) Harness wire (7) Water temperature sensor wire (4) Throttle cable (8) Choke cable (A) Pass the harness wire through the band.
Page 208 . GENERAL INFORMATION MXU 500 (1) Over flow (carburetor) (7) Gear position light switch (2) Crankcase breather hose (8) Speed sensor wire (3) Crankcase breather hose (9) Speed sensor (4) Harness wire (10) Engine ground cable (5) Crankcase breather hose joint (11) Fuel hose (6) Starter motor cable (12) AICV air supply hose...
Page 209 . GENERAL INFORMATION MXU 500 (1) Upper radiator hose (10) Rear parking brake cable (ON ROAD) (2) Ignition coil wire (11) Front brake hose (3) Air bleed hose (12) 2WD /4WD start switch//2WD/4WD motor connectors (4) Air bleed hose (13) Thermostat (5) Ignition coil (14) Fan motor switch (6) Water hose...
Page 210 . GENERAL INFORMATION MXU 500 (1) Air bleed hose (7) Water joint (2) Upper radiator hose (8) Rear brake hose (Brake lever) (3) Air bleed hose (9) Rear parking brake cable (ON ROAD) (4) AICV control solenoid valve (10) Water hose (5) Water bypass hose (11) Thermostat (6) Air bleed hose...
Page 211 . GENERAL INFORMATION MXU 500 (1) Rear brake hose (Brake pedal) (3) Rear brake hose (Brake lever) (2) Rear parking brake cable (ON ROAD) Pass the rear parking brake cable (ON ROAD) and rear brake hose (Brake lever) through the guide (A), (B), (C), band (D) and guide (E).
Page 212 . GENERAL INFORMATION MXU 500 (1) Rear caliper (Brake pedal) (5) Speed sensor (2) Rear caliper (Brake lever) (6) Speed sensor wire (3) Rear parking brake cable (ON ROAD) (7) Rear brake hose (Brake pedal) (4) Rear brake hose (Brake lever) (A) Pass the speed sensor wire through the guide.
Page 213 . GENERAL INFORMATION MXU 500 (1) Regulator/Rectifier (10) Fan motor connector (2) Hazard connector (ON ROAD) (11) Low radiator hose (3) Flasher relay (ON ROAD) (12) EMI filter (4) Instrument wire (13) Front brake hose (5) Over flow hose (reserve tank) (14) Horn (ON ROAD) (6) Siphon hose (15) Fuel flow hose...
Page 214 . GENERAL INFORMATION MXU 500 (1) Low radiator hose (3) Combined brake hose (ON ROAD) (2) Water bypass hose (4) Front brake hose (A) Pass the front brake hose (combined) and water bypass hose through the guide. (B) Pass the front brake hose through the guide. 1-31...
Page 215 . GENERAL INFORMATION MXU 500 (1) Harness wire (8) Water hose (2) Over flow (carburetor) (9) Low radiator hose (3) Crankcase breather hose (10) Water bypass hose (4) Fuel unit connectors (11) Combined brake hose (ON ROAD) (5) Fuel hose (12) AICV vacuum hose (Note) (6) AICV air supply hose (13) A.C.G.
Page 216 . GENERAL INFORMATION MXU 500 (1) Starter motor cable (8) Brake light switch (2) Engine ground cable (9) Speed sensor wire (3) Clutch diode (10) Rear brake hose (Brake pedal) (4) Harness wire (11) Rear brake hose (Brake pedal) (5) Combined brake hose (ON ROAD) (12) Rear caliper (Brake pedal) (6) Gear position light switch (13) Speed sensor...
Page 217 . GENERAL INFORMATION MXU 500 (1) Taillight/Brake light/Rear turn signal light connectors (OFF ROAD) (1) Taillight/Brake light/Rear turn signal light connectors (ON ROAD) (2) License light connector (ON ROAD) (3) Fuse box (4) Ignition unit (5) Starter MAG (6) Starter relay (7) Positive terminal lead (8) Negative terminal lead (9) Frame ground wire...
Page 218: Troubleshooting
. GENERAL INFORMATION MXU 500 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel reaches Fuel does not Clogged fuel tank cap breather...
Page 219 . GENERAL INFORMATION MXU 500 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Restricted fuel flow Engine speed does not Engine speed Clogged fuel tank cap breather hole increase sufficiently increases Clogged exhaust muffler Carburetor fuel level too low Check ignition timing...
Page 220 . GENERAL INFORMATION MXU 500 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Incorrect timing Correct timing Faulty pulser coil Check carburetor air screw adjustment Mixture too rich (turn screw Correctly adjusted Incorrectly adjusted out)
Page 221 . GENERAL INFORMATION MXU 500 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat Check fuel pump for fuel supply Empty fuel tank...
Page 222 . GENERAL INFORMATION MXU 500 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
Page 223 . GENERAL INFORMATION MXU 500 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose Loose spark plug cap...
Page 224 . FRAME COVERS/EXHAUST MUFFLER MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 2 TROUBLESHOOTING----------------------------------------------------- 2- 2 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 3 FRAME COVERS ----------------------------------------------------------- 2- 4 EXHAUST MUFFLER ----------------------------------------------------- 2-13...
Page 225 . FRAME COVERS/EXHAUST MUFFLER MXU 500...
Page 226: Service Information
. FRAME COVERS/EXHAUST MUFFLER MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler mounting bolt 3.5 kgf-m (35 Nm, 25 lbf-ft) Exhaust pipe mounting nut...
Page 227: Fastener Removal And Reinstallation
. FRAME COVERS/EXHAUST MUFFLER MXU 500 FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls close. Insert the fastener into the installation hole. ＊...
Page 228: Frame Covers
. FRAME COVERS/EXHAUST MUFFLER MXU 500 FRAME COVERS SEAT REMOVAL To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. Lever Seat INSTALLATION To install the seat, align the tabs on the seat with the grommets on the frame and press the seat down until it locks.
Page 229 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Remove the two mounting bolts from the front cargo rack right/left side under front fender. Remove the two mounting bolts from front cargo rack, remove the front cargo rack. Installation is in the reverse order of removal.
Page 230 . FRAME COVERS/EXHAUST MUFFLER MXU 500 FRONT CARRIER REMOVAL/INSTALLATION Remove front cargo rack (see page 2-5). Remove the three mounting bolts from front carrier left side. Remove the three mounting bolts from front carrier left side. Installation is in the reverse order of removal.
Page 231 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Remove two screws from the rear cargo rack. Remove the four bolts under rear fender. Remove the two mounting bolts from rear cargo rack, then remove rear cargo rack. Installation is in the reverse order of removal.
Page 232 . FRAME COVERS/EXHAUST MUFFLER MXU 500 RIGHT/LEFT SIDE COVER REMOVAL/INSTALLATION Remove the seat (page 2-4) and right or left footboard. (see page 2-7). Remove a screw and a fastener, then remove the right or left side cover. ＊ During removal, do not pull the joint claws forcedly to avoid damage.
Page 233 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Instrument Connector Accessory Socket Disconnect the ignition switch, instrument and accessory socket connectors, then remove the meter cover. Installation is in the reverse order of removal. Ignition Switch Connector Drive Select Grip FUEL TANK COVER REMOVAL/INSTALLATION Remove the seat (page 2-4), front center cover (page 2-8), right/left footboards (page...
Page 234 . FRAME COVERS/EXHAUST MUFFLER MXU 500 FRONT FENDER REMOVAL/INSTALLATION Remove the seat (page 2-4), front cargo rack (page 2-5), front carrier (page 2-6), front center cover (page 2-8), right/left footboards (page 2-7), right/left side covers (page 2-8) and fuel tank cover (page 2-9). Disconnect the right/left turn signal light connectors (ON ROAD) and headlight connectors.
Page 235 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Starter Relays Remove the starter relays and ignition control module and Ignition Control Module Fuse Box Push the lock clip under rear fender by finger and remove the fuse box. Remove the five mounting bolts from the rear fender, then remove the rear fender.
Page 236 . FRAME COVERS/EXHAUST MUFFLER MXU 500 BOTTOM COVER REMOVAL/INSTALLATION Remove the right and left footboards (page 2-7). Remove the two mounting bolts from bottom cover front side. Remove the four mounting bolts from bottom cover right/left side, then remove bottom cover. Installation is in the reverse order of removal.
Page 237: Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MXU 500 EXHAUST MUFFLER REMOVAL Loosen the exhaust pipe band bolt. Remove two muffler mounting bolts. Gasket Remove the muffler and gasket from the exhaust pipe Exhaust Muffler Remove the exhaust pipe joint nuts. 2-13...
Page 238 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Exhaust Pipe Remove the exhaust pipe and gasket. INSTALLATION Replace the gaskets with new ones. Install the exhaust pipe and tighten the joint nuts. Torque: Exhaust pipe mounting nut: 3.5 kgf-m (35 N-m, 14 lbf-ft) Gasket Install the muffler and tighten the mounting bolts...
Page 239 . INSPECTION/ADJUSTMENT MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 3 FUEL LINE/THROTTLE OPERATION --------------------------------- 3- 4 SPEED LIMITER/AIR CLEANER --------------------------------------- 3- 5 AIR FILTER FOR DRIVE BELT ----------------------------------------- 3- 7 SECONDARY AIR SUPPLY SYSTEM --------------------------------- 3- 8 SPARK PLUG---------------------------------------------------------------- 3- 9 VALVE CLEARANCE ----------------------------------------------------- 3-11 CARBURETOR IDLE SPEED -------------------------------------------- 3-12...
Page 240: Service Information
. INSPECTION/ADJUSTMENT MXU 500 SERVICE INFORMATION GENERAL ！ WARNING Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. Gasoline is extremely flammable and is explosive under some conditions.
Page 241 . INSPECTION/ADJUSTMENT MXU 500 Tire pressure 1 Rider Front 0.28 kgf/cm² (28 Kpa, 3.2 psi) Rear 0.28 kgf/cm² (28 Kpa, 3.2 psi) Tire size: Front : 25X8-12 Rear : 25X10-12 TORQUE VALUES Spark plug 1.2kgf-m (12 N-m, 8.6 lbf-ft) Tappet ADJ nut 0.9 kgf-m (9 N-m, 6.5 lbf-ft) Engine oil filter cap 1.5 kgf-m (15 N-m, 11 lbf-ft)
Page 242: Maintenance Schedule
. INSPECTION/ADJUSTMENT MXU 500 MAINTENANCE SCHEDULE This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
Page 243: Fuel Line/Throttle Operation
. INSPECTION/ADJUSTMENT MXU 500 Fuel tubes FUEL LINE Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area. Fuel Filter THROTTLE OPERATION Check the throttle to swing for smooth movement.
Page 244: Speed Limiter/Air Cleaner
. INSPECTION/ADJUSTMENT MXU 500 SPEED LIMITER The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV.
Page 245 . INSPECTION/ADJUSTMENT MXU 500 3. Loosen the screw (3) and remove the air cleaner assembly (4) from the air cleaner housing. 4. Unscrew the clamp (5) 5. Remove the outer air cleaner (7). 6. Remove the screw/washers (6) and remove the air cleaner assembly from the air cleaner holder (8).
Page 246: Air Filter For Drive Belt
. INSPECTION/ADJUSTMENT MXU 500 AIR CLEANER HOUSING DRAIN 1. Remove the drain tube (1) by removing the clip (3). 2. Drain the deposits. 3. Reinstall the drain tube, securing it with the clip. Fastener AIR FILTER FOR DRIVE BELT To clean the air filter: Remove front center cover (refer to the “FRAME COVERS”...
Page 247: Secondary Air Supply System
. INSPECTION/ADJUSTMENT MXU 500 SECONDARY AIR SUPPLY SYSTEM Check the AICV (air injection control valve) This model is equipped with a built-in hoses between the AICV control solenoid secondary air supply system. The pulse valve and cylinder head for deterioration, secondary air supply system is located on damage or loose connections.
Page 248: Spark Plug
. INSPECTION/ADJUSTMENT MXU 500 Ignition Coil Cap SPARK PLUG Disconnect the spark plug cap and clean around the spark plug. ＊ Clean around the spark plug base with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber.
Page 249 . INSPECTION/ADJUSTMENT MXU 500 Measure the spark plug gap between the center and side electrodes with the feeler gauge. If necessary, adjust the gap by bending the side electrode carefully. Spark plug gap: 0.6－0.7 mm (0.024－0.028 in) Install the spark plug in the cylinder head and hand tighten, then torque to the specification.
Page 250: Valve Clearance
. INSPECTION/ADJUSTMENT MXU 500 Timing Hole Cap/O-ring VALVE CLEARANCE ＊ Inspect and adjust the valve clearance while the engine is cold (Below 35°C/95°F). To adjust: Remove the right floorboard (refer to the “FRAME COVERS” section in the chapter Remove the cylinder head cover (refer to Crankshaft Hole Cap/O-ring the “CYLINDER HEAD COVER REMOVAL/INSTALLATION”...
Page 251: Carburetor Idle Speed
. INSPECTION/ADJUSTMENT MXU 500 Adjust by loosening the valve adjusting Wrench Thickness Gauge Valve Adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge. Valve clearance (when cold): IN.: 0.1 mm (0.004 in) EX.: 0.1 mm (0.004 in) Apply oil to the valve adjusting screw lock- nut threads and seating surface.
Page 252: Clinder Compression/Engine Oil
(H) and minimum (L) marks. If the level is low, add oil to raise it to the proper level. Recommended engine oil: KYMCO 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 5W50 ＊ Other viscosities shown in the chart may...
Page 253 . INSPECTION/ADJUSTMENT MXU 500 ENGINE OIL REPLACEMENT AND OIL FILTER CLEANING 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4. Remove the oil filler cap (1). ＊...
Page 254 . INSPECTION/ADJUSTMENT MXU 500 ENGINE OIL REPLACEMENT (WITH OR WITHOUT OIL FILTER CARTRIDGE REPLACEMENT) 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4.
Page 255 . INSPECTION/ADJUSTMENT MXU 500 7. Remove the oil filter cartridge (5) with an oil cartridge wrench. Special tool: Oil cartridge wrench A120E00061 8. Apply a light coat of clean engine oil to the O-ring (6) of the new oil filter cartridge.
Page 256: Rear Drive Gear Oil
. INSPECTION/ADJUSTMENT MXU 500 13. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, turn the engine off immediately and check for the cause. 14. Turn the engine off, and then check the oil level through the inspection window (7) and correct it if necessary.
Page 257: Front Drive Gear Oil
. INSPECTION/ADJUSTMENT MXU 500 6. Install the oil filler cap and oil level check bolt. Torque: Oil filler cap: 1.5 kgf-m (15 N-m, 12 lbf-ft) Oil level check bolt: 2 kgf-m (20 N-m, 15 lbf-ft) ＊ Be sure no foreign material enters the crankcase.
Page 258: Spark Arrester
. INSPECTION/ADJUSTMENT MXU 500 6. Remove the oil level check bolt (3). Make sure the oil level reaches the oil level check hole. 7. Install and tighten the oil filler bolt and oil level check bolt to the specified torque. Torque: Oil filler cap: 3.5 kgf-m (35 N-m, 25.5 lbf-ft)
Page 259: Drive Shaft Boots
. INSPECTION/ADJUSTMENT MXU 500 3. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary. 4.
Page 260: Drive Belt/Brake Pads Inspection
. INSPECTION/ADJUSTMENT MXU 500 DRIVE BELT Drive Belt Remove the left crankcase cover (refer to the “LEFT CRANKCASE COVER REMOVAL/INSTALLATION” section in the chapter 10). Inspect the drive belt for cracks, scaling, chipping or excessive wear. Measure the V-belt width Service limit (A): 30.8 mm (1.232 in) Replace the drive belt if out of specification.
Page 261: Brake Fluid Inspection/Headlight Aim
. INSPECTION/ADJUSTMENT MXU 500 BRAKE FLUID INSPECTION Inspection Window (R/L Brake Lever) Check if the fluid level is below the lower level mark through the inspection window. Inspection Window (Rear Brake Pedal) Adjust Screws HEADLIGHT AIM Turn the ignition switch ON and start the engine.
Page 262: Steering System Inspection
. INSPECTION/ADJUSTMENT MXU 500 STEERING SYSTEM INSPECTION Place the machine on a level place. Check the steering column bushings and bearings: Move the handlebar up and down, and/or back and forth. Replace the steering column bushings and or bearings if excessive play Check the tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then slightly move...
Page 263: Toe-In Adjustment
. INSPECTION/ADJUSTMENT MXU 500 TOE-IN ADJUSTMENT Place the machine on a level place. Measure the toe-in Adjust if out of specification. Toe-in measurement steps: Mark both front tire tread centers. Raise the front end of the machine so that there is no weight on the front tires. Fix the handlebar straight ahead.
Page 264: Wheels/Tires
. INSPECTION/ADJUSTMENT MXU 500 ＊ The threads on both rod-end must be of the same length. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. ＊ Tire pressure should be checked when tires are cold. TIRE PRESSURE 1 Rider Front...
Page 265 . INSPECTION/ADJUSTMENT MXU 500 Check the rear axle nut for looseness. If the axle nuts are loose, tighten them to the specified torque. Torque: Front: 7 kgf-m (70 N-m, 50 lbf-ft) Rear: 10 kgf-m (100 N-m, 72 lbf-ft) Rear Axle Nut Inspect the tire surfaces.
Page 266 . INSPECTION/ADJUSTMENT MXU 500 FRONT SHOCK ABSORBER ＊ Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. Adjustment Turn the adjuster to increase or decrease the spring preload. Standard position: 2 Minimum (Soft) position: 1 Maximum (Hard) position: 5...
Page 267 . INSPECTION/ADJUSTMENT MXU 500 3. Loosen the lock nuts (3) of rod (4). 4. Remove the bolt and nut from the rod end (shift arm side). Bolt/Nut 5. Shift the drive select lever to neutral along the shift guide. 6. Shift the gear to neutral by moving the Shift Arm shift arm (The neutral indicator lamp comes on.)
Page 268: Cable Inspection And Lubrication/Adjusting The Rear Brake Light Switch (Brake Pedal)
