Page 1 MXU 500 By KWANG YANG Motor Co., Ltd. First Edition, May 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100LAA001...
Page 2: Table Of Contents
MXU 500 PREFACE This Service Manual describes the TABLE OF CONTENTS technical features and servicing procedures for the MXU 500. GENERAL INFORMATION FRAME COVERS /EXHAUST MUFFLER Section 1 contains the precautions for all operations stated in this manual. INSPECTION/ADJUSTMENT Read them carefully before any LUBRICATION SYSTEM operation is started.
Page 3: General Information
. GENERAL INFORMATION MXU 500 __________________________________________________________________________________ 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 CABLE & HARNESS ROUTING ---------------------------------------- 1-21 TROUBLESHOOTING----------------------------------------------------- 1-35...
Page 4: Serial Number
. GENERAL INFORMATION MXU 500 SERIAL NUMBER (1) Location of Frame Serial Number (1) Location of Engine Serial Number...
Page 5: Specifications
. GENERAL INFORMATION MXU 500 SPECIFICATIONS Forced pressure & Lubrication type Model No. LAA0 Wet sump Name & Type MXU 500 Oil pump type Trochoid Overall length 2203 mm (88.12 in) Oil filter type Full-flow filtration Overall width 1223 mm (48.92 in) 3.6 L (3.17 lmp qt,...
Page 6: Service Precautions
. GENERAL INFORMATION MXU 500 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 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. Disconnect the battery negative (-) terminal before operation.
Page 8 . GENERAL INFORMATION MXU 500 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 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 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 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. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 12 . GENERAL INFORMATION MXU 500 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 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 TORQUE VALUES STANDARD TORQUE VALUES Torque Torque Item Item kgf-m (N-m, lbf-ft) kgf-m (N-m, lbf-ft) 5mm bolt and nut 0.5 (5, 3.6) 4mm screw 0.3 (3, 2.2) 6mm bolt and nut 1 (10, 7.2) 0.4 (4, 2.9)
Page 15 . GENERAL INFORMATION MXU 500 Thread dia. Torque Item Q‘ty Remarks (mm) kgf-m (N-m, lbf-ft) CYLINDER HEAD: Cylinder head bolt 4.8 (48, 34.6) Apply oil Cylinder head bolt 2.3 (23, 17) Apply oil Cylinder head nut 1 (10, 7) Cylinder head cover...
Page 16 . GENERAL INFORMATION MXU 500 FRAME Thread Torque Item Q‘ty Remarks dia. Kgf-m (N-m, (mm) lbf-ft) MAINTENANCE: Rear drive gear oil drain bolt 2 (20, 15) Rear drive gear oil filler cap 1.5 (15, 11) Rear drive gear oil level check bolt...
Page 17 . GENERAL INFORMATION MXU 500 Thread Torque Item Q‘ty Remarks dia. Kgf-m (N-m, (mm) lbf-ft) STEERING SYSTEM: Handlebar holder bolt 2.5 (25, 18) Steering bracket 2.2 (22, 16) Steering column nut 7 (70, 50) Tie-rod ball joint nut 2.1 (21, 16)
Page 18: Special Tools
. GENERAL INFORMATION MXU 500 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 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 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) A120E00068 Crankshaft bearing puller Ball joint remover (Refer to the “STEERING KNUCKLE REMOVAL/ A120F00012 INSPECTION/ INSTALLATION”...
Page 21 . GENERAL INFORMATION MXU 500 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Pinion bearing lock nut wrench (Refer to the “REAR DRIVE A120F00020 DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 13.)
Page 22: Lubrication Points
. GENERAL INFORMATION MXU 500 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYMCO Engine Oil (SAE5W-50) Camshaft protruding surface •API SJ Engine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt Piston surroundings and piston ring grooves...
Page 23 . GENERAL INFORMATION MXU 500 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the ATV.
Page 24: Cable & Harness Routing
. GENERAL INFORMATION MXU 500 CABLE & HARNESS ROUTING Remove the fuel tank and fuel valve together (refer to the “FUEL TANK” section in the chapter 5). Remove the front cooling duct (refer to the “ENGINE REMOVAL” section in the chapter 7).
Page 25 . GENERAL INFORMATION MXU 500 (1) Throttle cable (7) Brake light switch wire (2) Instrument connector (8) Rear brake hose (Brake lever) (3) Ignition switch wire (9) 2WD/4WD switch wire (4) Accessory socket connectors (10) Choke cable (5) Left handlebar switch...
Page 26 . GENERAL INFORMATION MXU 500 (1) Fan EMI filter (12) Ignition coil wire (2) Headlight connector (13) 2WD /4WD start switch Right front signal light connectors (ON ROAD) /2WD/4WD motor connectors (3) Harness wire (14) Left handlebar switch connectors (4) Siphon hose...
Page 27 . GENERAL INFORMATION MXU 500 (1) Fuel tank flow hose (connect the fuel tank cover, Note) (5) Crankcase breather hose (2) Hazard connector (ON ROAD) (6) Over flow (carburetor) (3) Harness wire (7) Water temperature sensor wire (4) Throttle cable (8) Choke cable (A) Pass the harness wire through the band.
Page 28 . GENERAL INFORMATION MXU 500 (1) Over flow (carburetor) (7) Gear position light switch (2) Crankcase breather hose (8) Speed sensor wire (3) Crankcase breather hose (9) Speed sensor (4) Harness wire (10) Engine ground cable (5) Crankcase breather hose joint...
Page 29 . GENERAL INFORMATION MXU 500 (1) Upper radiator hose (10) Rear parking brake cable (ON ROAD) (2) Ignition coil wire (11) Front brake hose (3) Air bleed hose (12) 2WD /4WD start switch//2WD/4WD motor connectors (4) Air bleed hose (13) Thermostat...
Page 30 . GENERAL INFORMATION MXU 500 (1) Air bleed hose (7) Water joint (2) Upper radiator hose (8) Rear brake hose (Brake lever) (3) Air bleed hose (9) Rear parking brake cable (ON ROAD) (4) AICV control solenoid valve (10) Water hose...
Page 31 . GENERAL INFORMATION MXU 500 (1) Rear brake hose (Brake pedal) (3) Rear brake hose (Brake lever) (2) Rear parking brake cable (ON ROAD) ● Pass the rear parking brake cable (ON ROAD) and rear brake hose (Brake lever) through the guide (A), (B), (C), band (D) and guide (E).
Page 32 . GENERAL INFORMATION MXU 500 (1) Rear caliper (Brake pedal) (5) Speed sensor (2) Rear caliper (Brake lever) (6) Speed sensor wire (3) Rear parking brake cable (ON ROAD) (7) Rear brake hose (Brake pedal) (4) Rear brake hose (Brake lever) (A) Pass the speed sensor wire through the guide.
