KYMCO MXU 450i Service Manual
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KYMCO MXU 450i Service Manual

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F
O
R
E
W
O
RD
This
I<YMCO
Service MaOUill
con!Q ins
service,
maintenance,
and troubleshooting information
for the
2010
KYMCO
MXU
4Q0i
.
Tho3
complete
manual
is
des\gned to
aid service
.
.personnel in service-or1ented
applications.
This manual
is
divided
intco
sections.
Each section
covers
a specific ATV
component or system
and,
in
addition to
the
standard service
procedures,
includes
disassembling,
inspecting,
and assembling
Instructions,
\M1en using lthis manual as a
guide,
the technician should use
discretion
as
lo
how
much disassembly
is
needed
to
correct any given
condition.
The service technician ::•hould pecome familiar with the operatlon
and
construction
of
each
component
or
system
KYMCO.
This
manual
will assist tl'le service technician
In
becoming
more
aware
of
and
efficient
With servicing procedures. Such efficiency no!
only
helps build consumer
confidence but also saves time and
labor.
All
KYMCO
ATV publications and decals display the words
warnrng, Cautton.
Note. and
At
This
Point
to
emphasize imoortant
information.
The
symbol @i!Hilii!J
Identifies
personal
safety-related
Information.
Be
sure to follow the directive because it deals
With the
possibility of severe personallnjury or even
death.
The symbol
E
'
·
"ii!·lll
identifies
unsafe practices
which may result in ATV-re
lated
damage.
Follow the dfrecbve because it deals
with the
possibility of damaging part or parts of
the
ATV.
The
symbol
•
NOTE:;
identifies supplementary
lnformaiion worthy
of particular
attention.
The
symbol
@AT THIS
POINT
directs the tech- nician to
certain
and specific procedures
to
promote
efficlency and to
improve
clarity.
At the time of publication, all
information,
photographs, and illustrations
were
technically correct.
Some photographs used
in this
manual are used
for clarity
purposes only and are not designed to
depict actual
conditions.
Because
KYMCO
Inc. constantly refines and
improves its
products,
no
retroactive obligation
is
i!'l(lllrred.
All materials and
specificaotions
are
subject
to change
without
notice.
Keep this manual
accessible
m
the shop area
for
reference.
KYMCO
Inc.
®
2010 KYMCO hie.
October
2010
®
""
Trademarks
of
KYMCO Inc., TaiWan

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Summary of Contents for KYMCO MXU 450i

  • Page 4 Standard Torque (frame Parts)
  • Page 5 Standard Torque (engine Parts)
  • Page 13 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. Insert the forming spring into the element with the closely wrapped end of the spring toward the open end of the element.
  • Page 17 Oil level stick...
  • Page 18 13. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. ! CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the “...