. INSPECTION/ADJUSTMENT MXU 500 7. Turn the rod clockwise or counterclockwise to align the joint ball in the rod with the hole on the shift arm, then install and tighten the bolt and nut. ＊ When align the joint ball in the rod with the hole on the shift arm.
Page 269: Cooling System
. INSPECTION/ADJUSTMENT MXU 500 COOLING SYSTEM COOLANT LEVEL INSPECTION Place the machine on the level ground. Remove the front center cover (refer to the “FRAME COVERS” section in the chapter Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature.
Page 270 . INSPECTION/ADJUSTMENT MXU 500 Check for any coolant leakage from the water pump, radiator hoses and hose joints. Check the radiator hoses for cracks or deterioration and replace if necessary. Check that all hose clamps are tight. Check the radiator air passages for clogs or damage.
Page 271: Parking Brake Adjustment (On Road)
. INSPECTION/ADJUSTMENT MXU 500 REAR PARKING BRAKE ADJUSTMENT (ON ROAD) Parking brake adjustment may be required if the parking brake does not work properly. Every time the brake pads are replaced, adjust the parking brake. To adjust: 1. Release the parking brake lever. Parking Brake Lever 2.
Page 272 . INSPECTION/ADJUSTMENT MXU 500 3. Loosen the lock nut and adjuster on the cable. 4. Turn the adjuster in or out until the specified brake cable end length “L” is obtained. Tighten the lock nut. Lock Nut Adjuster Parking brake cable end length: L: 53 ±...
Page 273 . INSPECTION/ADJUSTMENT MXU 500 7. Check the parking brake lever free play “C”. Free play: 0 mm (0 in) 8. If the free play is incorrect, adjust the free play by adjuster on the cable. Lock Nut Adjuster 3-34...
Page 274 . LUBRICATION SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM --------------------------------- 4- 1 SERVICE INFORMATION----------------------------------------------- 4- 2 TROUBLESHOOTING---------------------------------------------------- 4- 3 LUBRICATION CHECK HOLE ----------------------------------------- 4- 4 OIL PUMP REMOVAL/INSPECTION/INSTALLATION----------- 4- 5 OIL PUMP DISASSEMBLY/INSPECTION/ASSEMBLY ---------- 4- 9 RIGHT CRANKCASE COVER DISASSEMBLY/ASSEMBLY---- 4-12 OIL PRESSURE RELIEF VALVE--------------------------------------- 4-14 OIL PIPE REMOVAL/INSTALLATION ------------------------------- 4-15...
Page 275: Lubrication System Diagram
. LUBRICATION SYSTEM MXU 500 LUBRICATION SYSTEM DIAGRAM...
Page 276: Service Information
3.6 liter (3.17 lmp qt, 3.82 Us qt) capacity At draining and oil filter cartridge change 3.2 liter (2.82 lmp qt, 3.39 Us qt) KYMCO 4-stroke oil or equivalent motor oil Recommended engine oil API service classification SJ Viscosity: SAE 5W-50 Tip clearance 0.15 (0.006) max...
Page 277: Troubleshooting
. LUBRICATION SYSTEM MXU 500 TROUBLESHOOTING Oil level low High oil pressure Oil consumption Pressure relief valve stuck closed External oil leak Plugged oil filter, gallery, or metering orifice Worn piston ring Faulty oil pump Incorrect piston ring installation Worn valve guide or seal Seized engine No or low oil pressure Clogged oil orifice/passage...
Page 278: Lubrication Check Hole
. LUBRICATION SYSTEM MXU 500 Check Hole Plug/O-ring LUBRICATION CHECK HOLE Remove the check hole plug/O-ring. Start the engine. Check the oil gushed from the hole. If not, stop the engine immediately and determine the cause.
Page 279: Oil Pump Removal/Inspection/Installation
. LUBRICATION SYSTEM MXU 500 Oil Pump Drive Chain Guide OIL PUMP REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH REMOVAL/INSPECTION/INSTALLATI ON” section in the chapter 19). Remove the two bolts and oil pump drive chain guide.
Page 280 . LUBRICATION SYSTEM MXU 500 Dowel Pins Remove a bolt and then remove the oil pump holder. Remove the two dowel pins. Remove the two bolts and then remove the oil pump. Holder Oil Pump INSPECTION Oil pump drive chain guide Inspect the drive chain slipper surface of the drive chain guide for wear or damage.
Page 281 . LUBRICATION SYSTEM MXU 500 Dowel Pins Install and tighten the two bolts securely. Install two dowel pins Install the holder, then install a bolt but do not tighten. Oil Pump Holder Drive Chain Install the driven gear and drive chain. Driven Gear Install the snap ring.
Page 282 . LUBRICATION SYSTEM MXU 500 Oil Pump Drive Chain Guide Install the chain guide, then install and tighten the two bolts securely. Install the oil separator cover, then install and tighten the three bolts in a crisscross pattern in 2 or 3 steps. Oil Separator Cover...
Page 283: Oil Pump Disassembly/Inspection/Assembly
. LUBRICATION SYSTEM MXU 500 Oil Pump Shaft OIL PUMP DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the oil pump shaft. Oil Pump Cover Remove the screw and oil pump cover. Screw Oil Pump Body Dowel Pin Inner Rotor Remove the dowel pin, oil pump outer rotor and inner rotor.
Page 284 . LUBRICATION SYSTEM MXU 500 INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. Service limit: 0.2 mm (0.008 in) ＊ Measure at several points and use the largest reading to compare the service limit.
Page 285 . LUBRICATION SYSTEM MXU 500 Dowel Pin Oil Pump Cover ASSEMBLY Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor. Install the oil pump shaft. Install the dowel pin onto the oil pump body.
Page 286: Right Crankcase Cover Disassembly/Assembly
. LUBRICATION SYSTEM MXU 500 RIGHT CRANKCASE COVER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the right crankcase cover (refer to the “ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION” in the chapter 17) Right Crankcase Cover Remove the oil seal. Oil Seal Remove the snap ring. Remove the bearing by using the special tool. Special tool: Oil seal &...
Page 287 . LUBRICATION SYSTEM MXU 500 ASSEMBLY Install a new bearing by using the special tool. Special tool: Oil seal & bearing drive A120E00014 Bearing Drive Snap Ring Install a new oil seal. Oil Seal 4-13...
Page 288: Oil Pressure Relief Valve
. LUBRICATION SYSTEM MXU 500 Oil Pressure Relief Valve OIL PRESSURE RELIEF VALVE REMOVAL Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in the chapter 11). Remove the pressure relief valve and O-ring from the right crankcase. O-ring Piston INSPECTION...
Page 289: Oil Pipe Removal/Installation
. LUBRICATION SYSTEM MXU 500 Bolts/Washers (on the oil pipe) OIL PIPE REMOVAL/INSTALLATION REMOVAL Remove the two bolts, washers (on the oil pipe), oil pipe and washers (under oil pipe). Oil Pipe/Washer (under oil pipe) Washers INSTALLATIION Install the inner washers on the right crankcase.
Page 290 . LUBRICATION SYSTEM MXU 500 Bolts/Washers (on the oil pipe) 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) 4-16...
Page 291 . FUEL SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5- 2 TROUBLESHOOTING----------------------------------------------------- 5- 3 FUEL TANK ----------------------------------------------------------------- 5- 4 FUEL VALVE --------------------------------------------------------------- 5- 4 CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION-- 5- 7 CARBURETOR DISASSEMBLY/INSPECTION/ASSEMBLY ----- 5- 9 AIR CLEANER HOUSING ------------------------------------------------ 5-19 PAIR SOLENOID VALVE ------------------------------------------------ 5-20...
Page 292 . FUEL SYSTEM MXU 500...
Page 293: Service Information
. FUEL SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. Do not bend or twist control cables.
Page 294: Troubleshooting
. FUEL SYSTEM MXU 500 TROUBLESHOOTING Engine cranks but won’t start Engine lacks power No fuel in tank Clogged air cleaner No fuel to carburetor Faulty carburetor Cylinder flooded with fuel Faulty ignition system No spark at plug Clogged air cleaner Lean mixture Intake air leak Clogged carburetor fuel jets...
Page 295: Fuel Tank
. FUEL SYSTEM MXU 500 Fuel Tube FUEL TANK REMOVAL Warning Keep sparks and flames away from the work area. Wipe off any spilled gasoline. Remove the seat, right and left side frame cover and fuel tank cover (refer to the “FRAME COVERS”...
Page 296 . FUEL SYSTEM MXU 500 Control Shaft Screws Washer DISASSEMBLY Remove the two screws on the retaining ring and then remove retaining ring. Remove the washer and control shaft. Retaining Ring Fuel Valve Body Rubber Gasket Remove the rubber gasket from the fuel valve body.
Page 297 . FUEL SYSTEM MXU 500 ASSEMBLY Reverse the “DISASSEMBLY” procedures. Install rubber gasket, control shaft, washer and retaining ring. ＊ Aligning the tab on the control shaft with the outlet duct in the fuel valve body. Aligning the tab on the retaining ring with the outlet duct in the fuel valve Outlet Duct Outlet Duct...
Page 298: Carburetor Removal/Choke Inspection/Installation
. FUEL SYSTEM MXU 500 Over Flow Hose CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION REMOVAL Remove the fuel tank (refer to the “FUEL TANK” section in this chapter). Remove the air cleaner housing (refer to the “AIR CLEANER HOUSING” section in this chapter). Disconnect the over flow hose.
Page 299 . FUEL SYSTEM MXU 500 O-ring CHOKE INSPECTION Inspection the choke plunger, spring and O- ring for bends, wear or damage. Spring Choke Plunger INSTALLATION Installation is in the reverse order of removal. ＊ Make sure the lug on the carburetor into the cutout on the intake pipe.
Page 300: Carburetor Disassembly/Inspection/Assembly
. FUEL SYSTEM MXU 500 CARBURETOR DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the carburetor (refer to the “CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION” section in this chapter). Loosen the drain screw to drain the gasoline from the float chamber. ＊ Keep sparks and flames away from the Fuel Drain Plug work area.
Page 301 . FUEL SYSTEM MXU 500 Jet Needle Spring Retainer Remove the spring retainer, jet needle. Piston Valve Casting Enrichment Valve Cover/Spring O-ring Remove the two screws and casting enrichment valve cover and then take out the spring. Remove the casting enrichment valve and O- ring.
Page 302 . FUEL SYSTEM MXU 500 Remove the four screws and float chamber. Float Chamber Float Float Valve Pull float pin outs, then remove the float and float valve. Float Valve Slow Jet Needle Jet Holder Remove the slow jet. Remove choke jet. Remove main jet.
Page 303 . FUEL SYSTEM MXU 500 Needle Jet Remove the needle jet. Remove the pilot screw, spring, washer and O-ring. ＊ Before pilot screw removal, slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated.
Page 304 . FUEL SYSTEM MXU 500 INSPECTION CARBURETOR BODY/JETS CLEANING Check carburetor body and each jet for wear or damage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly-not just the perceived problem area.
Page 305 . FUEL SYSTEM MXU 500 Float Float Tang Check the float and float tang for deformation or damage. Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.
Page 306 . FUEL SYSTEM MXU 500 Check top cap and spring for cracks and damage. Top Cap Spring Spring Covers Check the diaphragms (coasting enrichment valve and accelerating pump) for tears. Check the spring (coasting enrichment valve and accelerating pump) and cover (coasting enricher and accelerating pump) for damage.
Page 307 . FUEL SYSTEM MXU 500 Insert the piston valve into the carburetor body, and check for free movement. If stick is found, replace the part with a new one. Check throttle valve for free movement. If stick is found, replace the part with a new carburetor.
Page 308 . FUEL SYSTEM MXU 500 ASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the following instructions. ＊ Assemble the parts taking consideration of their function. Before assembling, wash all of the parts in a clean petroleum based solvent.
Page 309 . FUEL SYSTEM MXU 500 Fit a new O-ring in to the float chamber groove securely. O-ring Small Convex O-ring Accelerating Pump Cover Assemble the accelerating pump diaphragm and new O-ring. ＊ Install the accelerating pump diaphragm with the small convex facing Accelerating Pump Diaphragm 5-18...
Page 310: Air Cleaner Housing
. FUEL SYSTEM MXU 500 Band Screw AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the seat and side covers (refer to the “FRAME COVERS” section in the chapter Loosen the carburetor-to-air cleaner connecting tube band screw. Remove the clip and disconnect the crankcase breather hose from the crankcase.
Page 311: Pair Solenoid Valve
. FUEL SYSTEM MXU 500 Vacuum Hose PAIR SOLENOID VALVE REMOVAL/INSTALLATION Disconnect air supply hose and vacuum hose from the air solenoid valve, then remove the air solenoid valve from frame. Air Supply Hose PAIR Solenoid Valve Installation is in the reverse order of removal.
Page 312 . COOLING SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SYSTEM FLOW PATTERN----------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 4 COOLING SYSTEM TESTING------------------------------------------- 6- 5 COOLANT REPLACEMENT --------------------------------------------- 6- 5 THERMOSTAT-------------------------------------------------------------- 6- 8 WATER PUMP -------------------------------------------------------------- 6-11 RADIATOR ------------------------------------------------------------------ 6-14 FAN MOTOR SWITCH ---------------------------------------------------- 6-15 FAN MOTOR ---------------------------------------------------------------- 6-16...
Page 313: System Flow Pattern
. COOLING SYSTEM MXU 500 SYSTEM FLOW PATTERN...
Page 314: Service Information
. COOLING SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS WARING: Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
Page 315 -37℃ -44.5℃ Cautions for Using Coolant: Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant concentrate + 975cc distilled water is 30%.) Do not mix coolant concentrate of different brands. Do not drink the coolant which is poisonous.
Page 316: Troubleshooting
. COOLING SYSTEM MXU 500 TORQUE VALUES Water pump cover bolt 1.3 kgf-m (13 N-m, 9 lbf-ft) Fan motor bolt 0.53 kgf-m (5 N-m, 3.8 lbf-ft) Fan motor switch 1.8 kgf-m (17 N-m, 13 lbf-ft) TROUBLESHOOTING Engine temperature too high Faulty radiator cap Faulty temperature gauge or thermosensor Air in system...
Page 317: Cooling System Testing
. COOLING SYSTEM MXU 500 COOLING SYSTEM TESTING Cap Tester RADIATOR CAP INSPECTION Remove the radiator cap (refer to the “COOLANT REPLACEMENT” section in this chapter). Pressure test the radiator cap. Replace the radiator cap if it does not hold Radiator Cap pressure, or if relief pressure is too high or too low.
Page 318 . COOLING SYSTEM MXU 500 Radiator Cap REPLACEMENT/AIR BLEEDING Remove the front center cover and right footboard (refer to the “FRAME COVERS” section in the chapter 2). ＊ When filling the system or reserve tank with coolant (checking the coolant level), place the machine in a vertical position on a flat, level surface.
Page 319 . COOLING SYSTEM MXU 500 Reserve Tank Cap Place the machine on a flat, level surface. Fill the reserve tank to the upper level (FULL) line. Filler Neck Fill the system with the recommended coolant through the filler opening up to the filler neck.
Page 320: Thermostat
. COOLING SYSTEM MXU 500 THERMOSTAT REMOVAL Remove the nut and thermostat housing stay from the frame. Remove the bolts, housing stay and thermostat housing cover. Housing stay Thermostat Housing Cover Thermostat Remove the O-ring from the housing cover. Remove the thermostat. O-ring Thermostat...
Page 321 . COOLING SYSTEM MXU 500 INSPECTION Visually inspect the thermostat for damage. Thermostat Heat the water with an electric heating Thermometer element to operating temperature for five minutes. Suspend the thermostat in heated water to check its operation. ＊ Keep flammable materials away from the electric heating element.
Page 322 . COOLING SYSTEM MXU 500 O-ring Install a new O-ring into the housing cover groove. Install the housing cover and housing stay to the housing. Tighten the bolts securely. Install the housing stay to the frame. Tighten the nut securely. Fill the system with recommended coolant and bleed the air (refer to the “COOLANT REPLACEMENT”...
Page 323: Water Pump
. COOLING SYSTEM MXU 500 WATER PUMP MECHANICAL SEAL INSPECTION Inspect the coolant leakage. If there is leakage, the mechanical seal is defective, and water pump body should be replaced. REMOVAL Drain the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter).
Page 324 . COOLING SYSTEM MXU 500 Water Pump Body Remove the water pump body from the crankcase. Align INSTALLATION Apply engine oil to a new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with oil pump shaft end.
Page 325 . COOLING SYSTEM MXU 500 Install the water pump cover and tighten the bolts to the specified toque. Torque: 1.3 kgf-m (13 N-m, 9 lbf-ft) Water Pump Cover/O-ring Water Hose Connect the water hoses and bypass hose, then tighten the hose bands. Fill the system with recommended coolant and bleed the air (refer to the “COOLANT REPLACEMENT”...
Page 326: Radiator
. COOLING SYSTEM MXU 500 Fan Guide RADIATOR REMOVAL Drain the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter). Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2). Remove the four mounting bolt from fan guide and then remove fan guide.
Page 327: Fan Motor Switch