Page 33 . GENERAL INFORMATION MXU 500 (1) Regulator/Rectifier (10) Fan motor connector (2) Hazard connector (ON ROAD) (11) Low radiator hose (3) Flasher relay (ON ROAD) (12) EMI filter (4) Instrument wire (13) Front brake hose (5) Over flow hose (reserve tank)
Page 34 . GENERAL INFORMATION MXU 500 (1) Low radiator hose (3) Combined brake hose (ON ROAD) (2) Water bypass hose (4) Front brake hose (A) Pass the front brake hose (combined) and water bypass hose through the guide. (B) Pass the front brake hose through the guide.
Page 35 . GENERAL INFORMATION MXU 500 (1) Harness wire (8) Water hose (2) Over flow (carburetor) (9) Low radiator hose (3) Crankcase breather hose (10) Water bypass hose (4) Fuel unit connectors (11) Combined brake hose (ON ROAD) (5) Fuel hose...
Page 36 . GENERAL INFORMATION MXU 500 (1) Starter motor cable (8) Brake light switch (2) Engine ground cable (9) Speed sensor wire (3) Clutch diode (10) Rear brake hose (Brake pedal) (4) Harness wire (11) Rear brake hose (Brake pedal) (5) Combined brake hose (ON ROAD)
Page 37 . GENERAL INFORMATION MXU 500 (1) Taillight/Brake light/Rear turn signal light connectors (OFF ROAD) (1) Taillight/Brake light/Rear turn signal light connectors (ON ROAD) (2) License light connector (ON ROAD) (3) Fuse box (4) Ignition unit (5) Starter MAG (6) Starter relay...
Page 38: Troubleshooting
. GENERAL INFORMATION MXU 500 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage...
Page 39 . GENERAL INFORMATION MXU 500 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Restricted fuel flow Engine speed does not Engine speed Clogged fuel tank cap breather hole increase sufficiently increases...
Page 40 . GENERAL INFORMATION MXU 500 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Incorrect timing Correct timing Faulty pulser coil Check carburetor air screw adjustment Mixture too rich (turn screw...
Page 41 . GENERAL INFORMATION MXU 500 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat...
Page 42 . GENERAL INFORMATION MXU 500 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
Page 43 . GENERAL INFORMATION MXU 500 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness...
Page 44: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MXU 500 __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER SERVICE INFORMATION------------------------------------------------ 2- 2 TROUBLESHOOTING----------------------------------------------------- 2- 2 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 3 FRAME COVERS ----------------------------------------------------------- 2- 4 EXHAUST MUFFLER ----------------------------------------------------- 2-13...
Page 45 . FRAME COVERS/EXHAUST MUFFLER MXU 500...
Page 46: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.
Page 47: Fastener Removal And Reinstallation
. FRAME COVERS/EXHAUST MUFFLER MXU 500 FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls close. Insert the fastener into the installation hole.
Page 48: Frame Covers
. FRAME COVERS/EXHAUST MUFFLER MXU 500 FRAME COVERS SEAT REMOVAL To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. Lever Seat INSTALLATION To install the seat, align the tabs on the seat with the grommets on the frame and press the seat down until it locks.
Page 49 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Remove the two mounting bolts from the front cargo rack right/left side under front fender. Remove the two mounting bolts from front cargo rack, remove the front cargo rack. Installation is in the reverse order of removal.
Page 50 . FRAME COVERS/EXHAUST MUFFLER MXU 500 FRONT CARRIER REMOVAL/INSTALLATION Remove front cargo rack (see page 2-5). Remove the three mounting bolts from front carrier left side. Remove the three mounting bolts from front carrier left side. Installation is in the reverse order of removal.
Page 51 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Remove two screws from the rear cargo rack. Remove the four bolts under rear fender. Remove the two mounting bolts from rear cargo rack, then remove rear cargo rack. Installation is in the reverse order of removal.
Page 52 . FRAME COVERS/EXHAUST MUFFLER MXU 500 RIGHT/LEFT SIDE COVER REMOVAL/INSTALLATION Remove the seat (page 2-4) and right or left footboard. (see page 2-7). Remove a screw and a fastener, then remove the right or left side cover. During removal, do not pull the joint claws forcedly to avoid damage.
Page 53 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Instrument Connector Accessory Socket Disconnect the ignition switch, instrument and accessory socket connectors, then remove the meter cover. Installation is in the reverse order of removal. Ignition Switch Connector Drive Select Grip FUEL TANK COVER...
Page 54 . FRAME COVERS/EXHAUST MUFFLER MXU 500 FRONT FENDER REMOVAL/INSTALLATION Remove the seat (page 2-4), front cargo rack (page 2-5), front carrier (page 2-6), front center cover (page 2-8), right/left footboards (page 2-7), right/left side covers (page 2-8) and fuel tank cover (page 2-9).
Page 55 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Starter Relays Remove the starter relays and ignition control module and Ignition Control Module Fuse Box Push the lock clip under rear fender by finger and remove the fuse box. Remove the five mounting bolts from the rear fender, then remove the rear fender.
Page 56 . FRAME COVERS/EXHAUST MUFFLER MXU 500 BOTTOM COVER REMOVAL/INSTALLATION Remove the right and left footboards (page 2-7). Remove the two mounting bolts from bottom cover front side. Remove the four mounting bolts from bottom cover right/left side, then remove bottom cover.
Page 57: Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MXU 500 EXHAUST MUFFLER REMOVAL Loosen the exhaust pipe band bolt. Remove two muffler mounting bolts. Gasket Remove the muffler and gasket from the exhaust pipe Exhaust Muffler Remove the exhaust pipe joint nuts. 2-13...
Page 58 . FRAME COVERS/EXHAUST MUFFLER MXU 500 Exhaust Pipe Remove the exhaust pipe and gasket. INSTALLATION Replace the gaskets with new ones. Install the exhaust pipe and tighten the joint nuts. Torque: Exhaust pipe mounting nut: 3.5 kgf-m (35 N-m, 14 lbf-ft)
Page 59: Inspection/Adjustment
. INSPECTION/ADJUSTMENT MXU 500 __________________________________________________________________________________ INSPECTION/ADJUSTMENT SERVICE INFORMATION------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 3 FUEL LINE/THROTTLE OPERATION --------------------------------- 3- 4 SPEED LIMITER/AIR CLEANER --------------------------------------- 3- 5 AIR FILTER FOR DRIVE BELT ----------------------------------------- 3- 7 SECONDARY AIR SUPPLY SYSTEM --------------------------------- 3- 8...
Page 60: Service Information
. INSPECTION/ADJUSTMENT MXU 500 SERVICE INFORMATION GENERAL WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.
