Troubleshooting Drive System; Troubleshooting Brake System - KYMCO MXU 450i Service Manual

Troubleshooting Drive
System
Problem: Power not transmitted from engine to wheels
Condition
1. Rear axle shafts serration worn - broken
Problem: Power not transmitted from engine to either front wheel
Condition
1. Secondary drive - driven gear teeth broken
2. Propeller shaft serration worn - broken
3. Coupling damaged
4. Coupling joint serration worn - damaged
5. Front drive - driven bevel gears broken - damaged
6. Front differential gears/pinions broken - damaged
7. Sliding dogs/shaft fork worn - damaged
8. Front drive axle worn - damaged
9. Front drive axle serration worn - damaged
Troubleshooting Brake
System
Problem: Braking poor
Condition
1. Pad worn
2. Pedal free-play excessive
3. Brake fluid leaking
4. Hydraulic system spongy
5. Master cylinder/brake cylinder seal worn
Problem: Brake lever travel excessive
Condition
1. Hydraulic system entrapped air
2. Brake fluid low
3. Brake fluid incorrect
4. Piston seal - cup worn
Problem: Brake fluid leaking
Condition
1. Connection joints loose
2. Hose cracked
3. Piston seal worn
6-22
Remedy
1. Replace shaft
Remedy
1. Replace gear(s)
2. Replace shaft
3. Replace coupling
4. Replace joint
5. Replace gear(s)
6. Replace gears - pinions
7. Replace gear(s)
8. Replace axle
9. Replace axle
Remedy
1. Replace pads
2. Replace pads
3. Repair - replace hydraulic system component(s)
4. Bleed hydraulic system - correct or repair leaks
5. Replace master cylinder
Remedy
1. Bleed hydraulic system
2. Add fluid to proper level
3. Drain system - replace with correct fluid
4. Replace master cylinder
Remedy
1. Tighten joint
2. Replace hose
3. Replace brake caliper