. COOLING SYSTEM MXU 500 FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors (refer to the “RADIATOR” section in this chapter). Remove the fan motor switch. Fan Motor Switch INSPECTION Place the fan motor switch in oil contained in a pan as shown and raise the oil temperature gradually to check for the temperature at which the switch starts to...
Page 328: Fan Motor
. COOLING SYSTEM MXU 500 Fan Motor Connector FAN MOTOR REMOVAL Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2) Disconnect the fan motor connector. Remove the four mounting bolts and then remove the fan motor INSPECTION Check the fan motor to operate using an available battery.
Page 329: Water Temperature Sensor
. COOLING SYSTEM MXU 500 Water Temperature Sensor WATER TEMPERATURE SENSOR Remove the right side body cover and right footboard (refer to the “FRAME COVERS” section in the chapter 2). Disconnect the water temperature sensor connector. Remove the water temperature sensor from the water joint.
Page 330: Raidator Reserve Tank
. COOLING SYSTEM MXU 500 RADIATOR RESERVE TANK REMOVAL Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2). Remove the two mounting bolts and then remove the radiator reserve tank from frame. Open the reserve tank cap and drain the coolant from the reserve tank.
Page 331 7. ENGINE REMOVAL/INSTALLATION MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 7- 1 ENGINE REMOVAL ------------------------------------------------------- 7- 2 ENGINE INSTALLATION ------------------------------------------------ 7- 8...
Page 332 7. ENGINE REMOVAL/INSTALLATION MXU 500 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 removal. Use shop towels to protect the machine body during engine removal. The following components require engine removal for serviced with the engine installed in the frame.
Page 333 7. ENGINE REMOVAL/INSTALLATION MXU 500 Lower Water Hose Rubber Band ENGINE REMOVAL Drain engine oil (refer to the “ENGINE OIL” section in the chapter 3). Remove frame covers and exhaust pipe (refer to the “FRAME COVERS” section in the chapter 2). Drain the engine coolant (refer to the “COOLANT REPLACEMENT”...
Page 334 7. ENGINE REMOVAL/INSTALLATION MXU 500 Water Hose Temperature Sensor Connector Disconnect the water hose, bleed hose and water temperature sensor connectors from water joint. Bleed Hose Spark Plug Cap Remove the spark plug cap and disconnect the AICV air supply hose from cylinder head.
Page 335 7. ENGINE REMOVAL/INSTALLATION MXU 500 Breather Hose Disconnect the breather hose from cylinder head cover and remove the mounting nut from breather housing holder, then remove the breather housing. Vacuum Hose Starter Cable Disconnect the vacuum hose from intake pipe. Slide the rubber sleeve back to expose the starter motor wire nut.
Page 336 7. ENGINE REMOVAL/INSTALLATION MXU 500 Disconnect the gear indicator light switch connector. Gear Indicator Light Switch Connector Speed Sensor Connector Disconnect the speed sensor connector. Front Propeller Shaft Remove the bolts and then remove the front propeller shaft from the engine assembly.
Page 337 7. ENGINE REMOVAL/INSTALLATION MXU 500 Lower Engine Mounting Bolt/Nut Remove the front lower engine mounting bolt/nut. Remove the four nuts under right and left engine hangers, then remove the engine hangers. Remove the rear lower engine mounting bolt/nut. Engine Hanger Nuts Engine Hanger Remove the upper engine mounting bolt/nut.
Page 338 7. ENGINE REMOVAL/INSTALLATION MXU 500 Rear Propeller Shaft Tap the rear propeller shaft with rubber hammer and remove the rear propeller shaft from the engine assembly. ＊ Take care not to lose the compression spring in the rear drive gear case end. Lower the cylinder head and rise the engine rear side, then move the engine from the frame left side.
Page 339 7. ENGINE REMOVAL/INSTALLATION MXU 500 ENGINE INSTALLATION Install the engine assembly into the frame. Apply grease Apply grease Apply lightweight lithium-soap base grease to the rear propeller shaft splines. Rear Propeller Shaft Rear Propeller Shaft Install the rear propeller shaft into the engine assembly.
Page 340 7. ENGINE REMOVAL/INSTALLATION MXU 500 Apply grease Pinion Gear Install the compression spring into the pinion gear. ＊ Apply lightweight lithium-soap base grease to the pinion gear splines. Move the engine rearward and engage the rear propeller shaft into the pinion gear. ＊...
Page 341 7. ENGINE REMOVAL/INSTALLATION MXU 500 Front Propeller Shaft Apply lightweight lithium-soap base grease to the front propeller shaft splines and front output splines. Apply grease Front Propeller Shaft Install the front propeller shaft into the engine assembly. Install and tighten the three new bolts to specified torque.
Page 342 7. ENGINE REMOVAL/INSTALLATION MXU 500 Install the rear cooling duct. ＊ Make sure the lug on the left crankshaft case into the cutout on the rear cooling duct. Install the removed parts in the reverse order of removal. Route the water hoses, wire and cable properly (refer to the “CABLE &...
Page 343 8. CYLINDER HEAD/VALVES MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 3 CYLINDER COMPRESSION TEST ------------------------------------- 8- 4 CYLINDER HEAD COVER REMOVAL/INSTALLATION--------- 8- 5 CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY--------- 8- 6 CAMSHAFT REMOVAL/INSPECTION/INSTALLATION --------- 8- 7 ROCKER ARMS REMOVAL/INSPECTION/INSTALLATION ---- 8-15 CYLINDER HEAD REMOVAL/INSTALLATION-------------------- 8-17...
Page 344: Schematic Drawing
8. CYLINDER HEAD/VALVES MXU 500 SCHEMATIC DRAWING...
Page 345: Service Information
8. CYLINDER HEAD/VALVES MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 346: Troubleshooting
8. CYLINDER HEAD/VALVES MXU 500 TORQUE VALUES Cylinder head bolt (1 – 4) 4.8 kgf-m (48 N-m, 35 lbf-ft) Apply engine oil to threads Cylinder head bolt (5 – 13) 2.3 kgf-m (23 N-m, 17 lbf-ft) Apply engine oil to threads Cylinder head nut 1 kgf-m (10 N-m, 7 lbf-ft) Cylinder head cover bolt...
Page 347: Cylinder Compression Test
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug (refer to the “SPARK PLUG” section in the chapter 3). Park Plug Cap Compression Gauge Install a compression gauge into the spark...
Page 348: Cylinder Head Cover Removal/Installation
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER HEAD COVER REMOVAL/INSTALLATION REMOVAL Disconnect the crankcase breather hose from the cylinder head cover (refer to the “ENGINE REMOVAL” section in the chapter 7). Remove the four bolts/rubber washers and cylinder head cover. Cylinder Head Cover Cylinder Head Cover Packing Remove the cylinder head cover packing.
Page 349: Cylinder Head Cover Disassembly/Assembly
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the three bolts and breather separator. Gasket Remove the gasket. ASSEMBLY Assembly is in the reverse order of disassembly. Torque: Breather separator bolt: 1.3 kgf-m (13 N-m, 9 lbf-ft)
Page 350: Camshaft Removal/Inspection/Installation
8. CYLINDER HEAD/VALVES MXU 500 CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION Bolt Washer REMOVAL Remove the cylinder head cover (refer to the “CYLINDER HEAD COVER REMOVAL/INSTALLATION” section in this chapter). Turn the crankshaft clockwise and align the “T” mark on the flywheel with the index mark on the right crankcase cover (refer to the “VALVE CLEARANCE”section in the chapter 3).
Page 351 8. CYLINDER HEAD/VALVES MXU 500 Bolts Loosen and remove the eight camshaft holder bolts in a crisscross pattern in several steps. Camshaft Holder Bolts/Washers Loosen and remove the four camshaft holder bolts/washers in a crisscross pattern in several steps, then remove the camshaft holders.
Page 352 8. CYLINDER HEAD/VALVES MXU 500 Cam Chain Slipper INSPECTION Cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage. Camshaft Holders Camshaft holder ＊ Always replace the camshaft holder and cylinder head in pairs Inspect the camshaft surface of each camshaft holder for scoring, scratches, or evidence of insufficient lubrication.
Page 353 8. CYLINDER HEAD/VALVES MXU 500 Camshaft Support both ends of the camshaft with V- blocks and check the camshaft runout with a dial gauge. Service limit: 0.05 mm (0.002 in) Inspect camshaft lobes for pitting/scratches/blue discoloration. Measure the cam lobe height. Service Limits: IN : 37.11 mm (1.4844 in) EX: 36.86 mm (1.4744 in) If any defects are found, replace the camshaft...
Page 354 8. CYLINDER HEAD/VALVES MXU 500 Cam chain tensioner Check the one-way cam operation (tensioner) Unsmooth operation Replace. INSTALLATION Turn the crankshaft clockwise, align the “T” mark on the flywheel with the index mark on the right crankcase cover (refer to the “VALVE CLEARANCE”...
Page 355 8. CYLINDER HEAD/VALVES MXU 500 Install the cam chain over the cam sprockets Punch Marks and then install the intake and exhaust camshafts. ＊ Install each camshafts to the correct locations. “IN”: no decompressor cam “EX”: has a decompressor cam Make sure the timing marks on the cam sprockets are flush with the cylinder head upper surface and punch marks...
Page 356 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 1 – 8) threads. Install the four bolts (No. 5 – 8). Install the four bolts/washers (No. 1 – 4). Tighten the holder bolts (No. 1 – 8) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 357 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 358: Rocker Arms Removal/Inspection/Installation
8. CYLINDER HEAD/VALVES MXU 500 Rocker Arms ROCKER ARMS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the camshafts (refer to the “CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the rocker arm shafts and washers, then remove the rocker arms. Rocker Arm Shafts/Washers INSPECTION Rocker Arm Shaft Rocker arm shaft...
Page 359 8. CYLINDER HEAD/VALVES MXU 500 Rocker Arm Shaft INSTALLATION Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms, rocker arm shafts and washers. Tighten the rocker arm shaft to the specified torque. Torque: 4.5 kgf-m (45 N-m, 32 lbf-ft) Rock Arm Washer 8-16...
Page 360: Cylinder Head Removal/Installation
8. CYLINDER HEAD/VALVES MXU 500 Intake Pipe CYLINDER HEAD REMOVAL/INSTALLATION ＊ Always replace the camshaft holder and cylinder head in pairs Remove the camshafts (refer to the “CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the two bolts and intake pipe. Remove the five bolts, then remove the pair reed valve cover and holder.
Page 361 8. CYLINDER HEAD/VALVES MXU 500 Remove the two nuts under the cylinder head. Remove the bolt and then remove the cylinder head. Dowel Pins Remove the dowel pins and gasket. Gasket 8-18...
Page 362 8. CYLINDER HEAD/VALVES MXU 500 Dowel Pins INSTALLATION Install the dowel pins and new gasket as shown. Gasket Install the cylinder head. Apply engine oil to the cylinder head bolt (9) threads. Install the bolt (9) but do not tighten it. Camshafts Intake Camshaft Holder Install the camshafts, intake camshaft holder...
Page 363 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 1 – 8) threads. Install the four bolts (No. 5 – 8). Install the four bolts/washers (No. 1 – 4). Tighten the holder bolts (No. 1 – 9) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 364 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 365 8. CYLINDER HEAD/VALVES MXU 500 Install and tighten the two nuts under the cylinder head to the specified torque. Torque: 1 kgf-m (10 N-m, 7 lbf-ft) Bolts Install the water stop collar, gasket and water joint. Install and tighten the two bolts to the specified torque.
Page 366 8. CYLINDER HEAD/VALVES MXU 500 O-ring Install the new O-ring onto the intake pipe. Intake Pipe Install the intake pipe and tighten the two bolts securely. 8-23...
Page 367: Cylinder Head Disassembly/Inspection/Assembly
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER HEAD DISASSEMBLY/INSPECTION/ Valve Spring Compressor ASSEMBLY Remove the cylinder head (refer to the “CYLINDER HEAD REMOVAL/INSTALLATION” section in this chapter). Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊...
Page 368 8. CYLINDER HEAD/VALVES MXU 500 INSPECTION Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D. Measure each valve guide I.D.
Page 369 8. CYLINDER HEAD/VALVES MXU 500 Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 3.5 kg (at 28.7 mm, 1.148 in) Outer: 13 kg (at 31.43 mm, 1.2572 in) Measure the spring tilt. Replace if out of specification. Standard: Inner: 1.2 mm (0.048) Outer: 1.2 mm (0.048)
Page 370 8. CYLINDER HEAD/VALVES MXU 500 Tap the valve stems gently with a plastic hammer for 2阡3 times to firmly seat the cotters. ＊ Be careful not to damage the valves. 8-27...
Page 371: Cam Chain Removal/Inspection/Installation
8. CYLINDER HEAD/VALVES MXU 500 CAM CHAIN REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cylinder (refer to the Guide Cam Chain “CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 9). Remove the oil pump drive chain (refer to “OIL PUMP REMOVAL/INSTALLATION” section in the chapter 4).
Page 372 8. CYLINDER HEAD/VALVES MXU 500 INSTALLATION Guide Cam Chain Installation is in the reverse order of removal. Install the cam chain guides to the right crankcase and tighten the bolts to the specified torque. Torque: 2 kgf-m (20 N-m, 15 lbf-ft) Guide 8-29...
Page 373 9. CYLINDER/PISTON MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 9-3...
Page 374: Schematic Drawing
9. CYLINDER/PISTON MXU 500 SCHEMATIC DRAWING...
Page 375: Service Information
9. CYLINDER/PISTON MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the frame. When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed. After disassembly, clean the removed parts and dry them with compressed air before inspection.
Page 376: Cylinder And Piston Removal/Inspection/ Installation
9. CYLINDER/PISTON MXU 500 Cylinder Block Pin CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD REMOVAL/INSTALLATION” section in the chapter 8). Take the block pin out. Remove the water hose from the cylinder. Remove the two cylinder bolts/washers. Water Hose Gasket Dowel Pins...
Page 377 9. CYLINDER/PISTON MXU 500 Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
Page 378 9. CYLINDER/PISTON MXU 500 Piston/Piston pin Measure the piston O.D. at the point (A) from the bottom and 90° to the piston pin hole. 10 mm Service Limit: 91.9 mm (3.676 in) at (A): 10 mm Calculate the cylinder-to-piston clearance. Measure the piston pin hole.
Page 379 9. CYLINDER/PISTON MXU 500 Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
Page 380 9. CYLINDER/PISTON MXU 500 Measure the connecting rod small end I.D.. Service Limit: 22.06 mm (0.8824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing ＊...
Page 381 9. CYLINDER/PISTON MXU 500 Piston “IN” Mark Cylinder/Piston Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole. Install the piston with the “IN”...
Page 382 9. CYLINDER/PISTON MXU 500 Cam Chain Cylinder Block Pin Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. ＊ Be careful not to damage the piston rings and cylinder walls.
Page 383 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE PULLEY/DRIVEN PULLEY/CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 10- 1 SERVICE INFORMATION------------------------------------------------ 10- 2 TROUBLESHOOTING----------------------------------------------------- 10- 2 LEFT CRANKCASE COVER REMOVAL/INSTALLATION ------- 10- 3 DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/ INSTALLATION ------------------------- 10- 5 DRIVE PULLEY DISASSEMBLY/INSPECTION/ASSEMBLY ---- 10- 9 DRIVEN PULLEY DISASSEMBLY/INSPECTION/ASSEMBLY-- 10-13...
Page 384: Schematic Drawing
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 SCHEMATIC DRAWING 10-1...
Page 385: Service Information
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed. Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 386: Left Crankcase Cover Removal/Installation
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Bolts LEFT CRANKCASE COVER REMOVAL/INSTALLATION REMOVAL Remove the left footboard (refer to the “FRAME COVERS” section in the chapter Remove the ten bolts, remove the left crankcase cover and rubber gasket. Left Front Cover Dowel Pins Remove the two dowel pins.
Page 387 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Bolts Install the left crankcase cover and tighten the ten bolts diagonally to specified torque. Torque: 1 kgf-m (10 N-m, 7.2 lbf-ft) Left Front Cover 10-4...
Page 388: Drive Pulley, Drive V-Belt And Driven Pulley
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/ INSTALLATION Drive Pulley Holder REMOVAL Use the special tool to hold the drive pulley, then remove the nut and washer. Special tool: Drive pulley holder A120E00058 Remove the drive pulley.
Page 389 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Remove the five bolts and then remove the Bolts fan guide. Fan Guide INSPECTION Inspect the drive belt for cracks, scaling, Drive Belt chipping or excessive wear. Measure the V-belt width Service limit (A): 30.8 mm (1.232 in) Replace the drive belt if out of specification.
Page 390 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Place a block on the plate nut. Block Compress the spring by using a commercially available puller, install the drive belt. ＊ The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turning direction.