Page 61 . INSPECTION/ADJUSTMENT MXU 500 Tire pressure 1 Rider Front 0.28 kgf/cm² (28 Kpa, 3.2 psi) Rear 0.28 kgf/cm² (28 Kpa, 3.2 psi) Tire size: Front : 25X8-12 Rear : 25X10-12 TORQUE VALUES Spark plug 1.2kgf-m (12 N-m, 8.6 lbf-ft) Tappet ADJ nut 0.9 kgf-m (9 N-m, 6.5 lbf-ft)
Page 62: Maintenance Schedule
. INSPECTION/ADJUSTMENT MXU 500 MAINTENANCE SCHEDULE 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. The need for costly overhaul work will be greatly reduced.
Page 63: Fuel Line/Throttle Operation
. INSPECTION/ADJUSTMENT MXU 500 Fuel tubes FUEL LINE Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage. Do not smoke or allow flames or sparks in your working area. Fuel Filter THROTTLE OPERATION Check the throttle to swing for smooth movement.
Page 64: Speed Limiter/Air Cleaner
. INSPECTION/ADJUSTMENT MXU 500 SPEED LIMITER The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV.
Page 65 . INSPECTION/ADJUSTMENT MXU 500 3. Loosen the screw (3) and remove the air cleaner assembly (4) from the air cleaner housing. 4. Unscrew the clamp (5) 5. Remove the outer air cleaner (7). 6. Remove the screw/washers (6) and remove the air cleaner assembly from the air cleaner holder (8).
Page 66: Air Filter For Drive Belt
. INSPECTION/ADJUSTMENT MXU 500 AIR CLEANER HOUSING DRAIN 1. Remove the drain tube (1) by removing the clip (3). 2. Drain the deposits. 3. Reinstall the drain tube, securing it with the clip. Fastener AIR FILTER FOR DRIVE BELT To clean the air filter: Remove front center cover (refer to the “FRAME COVERS”...
Page 67: Secondary Air Supply System
. INSPECTION/ADJUSTMENT MXU 500 SECONDARY AIR SUPPLY SYSTEM Check the AICV (air injection control valve) This model is equipped with a built-in hoses between the AICV control solenoid secondary air supply system. The pulse valve and cylinder head for deterioration, secondary air supply system is located on damage or loose connections.
Page 68: Spark Plug
. INSPECTION/ADJUSTMENT MXU 500 Ignition Coil Cap SPARK PLUG Disconnect the spark plug cap and clean around the spark plug. Clean around the spark plug base with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber.
Page 69 . INSPECTION/ADJUSTMENT MXU 500 Measure the spark plug gap between the center and side electrodes with the feeler gauge. If necessary, adjust the gap by bending the side electrode carefully. Spark plug gap: 0.6 0.7 mm (0.024 0.028 in) Install the spark plug in the cylinder head and hand tighten, then torque to the specification.
Page 70: Valve Clearance
. INSPECTION/ADJUSTMENT MXU 500 Timing Hole Cap/O-ring VALVE CLEARANCE Inspect and adjust the valve clearance while the engine is cold (Below 35°C/95°F). To adjust: Remove the right floorboard (refer to the “FRAME COVERS” section in the chapter Remove the cylinder head cover (refer to Crankshaft Hole Cap/O-ring the “CYLINDER HEAD COVER...
Page 71: Carburetor Idle Speed
. INSPECTION/ADJUSTMENT MXU 500 Adjust by loosening the valve adjusting Wrench Thickness Gauge Valve Adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge. Valve clearance (when cold): IN.: 0.1 mm (0.004 in) EX.: 0.1 mm (0.004 in)
Page 72: Clinder Compression/Engine Oil
. INSPECTION/ADJUSTMENT MXU 500 Compression Gauge CYLINDER COMPRESSION Warm up the engine before compression test. Remove the spark plug. Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression. Cylinder compression: 15 kg/cm² (1500 kPa, 213 psi)
Page 73 . INSPECTION/ADJUSTMENT MXU 500 ENGINE OIL REPLACEMENT AND OIL FILTER CLEANING 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4. Remove the oil filler cap (1).
Page 74 . INSPECTION/ADJUSTMENT MXU 500 ENGINE OIL REPLACEMENT (WITH OR WITHOUT OIL FILTER CARTRIDGE REPLACEMENT) 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine.
Page 75 . INSPECTION/ADJUSTMENT MXU 500 7. Remove the oil filter cartridge (5) with an oil cartridge wrench. Special tool: Oil cartridge wrench A120E00061 8. Apply a light coat of clean engine oil to the O-ring (6) of the new oil filter cartridge.
Page 76: Rear Drive Gear Oil
. INSPECTION/ADJUSTMENT MXU 500 13. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, turn the engine off immediately and check for the cause. 14. Turn the engine off, and then check the oil level through the inspection window (7) and correct it if necessary.
Page 77: Front Drive Gear Oil
. INSPECTION/ADJUSTMENT MXU 500 6. Install the oil filler cap and oil level check bolt. Torque: Oil filler cap: 1.5 kgf-m (15 N-m, 12 lbf-ft) Oil level check bolt: 2 kgf-m (20 N-m, 15 lbf-ft) Be sure no foreign material enters the crankcase.
Page 78: Spark Arrester
. INSPECTION/ADJUSTMENT MXU 500 6. Remove the oil level check bolt (3). Make sure the oil level reaches the oil level check hole. 7. Install and tighten the oil filler bolt and oil level check bolt to the specified torque.
Page 79: Drive Shaft Boots
. INSPECTION/ADJUSTMENT MXU 500 3. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary.
Page 80: Drive Belt/Brake Pads Inspection
. INSPECTION/ADJUSTMENT MXU 500 DRIVE BELT Drive Belt Remove the left crankcase cover (refer to the “LEFT CRANKCASE COVER REMOVAL/INSTALLATION” section in the chapter 10). Inspect the drive belt for cracks, scaling, chipping or excessive wear. Measure the V-belt width Service limit (A): 30.8 mm (1.232 in)
Page 81: Brake Fluid Inspection/Headlight Aim
. INSPECTION/ADJUSTMENT MXU 500 BRAKE FLUID INSPECTION Inspection Window (R/L Brake Lever) Check if the fluid level is below the lower level mark through the inspection window. Inspection Window (Rear Brake Pedal) Adjust Screws HEADLIGHT AIM Turn the ignition switch ON and start the engine.
Page 82: Steering System Inspection
. INSPECTION/ADJUSTMENT MXU 500 STEERING SYSTEM INSPECTION Place the machine on a level place. Check the steering column bushings and bearings: Move the handlebar up and down, and/or back and forth. Replace the steering column bushings and or bearings if excessive play...
Page 83: Toe-In Adjustment
. INSPECTION/ADJUSTMENT MXU 500 TOE-IN ADJUSTMENT Place the machine on a level place. Measure the toe-in Adjust if out of specification. Toe-in measurement steps: Mark both front tire tread centers. Raise the front end of the machine so that there is no weight on the front tires.