  • Page 19: Front Differential/Rear Drive Lubricant

    CC163D KC0077A 3. Drain the oil into a drain pan by removing the AT THIS POINT drain plug from each. To check/service oil strainer, see Section 3. 4. Place the oil strainer into position beneath the crankcase and secure with the cap screws. Tighten securely.
  • Page 22 raise a headlight beam, turn the adjusting bolt in direction (a). lower a headlight beam, turn the adjusting bolt in direction (b). inner a headlight beam, turn the adjusting bolt in direction (c). outer a headlight beam, turn the adjusting bolt in direction (d).
  • Page 23 Low range High range Neutral Reverse...
  • Page 24 Bleeder Screw...
  • Page 25 1 mm (0.039 in.)
  • Page 26 KC149A KC128 2. Slide the auxiliary brake pedal part way off the 4. Thread a cap screw from the V-belt cover into the pivot stud but do not remove; then remove the cap driven pulley fixed face and push the movable face screws from the V-belt housing and remove the open allowing the V-belt to drop down between cover.
  • Page 27 3. With two drops of red Loctite #271 on the threads and with the splines of the clutch shaft protruding through the movable drive face, install the nut and tighten to 147 ft-lb. KC135 KC152A KC131 2. Install the bushing over the clutch shaft; then install the movable drive face assembly on the clutch shaft.
  • Page 30 Oil Filter Wrench E052 NOTE: KYMCO recommends the use of new Piston Pin Puller gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/ Side Case Puller transmission.
  • Page 35 Disconnect the water temperature sensor connector. Remove the water hose to thermostat. Water Temperature Sensor Water Hose Clip Disconnect the water hose with the water pump. Disconnect the water hose with the thermostat. From Radiator To Cylinder To Thermostat...
  • Page 42 2. Remove the valve seal and the lower remaining 2. Acceptable diameter range (intake valve) must be spring seat. Discard the valve seal. within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face.
  • Page 45 ATV-1069 ATV-1085B 2. Install the compression rings (1 and 2) so the let- Measuring Piston Skirt/ ter(s) on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring Cylinder Clearance end gaps are on directly opposite sides of the pis- ton according to the illustration.
  • Page 47 CC127D ATV-1068A 2. Wash the cylinder in parts-cleaning solvent. Measuring Camshaft Runout 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the sur- NOTE: If the camshaft is out of tolerance, it must face using a ball hone. be replaced.
  • Page 48 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance 1. Remove the adjuster screws and jam nuts. CC145D 6.
  • Page 49 CF060A MD1343A 2. If damaged, the camshaft must be replaced. ! CAUTION Incorrect installation of the piston rings will result in engine damage. Installing Top-Side 1. Install the piston on the connecting rod making Components sure there is a circlip on each side and the open end of the circlip is directed upwards or down- wards.
  • Page 54 Removing Left-Side Components A. Cover/Stator Assembly 1. Remove the cap screws securing the outer mag- neto cover and remove the cover. 2. Remove the left-side cover-to-crankcase mounting cap screws noting the location of the 8 mm cap MD1188 screw with the washer near the middle of the left-side cover.
  • Page 56 4. Install the cam stopper assembly. 5. Install the gear shift shaft assembly and washer making sure to align the alignment marks. MD1122 Installing Left-Side MD1239 Components 6. Install starter idler gear (No. 2) and starter idler gear (No. 1). A.
  • Page 57 Right-Side Components AT THIS POINT To service center crankcase components only, pro- ceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those KC142A components.
  • Page 58 MD1034 MD1068 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Remove the V-belt. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the posi- tions of the different-lengthed cap screws for installing purposes.
  • Page 59 11. Remove the cap screw holding the gear shift posi- tion switch onto the right-side crankcase half. MD1014 KC324A 12. Remove the gear shift position switch. Account for a spacer. MD1016 15. Remove the cam chain. KC326A 13. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes.
  • Page 60 MD1017 MD1060 18. Remove the snap ring holding the oil pump driven 21. Remove the four cap screws securing the oil gear. strainer cover; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. NOTE: Note the directional arrow for installing purposes.
  • Page 61 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must Servicing Right-Side be replaced. Components NOTE: The oil pump is a non-serviceable compo- nent and must be replaced as a complete assem- bly.
  • Page 62 MD1060 MD1017 4. Place the pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. NOTE: Always use a new snap ring when install- ing the oil pump driven gear.
  • Page 63 KC325A MD1117 12. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. KC326B B. Clutch Cover C. Fixed Drive Face MD1342 D. Movable Drive Face 13. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loc- NOTE: Steps 1-9 in the preceding sub-section tite #271).
  • Page 64 14. Slide the fixed drive face assembly onto the front shaft. 15. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approxi- mately 3/4 in.
  • Page 65 Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining pur- poses. MD1313 Disassembling Crankcase Half 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the pinion gear.
  • Page 66 MD1326 KC325 4. Remove the shift fork shaft and the outer shift 7. Remove the counterbalance gear. Account for the fork. key. 8. Remove the counterbalance shaft. MD1327 5. Remove snap ring and gear from the output side of the gear cluster. Remove the gear cluster and the MD1024 9.
  • Page 67 10. Remove the secondary drive gear/secondary NOTE: Continue to remove, measure, and install driven gear retaining nut. From inside the crank- until backlash measurement is within tolerance. case using a rubber mallet, drive out the output Note the following chart. shaft assembly.
  • Page 68 ATV-0104 CC290D 2. Maximum diameter must not exceed specifica- Correcting Tooth Contact tions. Measuring Connecting Rod NOTE: If tooth contact pattern is comparable to (Small End Deflection) the correct pattern illustration, no correction is necessary. 1. Place the crankshaft on a set of V-blocks and If tooth contact pattern is comparable to an incorrect mount a dial indicator and base on the surface pattern, correct tooth contact according to the follow-...
  • Page 69 Measuring Connecting Rod 2. Acceptable width range must be within specifica- tions. (Big End Width) COUNTERSHAFT 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. ! CAUTION 2. Acceptable width range must be within specifica- When disassembling the countershaft, care must be tions.
  • Page 70 3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing Assembling Crankcase until the oil begins to smoke; then slide the crank- Half shaft assembly into place. NOTE: For ease of assembly, install components on the right-side crankcase half.
  • Page 71 9. Install the input driveshaft. KC325 7. Align the inner shift fork with the gear cluster and with the inner washer in place, install the gear MD1326 10. Install the washer, spacer, sleeve, and reverse idler cluster and inner shift fork. While holding the gear gear.