Page 391 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Install the drive pulley assembly. Drive Pulley Holder Install the washer and nut. ＊ Make sure the “OUT SIDE” marks on the washer faces the left crankcase cover. Use the special tool to hold drive pulley, then tighten the nut to the specified torque.
Page 392: Drive Pulley Disassembly/Inspection/Assembly
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 DRIVE PULLEY Drive Face Boss DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the drive pulley (refer to “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section) Remove the drive face boss. Ramp Plate Slide Pieces Remove the ramp plate and four slide pieces.
Page 393 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 29.5 mm (1.18 in) Movable drive face/Slide pieces/Drive pulley face Check the slide pieces and movable drive face splines for wear, cracks or damage. Check the ramp plate for cracks or damage.
Page 394 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Dust Seals Check the dust seals on the movable drive face for wear or damage. Movable Drive Face Drive Face Boss ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss.
Page 395 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Install the slide pieces and ramp plate. Ramp Plate Slide Pieces Install the drive face boss. Drive Face Boss 10-12...
Page 396: Driven Pulley Disassembly/Inspection/Assembly
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 DRIVEN PULLEY Spring Compressor DISASSEMBLY/INSPECTION/ ASSEMBLY Compressor Nut Nut Wrench DISASSEMBLY Remove the driven pulley (refer to the “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section in this chapter). Use the special tool to remove the nut. Special tool: Driven pulley spring compressor A120E00059...
Page 397 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Remove the O-rings and dust seals from the Dust Seal Dust Seal movable driven face. O-ring O-ring Grooves INSPECTION Check the driven pulley for smooth operation. If any scratches or damage is found then replace as a set.
Page 398 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Dust Seal Dust Seal ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Apply grease to lips of the new dust seals and install into the movable driven face. Coat new O-rings with grease and install them into the movable driven face grooves.
Page 399 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Install spring collar. Spring Compressor Use the special tool to install spring and Compressor Nut Nut Wrench spring seat, then install and tighten the nut to the specified torque. Torque: 7.5 kgf-m (75 N-m, 54 lbf-ft) Special tool: Driven pulley spring compressor A120E00059...
Page 400 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 One-way Clutch Bearing CLUTCH REMOVAL/INSTALLATION REMOVAL Remove the fan guide (refer to the “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section in this chapter). Remove the nine bolts and then remove the clutch housing assembly and one-way clutch bearing.
Page 401 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 (USA type: Nut/Collar) Y-type Holder Use the special tool to hold clutch carrier assembly. Special tool: Y-type holder A120E00056 Not USA type: Use the special tool to remove the nut and washer. Special tool: Lock nut wrench A120E00067 (Not USA type: Nut/Washer)
Page 402 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Collar INSTALLATION Apply clean engine oil to the clutch carrier assembly and collar, then install the collar and clutch carrier assembly. Clutch Carrier Assembly (Not USA type: Washer) Install the washer (Not USA type). Install the collar (USA type).
Page 403 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Dowel Pins Install the dowel pins and gasket. Gasket Nut/Washer One-way Clutch Bearing Apply molybdenum disulfide grease to the one-way clutch bearing, then install it. Install the clutch housing and tighten the bolts to the specified torque in a crisscross pattern in 2-3 steps.
Page 404 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 CLUTCH DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the clutch housing and clutch carrier assembly (refer to the “CLUTCH REMOVAL/INSTALLATION” section in this chapter). Remove the one-way clutch bearing from the clutch housing. One-way Clutch Bearing Oil Seal Clutch housing removal (not USA type): Remove the oil seal.
Page 405 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Clutch Housing Clutch housing removal (USA type): Remove the clutch housing. Oil Seal Remove the oil seal, then remove the bearing. Bearing 10-22...
Page 406 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 INSPECTION Check the clutch housing for heat damage, wear or damage. Check the one-way clutch bearing for chafing, wear or damage. ＊ Replace the one-way clutch assembly and clutch housing as a set. Check the clutch shoe for heat damage. Measure the clutch shoe thickness.
Page 407 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Check operation (not USA type): Install the one-way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly. When turning the clutch housing clockwise, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty.
Page 408 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Snap Ring ASSEMBLY Clutch housing installation (not USA type): Apply clean engine oil, then install the new bearing. Install the snap ring. Bearing Oil Seal Install the clutch housing. Install the snap ring. Apply lightweight lithium-soap base grease to the new oil seal lip, then install the new oil seal.
Page 409 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Oil Seal Apply lightweight lithium-soap base grease to the new oil seal lip, then install the new oil seal. Clutch Housing Install the clutch housing. One-way clutch bearing installation: Install the one-way clutch bearing into the clutch housing.
Page 410 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION/TRANSMISSION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 11- 2 TROUBLESHOOTING----------------------------------------------------- 11- 2 SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/INSTALLATION -------------------------------- 11- 3 SECONDARY GEAR SHIMS ADJUSTMENT ------------------------ 11- 8 RIGHT CRANKCASE REMOVAL/INSTALLATION---------------- 11-10 BEARING REPLACEMENT IN THE RIGHT CRANKCASE ------- 11-12 TRANSMISSION REMOVAL/INSPECTION/INSTALLATION --- 11-17 UPPER SHIFT FORK DISASSEMBLY/ASSEMBLY ---------------- 11-25...
Page 411 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 11-1...
Page 412: Final Reduction/Transmission System
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS The bevel gear and output shaft can be serviced with the engine installed in the frame. SPECIAL TOOL Y-type holder A120E00056 Bearing puller A120E00037 Bearing drive A120E00014 Nut wrench A120E00066 TORQUE VALUES Crankcase bolt 1.2 kgf-m (12 N-m, 8.6 lbf-ft)
Page 413: Secondary Drive/Driven Bevel Gear
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/INSTAL LATION REMOVAL Drain engine oil into a clean container. (Refer to the “ENGINE OIL” section in the chapter Move the engine assembly forward (refer to the “ENGINE REMOVAL” section in the chapter 6) or remove the rear propeller (refer to the “REAR PROPELLER SHAFT Bevel Gear Case Cover...
Page 414 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Front Drive Shaft Install the front drive shaft. Hold universal joint nut by using a suitable bar, then remove the rear propeller shaft nut. Universal Joint Remove the rear middle joint. Rear Middle Joint Output Shaft Tap the output shaft by using a rubber hammer, then remove the output shaft,...
Page 415 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Secondary Drive Bevel Gear/Shim Using a chisel, unlock the nut. Hold the driven pulley by using the special tool (refer to the “DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/INSTALLATIO N” section in the chapter 10), then remove the nut.
Page 416 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Inspect the rear middle joint splines for wear or damage. Inspect the output shaft splines for wear or damage. Secondary Drive Bevel Gear/Shim INSTALLATION Install the shim and secondary drive bevel gear. Holder the driven pulley by using the special tool, then install and tighten the nut to the specified torque.
Page 417 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Front Drive Shaft Install the output shaft, secondary driven bevel gear and shim Install the rear middle joint. Install the front drive shaft. Hold universal joint nut by using a suitable bar, then install and tighten the rear middle joint nut to the specified torque.
Page 418 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM SECONDARY GEAR SHIMS ADJUSTMENT Set a dial gauge on the driven bevel gear as shown. Measure the backlash by turning the rear propeller shaft in each direction, reading the total backlash on the dial gauge. If the backlash is not within specification, the shim must be changed and the backlash should be rechecked until correct.
Page 419 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: Remove the driven bevel gear. Clean and degrease several teeth of the drive and driven bevel gears. Apply a coating of machinist’s layout dye or paste to several teeth of the driven bevel gear.
Page 420: Removal/Inspection/Installation
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM RIGHT CRANKCASE REMOVAL/INSTALLATION REMOVAL Remove the cam chain (refer to the “CAM CHAIN REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 8) Remove the secondary drive and driven bevel gear (refer to the “SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/ INSTALLATION”...
Page 421 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Remove the fifteen bolts from right crankcase. Remove the two dowel pins. INSTALLATION Apply a light but through coating of liquid gasket (Threebond 1215 or equivalent) to all crankcase mating surfaces except the oil passage area.
Page 422: Bearing Replacement In The Right Crankcase
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Install and tighten the bolts in a crisscross pattern in 2 or 3 steps Torque: 1.2 kgf-m (12 N-m, 8.6 lbf-ft) Apply oil Washer Plug Stopper Install the stopper, spring, washer and plug. Tighten the stopper plug to the specified torque.
Page 423 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Bearing Drive Install the new balance shaft/countershaft/primary drive shaft bearing by using the special tool. Special tool: Bearing driver A120E00014 Set Plate DRIVE SHAFT BEARING REPLACEMENT Remove the four bolts and two set plates. Remove the bearing.
Page 424 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Rear Side Bearing OUTPUT SHAFT FRONT/REAR BEARING REPLACEMENT ＊ The output shaft bearings can be replaced when the crankcase is assembly. Front Side Bearing REAR SIDE BEARING Remove the oil seal. Remove the nut by using the special tool. Special tool: Nut wrench A120E00066...
Page 425 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Install and tighten the nut to the specified torque by using the special tool. Torque: 11 kgf-m (110 N-m, 79.2 lb-ft) Special tool: Nut wrench A120E00066 Apply clean engine oil to the new oil seal lip then install the oil seal.
Page 426 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Install the snap ring. Apply clean engine oil to the new oil seal lip then install the new seal. Snap Ring Oil Seal 11-16...
Page 427: Transmission Removal/Inspection/Installation
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Shift Arm TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the bolt and then remove the shift arm. Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in this chapter) Bolt Shift Shaft Remove the shift shaft. Guide Bar Remove the transmission guide bar.
Page 428 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Upper Shift Fork Lower Shift Fork Remove the upper shift fork. Remove the lower shift fork. Remove the shift cam. Shift Cam Countershaft Assembly Remove the countershaft and driveshaft as an assembly. Disassemble the countershaft and the driveshaft.
Page 429 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Primary Drive Shaft Remove the primary drive shaft. Spring Remove the bolt/washer, then remove the stopper lever and spring. Stopper Lever Bolt/Washer INSPECTION Guide bar Measure the guide bar runout. Out of specification Replace. Service Limit: Less than 0.03 mm (0.0012 in) ＊...
Page 430 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Pawl Cam Follower Upper shift fork Inspect the shift fork cam follower and shift fork pawl. Scoring/beads/wear Replace a set. Inspection the spring. Cracks or damage Replace a set.. Spring Cam Follower Lower shift fork Inspect the shift fork cam follower and shift fork pawl.
Page 431 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Spring Stopper lever Check the stopper lever pawl for bends, damage or wear. Inspect the spring for cracks or damage. Stopper Lever Pawl Check the shift cam groove and shift cam gear. Wear or damage Replace.
Page 432 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Stopper Lever Shaft INSTALLATION Make sure the shaft nut specified torque in the V-belt compartment while holds the stopper lever shaft. Torque: 3 kgf-m (30 N-m, 21.6 lbf-ft) Stopper Lever Hook the spring onto the hook part of the stopper lever, squeeze the spring in to the groove of the left crankcase.
Page 433 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Primary Drive Shaft Countershaft Assembly Apply clean engine oil to the countershaft assembly, driveshaft assembly and primary drive shaft. Install the primary drive shaft. Install the countershaft and drive shaft assemblies as a set into the left crankcase. Drive shaft Assembly Apply clean engine oil to the shift cam, then install the shift cam.
Page 434 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Guide Bar Apply clean engine oil to the guide bar, install the guide bar. Align The Marks Install the shift shaft. ＊ Align the mark on the shift shaft gear with the mark on the shift cam gear. Shift Shaft Check the transmission operation.
Page 435: Upper Shift Fork Disassembly/Assembly
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Snap Ring/Washer Spring UPPER SHIFT FORK DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the upper shift fork (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the snap ring, washer and fork. Fork Washer Cam Pawl Remove the spring, cam pawl and washer.
Page 436: Drive Shaft Disassembly/Assembly/Inspection
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Reverse Gear DRIVE SHAFT DISASSEMBLY/ASSEMBLY/ INSPECTION DISASSEMBLY Remove the drive shaft assembly (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the washer (thick) and reverse gear. Washer (Thick) Washer (Thin) Remove the washer (thin). ASSEMBLY/INSPECTION Inspect the gear teeth.
Page 437: Countershaft Disassembly/Assembly/Inspection
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Washer Washer COUNTERSHAFT DISASSEMBLY/ASSEMBLY/ INSPECTION DISASSEMBLY Remove the countershaft assembly (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the washer and high drive gear. High Drive Gear High/Low Gear Clutch Remove the high/low gear clutch dog Stopper Wheel Remove the clip, then remove the washer and low drive gear.
Page 438 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM ASSEMBLY/INSPECTION Washer Washer Washer Clip Countershaft Stopper Wheel Reverse Drive Gear High Drive Gear Washer High/Low Gear Clutch dog Clip Low Drive Gear Clip Reverse Gear Clutch dog Inspect the gear teeth. Clip Blue discoloration/pitting/wear Replace.
Page 439 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 12- 2 TROUBLESHOOTING----------------------------------------------------- 12- 2 CRANK SHAFT AND BALANCE SHAFT REMOVAL/INSPECTION/INSTALLATION -------------------------- 12- 3 BEARING/OIL SEAL REPLACEMENT IN THE LEFT CRANKCASE---------------------------------------------------------------- 12- 6 12-0...
Page 440 .LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 12-1...
Page 441: Service Information
.LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. The following parts must be removed before separating the crankcase. Cylinder head ( Chapter 8) Cylinder/piston ( Chapter 9) Drive and driven pulleys ( Chapter 10) A.C.
Page 442: Crankshaft And Balance Shaft
.LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Balance Shaft Crankshaft CRANKSHAFT AND BALANCE SHAFT REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in the chapter 11). Remove the crankshaft and balance shaft together. INSPECTION Balance shaft Inspect the balance shaft gear teeth.
Page 443 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Measure the connecting rod small end free play (A). Out of specification: 0.8 ~ 1 mm (0.032 ~ 0.04 in) Replace the crankshaft. Measure the crankshaft run out (B). Service Limit (replace if over): 0.1 mm (0.004 in) Measure the connecting rod big end side clearance (C).