Page 84: Wheels/Tires
. INSPECTION/ADJUSTMENT MXU 500 The threads on both rod-end must be of the same length. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. Tire pressure should be checked when tires are cold. TIRE PRESSURE...
Page 85 . INSPECTION/ADJUSTMENT MXU 500 Check the rear axle nut for looseness. If the axle nuts are loose, tighten them to the specified torque. Torque: Front: 7 kgf-m (70 N-m, 50 lbf-ft) Rear: 10 kgf-m (100 N-m, 72 lbf-ft) Rear Axle Nut Inspect the tire surfaces.
Page 86: Drive Select Lever Adjustment
. INSPECTION/ADJUSTMENT MXU 500 FRONT SHOCK ABSORBER Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. Adjustment Turn the adjuster to increase or decrease the spring preload.
Page 87 . INSPECTION/ADJUSTMENT MXU 500 3. Loosen the lock nuts (3) of rod (4). 4. Remove the bolt and nut from the rod end (shift arm side). Bolt/Nut 5. Shift the drive select lever to neutral along the shift guide. 6. Shift the gear to neutral by moving the...
Page 88: Cable Inspection And Lubrication/Adjusting The Rear Brake Light Switch (Brake Pedal)
. INSPECTION/ADJUSTMENT MXU 500 7. Turn the rod clockwise or counterclockwise to align the joint ball in the rod with the hole on the shift arm, then install and tighten the bolt and nut. When align the joint ball in the rod with the hole on the shift arm.
Page 89: Cooling System
. INSPECTION/ADJUSTMENT MXU 500 COOLING SYSTEM COOLANT LEVEL INSPECTION Place the machine on the level ground. Remove the front center cover (refer to the “FRAME COVERS” section in the chapter Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature.
Page 90 . INSPECTION/ADJUSTMENT MXU 500 Check for any coolant leakage from the water pump, radiator hoses and hose joints. Check the radiator hoses for cracks or deterioration and replace if necessary. Check that all hose clamps are tight. Check the radiator air passages for clogs or damage.
Page 91: Parking Brake Adjustment (On Road)
. INSPECTION/ADJUSTMENT MXU 500 REAR PARKING BRAKE ADJUSTMENT (ON ROAD) Parking brake adjustment may be required if the parking brake does not work properly. Every time the brake pads are replaced, adjust the parking brake. To adjust: 1. Release the parking brake lever.
Page 92 . INSPECTION/ADJUSTMENT MXU 500 3. Loosen the lock nut and adjuster on the cable. 4. Turn the adjuster in or out until the specified brake cable end length “L” is obtained. Tighten the lock nut. Lock Nut Adjuster Parking brake cable end length: L: 53 ±...
Page 93 . INSPECTION/ADJUSTMENT MXU 500 7. Check the parking brake lever free play “C”. Free play: 0 mm (0 in) 8. If the free play is incorrect, adjust the free play by adjuster on the cable. Lock Nut Adjuster 3-34...
Page 94: Lubrication System
. LUBRICATION SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM --------------------------------- 4- 1 SERVICE INFORMATION----------------------------------------------- 4- 2 TROUBLESHOOTING---------------------------------------------------- 4- 3 LUBRICATION CHECK HOLE ----------------------------------------- 4- 4 OIL PUMP REMOVAL/INSPECTION/INSTALLATION----------- 4- 5 OIL PUMP DISASSEMBLY/INSPECTION/ASSEMBLY ---------- 4- 9...
Page 95: Lubrication System Diagram
. LUBRICATION SYSTEM MXU 500 LUBRICATION SYSTEM DIAGRAM...
Page 96: Service Information
. LUBRICATION SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The oil pump service may be done with the engine installed in the frame. • When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
Page 97: Troubleshooting
. LUBRICATION SYSTEM MXU 500 TROUBLESHOOTING Oil level low High oil pressure • Oil consumption • Pressure relief valve stuck closed • External oil leak • Plugged oil filter, gallery, or metering orifice • Worn piston ring • Faulty oil pump •...
Page 98: Lubrication Check Hole
. LUBRICATION SYSTEM MXU 500 Check Hole Plug/O-ring LUBRICATION CHECK HOLE Remove the check hole plug/O-ring. Start the engine. Check the oil gushed from the hole. If not, stop the engine immediately and determine the cause.
Page 99: Oil Pump Removal/Inspection/Installation
. LUBRICATION SYSTEM MXU 500 Oil Pump Drive Chain Guide OIL PUMP REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH REMOVAL/INSPECTION/INSTALLATI ON” section in the chapter 19). Remove the two bolts and oil pump drive chain guide.
Page 100 . LUBRICATION SYSTEM MXU 500 Dowel Pins Remove a bolt and then remove the oil pump holder. Remove the two dowel pins. Remove the two bolts and then remove the oil pump. Holder Oil Pump INSPECTION Oil pump drive chain guide Inspect the drive chain slipper surface of the drive chain guide for wear or damage.
Page 101 . LUBRICATION SYSTEM MXU 500 Dowel Pins Install and tighten the two bolts securely. Install two dowel pins Install the holder, then install a bolt but do not tighten. Oil Pump Holder Drive Chain Install the driven gear and drive chain.
Page 102 . LUBRICATION SYSTEM MXU 500 Oil Pump Drive Chain Guide Install the chain guide, then install and tighten the two bolts securely. Install the oil separator cover, then install and tighten the three bolts in a crisscross pattern in 2 or 3 steps.
Page 103: Oil Pump Disassembly/Inspection/Assembly
. LUBRICATION SYSTEM MXU 500 Oil Pump Shaft OIL PUMP DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the oil pump shaft. Oil Pump Cover Remove the screw and oil pump cover. Screw Oil Pump Body Dowel Pin Inner Rotor Remove the dowel pin, oil pump outer rotor and inner rotor.
Page 104 . LUBRICATION SYSTEM MXU 500 INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. Service limit: 0.2 mm (0.008 in) Measure at several points and use the largest reading to compare the service limit.
Page 105 . LUBRICATION SYSTEM MXU 500 Dowel Pin Oil Pump Cover ASSEMBLY Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor. Install the oil pump shaft.
Page 106: Right Crankcase Cover Disassembly/Assembly
. LUBRICATION SYSTEM MXU 500 RIGHT CRANKCASE COVER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the right crankcase cover (refer to the “ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION” in the chapter 17) Right Crankcase Cover Remove the oil seal. Oil Seal Remove the snap ring. Remove the bearing by using the special tool.
Page 107 . LUBRICATION SYSTEM MXU 500 ASSEMBLY Install a new bearing by using the special tool. Special tool: Oil seal & bearing drive A120E00014 Bearing Drive Snap Ring Install a new oil seal. Oil Seal 4-13...
