Service Information; Troubleshooting - KYMCO 2006 MXU 500 Off-Road Owner's Manual

13
. DRIVE TRAIN

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.
An apparent oil leak on a new or nearly new machine may be the result of a rust-preventative
coating or excessive seal lubrication.
Always clean the machine and recheck the suspected location of an apparent leakage.
TORQUE VALUES
Front drive gear case mounting bolt
Front propeller shaft bolt
Shifting fork shaft plug
Front drive gear case bolt
2WD/4WD shift motor mounting bolt (M8) 2.3 kgf-m (23 N-m, 16.5 lbf-ft) Apply threebond: 1215
2WD/4WD shift motor mounting bolt (M6) 1.2 kgf-m (12 N-m, 8.5 lbf-ft)
Rear drive gear case mounting nut
Rear drive gear case bolt (M10)
Rear drive gear case bolt (M8)
SPECIAL TOOLS
Oil seal & bearing installer
Bearing puller
Joint yoke remover
Drive shaft puller
Yoke bearing puller
Pinion puller set
Bearing lock nut wrench

TROUBLESHOOTING

1. A pronounced hesitation movement during acceleration, deceleration, or sustained speed.
(This must not be confused with engine surging or transmission characteristics.)
2. A "rolling rumble" noticeable at low speed; a high-pitched whine from front drive
component or area.
3. A locked-up condition of the shaft drive train mechanism, no power transmitted from the
engine to the front and /or rear wheel.
Bearing damage
Improper backlash
Gear tooth damage
Broken propeller shaft
Broken gear teeth
Seizure due to lack of lubrication
Small foreign objects lodged between the moving parts.
4 kgf-m (40 Nm, 29 lbf-ft)
4.5 kgf-m (45 N-m, 32.4 lbf-ft)
1.5 kgf-m (15 N-m, 11 lbf-ft) Apply threebond: 1215
2.3 kgf-m (23 N-m, 16.5 lbf-ft) Apply threebond: 1215
5.5 kgf-m (55 Nm, 40 lbf-ft)
5 kgf-m (49 N-m, 36 lbf-ft) Apply threebond: 1215
2.5 kgf-m (25 N-m, 19 lbf-ft) Apply threebond: 1215
A120E00014
A120E00037
A120F00016
A120F00017
A120F00018
A120F00021
A120F00020
MXU 500
13-2