Page 444 .LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Mark (on the Balance Shaft) INSTALLATION Install the balance shaft and crankshaft into the left crankcase. ＊ Align the mark on the balance shaft with the mark on the crankshaft. Mark (on the Crankshaft) 12-5...
Page 445: Bearing/Oil Seal Replacement In The Left Crankcase
.LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Bearing Puller Primary Drive Shaft Bearing BEARING/OIL SEAL REPLACEMENT IN THE LEFT CRANKCASE BALANCE SHAFT/COUNTERSHAFT/ PRIMARY DRIVE SHAFT/BALANCE SHAFT BEARING REPLACEMENT Remove the balance shaft/countershaft/primary drive shaft /drive shaft bearing by using the special tool. Special tool: Bearing puller A120E00037...
Page 446 . DRIVE TRAIN MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE TRAIN __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 13- 2 TROUBLESHOOTING----------------------------------------------------- 13- 2 FRONT DRIVE SHAFT REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 13- 3 FRONT DRIVE SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY------------------------------------------------------------------ 13- 5 FRONT DRIVE REMOVAL/INSPECTION/INSTALLATION--------- 13-11 FRONT DRIVE DISASSEMBLY/INSPECTION/ASSEMBLY------ 13-14 FRONT DRIVE SHIM ASJUSTMENT ---------------------------------- 13-32 REAR DRIVE REMOVAL/INSPECTION/INSTALLATION ---------- 13-36 REAR DRIVE DISASSEMBLY/INSPECTION/ASSEMBLY ------- 13-40...
Page 447 . DRIVE TRAIN MXU 500 FRONT DRIVE REAR DRIVE 13-1...
Page 448: Service Information
. DRIVE TRAIN MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS Too little backlash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. Stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive assembly locking up, causing loss of control of the machine and possible injury to the rider.
Page 449: Installation
. DRIVE TRAIN MXU 500 FRONT DRIVE SHAFT REOMVAL/INSPECTION/ INSTALLATION REMOVAL Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14). Front Drive Shaft Remove the front drive shaft from front drive assembly. ＊ If it is difficult to remove the front drive shaft by hand, use the special tools.
Page 450 . DRIVE TRAIN MXU 500 Inspect the free play by using a push-and- pull motion (thrust movement). Excessive play Replace the joint assembly. INSTALLATION Install a new circlip into its groove in the splines. Circlip Apply lightweight lithium-soap base grease to the splines of the drive shafts and install the drive shaft to the front drive gear case.
Page 451: Front Drive Shaft Disassembly/Inspection/ Assembly
. DRIVE TRAIN MXU 500 FRONT DRIVE SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front drive shaft (refer to the “FRONT DRIVE SHAFT REOMVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the boot band of the case side joint. Band Slide the boot toward the center of the front drive shaft and remove the circlip from the case side joint.
Page 452 . DRIVE TRAIN MXU 500 Wipe off any grease and remove the snap ring from the groove on the front drive shaft. Snap Ring Remove the cage and boot from the front drive shaft. ＊ Do not disassemble the wheel side joint. If any damages are found, replace the wheel side joint with a new one.
Page 453 . DRIVE TRAIN MXU 500 Inspect the front drive shaft spline for wear or damage. If any damages are found, replace them with a new one. Inspect the front drive shaft for bends. If any damages are found, replace them with a new one.
Page 454 . DRIVE TRAIN MXU 500 Fit a boot on the drive shaft end, fitting the small diameter side of the boot to the shaft groove, fix its end with a new band. Band Cage Install the cage on the shaft. ＊...
Page 455 . DRIVE TRAIN MXU 500 Apply molybdenum disulfide grease to the entire surface of the cage and the inside of the case side joint/wheel side joint. Position Case side joint Wheel side joint Grease Quantity 85 g (2.8 oz) 45 g (1.5 oz) ＊...
Page 456 . DRIVE TRAIN MXU 500 After fitting the boot on the case side joint, insert a screw driver into the boot on the case side joint and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure.
Page 457: Front Drive Removal/Inspection/Installation
. DRIVE TRAIN MXU 500 FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Drain the front drive gear oil (refer to the “FRONT DRIVE GEAR OIL” in the chapter 3). Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14).
Page 458 . DRIVE TRAIN MXU 500 Remove the three bolts from front propeller shaft. Front Propeller Shaft Remove two front drive case mounting bolts/nuts from frame, then remove the case out of the frame. INSPECTION Check the breather rubber case for wear or damage.
Page 459 . DRIVE TRAIN MXU 500 INSTALLATION Install the front drive case into the frame. Install and tighten the two mounting bolts/nuts to the specified torque. Torque: 4 kgf-m (40 N-m, 29 lbf-ft) Install the front propeller shaft. Install and tighten the three new bolts to specified torque.
Page 460: Front Drive Disassembly/Inspection/Assembly
. DRIVE TRAIN MXU 500 FRONT DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY Remove the front drive case assembly (refer to the “FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the three bolts and then remove the 2WD/4WD shifting motor assembly. Shifting Motor Assembly Remove the 2WD/4WD shifting pinion and O-ring by hand.
Page 461 . DRIVE TRAIN MXU 500 Shim Remove the shim from right gear case. Front Drive Assembly Remove the front drive assembly from the left gear case. ＊ Do not attempt to disassembly the front drive assembly. The front drive is available only as an assembly.
Page 462 . DRIVE TRAIN MXU 500 Bearing Bearing Remove the bearings from the front drive assembly by using a commercially available bearing puller. ＊ If there is no abnormal condition, the bearing removal is not necessary The removed bearing must be replaced with a new one.
Page 463 . DRIVE TRAIN MXU 500 Remove the snap ring out of its groove and slide it towards the shifting sleeve. Snap Ring Remove the universal joint yoke assembly by using the special tool. Special tool: Joint yoke remover A120F00016 Snap Ring Remove the snap ring Remove the oil seal out of the right gear case.
Page 464 . DRIVE TRAIN MXU 500 Snap Ring Bearing Remove the snap ring. Remove the bearing by using the special tool. Special tool: Yoke bearing puller A120F00018 ＊ If there is no abnormal condition, the bearing removal is not necessary The removed bearing must be replaced with a new one.
Page 465 . DRIVE TRAIN MXU 500 Bearing Pull the pinion bearing from the shaft with a commercially available bearing puller. ＊ If there is no abnormal condition, the bearing removal is not necessary The removed bearing must be replaced with a new one. Bearing Remove the pinion gear pilot bearing by using the special tools.
Page 466 . DRIVE TRAIN MXU 500 Tap the C-ring out by using the special tool. Special Tool Insert a screwdriver into the hole on the special tool, then pull it out. Bearing Remove the bearings by tapping the universal joint with a copper hammer. ＊...
Page 467 . DRIVE TRAIN MXU 500 Oil Seal Oil Seal INSPECTION Inspect the gear case and oil seals for wear or damage. If any wear or damage is found, replace the oil seal with a new one. Fork Inspect the shifting fork and its rack-and- pinion for wear and damage.
Page 468 . DRIVE TRAIN MXU 500 Inspect the right gear case and oil seal for wear or damage. If any wear or damage is found, replace the oil seal with a new one. Check the right gear case bearing for wear or damage.
Page 469 . DRIVE TRAIN MXU 500 Inspect the splines of universal joint for wear or damage. If any defects are found, replace the universal joint yoke with a new one. Inspect the universal joint, wear and damage. If any defects are found, replace the bearings and universal joint as a set.
Page 470 . DRIVE TRAIN MXU 500 ASSEMBLY ＊ Before reassembly, thoroughly clean all parts in cleaning solvent. 13-24...
Page 471 . DRIVE TRAIN MXU 500 Install the new bearings to the front drive. Apply lightweight lithium-soap base grease to the new oil seal lips. Install the new oil seals into the gear cases by using the special tool. Special tool: Oil seal &...
Page 472 . DRIVE TRAIN MXU 500 Bearing Install the new bevel pinion gear pilot bearing into the right gear case by using a proper shaft. Pinion Gear/Bearing Snap Ring Install the pinion gear assembly and fix the bearing race with the snap ring. Install the shifting sleeve to the pinion gear shaft.
Page 473 . DRIVE TRAIN MXU 500 Snap Ring Install the new bearing into the right gear case by using the special tool and fix it with the snap ring. Special tool: Oil seal & bearing installer A120E00014 Dust Seal Install the new oil seal into the right gear case.
Page 474 . DRIVE TRAIN MXU 500 After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. Before install the universal joint yoke assembly, place the snap ring between the shifting sleeve and splines of universal joint.
Page 475 . DRIVE TRAIN MXU 500 Fix the universal joint yoke with the snap ring. Snap Ring Rack Fork Shaft Install the 2WD/4WD shifting fork, springs and shifting rack as shown. Apply sealant (three bond: 1215) to the shifting fork shaft plug and tighten it to the specified torque.
Page 476 . DRIVE TRAIN MXU 500 Front Drive Assembly Install the front drive to the right gear case. Install the dowel pin and apply a sealant (threebond: 1215) to the mating surface of the case. ＊ After the backlash and tooth contact have been checked or adjusted, apply a sealant to the mating surface of the case.
Page 477 . DRIVE TRAIN MXU 500 O-ring Coat a new O-ring with lightweight lithium- soap base grease and install the 2WD/4WD shifting pinion. Shifting Pinion Apply three bond: 1215 to the M8 bolt. Install the 2D/4WD shifting motor and tighten its mounting bolts to the specified torque.
Page 478: Front Drive Shim Asjustment
. DRIVE TRAIN MXU 500 Pinion Gear Wooden Piece or Plastic piece FRONT DRIVE SHIM ADJUSTMENT BACKLASH Install the removed left and right side shims and front drive assembly. Assemble the gear case (refer to the “FRONT DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in this chapter). ＊...
Page 479 . DRIVE TRAIN MXU 500 If the backlash it too small, replace the right side shim(s) with a thicker one. If the backlash too large, replace the right side shim(s) with a thinner one. If the right side shim was changed with a 0.1 mm thicker shim, replace the left side shim with one that is 0.1 mm thinner.
Page 480 . DRIVE TRAIN MXU 500 Remove the gear case. Measure the thickness of compressed solder with the micrometer. Shim thickness Select the proper size of shim(s) from the right chart, according as the compressed 0.7 mm (0.0276 in) solder thickness. 0.75 mm (0.0295 in) After selecting the proper size of shim(s), 0.8 mm (0.0315 in)
Page 481 . DRIVE TRAIN MXU 500 TOOTH CONTACT After backlash adjustment and left side shim selection are carried out, the tooth contact must be checked. Pay attention to the following points: Remove the drive ring gear. Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or Incorrect: Contact at tooth top...
Page 482: Rear Drive Removal/Inspection/Installation
. DRIVE TRAIN MXU 500 REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the left rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 15). Remove the four mounting nuts from the right rear axle housing. Rear Propeller Shaft Remove the rear drive assembly and rear propeller shaft together.
Page 483 . DRIVE TRAIN MXU 500 INSPECTION Check the breather rubber case for wear or damage. Also, check that the joint of the rubber case fits tightly. Turn the pinion gear and check that the gear turns smoothly and quietly without binding. If the gears do not turn smoothly or quietly, the gears and/or bearing may be damaged or faulty.
Page 484 . DRIVE TRAIN MXU 500 Apply Grease Compression Spring Install the compression spring into the pinion gear. Apply lightweight lithium-soap base grease to the pinion gear splines and inner. Apply Grease Rear Propeller Shaft Install the rear propeller shaft to the rear drive assembly.
Page 485 . DRIVE TRAIN MXU 500 Rear Propeller Shaft Rear Drive Assembly Install and tighten the four mounting nuts to the specified torque in a crisscross pattern in 2 or 3 steps. Torque: 5.5 kgf-m (55 Nm, 40 lbf-ft) 13-39...
Page 486: Rear Drive Disassembly/Inspection/Assembly
. DRIVE TRAIN MXU 500 O-ring (Case) REAR DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the rear drive assembly (refer to the “REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the O-rings from the gear case and cover grooves. O-ring (Cover) Remove the eight cover bolts in a crisscross pattern in several steps.
Page 487 . DRIVE TRAIN MXU 500 Oil Seal Bearing Remove the oil seal, then remove the bearing from the cover by using a proper pipe. ＊ If there is no abnormal condition, the oil seal or bearing removal is not necessary The removed oil seal and bearing must be replaced with new ones.
Page 488 . DRIVE TRAIN MXU 500 Shim Remove the left ring gear shim. Oil Seal Bearing Remove the oil seal, then remove the bearing from the case by using a proper pipe. ＊ If there is no abnormal condition, the oil seal or bearing removal is not necessary The removed oil seal and bearing must be replaced with new ones.
Page 489 . DRIVE TRAIN MXU 500 Remove the oil seal. ＊ If there is no abnormal condition, the oil seal removal is not necessary The removed oil seal must be replaced with a new one. Oil Seal Remove the bearing lock nut by using special tool.
Page 490 . DRIVE TRAIN MXU 500 Snap Ring/Bearing Remove the snap ring. Remove the pinion gear pilot bearing by using the special tools. Special tool: Bearing puller A120E00037 Bearing Pull the pinion bearing from the shaft with a commercially available bearing puller. ＊...
Page 491 . DRIVE TRAIN MXU 500 Oil Seal Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft. Inspect the pinion gear for wear or damage. If the pinion gear is damaged, inspect the ring gear.
Page 492 . DRIVE TRAIN MXU 500 Inspect the ring gear for wear or damage. If the ring gear is damaged, inspect the pinion gear also. If any defects are found, replace the bearings and ring gear with the new ones. ASSEMBLY ＊...
Page 493 . DRIVE TRAIN MXU 500 Bearing Install the shim(s) onto the pinion gear shaft, then install the new bearing onto the pinion shaft by using a proper pipe. Shim(s) Snap Ring/Bearing Install the new bevel pinion gear pilot bearing into the gear case by using a proper shaft.
Page 494 . DRIVE TRAIN MXU 500 Apply lightweight lithium-soap base grease to the new oil seal lips. Install the new oil seal into the gear case by using a proper pipe. Install the new water proof plate by using a proper pipe. Oil Seal Water Proof Plate Bearing...
Page 495 . DRIVE TRAIN MXU 500 Install the removed left shim to the gear Shim case. Ring Gear Install ring gear to the gear case. Shim Install the removed right shim to the ring gear. 13-49...
Page 496 . DRIVE TRAIN MXU 500 Apply a sealant (three bond: 1215) to the mating surface of the case, then install the gear cover. ＊ After the backlash and tooth contact have been checked or adjusted, apply a sealant to the mating surface of the case. Apply three bond: 1215 to the case bolts and tighten them to the specified torque in a crisscross pattern in 2 or 3 steps.
Page 497: Rear Drive Shim Adjustment
. DRIVE TRAIN MXU 500 REAR DRIVE SHIM Wooden Piece or Plastic piece Pinion Gear ADJUSTMENT BACKLASH Install the removed left and right side shims and rear drive assembly. Assemble the gear case (refer to the “REAR DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in this chapter). ＊...
Page 498 . DRIVE TRAIN MXU 500 If the backlash is not within specification, the shim must be changed and the backlash should be re-checked until correct. Right/Left Shim thickness Refer to the chart at the right for the A 1.55 mm (0.062 in) appropriate shim thickness.
Page 499 . DRIVE TRAIN MXU 500 Install and tighten its bolts to the specified torque in a crisscross pattern in 2 or 3 steps. Torque: 10-mm bolt: 5 kgf-m (49 N-m, 36 lbf-ft) 8-mm bolt: 2.5 kgf-m (25 N-m, 19 lbf-ft) ＊...
Page 500 . DRIVE TRAIN MXU 500 TOOTH CONTACT After backlash adjustment and right side shim selection are carried out, the tooth contact must be checked. Pay attention to the following points: Remove the ring gear. Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.
Page 501 . DRIVE TRAIN MXU 500 ＊ Make sure to check the backlash and Pinion Gear Shim thickness shim thickness after the tooth contact has A 2.05 mm (0.052 in) been adjusted, since it may have B 2 mm (0.08 in) changed.
Page 502: Front Propeller Shaft Disassembly/Inspection
. DRIVE TRAIN MXU 500 FRONT PROPELLER SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front propeller shaft (refer to the “FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). ” Front Propeller Shaft Compression Spring Boot Slide the spring rings back, then remove the boot, universal joint yoke, shaft and compression spring.
Page 503 . DRIVE TRAIN MXU 500 Bearings Remove the bearings by tapping the universal joint with a copper hammer. ＊ If there is no abnormal condition, the dust seal or bearing removal is not necessary. The removed dust seal and bearing must be replaced with new ones.