Page 108: Oil Pressure Relief Valve
. LUBRICATION SYSTEM MXU 500 Oil Pressure Relief Valve OIL PRESSURE RELIEF VALVE REMOVAL Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in the chapter 11). Remove the pressure relief valve and O-ring from the right crankcase.
Page 109: Oil Pipe Removal/Installation
. LUBRICATION SYSTEM MXU 500 Bolts/Washers (on the oil pipe) OIL PIPE REMOVAL/INSTALLATION REMOVAL Remove the two bolts, washers (on the oil pipe), oil pipe and washers (under oil pipe). Oil Pipe/Washer (under oil pipe) Washers INSTALLATIION Install the inner washers on the right crankcase.
Page 110 . LUBRICATION SYSTEM MXU 500 Bolts/Washers (on the oil pipe) Apply clean engine oil to the bolts, then install the outer washers and two bolts. Tighten the two bolts to the specified torque. Torque: 3.5 kgf-m (35 N-m, 25.2 lbf•ft)
Page 111: Fuel System
. FUEL SYSTEM MXU 500 __________________________________________________________________________________ FUEL SYSTEM SERVICE INFORMATION------------------------------------------------ 5- 2 TROUBLESHOOTING----------------------------------------------------- 5- 3 FUEL TANK ----------------------------------------------------------------- 5- 4 FUEL VALVE --------------------------------------------------------------- 5- 4 CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION-- 5- 7 CARBURETOR DISASSEMBLY/INSPECTION/ASSEMBLY ----- 5- 9 AIR CLEANER HOUSING ------------------------------------------------ 5-19...
Page 112 . FUEL SYSTEM MXU 500...
Page 113: Fuel System
. FUEL SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.
Page 114: Troubleshooting
. FUEL SYSTEM MXU 500 TROUBLESHOOTING Engine cranks but won’t start Engine lacks power • No fuel in tank • Clogged air cleaner • No fuel to carburetor • Faulty carburetor • Cylinder flooded with fuel • Faulty ignition system •...
Page 115: Fuel Tank
. FUEL SYSTEM MXU 500 Fuel Tube FUEL TANK REMOVAL Warning • Keep sparks and flames away from the work area. • Wipe off any spilled gasoline. Remove the seat, right and left side frame cover and fuel tank cover (refer to the “FRAME COVERS”...
Page 116 . FUEL SYSTEM MXU 500 Control Shaft Screws Washer DISASSEMBLY Remove the two screws on the retaining ring and then remove retaining ring. Remove the washer and control shaft. Retaining Ring Fuel Valve Body Rubber Gasket Remove the rubber gasket from the fuel valve body.
Page 117 . FUEL SYSTEM MXU 500 ASSEMBLY Reverse the “DISASSEMBLY” procedures. Install rubber gasket, control shaft, washer and retaining ring. • Aligning the tab on the control shaft with the outlet duct in the fuel valve body. • Aligning the tab on the retaining ring...
Page 118: Carburetor Removal/Choke Inspection/Installation
. FUEL SYSTEM MXU 500 Over Flow Hose CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION REMOVAL Remove the fuel tank (refer to the “FUEL TANK” section in this chapter). Remove the air cleaner housing (refer to the “AIR CLEANER HOUSING” section in this chapter).
Page 119 . FUEL SYSTEM MXU 500 O-ring CHOKE INSPECTION Inspection the choke plunger, spring and O- ring for bends, wear or damage. Spring Choke Plunger INSTALLATION Installation is in the reverse order of removal. Make sure the lug on the carburetor into the cutout on the intake pipe.
Page 120: Carburetor Disassembly/Inspection/Assembly
. FUEL SYSTEM MXU 500 CARBURETOR DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the carburetor (refer to the “CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION” section in this chapter). Loosen the drain screw to drain the gasoline from the float chamber. • Keep sparks and flames away from the Fuel Drain Plug work area.
Page 121 . FUEL SYSTEM MXU 500 Jet Needle Spring Retainer Remove the spring retainer, jet needle. Piston Valve Casting Enrichment Valve Cover/Spring O-ring Remove the two screws and casting enrichment valve cover and then take out the spring. Remove the casting enrichment valve and O- ring.
Page 122 . FUEL SYSTEM MXU 500 Remove the four screws and float chamber. Float Chamber Float Float Valve Pull float pin outs, then remove the float and float valve. Float Valve Slow Jet Needle Jet Holder Remove the slow jet. Remove choke jet.
Page 123 . FUEL SYSTEM MXU 500 Needle Jet Remove the needle jet. Remove the pilot screw, spring, washer and O-ring. Before pilot screw removal, slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly.
Page 124 . FUEL SYSTEM MXU 500 INSPECTION CARBURETOR BODY/JETS CLEANING Check carburetor body and each jet for wear or damage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly-not just the perceived problem area.
Page 125 . FUEL SYSTEM MXU 500 Float Float Tang Check the float and float tang for deformation or damage. Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.
Page 126 . FUEL SYSTEM MXU 500 Check top cap and spring for cracks and damage. Top Cap Spring Spring Covers Check the diaphragms (coasting enrichment valve and accelerating pump) for tears. Check the spring (coasting enrichment valve and accelerating pump) and cover (coasting enricher and accelerating pump) for damage.
Page 127 . FUEL SYSTEM MXU 500 Insert the piston valve into the carburetor body, and check for free movement. If stick is found, replace the part with a new one. Check throttle valve for free movement. If stick is found, replace the part with a new carburetor.
Page 128 . FUEL SYSTEM MXU 500 ASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the following instructions. ● Assemble the parts taking consideration of their function. ● Before assembling, wash all of the parts in a clean petroleum based solvent.
Page 129 . FUEL SYSTEM MXU 500 Fit a new O-ring in to the float chamber groove securely. O-ring Small Convex O-ring Accelerating Pump Cover Assemble the accelerating pump diaphragm and new O-ring. Install the accelerating pump diaphragm with the small convex facing...
Page 130: Air Cleaner Housing
. FUEL SYSTEM MXU 500 Band Screw AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the seat and side covers (refer to the “FRAME COVERS” section in the chapter Loosen the carburetor-to-air cleaner connecting tube band screw. Remove the clip and disconnect the crankcase breather hose from the crankcase.
Page 131: Pair Solenoid Valve
. FUEL SYSTEM MXU 500 Vacuum Hose PAIR SOLENOID VALVE REMOVAL/INSTALLATION Disconnect air supply hose and vacuum hose from the air solenoid valve, then remove the air solenoid valve from frame. Air Supply Hose PAIR Solenoid Valve Installation is in the reverse order of removal.