  • Page 86: Stator Coil

    2. Select the OHMS position on the tester and con- RESISTANCE (Charging Coil) nect the red tester lead to the lavender/red wire; then move the gear shift lever to the R (reverse) CAUTION position. The meter must read less than 1 ohm. 3.
  • Page 92 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-14 Rear Gear Case ............ 6-18 Hub................ 6-19 Hydraulic Brake Caliper......... 6-20 Troubleshooting Drive System....... 6-22 Troubleshooting Brake System......
  • Page 95 ATV0082A AF628D 3. Remove the front wheels. 9. Pull the steering knuckle away from the axle tak- ing care not to damage the seals as the axle clears 4. Pump up the hand brake; then engage the brake the knuckle. lever lock.
  • Page 96 KC291A CD106 3. Using a side-cutter (or suitable substitute), remove Disassembling Input Shaft the boot clamps; then remove the boots and splined drive from the input shaft. NOTE: This procedure can be performed on a 4. Remove the input shaft from the pinion housing. rear gear case;...
  • Page 97 AF983 AF993 AF984 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulphide Grease. NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air;...
  • Page 98 1. Remove the cap screws securing the pinion hous- ing. Account for the coupler, fork, and spring. KX222 4. Install the input shaft into the housing; then install the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot KX209 2.
  • Page 99 KX178 CC875 5. Place the differential with the open side down; then lift the housing off the spider assembly. Account for shim(s) and mark as right-side. CC876 7. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 101 CC884 CC892 3. Install the pinion gear assembly into the housing. 6. Install the shift fork assembly making sure the fork Using the 48 mm Internal Hex Socket, secure the leg is facing upward. Apply a small amount of oil pinion gear assembly with the existing lock collar.
  • Page 102 CD110 CF267A 8. Install the proper shim onto the ring gear spider 10. Apply a liberal amount of grease to the O-ring; assembly making sure the chamfer side of the then install it on the assembled cover assembly shim is facing toward the ring gear. Install the ring making sure to seat the O-ring down around the gear in the housing;...
  • Page 103 CC886 CC889 3. Using a flat-nosed punch, drive the bearing out of 3. Install the pinion shaft and secure with the existing the housing. 48 mm lock collar. Tighten to 125 ft-lb. CC887 CC890 4. Place a punch on the edge of the lock collar in the Installing Needle Bearing oil gallery area;...