Page 504 . DRIVE TRAIN MXU 500 Inspect the universal joint, wear and damage. If any defects are found, replace the bearings, dust seal and universal joint as a set. Insert the universal joint to the new bearing and check the play by turning the universal joint, as shown.
Page 505 . DRIVE TRAIN MXU 500 Snap Ring ASSEMBLY Install the universal joint, new dust seal and new bearings. Install the snap rings. After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly.
Page 506 . DRIVE TRAIN MXU 500 Compression Spring Boot Fix the boot and spring ring, taking care not distort the boot. ＊ The dust boot should be fastened with the spring ring at the grooves in the propeller shaft. Universal Joint Yoke Spring 13-60...
Page 507: Rear Propeller Shaft Disassembly/Inspection
. DRIVE TRAIN MXU 500 REAR PROPELLER SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front propeller shaft (refer to the “REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Boot Slide the spring ring back, then remove the boot. Spring Snap Ring Remove the snap rings from the universal joint.
Page 508 . DRIVE TRAIN MXU 500 Bearings Remove the bearings by tapping the universal joint with a copper hammer. ＊ If there is no abnormal condition, the dust seal or bearing removal is not necessary. The removed dust seal and bearing must be replaced with new ones.
Page 509 . DRIVE TRAIN MXU 500 Inspect the universal joint, wear and damage. If any defects are found, replace the bearings, dust seals and universal joint as a set. Insert the universal joint to the new bearing and check the play by turning the universal joint, as shown.
Page 510 . DRIVE TRAIN MXU 500 After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. Boot Fix the boot and spring ring, taking care not distort the boot.
Page 511 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 14- 2 TROUBLESHOOTING----------------------------------------------------- 14- 3 FRONT WHEEL REMOVAL/INSPECTION/INSTALLATION ---- 14- 4 FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 5 FRONT SHOCK ABSORBER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 7 STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 8...
Page 512 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 14-1...
Page 513: Service Information
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. During servicing, keep oil or grease off the brake disk Inspect the brake system before riding. Unit: mm (in) SPECIFICATIONS Item...
Page 514: Troubleshooting
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling Insufficient tire pressure Bent rim Excessive wheel bearing play Bent spoke plate Faulty tire Improperly tightened axle nut Steers to one side or does not track straight Uneven front shock absorbers Soft front shock absorber Bent front arm...
Page 515: Front Wheel Removal/Inspection/Installation
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove four nuts from front wheel. Elevate the front wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over.
Page 516 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Cotter Pin FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove the front wheel ( refer to the “ FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Elevate the front wheels by placing a suitable stand under the frame.
Page 517 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 INSTALLATION Install the wheel hub, washer and nut. Cotter Pin ＊ Apply grease onto the wheel hub splines. Apply the front brake and then tighten the nut to the specified torque. Torque: 7 kgf-m (70 N-m, 50 lbf-ft) Install the cotter pin and band ends of cotter pin.
Page 518 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 FRONT SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION REMOVAL Remove the front shock absorber upper mount and lower mount bolts/nuts, then remove the front shock absorber. Shock Absorber INSPECTION Bush Collar/Bush/Dust Seals Inspect the shock absorber rod. Bends/damage Replace the shock absorber assembly.
Page 519: Front Wheel Hub Removal/Inspection
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Elevate the front wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over. Remove the front wheel hub (refer to the “FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION”...
Page 520 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Tie-rod Release the tie-rod ball joint/upper arm ball joint off the knuckle, using the special tool according to the following instructions. Special tool: Ball join remover A120F00012 Apply grease to the ball joint remover at the point shown.
Page 521 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Knuckle End Boot INSPECTION Inspect the knuckle end boot for wear or damage. If any damages are found, replace the knuckle end with a new one. Inspect the brake disc protection plate for damage.
Page 522: Installation
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 INSTALLATION Apply lightweight lithium-soap base grease to the bearings of the steering knuckle and lips of the dust seal before install the steering knuckle. Install the steering knuckle onto the upper and lower front arms and tighten the nuts to the specified torque.
Page 523 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Install the brake disc protection plate and then tighten the three bolts securely. Plate 14-12...
Page 524: Steering Knuckle Removal/Inspection
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Snap Ring STEERING KNUCKLE DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the knuckle end by using the appropriate collar. Collar Dust Seal Remove the dust seals.
Page 525 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Inspect the inner race play of the bearing by Play hand while it is in the steering knuckle. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Play If there is anything unusual, replace the bearing with a new one.
Page 526 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Spacer Install the new inner bearing by using the special tool. Special tool: Oil seal and bearing driver A120E00014 Install the spacer into the steering knuckle. ＊ Make sure the long side of the spacer faces the outer bearing Bearing Driver Install the new outer bearing by using the...
Page 527 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Install the steering knuckle end by using a appropriate pipe. Pipe Snap Ring Install the snap ring. 14-16...
Page 528: Front Arms Inspection/Removal/Installation
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 FRONT ARMS INSPECTION/REMOVAL/ INSTALLATION INSPECTION Remove the brake disc protection plate (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the front shock absorber (refer to the “FRONT SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION”...
Page 529 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Check the front upper arm vertical movement by moving it up and down. If vertical movement is tight, binding or roughs, replace the inner bushes as a set. Check the front lower arm bracket of the frame.
Page 530 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Front Upper Arm REMOVAL Remove the bolt on the hose clamp and then remove the brake hose from front upper arm. Remove the mounting bolt/nut from the front upper arm, then remove the front upper arm.
Page 531: Front Arms Disassembly/Inspection/Assembly
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 FRONT ARMS DISASSEMBLY/INSPECTION/ Snap Ring ASSEMBLY DISASSEMBLY Upper arm Remove the snap ring. Remove the upper arm end by using a appropriate collar. Front Protector Lower arm Remove the bolt and then remove the front protector.
Page 532 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Inspect the front upper arm. Cracks/bends/damage Replace. ＊ Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Inspect bushes. Wear/damage Replace. Front Protector Inspect the front lower arm. Cracks/bends/damage Replace.
Page 533 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Snap Ring Install the snap ring. Front Protector Install the front protector, then install and tighten the bolt securely. 14-22...
Page 534: Tie-Rod Removal/Inspection/Installation
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 TIE-ROD REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cotter pin and nut from tie-rod end steering knuckle side (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the cotter pin and nut from tie-rod end steering column side.
Page 535 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Adjustment steps: (The following procedures are done on both tie-rods, right and left.) Loosen the lock nuts. Adjust the tie-rod length by tuning both tie- rod ends. Tie rod length: 379.75±0.25 mm (15.19±0.01 in) Lock Nut Indentation Surface Lock Nut...
Page 536 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 INSTALLATION Install the tie-rod and onto the steering knuckle and steering column, then tighten the nuts. Torque: Steering knuckle side: 2.1 kgf-m (21 N-m, 16 lbf-ft) Steering column side: 2.1 kgf-m (21 N-m, 16 lbf-ft) ＊...
Page 537: Handlebar Removal/Inspection/Installation
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Master Cylinder HANDLEBAR REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the frame cover (refer to the “FRAME COVERS” section in the chapter Remove the two bolts and then remove left master cylinder from the handlebar. Remove the band and then remove the brake light switch wire from the handlebar.
Page 538 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Remove the four bolts, then remove the handlebar holders Handlebar Holders INSPECTION Inspect the handlebar. Cracks/bends/damage Replace. INSTALLATION Install handlebar and handlebar holder, then tighten the four bolts. Torque: 2.5 kgf-m (25 N-m, 18 lbf-ft) ＊...
Page 539 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 ＊ Be sure the handlebar holder mark face to front. First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. Install the handlebar switch by aligning the pin on the handlebar switch with the hole in the handlebar and then tighten the two screws securely.
Page 540 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Install the throttle assembly by aligning the upper holder lip with the mark in the handlebar and then install the lower holder and tighten the two screws securely. 14-29...
Page 541: Steering Column
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 STEERING COLUMN REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove frame covers (refer to the “FRAME COVERS” section in the chapter Remove the tie-rods (refer to the “TIE- ROD REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the handlebar (refer to the “HANDLEBAR REMOVAL/INSPECTION/ INSTALLATION”...
Page 542 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Remove the cotter pin and nut from the steering column under the frame body, then remove steering column. Remove the collar and dust seal. Collar Dust Seal Dust Seal Remove the dust seal. Remove the snap ring.
Page 543 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Replace the bearing by using the special Bearing Driver tool. Special tool: Oil seal and bearing driver A120E00014 Bearing Driver INSPECTION Inspect the steering column. Bends/damage Replace. ＊ Do not attempt to straighten a bent steering column, this may dangerously weaken the steering column.
Page 544 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Steering Bracket Cable Holder Install the dust seal, steering brackets and cable holder. Install and tighten the two bolts to the specified torque. Torque: 2.2 kgf-m (22 N-m, 16 lbf-ft) 14-33...
Page 545 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 15- 2 TROUBLESHOOTING----------------------------------------------------- 15- 2 REAR WHEEL REMOVAL/INSPECTION/INSTALLATION ------ 15- 3 REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 15- 4 REAR SHOCK ABSORBER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 15- 6 REAR AXLE REMOVAL/INSPECTION/INSTALLATION--------- 15- 7 REAR AXLE HOUSING...
Page 546 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 15-1...
Page 547: Service Information
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. During servicing, keep oil or grease off the brake disk Inspect the brake system before riding. Unit: mm (in) SPECIFICATIONS Item...
Page 548: Rear Wheel Removal/Inspection/Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove four nuts from rear wheel. Elevate the rear wheels by placing a suitable stand under the frame. ＊ Support the machine securely so there is no danger of it falling over.
Page 549 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Nut/Washer REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove the rear wheel ( refer to the “REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Elevate the rear wheels by placing a suitable stand under the frame.
Page 550 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Apply grease INSTALLATION Install the wheel hub and nut. ＊ Apply lightweight lithium-soap base grease onto the wheel hub splines, rear axle splines and dust seal lips of the axle housing. Apply grease Apply the front brake and then tighten the nut to the specified torque.
Page 551: Rear Shock Absorber Removal/Inspection/ Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Shock Absorber REAR SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION REMOVAL Remove the rear shock absorber upper mount nut and washer. Remove the lower mount bolt/nut, then remove the rear shock absorber. INSPECTION Collar/Bush/Dust Seals Rubber Bush Inspect the shock absorber rod.
Page 552: Rear Axle Removal/Inspection/Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR AXLE REMOVAL/INSPECTION/ INSTALLATION Rear Axle REMOVAL Remove the rear wheel hubs (refer to the “REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the rear axle from axle housing right side. ＊ Tap the axle and with a rubber hammer, this will avoid damage the axle thread.
Page 553: Rear Axle Housing
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the rear axle (refer to the “REAR AXLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the bolt from skid plate under the left axle housing. Skid Plate Remove the four nuts/bolts from the left housing (attaching the rear swing arm).
Page 554 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Remove the rear drive case assembly (refer to the “REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 13). Remove the four nuts/bolts from right housing. Remove the shock absorber lower mounting bolt/nut, then remove the right rear axle housing.
Page 555 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 INSTALLATION Install the right rear axle housing and four bolts onto the rear swing arm. Install and tighten the four nuts to the specified torque in a crisscross pattern in 2 or 3 steps. Torque: 5.5 kgf-m (55 N-m, 40 lbf-ft) Install rear shock absorber and lower mounting bolt onto the right axle housing.
Page 556: Rear Axle Housing Disassemblt/Assembly
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR AXLE HOUSING DISASSEMBLY/ASSEMBLY DISASSEMBLY/ASSEMBLY Remove the rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Left rear axle housing Remove the rear axle collar from axle housing. Collar Snap Ring Remove the dust seal from the axle housing.
Page 557 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Apply lightweight lithium-soap base grease to the new bearings of the axle housing and lips of the new dust seal before install them. Lightweight lithium-soap base grease Snap Ring Install the new bearings by using the special tool.
Page 558 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Right rear axle housing Dust Seal Snap Ring Remove the dust seal from the axle housing. Remove the snap ring from the axle housing. Remove the bearing using the proper shaft. Apply lightweight lithium-soap base grease to the new bearings of the axle housing and lips of the new dust seal before install them.
Page 559 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Dust Seal Snap Ring Install the new bearing by using the special tool. Special tool: Oil seal & bearing driver A120E00014 Install the snap ring. Install a new dust seal. 15-14...
Page 560: Rear Swing Arm Removal/Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR SWING ARM REMOVAL/INSTALLATION REMOVAL Remove the rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the swing arm pivot bolt cap. Remove the right pivot bolt. Remove the bolt and band, then remove the rear brake fluid hoses from swing arm.
Page 561 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Lock Nut Wrench INSTALLATION Install the right pivot bolt and the left pivot adjusting bolt. Tighten the right pivot bolt to the specified torque. Actual: 11.8 kgf-m (118 N-m, 85 lbf-ft) Tighten the left pivot adjusting bolt to the specified torque.
Page 562: Rear Swing Arm Disassembly/Inspection
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Skid Plate REAR SWING ARM DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY/INSPECTION Remove the three bolts and then remove the skid plate from swing arm. Inspect the skid plate for damage. If any damages are found, replace the skid plate with a new one.