Page 132: Cooling System
. COOLING SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SYSTEM FLOW PATTERN----------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 4 COOLING SYSTEM TESTING------------------------------------------- 6- 5 COOLANT REPLACEMENT --------------------------------------------- 6- 5 THERMOSTAT-------------------------------------------------------------- 6- 8 WATER PUMP -------------------------------------------------------------- 6-11...
Page 133: System Flow Pattern
. COOLING SYSTEM MXU 500 SYSTEM FLOW PATTERN...
Page 134: Service Information
. COOLING SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS WARING: Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
Page 135 . COOLING SYSTEM MXU 500 COOLANT GRAVITY CHART Temp. Coolant concentration 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.009 0.997 1.018 1.107 1.017 1.016 1.015 1.014 0.013 1.011 1.009 1.007 1.005 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019...
Page 136: Troubleshooting
. COOLING SYSTEM MXU 500 TORQUE VALUES Water pump cover bolt 1.3 kgf-m (13 N-m, 9 lbf-ft) Fan motor bolt 0.53 kgf-m (5 N-m, 3.8 lbf-ft) Fan motor switch 1.8 kgf-m (17 N-m, 13 lbf-ft) TROUBLESHOOTING Engine temperature too high •...
Page 137: Cooling System Testing
. COOLING SYSTEM MXU 500 COOLING SYSTEM TESTING Cap Tester RADIATOR CAP INSPECTION Remove the radiator cap (refer to the “COOLANT REPLACEMENT” section in this chapter). Pressure test the radiator cap. Replace the radiator cap if it does not hold...
Page 138 . COOLING SYSTEM MXU 500 Radiator Cap REPLACEMENT/AIR BLEEDING Remove the front center cover and right footboard (refer to the “FRAME COVERS” section in the chapter 2). When filling the system or reserve tank with coolant (checking the coolant level), place the machine in a vertical position on a flat, level surface.
Page 139 . COOLING SYSTEM MXU 500 Reserve Tank Cap Place the machine on a flat, level surface. Fill the reserve tank to the upper level (FULL) line. Filler Neck Fill the system with the recommended coolant through the filler opening up to the filler neck.
Page 140: Thermostat
. COOLING SYSTEM MXU 500 THERMOSTAT REMOVAL Remove the nut and thermostat housing stay from the frame. Remove the bolts, housing stay and thermostat housing cover. Housing stay Thermostat Housing Cover Thermostat Remove the O-ring from the housing cover. Remove the thermostat.
Page 141 . COOLING SYSTEM MXU 500 INSPECTION Visually inspect the thermostat for damage. Thermostat Heat the water with an electric heating Thermometer element to operating temperature for five minutes. Suspend the thermostat in heated water to check its operation. ● Keep flammable materials away from the electric heating element.
Page 142 . COOLING SYSTEM MXU 500 O-ring Install a new O-ring into the housing cover groove. Install the housing cover and housing stay to the housing. Tighten the bolts securely. Install the housing stay to the frame. Tighten the nut securely.
Page 143: Water Pump
. COOLING SYSTEM MXU 500 WATER PUMP MECHANICAL SEAL INSPECTION Inspect the coolant leakage. If there is leakage, the mechanical seal is defective, and water pump body should be replaced. REMOVAL Drain the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter).
Page 144 . COOLING SYSTEM MXU 500 Water Pump Body Remove the water pump body from the crankcase. Align INSTALLATION Apply engine oil to a new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with oil pump shaft end.
Page 145 . COOLING SYSTEM MXU 500 Install the water pump cover and tighten the bolts to the specified toque. Torque: 1.3 kgf-m (13 N-m, 9 lbf-ft) Water Pump Cover/O-ring Water Hose Connect the water hoses and bypass hose, then tighten the hose bands.
Page 146: Radiator
. COOLING SYSTEM MXU 500 Fan Guide RADIATOR REMOVAL Drain the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter). Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2). Remove the four mounting bolt from fan guide and then remove fan guide.
Page 147: Fan Motor Switch
. COOLING SYSTEM MXU 500 FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors (refer to the “RADIATOR” section in this chapter). Remove the fan motor switch. Fan Motor Switch INSPECTION Place the fan motor switch in oil contained...
Page 148: Fan Motor
. COOLING SYSTEM MXU 500 Fan Motor Connector FAN MOTOR REMOVAL Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2) Disconnect the fan motor connector. Remove the four mounting bolts and then remove the fan motor...
Page 149: Water Temperature Sensor
. COOLING SYSTEM MXU 500 Water Temperature Sensor WATER TEMPERATURE SENSOR Remove the right side body cover and right footboard (refer to the “FRAME COVERS” section in the chapter 2). Disconnect the water temperature sensor connector. Remove the water temperature sensor from the water joint.
Page 150: Raidator Reserve Tank
. COOLING SYSTEM MXU 500 RADIATOR RESERVE TANK REMOVAL Remove the front fender (refer to the “FRAME COVERS” section in the chapter 2). Remove the two mounting bolts and then remove the radiator reserve tank from frame. Open the reserve tank cap and drain the coolant from the reserve tank.
Page 151: Engine Removal
7. ENGINE REMOVAL/INSTALLATION MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 7- 1 ENGINE REMOVAL ------------------------------------------------------- 7- 2 ENGINE INSTALLATION ------------------------------------------------ 7- 8...
Page 152 7. ENGINE REMOVAL/INSTALLATION MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the machine body, cables and wires during engine removal. • Use shop towels to protect the machine body during engine removal.
Page 153 7. ENGINE REMOVAL/INSTALLATION MXU 500 Lower Water Hose Rubber Band ENGINE REMOVAL Drain engine oil (refer to the “ENGINE OIL” section in the chapter 3). Remove frame covers and exhaust pipe (refer to the “FRAME COVERS” section in the chapter 2).
Page 154 7. ENGINE REMOVAL/INSTALLATION MXU 500 Water Hose Temperature Sensor Connector Disconnect the water hose, bleed hose and water temperature sensor connectors from water joint. Bleed Hose Spark Plug Cap Remove the spark plug cap and disconnect the AICV air supply hose from cylinder head.
Page 155 7. ENGINE REMOVAL/INSTALLATION MXU 500 Breather Hose Disconnect the breather hose from cylinder head cover and remove the mounting nut from breather housing holder, then remove the breather housing. Vacuum Hose Starter Cable Disconnect the vacuum hose from intake pipe.
Page 156 7. ENGINE REMOVAL/INSTALLATION MXU 500 Disconnect the gear indicator light switch connector. Gear Indicator Light Switch Connector Speed Sensor Connector Disconnect the speed sensor connector. Front Propeller Shaft Remove the bolts and then remove the front propeller shaft from the engine assembly.
Page 157 7. ENGINE REMOVAL/INSTALLATION MXU 500 Lower Engine Mounting Bolt/Nut Remove the front lower engine mounting bolt/nut. Remove the four nuts under right and left engine hangers, then remove the engine hangers. Remove the rear lower engine mounting bolt/nut. Engine Hanger Nuts...
