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KYMCO MXU 500i/700i Repair Manual
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KYMCO MXU 700i and MXU 500i Service Information
Models Covered:
2013 KYMCO MXU 700i
2013 KYMCO MXU 500i
Using this manual
This manual has been designed to assist trained mechanics in servicing the
models listed above. If you do not have the proper training or tools to perform a
particular task it is best if you seek out a service professional.
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Summary of Contents for KYMCO MXU 500i
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Page 1: Models Covered
KYMCO MXU 500i/700i Repair Manual Home KYMCO MXU 700i and MXU 500i Service Information Models Covered: 2013 KYMCO MXU 700i 2013 KYMCO MXU 500i Using this manual This manual has been designed to assist trained mechanics in servicing the models listed above. If you do not have the proper training or tools to perform a... - Page 2 This manual was written using the latest information available at the time of publication. Illustrations in this manual are shown to help you with the basics of performing the jobs listed. The pictures in this manual may not depict the actual vehicle you’re working on, however the procedures will be similar.
- Page 3 1.Quick Reference This chapter provides a quick reference source of technical specifications and information for the KYMCO MXU 700i and MXU 500i models. 1.Break In Procedure ..............1-2 2.General Information ..............1-3 3.VIN and Warning Stickers ............1-26 4.Special Tools ................1-27 5.Specifications ................
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Page 4: Periodic Maintenance
2.Periodic Maintenance This chapter covers the location and servicing of the periodic maintenance items for the KYMCO MXU 700i and MXU 500i models. 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. - Page 5 3.Fuel System This chapter covers the location and servicing of the fuel system components. 1.Airbox ..................3-4 2.Check Engine Lamp (CELP) ............3-10 3.Component Location ..............3-15 4.Diagnostic Tool ................3-21 5.Fuel Injection Sensors ............... 3-37 6.Fuel Injector ................3-51 7.Fuel Pump ...................
- Page 6 4.External Components This chapter covers the location and servicing of the external components. 1.Drive Selector ................4-5 2.Exhaust System ................. 4-14 3.Front Bumper ................4-24 4.Front Cover ................. 4-29 5.Front Fender ................4-33 6.Fuel Tank ..................4-45 7.Instrument Cover ............... 4-63 8.Mudguards and Footrests ............
- Page 7 5.Engine MXU700i This chapter covers the location and servicing of the engine components for the KYMCO MXU 700i models. For the MXU 500i models see the Engine MXU 500i topic 1.Engine Specifications ..............5-11 2.Engine Removal ................. 5-19 3.Engine Installation ..............5-29 4.Rocker Cover ................
- Page 8 5.Engine MXU 500i This chapter covers the location and servicing of the engine components for the KYMCO MXU 500i. For the engine in the MXU 700i see the Engine MXU700i topic. 1.Cylinder Head Cover ..............5-8 2.Camshaft ..................5-18 3.Camshaft Installation ..............5-39 4.Cylinder Head ................
- Page 9 6.Cooling System This chapter covers the location and servicing of the external components for the KYMCO MXU 700i and MXU 500i models. 1.Coolant ..................6-4 2.Pressure Testing ................ 6-13 3.Radiator ..................6-16 4.Thermostat .................. 6-30 5.Water Pump ................6-37 7. CVT Continuously Variable Transmission...
- Page 10 4.Clutch Removal ................7-51 5.Clutch Installation ..............7-64 8.Final Drive This chapter covers the location and servicing of the final drive components for the KYMCO MXU 700i and MXU 500i models. 1.Drive Shafts ................8-3 2.Differential Removal ..............8-19 3.Differential Installation .............. 8-23 4.Differential Disassembly ............
- Page 11 9.Brake System This chapter covers the location and servicing of the front brake components for the KYMCO MXU 700i and MXU 500i models. 1.Brake Discs ................. 9-3 2.Brake Pedal ................. 9-10 3.Front Brake Calipers ..............9-30 4.Rear Brake Calipers ..............9-43 5.Master Cylinders ................
- Page 12 12.Front Suspension This chapter covers the location and servicing of the front suspension components for the KYMCO MXU 700i and MXU 500i models. A-arms .................... 12-2 Front Shock Absorbers ..............12-11 13.Rear Suspension This chapter provides the rear suspension specifications for the KYMCO MXU 700i and MXU 500i models.