Page 563 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Bearing Bearing Remove the bearings. Bearing Bearing Plate Inspect the swing arm bearings, outer races and bearing plates, if any damages are found, replace the them with new ones. Outer Race Remove the swing arm bearings outer races and bearing plates by using a proper pipe.
Page 564 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Bearing Plate ASSEMBLY Install the new swing arm bearing outer race and its new plate to the swing arm by using the special tool. Special tool: Oil seal & bearing driver A120E00014 ＊ When installing the bearing plate, make sure that the bulge of bearing plate faces inside.
Page 565 . BRAKE SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ BRAKE SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 16- 2 TROUBLESHOOTING----------------------------------------------------- 16- 3 BRAKE PADS REPLACEMENT----------------------------------------- 16- 4 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 16- 9 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 16-10 FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD)----- 16-11 REAR BRAKE FLUID CHANG/AIR BLEED-------------------------- 16-14 COMBINATION BRAKE FLUID CHANG/ AIR BLEED (ON ROAD) --------------------------------------------------- 16-17...
Page 566 . BRAKE SYSTEM MXU 500 16-1...
Page 567: Service Information
. BRAKE SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS During servicing, keep oil or grease off the brake pads and brake disk. Drain the brake fluid from the hydraulic brake system before disassembly. Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads.
Page 568: Troubleshooting
. BRAKE SYSTEM MXU 500 TROUBLESHOOTING Loose brake lever Tight brake lever Air in hydraulic brake system Seized piston Brake fluid level too low Clogged hydraulic brake system Hydraulic brake system leakage Smooth or worn brake pad Poor brake performance Brake noise Air in brake system Contaminated brake pad surface...
Page 569: Brake Pads Replacement
. BRAKE SYSTEM MXU 500 BRAKE PADS REPLACEMENT FRONT BRAKE PADS Remove the front wheel. ( refer to the “ FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION ” section in the chapter 14 ). Remove the two brake pad pins from the brake caliper. Remove the two mounting bolts from brake caliper and then remove brake caliper.
Page 570 . BRAKE SYSTEM MXU 500 A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins. Install the brake caliper mounting bolts to the specified torque.
Page 571 . BRAKE SYSTEM MXU 500 REAR BRAKE PADS (ON ROAD) Rear brake Remove the rear wheel. ( refer to the “ REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION ” section in the chapter 15 ). The replacement of rear brake and front brake pads are the same. Rear brake (combined) Remove the rear wheel.
Page 572 . BRAKE SYSTEM MXU 500 Compress the brake caliper holder and remove brake pads. A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins.
Page 573 . BRAKE SYSTEM MXU 500 Install the brake caliper mounting bolts to the specified torque. Torque: 3.2 kgf-m (32 Nm, 25 lbf-ft) Tighten the brake pad mounting pins. Torque: 1.8 kgf-m (18 Nm, 13 lbf-ft) 16-8...
Page 574: Front Brake Discs Removal/Inspection/ Installation
. BRAKE SYSTEM MXU 500 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the front wheel hub (refer to the “FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14). Remove the four bolts and then remove the brake disc. INSPECTION Measure the brake disc thickness.
Page 575: Rear Brake Disc Removal/Inspection/ Installation
. BRAKE SYSTEM MXU 500 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the rear wheel hub (refer to the “REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 15). Remove the four bolts and then remove the brake disc. Brake Disc INSPECTION Measure the brake disc thickness.
Page 576: Front Brake Fluid Change/Air Bleed (Off Road)
. BRAKE SYSTEM MXU 500 FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD) BRAKE FLUID CHANGE Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. ＊ Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
Page 577 . BRAKE SYSTEM MXU 500 Connect a transparent hose to the right caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose. Then, tighten the bleed valve nut.
Page 578 . BRAKE SYSTEM MXU 500 BRAKE SYSTEM BLEEDING 1. Connect a transparent hose to the bleed valves (right and left caliper). 2. Fully apply the brake lever after continuously pull it several times. Then, loosen the right caliper bleed valve nut to bleed air from the brake system.
Page 579: Rear Brake Fluid Chang/Air Bleed
. BRAKE SYSTEM MXU 500 REAR BRAKE FLUID CHANGE/AIR BLEED BRAKE LEVER Brake fluid change Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. ＊ Reservoir Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
Page 580 . BRAKE SYSTEM MXU 500 Brake system bleeding Bleed Valve 1. Connect a transparent hose to the bleed valve. 2. Fully apply the brake lever after continuously pull it several times. Then, loosen the caliper bleed valve nut to bleed air from the brake system. 3.
Page 581 . BRAKE SYSTEM MXU 500 Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.
Page 582: Combination Brake Fluid Chang
. BRAKE SYSTEM MXU 500 COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD) BRAKE FLUID CHANGE Place the machine on the level ground and set the handlebar upright. 1. Remove the two screws from the brake fluid reservoir cap. 2. Remove the brake fluid reservoir cap (front brake lever).
Page 583 . BRAKE SYSTEM MXU 500 Reservoir 4. Remove the brake fluid reservoir cap (brake pedal). ＊ Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. 5. Connect a transparent hose to the front brake caliper bleed valve (front right and left calipers) and then loosen the bleed valve nut.
Page 584 . BRAKE SYSTEM MXU 500 Reservoir 7. Fill the brake reservoir (front brake lever) with brake fluid. Bleed Valve 8. Loosen the delay valve bleed valve nut. Connect the transparent hose to the bleed valve. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.
Page 585 . BRAKE SYSTEM MXU 500 10. Connect a transparent hose to the right caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.
Page 586 . BRAKE SYSTEM MXU 500 Bleed Valve DELAY VALVE BLEEDING 1. Connect a transparent hose to the bleed valve (delay valve). 2. Fully apply the front brake lever after continuously pull it several times. Then, loosen the bleed valve nut (delay valve) to bleed air between the front brake master cylinder and the delay valve.
Page 587 . BRAKE SYSTEM MXU 500 6. Repeat these steps until the brake system is free of air. Then tighten the bleed valve nuts. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) ＊ When bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height (brake pedal).
Page 588: Brake Master Cylinders Removal/Inspection/ Installation
. BRAKE SYSTEM MXU 500 BRAKE MASTER CYLINDERS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Front/rear master cylinder Remove the brake reservoir cap and drain the brake fluid from the hydraulic brake system (refer to the “FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD” section or “REAR BRAKE Brake Lever FLUID CHANGE/AIR BLEED”...
Page 589 . BRAKE SYSTEM MXU 500 Rear Brake Master Cylinder Push the hole under the front brake master cylinder and then remove the brake light switch. Remove the screw and then remove the brake light switch from the rear brake master cylinder. Front Brake Master Cylinder Brake pedal master cylinder Remove the brake reservoir cap and drain...
Page 590 . BRAKE SYSTEM MXU 500 Remove fluid hose bolt/two washers and then disconnect the fluid hose. ＊ When removing the brake fluid hose bolt, be sure to place towels under the hose and plug the hose end to avoid brake fluid leakage and contamination. Remove the two mounting bolts and remove the master cylinder.
Page 591 . BRAKE SYSTEM MXU 500 ＊ ON ROAD TYPE: Refer to the “REAR PARKING SYSTEM” section in this chapter to install the left master cylinder holder. Install the brake fluid hose with the attaching bolt and two new sealing washers, then tighten the bolt to the specified torque.
Page 592 . BRAKE SYSTEM MXU 500 Brake pedal master cylinder Install and tighten the two mounting bolts to the specified torque. Torque: 1.2 kg-m (12 Nm, 8.6 lbf-ft) Install the brake fluid hose (ON ROAD: two brake fluid hose) with the attaching bolt and two (ON ROAD: three) new sealing washers, then tighten the bolt to the specified torque.
Page 593: Brake Master Cylinder Disassembly/Inspection
. BRAKE SYSTEM MXU 500 BRAKE MASTER CYLINDER DISASSEMBLY/INSPECTION/ Snap Ring ASSEMBLY DISASSEMBLY Front/rear brake master cylinder Remove the brake master cylinder (refer to the “BRAKE MASTER CYLINDERS REMOVAL/INSTALLATION” section in this chapter). Remove the piston dust boot and snap ring from the brake master cylinder.
Page 594 . BRAKE SYSTEM MXU 500 Dust Boot Snap Ring Remove the dust boot. Remove the snap ring, then remove the piston and spring together. INSPECTION Check the cylinder inside wall for scratch, corrosion or other abnormal condition. If any abnormal condition is found, replace the master cylinder.
Page 595: Assembly
. BRAKE SYSTEM MXU 500 ASSEMBLY ＊ Wash the master cylinder components with new brake fluid before reassembly. Do not wipe the brake fluid off with a rag after washing the components. When washing the components, use the specified brake fluid (DOT 4). Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Page 596 . BRAKE SYSTEM MXU 500 RELAY VALVE REMOVAL/DISASSEMBLY/INSP ECTION/ASSEMBLY/ INSTALLATION (ON ROAD) REMOVAL Drain brake fluid (refer to the “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter). ＊ Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts.
Page 597 . BRAKE SYSTEM MXU 500 Spring Delay Valve Body Push the piston out with a screwdriver. INSPECTION Check the delay valve body inside wall for scratch, corrosion or other abnormal condition. If any abnormal condition is found, replace the delay valve. Check the spring and piston for scratch, corrosion or other abnormal condition.
Page 598 . BRAKE SYSTEM MXU 500 INSTALLATION Install and tighten the mounting bolts to the specified torque. Torque: 1.2 kgf-m (12 Nm, 8.6 lbf-ft) Install the all brake fluid hoses with the attaching bolts and new sealing washers, then tighten the bolts to the specified torque. Torque: 3.5 kgf-m (35 Nm, 25 lbf-ft) Fill the specified brake fluid and bleed air from the brake system (refer to the...
Page 599: Front Brake Calipers Removal/Inspection/ Installation
. BRAKE SYSTEM MXU 500 FRONT BRAKE CALIPERS REMOVAL/INSTALLATION REMOVAL Drain the brake fluid from the hydraulic brake system (refer to the “FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD)” section or “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter). Remove the brake fluid hose bolt and two washers from the caliper.
Page 600: Rear Brake Calipers Removal/Inspection/ Installation
. BRAKE SYSTEM MXU 500 Caliper (Brake Lever) REAR BRAKE CALIPERS REMOVAL/INSTALLATION Drain the brake fluid from the hydraulic brake system (refer to the “REAR BRAKE FLUID CHANGE/AIR BLEED” section in this chapter). Remove the brake fluid hose bolt and two washers from the caliper.
Page 601: Rear Brake/Parking Brake Caliper Removal
. BRAKE SYSTEM MXU 500 Parking Brake Cable REAR BRAKE/PARKING BRAKE CALIPER REMOVAL/INSTALLATION (ON ROAD) Drain the brake fluid from the hydraulic brake system (refer to the “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter). Disconnect the parking brake cable from the caliper.
Page 602: Brake Caliper Disassembly/Inspection/Assembly
. BRAKE SYSTEM MXU 500 BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front or rear brake caliper (refer to the “FRONT BRAKE CALIPERS REMOVAL/INSTALLATION” section or “REAR BRAKE CALIPERS REMOVAL/INSTALLATION” section in this chapter). Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper.
Page 603 . BRAKE SYSTEM MXU 500 Push the piston dust seal inward to remove. Dust Seal Inner Oil Seal Pushing the piston oil seal outward to remove it. Clean the seals groove with brake fluid. ＊ Be careful not to damage the piston surface.
Page 604 . BRAKE SYSTEM MXU 500 ASSEMBLY ＊ Wash the brake caliper components with new brake fluid before reassembly. Do not wipe the brake fluid off with a rag after washing the components. When washing the components, use the specified brake fluid (DOT 4). Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Page 605: Rear Brake/Parking Brake Caliper
. BRAKE SYSTEM MXU 500 REAR BRAKE/PARKING BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY (ON ROAD) DISASSEMBLY/INSPECTION Remove parking brake caliper (refer to the “REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION ” section in this chapter). (ON ROAD Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper.
Page 606 . BRAKE SYSTEM MXU 500 Dust Boot Inspect the dust boots for deterioration or damage. If any damages are found, replace them with a new ones. Remove the caliper bracket. Remove the dust boot. Caliper Bracket Remove the dust seal and piston seal. Dust Seal Piston Seal Adjusting Bolt...
Page 607 . BRAKE SYSTEM MXU 500 Dust Boot Drive Bolt Inspect the dust boot for deterioration or damage. If any damage is found, replace it with a new one. Remove the drive bolt and dust boot. Brake Shaft Shaft Guide Inspect the drive shaft and shaft guide for wear or damage.
Page 608 . BRAKE SYSTEM MXU 500 O-ring Remove the O-ring. O-ring Inspect the O-ring for wear or damage. If any damages are found, replace it with a new one. O-ring INSTALLATION Apply silicone grease to the new O-ring, then install the new O-ring. 16-43...
Page 609 . BRAKE SYSTEM MXU 500 Parking Brake Case Install the parking brake case and two bolts. Tighten the bolts securely. Piston Seal/Dust Seal Apply silicone grease to the new piston seal and new dust seal, then install them. Install the piston. Piston Dust Boot Apply silicone grease to the brake shaft, then...
Page 610 . BRAKE SYSTEM MXU 500 Dust Boot Press the piston and turn the brake shaft counterclockwise to expand boot, then the brake shaft does not touch piston. Piston Parking Brake Arm Spring Install the parking brake arm and spring. ＊ Align the parking brake arm with the brake fluid inlet hole as shown.
Page 611 . BRAKE SYSTEM MXU 500 Dust Boot Install the dust boots. Apply silicone grease to caliper bracket, then install it. Caliper Bracket Install the spring plate. Spring Plate Install the parking brake caliper (refer to the “REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION ”...
Page 612 . BATTERY/CHARGING SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT/CHARGING CIRCUIT ----------- 17- 1 SERVICE INFORMATION------------------------------------------------ 17- 2 TROUBLESHOOTING----------------------------------------------------- 17- 4 BATTERY -------------------------------------------------------------------- 17- 5 CHARGING SYSTEM INSPECTION ----------------------------------- 17- 6 ALTERNATOR CHARGING COIL-------------------------------------- 17- 7 REGULATOR/RECTIFIER------------------------------------------------ 17- 8 ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 17-11...
Page 613 . BATTERY/CHARGING SYSTEM MXU 500 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT 12V 18AH BATTERY 17-1...
Page 614: Service Information
. BATTERY/CHARGING SYSTEM MXU 500 SERVICE INFORMATION GENERAL CAUTION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
Page 615 . BATTERY/CHARGING SYSTEM MXU 500 BATTERY CHARGING This model comes with a maintenance free (MF) battery. Remember the following about MF batteries. Use only the electrolyte that comes with the battery. Use all of the electrolyte Seal the battery properly Never open the seals again For battery charging, do not exceed the charging current and time specified on the battery.
Page 616: Troubleshooting
. BATTERY/CHARGING SYSTEM MXU 500 TROUBLESHOOTING Battery is damaged or weak Remove the battery. Incorrect Faulty battery Check the battery condition. Correct Disconnect the regulator/rectifier Incorrect connectors and recheck the battery Install the battery. Check the battery current leakage. current leakage. Correct Specified current leakage: 0.5 Ma Incorrect...
Page 617: Battery
. BATTERY/CHARGING SYSTEM MXU 500 BATTERY REMOVAL/INSTALLATION Battery removal 1. Make sure the ignition switch is OFF. 2. Remove the seat (refer to the “FRAME COVERS” section in the chapter 2) 3. Release the rings and remove the rubber band (1). 4.
Page 618: Charging System Inspection
. BATTERY/CHARGING SYSTEM MXU 500 BATTERY CHARGING Remove the battery (see page 17-5). Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. ＊ Turn the power ON/OFF at the charger, not at the battery terminals.
Page 619: Alternator Charging Coil
. BATTERY/CHARGING SYSTEM MXU 500 CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. ＊ Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.
Page 620: Regulator/Rectifier
. BATTERY/CHARGING SYSTEM MXU 500 Measure the resistance between each Yellow wire terminals. Standard: 0.1－0.3 (20ºC/68ºF) Check for continuity between each Yellow wire terminal of the alternator side connector and ground. There should be no continuity. Replace the alternator stator if resistance is out of specification, or if any wire has continuity to ground.