Page 158 7. ENGINE REMOVAL/INSTALLATION MXU 500 Rear Propeller Shaft Tap the rear propeller shaft with rubber hammer and remove the rear propeller shaft from the engine assembly. Take care not to lose the compression spring in the rear drive gear case end.
Page 159 7. ENGINE REMOVAL/INSTALLATION MXU 500 ENGINE INSTALLATION Install the engine assembly into the frame. Apply grease Apply grease Apply lightweight lithium-soap base grease to the rear propeller shaft splines. Rear Propeller Shaft Rear Propeller Shaft Install the rear propeller shaft into the engine assembly.
Page 160 7. ENGINE REMOVAL/INSTALLATION MXU 500 Apply grease Pinion Gear Install the compression spring into the pinion gear. Apply lightweight lithium-soap base grease to the pinion gear splines. Move the engine rearward and engage the rear propeller shaft into the pinion gear.
Page 161 7. ENGINE REMOVAL/INSTALLATION MXU 500 Front Propeller Shaft Apply lightweight lithium-soap base grease to the front propeller shaft splines and front output splines. Apply grease Front Propeller Shaft Install the front propeller shaft into the engine assembly. Install and tighten the three new bolts to specified torque.
Page 162 7. ENGINE REMOVAL/INSTALLATION MXU 500 Install the rear cooling duct. Make sure the lug on the left crankshaft case into the cutout on the rear cooling duct. Install the removed parts in the reverse order of removal. Route the water hoses, wire and cable properly (refer to the “CABLE &...
Page 163: Cylinder Head/Valves
8. CYLINDER HEAD/VALVES MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 3 CYLINDER COMPRESSION TEST ------------------------------------- 8- 4 CYLINDER HEAD COVER REMOVAL/INSTALLATION--------- 8- 5 CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY--------- 8- 6...
Page 164: Schematic Drawing
8. CYLINDER HEAD/VALVES MXU 500 SCHEMATIC DRAWING...
Page 165: Service Information
8. CYLINDER HEAD/VALVES MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 166: Troubleshooting
8. CYLINDER HEAD/VALVES MXU 500 TORQUE VALUES Cylinder head bolt (1 – 4) 4.8 kgf-m (48 N-m, 35 lbf-ft) Apply engine oil to threads Cylinder head bolt (5 – 13) 2.3 kgf-m (23 N-m, 17 lbf-ft) Apply engine oil to threads...
Page 167: Cylinder Compression Test
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug (refer to the “SPARK PLUG” section in the chapter 3).
Page 168: Cylinder Head Cover Removal/Installation
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER HEAD COVER REMOVAL/INSTALLATION REMOVAL Disconnect the crankcase breather hose from the cylinder head cover (refer to the “ENGINE REMOVAL” section in the chapter 7). Remove the four bolts/rubber washers and cylinder head cover. Cylinder Head Cover Cylinder Head Cover Packing Remove the cylinder head cover packing.
Page 169: Cylinder Head Cover Disassembly/Assembly
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the three bolts and breather separator. Gasket Remove the gasket. ASSEMBLY Assembly is in the reverse order of disassembly. Torque: Breather separator bolt: 1.3 kgf-m (13 N-m, 9 lbf-ft)
Page 170 8. CYLINDER HEAD/VALVES MXU 500 CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION Bolt Washer REMOVAL Remove the cylinder head cover (refer to the “CYLINDER HEAD COVER REMOVAL/INSTALLATION” section in this chapter). Turn the crankshaft clockwise and align the “T” mark on the flywheel with the index mark on the right crankcase cover (refer to the “VALVE CLEARANCE”section in the...
Page 171 8. CYLINDER HEAD/VALVES MXU 500 Bolts Loosen and remove the eight camshaft holder bolts in a crisscross pattern in several steps. Camshaft Holder Bolts/Washers Loosen and remove the four camshaft holder bolts/washers in a crisscross pattern in several steps, then remove the camshaft holders.
Page 172 8. CYLINDER HEAD/VALVES MXU 500 Cam Chain Slipper INSPECTION Cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage. Camshaft Holders Camshaft holder Always replace the camshaft holder and cylinder head in pairs...
Page 173 8. CYLINDER HEAD/VALVES MXU 500 Camshaft Support both ends of the camshaft with V- blocks and check the camshaft runout with a dial gauge. Service limit: 0.05 mm (0.002 in) Inspect camshaft lobes for pitting/scratches/blue discoloration. Measure the cam lobe height.
Page 174 8. CYLINDER HEAD/VALVES MXU 500 Cam chain tensioner Check the one-way cam operation (tensioner) Unsmooth operation → Replace. INSTALLATION Turn the crankshaft clockwise, align the “T” mark on the flywheel with the index mark on the right crankcase cover (refer to the “VALVE CLEARANCE”...
Page 175 8. CYLINDER HEAD/VALVES MXU 500 Install the cam chain over the cam sprockets Punch Marks and then install the intake and exhaust camshafts. Install each camshafts to the correct locations. “IN”: no decompressor cam “EX”: has a decompressor cam Make sure the timing marks on the cam...
Page 176 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 1 – 8) threads. Install the four bolts (No. 5 – 8). Install the four bolts/washers (No. 1 – 4). Tighten the holder bolts (No. 1 – 8) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 177 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 178: Camshaft Removal/Inspection/Installation
8. CYLINDER HEAD/VALVES MXU 500 Rocker Arms ROCKER ARMS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the camshafts (refer to the “CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the rocker arm shafts and washers, then remove the rocker arms. Rocker Arm Shafts/Washers...
Page 179 8. CYLINDER HEAD/VALVES MXU 500 Rocker Arm Shaft INSTALLATION Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms, rocker arm shafts and washers. Tighten the rocker arm shaft to the specified torque. Torque: 4.5 kgf-m (45 N-m, 32 lbf-ft)
Page 180: Cylinder Head Removal/Installation
8. CYLINDER HEAD/VALVES MXU 500 Intake Pipe CYLINDER HEAD REMOVAL/INSTALLATION Always replace the camshaft holder and cylinder head in pairs Remove the camshafts (refer to the “CAMSHAFT REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the two bolts and intake pipe.
Page 181 8. CYLINDER HEAD/VALVES MXU 500 Remove the two nuts under the cylinder head. Remove the bolt and then remove the cylinder head. Dowel Pins Remove the dowel pins and gasket. Gasket 8-18...
Page 182 8. CYLINDER HEAD/VALVES MXU 500 Dowel Pins INSTALLATION Install the dowel pins and new gasket as shown. Gasket Install the cylinder head. Apply engine oil to the cylinder head bolt (9) threads. Install the bolt (9) but do not tighten it.