  • Page 105: Drive Axles

    Drive Axles REMOVING REAR DRIVE AXLES 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- AF610D port stand to avoid injury. 2. Pump up the hand brake; then engage the brake lever lock.
  • Page 106 NOTE: If a boot is damaged in any way, it must be replaced with a boot kit. 3. Inspect the gear case seals for nicks or damage. DISASSEMBLING AXLES 1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot. KC285 9.
  • Page 107 8. Apply 40 grams (1/3 of contents) of grease from NOTE: The recess of the bearing must face the Grease Pack into the knuckles and the new out- toward the housing. side boot. CD022 ATV-1052 5. Inspect the splines of the shaft, the bearing ring, and the housing for damage.
  • Page 108 CD024 CD022 ! CAUTION ASSEMBLING AXLES The bearing ring must go onto the shaft with the 1. Install the inner boot with the small clamp making side without splines facing toward the small clamp sure the ends of the clamp are positioned correctly. of the inner boot or severe damage will result.

  • Page 109: Rear Gear Case

    4. Tighten the hub hex nut (from step 2) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. CD024 8. Inspect the axle components for correct position- ing of the four clamps.

  • Page 110: Hub

    REMOVING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the sup- KC169 port stand to avoid injury. 3. Remove the two cap screws and lock nuts securing 2.

  • Page 111: Hydraulic Brake Caliper

    3. Install the hub assembly onto the shaft. 2. Drain the brake fluid from the caliper, hose, and master cylinder. 4. Secure the hub assembly with the nut. Tighten only until snug. ! CAUTION 5. Secure the brake caliper to the knuckle with the Brake fluid is highly corrosive.
  • Page 112 2. Compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. PR240A CLEANING AND INSPECTING 1. Clean all caliper components (except the brake PR238 pads) with parts-cleaning solvent. 2. Inspect the brake pads for damage and excessive wear.

  • Page 113: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.
  • Page 114 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-2 Rear A-Arms ............7-3 Wheels and Tires ............ 7-4 Troubleshooting ............7-6...

  • Page 115: Suspension

    Suspension Front A-Arms REMOVING NOTE: Critical torque specifications are located in Section 1. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. Shock Absorbers ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.

  • Page 116: Rear A-Arms

    5. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to 35 ft-lb. 6. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. 7. Secure the hub assembly with the nut. Tighten only until snug.

  • Page 119: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1.
  • Page 120 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-3 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-5 Front Rack ............... 8-6 Front Bumper Assembly .......... 8-6 Front Body Panel/Fender......... 8-7 Exhaust System ............8-8 Rear Body Panel/Rack ..........

  • Page 123: Steering Knuckles

    KC308 PR287A 3. Using a sharp utility knife, split the handlebar grip from end to end and peel off the rubber. 4. Using an adhesive solvent, clean all glue residue from the handlebar. INSTALLING 1. Apply a liberal amount of Handlebar Grip Adhe- sive to the inside of the new grip.

  • Page 124: Measuring/Adjusting Toe-In

    PR287A KC283 2. Install the knuckle to the upper and lower ball 8. Pump the hand brake lever; then engage the brake joints and secure with the two cap screws. Tighten lever lock. to 35 ft-lb. 9. Secure the hub nut (from step 6) to the shaft. Tighten to 200 ft-lb.

  • Page 125: Front Rack

    CLEANING AND INSPECTING 6. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the belly panel). NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
  • Page 127 LCD Gauge Connector LCD Gauge Connector...

  • Page 130: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.
  • Page 131 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-2 LCD Gauge ............. 9-3...
  • Page 132 4. Inspect the banjo-fitting and bolt for cracks and deterioration and the condition of the fittings Hand Brake Lever/ (threaded and compression). Master Cylinder INSTALLING Assembly 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. NOTE: The master cylinder is a non-serviceable 2.
  • Page 134 NOTES...
  • Page 136 SECTION 10 - COOLING SYSTEM TABLE OF CONTENTS Radiator...........10-2 Hoses/Thermostat......10-3 Coolant Mixture........10-4 Fan/Water Pump.......10-5 10-1...