Page 621 . BATTERY/CHARGING SYSTEM MXU 500 Ground line Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Charging coil line Measure the resistance between each Yellow wire terminals. Standard: 0.1－0.3 (20ºC/68ºF) Check for continuity between each Yellow wire terminal and ground.
Page 622 . BATTERY/CHARGING SYSTEM MXU 500 Regulator/Rectifier Connector REMOVAL/INSTALLATION Disconnect the regulator/rectifier connectors. Remove the two bolts and then remove the regulator/rectifier. Installation is in the reverse order of removal. Regulator/Rectifier 17-10...
Page 623: Alternator Stator Removal/Inspection
. BATTERY/CHARGING SYSTEM MXU 500 ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION REMOVAL Drain the engine oil (refer to the “ENGINE OIL” section in the chapter 3). Disconnect the alternator stator connectors. Alternator Stator Connectors Oil Filler Plug Remove the starter pulley (refer to the “STARTER PULLEY REMOVAL/INSPECTION/INSTALLATI ON”...
Page 624 . BATTERY/CHARGING SYSTEM MXU 500 Dowel Pins Remove the two dowel pins and gasket. Gasket Remove the two pulse coil mount bolts. Remove the three stator mount bolts, grommet and the stator from the right crankcase cover. Stator Pulse Coil INSPECTION Check the stator and pulse coil for damage.
Page 625 . BATTERY/CHARGING SYSTEM MXU 500 INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1.2 kgf-m (12 N-m, 9 lbf-ft) Apply sealant to the grommet seating surface and install it to the cover groove properly. Install the pulse coil and tighten mount bolts to the specified torque.
Page 626 . IGNITION SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT------------------------------------------- 18-1 IGNITION CIRCUIT ------------------------------------------------------- 18-2 SERVICE INFORMATION------------------------------------------------ 18-3 TROUBLESHOOTING----------------------------------------------------- 18-4 IGNITION COIL INSPECTION ------------------------------------------ 18-5 IGNITION CONTROL MODULE ---------------------------------------- 18-6 18-0...
Page 627: Ignition System Layout
. IGNITION SYSTEM MXU 500 IGNITION SYSTEM LAYOUT 18-1...
Page 628: Ignition Circuit
. IGNITION SYSTEM MXU 500 IGNITION CIRCUIT (ON ROAD) (OFF ROAD) 18-2...
Page 629: Service Information
. IGNITION SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. When servicing the ignition system, always follow the steps in the troubleshooting on page 18-3. The ignition timing cannot be adjusted since the ignition control module is factory preset.
Page 630: Troubleshooting
. IGNITION SYSTEM MXU 500 TROUBLESHOOTING LOW PEAK VOLTAGE Cranking speed is too low (battery is undercharged). Poorly connected connectors or an open circuit in the ignition system. Faulty ignition-coil. Faulty ignition control module. NO PEAK VOLTAGE Short circuit in engine stop switch or ignition switch wire. Faulty engine stop switch or ignition switch.
Page 631: Ignition Coil Inspection
. IGNITION SYSTEM MXU 500 IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Check cylinder compression and check that the spark plugs is installed correctly in the cylinder. Disconnect the spark plug cap from the spark plug. Spark Plug Cap Spark Plug Connect known good spark plug to the spark plug cap and ground the spark plugs to the...
Page 632: Ignition Control Module
. IGNITION SYSTEM MXU 500 IGNITION PULSE GENERATOR INSPECTION Disconnect the ignition pulse generator connector. Measure the ignition pulse generator resistance between the Green/White wire and Blue/Yellow wire. Standard: 791 (20ºC/68ºF) Ignition Pulse Generator Connector IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug cap from the spark plug (page 18-4).
Page 633 . IGNITION SYSTEM MXU 500 ＊ Due to the semiconductor in circuit, it RESISTANCE INSPECTION is necessary to use a specified tester for accurate testing. Use of an improper Measure the resistance between the terminals. tester in an improper range may give false readings.
Page 634 . STARTER SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTER SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19- 1 STARTING CIRCUIT ------------------------------------------------------ 19- 2 SERVICE INFORMATION------------------------------------------------ 19- 3 TROUBLESHOOTING----------------------------------------------------- 19- 3 STARTER MOTOR --------------------------------------------------------- 19- 6 STARTER RELAY SWITCH/STARTER MAG ----------------------- 19- 7 RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 19- 9 RECOIL STARTER HANDLE REPLACE ------------------------------ 19-11...
Page 635: Starting System Layout
. STARTER SYSTEM MXU 500 STARTING SYSTEM LAYOUT 19-1...
Page 636: Starting Circuit
. STARTER SYSTEM MXU 500 STARTING CIRCUIT (ON ROAD) (OFF ROAD) 19-2...
Page 637: Service Information
. STARTER SYSTEM MXU 500 SERVICE INFORMATION GENERAL Always turn the ignition switch to “OFF” before servicing the starter motor. The motor could suddenly start, causing serious injury. The starter motor can be serviced with the engine in the frame. When checking the starter system, always follow the steps in the troubleshooting flow chart (page 19-2).
Page 638 . STARTER SYSTEM MXU 500 (From previous page) Check for loose or poorly Poorly connected terminal Abnormal connected starter MAG terminals. Normal Check for loose or poorly Poorly connected starter motor cable. Abnormal connected or broken starter Open circuit in starter motor cable. motor cable.
Page 639 . STARTER SYSTEM MXU 500 (From previous page) Check the starter MAG Faulty engine stop switch (OFF ROAD). No voltage voltage (page 19-7). Faulty starter switch. Loose or poor contact of connector. Battery voltage registers Open circuit in wire harness. Check the starter relay for a Abnormal Faulty starter MAG.
Page 640: Starter Motor
. STARTER SYSTEM MXU 500 Starter Motor Cable STARTER MOTOR INSPECTION Disconnect the starter motor cable from the starter MAG. Turn the ignition switch to “ON”. Connect the starter motor cable directly to the battery positive terminal. If the starter motor does not turn, the starter motor is faulty.
Page 641: Starter Relay Switch/Starter Mag
. STARTER SYSTEM MXU 500 Starter MAG STARTER RELAY SWITCH/STARTER MAG INSPECTION Turn the ignition switch to “ON”. Squeeze the brake lever or pedal fully. The coil is normal if the starter relay switch clicks. Squeeze and hold the brake lever or pedal fully then push the starter switch.
Page 642 . STARTER SYSTEM MXU 500 Starter MAG CONTINUTY INSPECTION Disconnect the starter MAG switch connector and cables. Connect a fully charged 12 V battery positive wire to the relay switch Yellow/Red wire terminal and negative wire to the Yellow/Green wire terminal. There should be continuity between the cable terminals while the battery is connected, and no continuity when the battery is...
Page 643: Recoil Starter Removal/Inspection/ Installation
. STARTER SYSTEM MXU 500 Recoil Starter RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION ＊ The recoil starter can not start the engine when the battery is removal. REMOVAL Remove the six bolts, then remove the recoil starter assembly. Remove the two dowel pins. Dowel Pins INSTALLATION Install the dowel pins.
Page 644 . STARTER SYSTEM MXU 500 Recoil Starter Install the recoil starter assembly. Install and tighten the six bolts diagonally. 19-10...
Page 645: Recoil Starter Handle Replace
. STARTER SYSTEM MXU 500 RECOIL STARTER HANDLE REPLACE Remove the recoil starter assembly (refer to the “RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the cap on the handle. Knot Replace the handle. ＊ Before untying the knot above the starter handle, make a knot in the rope so that the rope is not pulled into the housing.
Page 646: Recoil Starter Disassembly/Inspection
. STARTER SYSTEM MXU 500 RECOIL STARTER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the recoil starter assembly (refer to the “RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the handle (refer to the “RECOIL STARTER HANDLE REPLACE” section Knot in this chapter). Rope Untying the knot, then turn the reel clockwise with the rope slowly.
Page 647 . STARTER SYSTEM MXU 500 Coil Spring Remove the reel, then remove the coil spring. ＊ Wear hand and eye protection when removing the reel, since the spring may quickly unwind and cause and injury. Reel INSPECTION Pull the rope and check that the ratchet is pushed out.
Page 648 . STARTER SYSTEM MXU 500 Coil Spring Inspect the coil spring for fatigue. Hook ASSEMBLY Apply molybdenum disulfide grease to the coil spring, then install the coil spring. ＊ Wear hand and eye protection when installing the spring, since the spring may quickly unwind and cause and injury.
Page 649 . STARTER SYSTEM MXU 500 Coil Spring Install the reel. ＊ Wear hand and eye protection when installing the reel, since the spring may quickly unwind and cause and injury. Engage the part of the reel with coil spring end. Reel Housing Collar...
Page 650 . STARTER SYSTEM MXU 500 Unhook the rope, then turn the reel clockwise with the rope slowly. Apply Grease Apply Grease Apply molybdenum disulfide grease to the washer and friction plate. Spring Bolt/Washer/Plate/Spring Install the pawl spring, friction plate/washer. Install and tighten the new bolt securely. 19-16...
Page 651 . STARTER SYSTEM MXU 500 Pull the rope and check that the ratchet is pushed out. 19-17...
Page 652: Starter Pulley Removal/Inspection/ Installation
. STARTER SYSTEM MXU 500 STARTER PULLEY REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the recoil starter assembly (refer to the “RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the starter pulley nut by using a suitable bar. Nut/Washer INSPECTION Inspect the starter pulley for cracks or pitting. Inspect the O-ring for wear or damage.
Page 653 . STARTER SYSTEM MXU 500 INSTALLATION Install the starter pulley and washer. Install and tighten the nut to the specified torque by using suitable bar. Torque: 5.5 kgf-m (55 N-m, 40 lbf-ft) Nut/Washer 19-19...
Page 654: Starter Clutch Removal/Inspection/ Installation
. STARTER SYSTEM MXU 500 Flywheel Puller STARTER CLUTCH REMOVAL/INSPECTION/ INSTALLATION REMVOAL Remove the right crankcase cover (refer to the “ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 17). Remove the flywheel/driven gear by using the special tool. Flywheel/Driven Gear Special tool: Flywheel puller A120E00060...
Page 655 . STARTER SYSTEM MXU 500 INSPECTION Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise. Remove the starter driven gear by turning the driven gear.
Page 656 . STARTER SYSTEM MXU 500 Reduction Gear INSTALLATION Apply oil to the starter reduction gear. Install the starter reduction gear to the right crankcase. Woodruff Key Install the woodruff key in the crankshaft key groove. Apply molybdenum oil solution to the starter driven gear bushing.
Page 657 . STARTER SYSTEM MXU 500 Reduction Gear Driven Gear Clean any oil from the tappered portion of the flywheel I.D. Install the flywheel/driven gear onto the crankshaft, aligning the key way with woodruff key. Flywheel 19-23...
Page 658 20. LIGHTS/SWITCHES MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/SWITHCES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 20- 1 BULBS REMOVAL--------------------------------------------------------- 20- 2 HORN (ON ROAD) --------------------------------------------------------- 20- 4 IGNITION SWITCH -------------------------------------------------------- 20- 5 HANDLEBAR SWITCH --------------------------------------------------- 20- 5 GEAR INDICATOR SWITCH -------------------------------------------- 20- 8 SPEED SENSOR ------------------------------------------------------------ 20- 9 2WD/4WD SELECTING SYSTEM -------------------------------------- 20-10 FUEL UNIT ------------------------------------------------------------------ 20-13...
Page 659: Service Information
20. LIGHTS/SWITCHES MXU 500 SERVICE INFORMATION A continuity test can be made with the switches installed on the vehicle. All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be made without removing the pat from the vehicle.
Page 660: Bulbs Removal
20. LIGHTS/SWITCHES MXU 500 Headlight Connector BULBS REMOVAL HEADLIGHT Disconnect the headlight wire connector. Remove the rubber boot from the headlight case. Rubber Boot Lock Clip Relax the lock clip to remove the bulb and replace with a new one. Install the bulb, aligning the bulb socket groove with the bulb tab and set the lock clip.
Page 661 20. LIGHTS/SWITCHES MXU 500 Bulb TAIL/BRAKE LIGHT Bulb Socket Remove the bulb socket by turning it counterclockwise. Remove the bulb. Install the bulb in the reverse order of removal. Rubber Boot TURN SIGNAL LIGHT (ON ROAD) FRONT Remove the rubber boot from the turn signal light case.
Page 662: Horn (On Road)
20. LIGHTS/SWITCHES MXU 500 Bulb REAR Remove the bulb socket by turning it counterclockwise. Remove the bulb. Install the bulb in the reverse order of removal. Bulb Socket LICENCE LIGHT BULB (ON ROAD) Remove the two screws and licence light cover.
Page 663: Ignition Switch
20. LIGHTS/SWITCHES MXU 500 IGNITION SWITCH INSPECTION Disconnect the ignition switch connectors. (Refer to the “FRAME COVER” section in the chapter 2.) Check for continuity between the switch side connector terminals in each switch position. Continuity should exist between the color coded wires as right: REPLACEMENT Release the switch wire from the wire clips...
Page 664 20. LIGHTS/SWITCHES MXU 500 Hazard Switch (ON ROAD) Winker Switch Horn Switch Light Switch Start Switch 2WD/4WD Select Button 20-6...
Page 665 20. LIGHTS/SWITCHES MXU 500 Dimmer Switch (OFF ROAD) Start Switch Engine Stop Switch Passing Switch 2WD/4WD Select Button 20-7...
Page 666: Gear Indicator Switch
20. LIGHTS/SWITCHES MXU 500 GEAR INDICATOR LIGHT SWITCHES INSPECTION Disconnect the gear indicator light switch wire connector. Check for continuity between the switch side connector terminal and engine ground. Gear Indicator Light Switch REPLACEMENT Disconnect the gear indicator light switch connector.
Page 667: Speed Sensor
20. LIGHTS/SWITCHES MXU 500 SPEED SENSOR Disconnect the connector. Remove the bolt then remove the speed sensor. If the speedometer, odometer or trip meter does not function properly. Inspect the connection of speed sensor connector. If the connection is all right, replace the speedometer with a new one.
Page 668: 2Wd/4Wd Selecting System
20. LIGHTS/SWITCHES MXU 500 2WD/4WD SELECTING SYSTEM The 2WD/4WD selecting system consists of the following components: 2WD/4WD selecting button 2WD switch 4WD switch 2WD/4WD change ECU 2WD/4WD motor Battery TROUBLSHOOTING Does not shift to 2WD/4WD (2WD/4WD motor will not run.) Turn on the ignition switch.
Page 669 20. LIGHTS/SWITCHES MXU 500 Check the 2WD switch or 4WD switch. Faulty 2WD/ switch or 4WD Incorrect (See page 12) switch Correct Open circuit in wire harness The 2WD/4WD motor runs, but does not shift to 2WD/4WD. Check the front drive sliding dog (refer to the “FRONT DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY”...
Page 670 20. LIGHTS/SWITCHES MXU 500 2WD/4WD change ECU Make sure the 2WD/4WD selecting button is correct (see page 20-11). Disconnect the 2WD/4WD motor connector. Turn on the ignition switch. Listen for a click from the 2WD/4WD change ECU when the 2WD/4WD selecting button is pushed.
Page 671: Fuel Unit
20. LIGHTS/SWITCHES MXU 500 Apply three bond: 1215 to the 2WD/4WD switches and tighten them to the specified torque. Torque: 2.2 kgf-m (22 N-m, 16 lbf-ft) FUEL UNIT REMOVAL Remove the fuel tank cover (refer to the “FRAME COVERS” section in the chapter Remove the fuel unit connectors.
Page 672 . WIRING DIAGRAMS MXU 500 21-0...
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Page 676 MXU 500 Wiring Diagram (ON ROAD Type) WIRE COLORS (GROUNG/MARKING) POSITION LIGHT B: BLACK G: GREEN L: BLUE O: ORANGE FUSE R: RED V: VIOLET W: WHITE W/B(1) Y: YELLOW BR: BROWN BR/B GR: GRAY LG: LIGHT GREEN BAT+ SB: SKY BLUE BR/L BR/B BACK LIGHT...
Page 677 MXU 500 Wiring Diagram (ON ROAD Type) WIRE COLORS (GROUNG/MARKING) POSITION LIGHT B: BLACK G: GREEN L: BLUE O: ORANGE FUSE R: RED V: VIOLET W: WHITE W/B(1) Y: YELLOW BR: BROWN BR/B GR: GRAY LG: LIGHT GREEN BAT+ SB: SKY BLUE BR/L BR/B BACK LIGHT...

KYMCO 2006 MXU 500 Off-Road Owner's Manual

Table of Contents

Location of the Warning and Specification Labels

Safety Information

Description and Machine Identification

Control Functions Ignition Switch

Pre-Operation Checks

Operation

Riding Your Atv

Periodic Maintenance and Adjustment

Cleaning and Storage

General Information

2. Frame Covers/Exhaust Muffler

3. Inspection/Adjustment

4. Lubrication System

5. Fuel System 5

6 Cooling System

Cylinder Head/Valves

Cylinder/Piston

Drive Pulley/Driven Pulley/Clutch

Transmission System 11

Left Crankcase/Crankshaft/ Balance Shaft

Drive Train

Front Wheel/Front Suspension Steering System

15. Rear Wheel/Axle/Shock Absorber/Swing Arm

16 Brake System

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for KYMCO 2006 MXU 500 Off-Road