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KYMCO MXU 500 IRS Manual
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KYMCO MXU 500 IRS Manual

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MXU 500 IRS
By KWANG YANG Motor Co., Ltd.
First Edition, Dec. 2008
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-LAA0CD-IT

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Summary of Contents for KYMCO MXU 500 IRS

  • Page 1 MXU 500 IRS By KWANG YANG Motor Co., Ltd. First Edition, Dec. 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-LAA0CD-IT...
  • Page 2 MXU 500 IRS PREFACE This Service Manual describes the TABLE OF CONTENTS technical features and servicing procedures for the MXU 500 IRS. GENERAL INFORMATION FRAME COVERS /EXHAUST MUFFLER Section 1 contains the precautions for all operations stated in this manual.

  • Page 3: Table Of Contents

    . GENERAL INFORMATION MXU 500 IRS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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...

  • Page 4: Serial Number

    . GENERAL INFORMATION MXU 500 IRS SERIAL NUMBER (1) Location of Frame Serial Number (1) Location of Engine Serial Number...

  • Page 5: Specifications

    . GENERAL INFORMATION MXU 500 IRS SPECIFICATIONS Forced pressure & Lubrication type Model No. LAA0CA/LAA0CD Wet sump Name & Type MXU 500 IRS Oil pump type Trochoid Overall length 2203 mm Oil filter type Full-flow filtration Overall width 1223 mm 3.6 L...

  • Page 6: Service Precautions

    . GENERAL INFORMATION MXU 500 IRS 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 7 . GENERAL INFORMATION MXU 500 IRS 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.
  • Page 8 . GENERAL INFORMATION MXU 500 IRS 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 9 . GENERAL INFORMATION MXU 500 IRS 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 10 . GENERAL INFORMATION MXU 500 IRS 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 11 . GENERAL INFORMATION MXU 500 IRS 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.
  • Page 12 . GENERAL INFORMATION MXU 500 IRS 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.
  • Page 13 . GENERAL INFORMATION MXU 500 IRS 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.

  • Page 14: Torque Values

    . GENERAL INFORMATION MXU 500 IRS TORQUE VALUES ENGINE 1-11...
  • Page 15 . GENERAL INFORMATION MXU 500 IRS 1-12...
  • Page 16 . GENERAL INFORMATION MXU 500 IRS FRAME (Cont’d) 1-13...
  • Page 17 . GENERAL INFORMATION MXU 500 IRS 1-14...

  • Page 18: Special Tools

    . GENERAL INFORMATION MXU 500 IRS 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 19 . GENERAL INFORMATION MXU 500 IRS 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.)
  • Page 20 . GENERAL INFORMATION MXU 500 IRS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Crankshaft bearing puller A120E00068 Ball joint remover (Refer to the “STEERING KNUCKLE REMOVAL/...
  • Page 21 Carburetor adjustment Adjust pilot screw position A120E00076 FRONT ASSY GEAR CASE F025 A120 F00025 COLLAR LOCK M54*15 MXU 400 /UXV 500/MXU 500 IRS WRENCH REAR ASSY GEAR CASE F026 A120 F00026 UXV 500/MXU 500 IRS PINION GEAR PULLER F027 A120 F00027 BEARING PULLER...

  • Page 22: Lubrication Points

    . GENERAL INFORMATION MXU 500 IRS LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil Valve guide/valve stem movable part Camshaft protruding surface •API SJ Engine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt Piston surroundings and piston ring grooves...