  • Page 137: Radiator

    10-2...

  • Page 138: Hoses/Thermostat

    10-3...

  • Page 139: Coolant Mixture

    10-4...

  • Page 140: Fan/Water Pump

    10-5...
  • Page 141 10-6...
  • Page 142 . EFI SYSTEM MXU 450i FUEL INJECTION SYSTEM FUEL PUMP/FUEL LEVEL SENSOR ---------------------------------------- 11- 2 WATER TEMPERATURE SENSOR ------------------------------------------ 11- 5 THROTTLE BODY/T-MAP SENSOR/ISC/TPS ---------------------------- 11- 6 DIAGNOSTIC TOOL CONNECTOR ----------------------------------------- 11- 9 TPS/ISC RESET ------------------------------------------------------------------- 11-10 ECU ---------------------------------------------------------------------------------- 11-11...

  • Page 143: Fuel Pump/Fuel Level Sensor

    . EFI SYSTEM MXU 450i FUEL PUMP/FUEL LEVEL SENSOR The electric fuel pump and fuel level sensor are serviceable components. either component fails, it must be replaced as a set. TESTING ＊ Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in...
  • Page 144 . EFI SYSTEM MXU 450i 5. Connect a multimeter to the power supply leads with the orange/red tester lead to the red wire and the black tester lead to the black wire; then turn the ignition switch to the ON position. The meter should read battery voltage.

  • Page 146: Water Temperature Sensor

    . EFI SYSTEM MXU 450i WTS SENSOR (Water Temperature Sensor) REMOVAL / INSTALLATION Drain the coolant from the cooling system. Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring. Install a new O-ring and WTS sensor.

  • Page 147: Throttle Body/T-Map Sensor/Isc/Tps

    ● Do not damage the throttle body, it may cause the throttle and idle valve isn’t synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it by a wrong way. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
  • Page 148 . EFI SYSTEM MXU 450i TPS INSPECTION Support the ATV on a level surface. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector. Terminal Normal V/R (+) -V/G(-) Throttle position sensor (TPS) resistance 3500~6500Ω(at 20°C/68°F)
  • Page 149 . EFI SYSTEM MXU 450i DISASSEMBLY Screw T-MAP sensor Remove the screws and then remove the ISC. Remove the screw. Remove the T-MAP sensor. Remove the screw and then remove the TPS. ASSEMBLY ＊ The throttle position sensor (TPS) and idle...

  • Page 150: Diagnostic Tool Connector

    . EFI SYSTEM MXU 450i Injector Apply oil onto a new O-ring. When install the T-MAP sensor onto the throttle body, being careful not to damage the O-ring. ＊ Always replace an O-ring with a new one. Install the set plate and tighten the screw O-ring securely.

  • Page 151: Tps/Isc Reset

    . EFI SYSTEM MXU 450i TPS/ISC RESET ● If close or open the throttle grip randomly, the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled. It can cause hard to start engine or idling speed is not smooth when engine installation.

  • Page 152: Ecu

    . EFI SYSTEM MXU 450i ECU Connector ELECTRIC CONTROL UNIT (ECU) ＊ ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; cause damaged. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be...
  • Page 153 . EFI SYSTEM MXU 450i INSPECTION Outlook checking Checking for ECU pin(1-48) if has damage. Checking for ECU part number is as 3920A-LKK7-E00 Voltage inspection Connect the meter (+) probe to the B4(R/W)wire and the meter (-) probe to the M3(G/B) wire to measure the voltage.

  • Page 154: Celp

    . EFI SYSTEM MXU 450i CHECK ENGINE LAMP (CELP) When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to CELP (Check Engine Lamp) know the lamp is available and connect to ECU.
  • Page 155 . EFI SYSTEM MXU 450i How To Show Failure Code You can read the failure code by as below : Turn switch on. The CELP will be lighted for 2 seconds then off. The CELP start to blink to show the failure codes (The number of blinks from 1 to 22).

  • Page 156: Celp Failure Codes List

    . EFI SYSTEM MXU 450i CELP FAILURE CODES LIST Blink Failure Fault description Priority Solution Codes Slow down the vehicle and go to workshop for Engine temperature checking immediately. P0217 overheat Confirm if the engine temperature sensor or electric circuit is abnormality.
  • Page 157 . EFI SYSTEM MXU 450i Blink Failure Fault description Priority Solution Codes Check if the connector of ignition coil is loosen. Ignition coil or electric Check if the ECU is signaled to Ignition coil. P0350 circuit malfunction Check if the power source and resistance is...

  • Page 158: Tilt Switch

    . EFI SYSTEM MXU 450i TILT SWITCH(ROLL SENSOR) INSPECTION Support the ATV level surface. Turn the ignition switch to “OFF” Remove the screws, washers and tilt switch. ＊ disconnect tilt switch connector during inspection. Place the tilt switch vertical as shown, and turn the ignition switch to “ON”.

  • Page 160: Diagnostic Report

    11. EFI SYSTEM MXU 450i Diagnostic Report LKK7 SF : Customer : Eng. No: Production Service Mileage : Date : Date : Reason of repair: □ maintenance □ breakdown Item Memo Date Reference ECU No Hardware Ver Software Ver QK120010...
  • Page 161 11. EFI SYSTEM MXU 450i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A-LEB2-E00(ENGLISH VERSION) Version:V1.0.7 11-20...
  • Page 162 11. EFI SYSTEM MXU 450i 1. FI DIAGNOSTIC TOOL  This tool is developed by KYMCO and for KYMCO vehicle only.  Please refer to the specification when serving this vehicle.  This tool is without battery inside. The power is provided from vehicle.
  • Page 163 11. EFI SYSTEM MXU 450i 2. DTC INSPECTION PROCEDURE To Show four functions on the screen when switching on power. LKK7 LKK7 is for MXU450i A). ECU version: Including of model name, ECU number, identifications number and software version. Press the “Enter” button Press the "...
  • Page 164 11. EFI SYSTEM MXU 450i B). Press the " Down " button and then turn to the first page. LKK7 C). Press the " Enter " button to check the DTC failure code LKK7 11-23...
  • Page 165 11. EFI SYSTEM MXU 450i D). Press the " Enter " button E). Press the " Enter " button F). Display what's DTC number on this DTC-List. Press the " Enter " button and then turn to the previous page...
  • Page 166 11. EFI SYSTEM MXU 450i G). Press the " UP " button H). Press the " Enter " button and then turn to the previous page . I). Press the " UP " button 11-25...
  • Page 167 11. EFI SYSTEM MXU 450i J). Press the " Enter " button and then turn to the first page. LKK7 11-26...
  • Page 168 11. EFI SYSTEM MXU 450i 3. DTC CLEAR PROCEDURE ). Check the DTC LKK7 ). Press the " Enter " button LKK7 ). Choose " Load DTC " Press the " Down " button 11-27...
  • Page 169 11. EFI SYSTEM MXU 450i ). Press the " Enter " button and the indicator is lighting. LKK7 ). Clearing DTC completed if the indicator is off. LKK7 11-28...
  • Page 170 11. EFI SYSTEM MXU 450i 4. DATA ANALYSIS PROCEDURE ). Press the " Down " twice LKK7 ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 LKK7 ). Down-page 01 The measure figures including of Engine speed, Battery voltage and Engine speed.
  • Page 171 11. EFI SYSTEM MXU 450i ). Down-page 02 The measure figures including of TPS position, TPI idle adapted and ISC step . Press the “ Down” button to enter page 03. ). Down-page 03 The measure figures including of engine temperature, air temperature and intake pressure.
  • Page 172 11. EFI SYSTEM MXU 450i ). Down-page 05 The measure figures including of gear position and gear ratio. Press the “ Down” button to enter page 06. ). Down-page 06 The measure figures including of rollover voltage ( The function setting is not allowed).

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