Page 183 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 1 – 8) threads. Install the four bolts (No. 5 – 8). Install the four bolts/washers (No. 1 – 4). Tighten the holder bolts (No. 1 – 9) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 184 8. CYLINDER HEAD/VALVES MXU 500 Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in five steps to the specified torque as follow diagram.
Page 185 8. CYLINDER HEAD/VALVES MXU 500 Install and tighten the two nuts under the cylinder head to the specified torque. Torque: 1 kgf-m (10 N-m, 7 lbf-ft) Bolts Install the water stop collar, gasket and water joint. Install and tighten the two bolts to the specified torque.
Page 186 8. CYLINDER HEAD/VALVES MXU 500 O-ring Install the new O-ring onto the intake pipe. Intake Pipe Install the intake pipe and tighten the two bolts securely. 8-23...
Page 187: Cylinder Head Disassembly/Inspection/Assembly
8. CYLINDER HEAD/VALVES MXU 500 CYLINDER HEAD DISASSEMBLY/INSPECTION/ Valve Spring Compressor ASSEMBLY Remove the cylinder head (refer to the “CYLINDER HEAD REMOVAL/INSTALLATION” section in this chapter). Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor.
Page 188 8. CYLINDER HEAD/VALVES MXU 500 INSPECTION Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D.
Page 189 8. CYLINDER HEAD/VALVES MXU 500 Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 3.5 kg (at 28.7 mm, 1.148 in) Outer: 13 kg (at 31.43 mm, 1.2572 in) Measure the spring tilt. Replace if out of specification.
Page 190 8. CYLINDER HEAD/VALVES MXU 500 Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters. Be careful not to damage the valves. 8-27...
Page 191: Cam Chain Removal/Inspection/Installation
8. CYLINDER HEAD/VALVES MXU 500 CAM CHAIN REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cylinder (refer to the Guide Cam Chain “CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 9). Remove the oil pump drive chain (refer to “OIL PUMP REMOVAL/INSTALLATION” section in the chapter 4).
Page 192 8. CYLINDER HEAD/VALVES MXU 500 INSTALLATION Guide Cam Chain Installation is in the reverse order of removal. Install the cam chain guides to the right crankcase and tighten the bolts to the specified torque. Torque: 2 kgf-m (20 N-m, 15 lbf-ft)
Page 193: Cylinder/Piston
9. CYLINDER/PISTON MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 9-3...
Page 194 9. CYLINDER/PISTON MXU 500 SCHEMATIC DRAWING...
Page 195 9. CYLINDER/PISTON MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
Page 196 9. CYLINDER/PISTON MXU 500 Cylinder Block Pin CYLINDER AND PISTON REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD REMOVAL/INSTALLATION” section in the chapter 8). Take the block pin out. Remove the water hose from the cylinder. Remove the two cylinder bolts/washers.
Page 197 9. CYLINDER/PISTON MXU 500 Spread each piston ring and remove it by lifting up at a point opposite the gap Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
Page 198 9. CYLINDER/PISTON MXU 500 Piston/Piston pin Measure the piston O.D. at the point (A) from the bottom and 90° to the piston pin hole. 10 mm Service Limit: 91.9 mm (3.676 in) at (A): 10 mm Calculate the cylinder-to-piston clearance.
Page 199 9. CYLINDER/PISTON MXU 500 Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
Page 200 9. CYLINDER/PISTON MXU 500 Measure the connecting rod small end I.D.. Service Limit: 22.06 mm (0.8824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing Be careful not to damage the piston and rings.
Page 201 9. CYLINDER/PISTON MXU 500 Piston “IN” Mark Cylinder/Piston Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole.
Page 202 9. CYLINDER/PISTON MXU 500 Cam Chain Cylinder Block Pin Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. Be careful not to damage the piston rings and cylinder walls.
Page 203: 10. Drive Pulley/Driven Pulley/Clutch
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 __________________________________________________________________________________ DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SCHEMATIC DRAWING ------------------------------------------------- 10- 1 SERVICE INFORMATION------------------------------------------------ 10- 2 TROUBLESHOOTING----------------------------------------------------- 10- 2 LEFT CRANKCASE COVER REMOVAL/INSTALLATION ------- 10- 3 DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/ INSTALLATION ------------------------- 10- 5...
Page 204 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 SCHEMATIC DRAWING 10-1...
Page 205: 10. Drive Pulley/Driven Pulley/Clutch
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 206: Left Crankcase Cover Removal/Installation
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Bolts LEFT CRANKCASE COVER REMOVAL/INSTALLATION REMOVAL Remove the left footboard (refer to the “FRAME COVERS” section in the chapter Remove the ten bolts, remove the left crankcase cover and rubber gasket. Left Front Cover Dowel Pins Remove the two dowel pins.
Page 207 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Bolts Install the left crankcase cover and tighten the ten bolts diagonally to specified torque. Torque: 1 kgf-m (10 N-m, 7.2 lbf-ft) Left Front Cover 10-4...
Page 208: Drive Pulley, Drive V-Belt And Driven Pulley Removal/Inspection/ Installation
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/ INSTALLATION Drive Pulley Holder REMOVAL Use the special tool to hold the drive pulley, then remove the nut and washer. Special tool: Drive pulley holder A120E00058 Remove the drive pulley.
Page 209 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Remove the five bolts and then remove the Bolts fan guide. Fan Guide INSPECTION Inspect the drive belt for cracks, scaling, Drive Belt chipping or excessive wear. Measure the V-belt width Service limit (A): 30.8 mm (1.232 in) Replace the drive belt if out of specification.
Page 210 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Place a block on the plate nut. Block Compress the spring by using a commercially available puller, install the drive belt. ● The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turning direction.
Page 211 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Install the drive pulley assembly. Drive Pulley Holder Install the washer and nut. Make sure the “OUT SIDE” marks on the washer faces the left crankcase cover. Use the special tool to hold drive pulley, then tighten the nut to the specified torque.
Page 212: Drive Pulley Disassembly/Inspection/Assembly
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 DRIVE PULLEY Drive Face Boss DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the drive pulley (refer to “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section) Remove the drive face boss. Ramp Plate Slide Pieces Remove the ramp plate and four slide pieces.
Page 213 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 29.5 mm (1.18 in) Movable drive face/Slide pieces/Drive pulley face Check the slide pieces and movable drive face splines for wear, cracks or damage.
Page 214 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Dust Seals Check the dust seals on the movable drive face for wear or damage. Movable Drive Face Drive Face Boss ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss.
Page 215 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Install the slide pieces and ramp plate. Ramp Plate Slide Pieces Install the drive face boss. Drive Face Boss 10-12...
Page 216: Driven Pulley Disassembly/Inspection/Assembly
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 DRIVEN PULLEY Spring Compressor DISASSEMBLY/INSPECTION/ ASSEMBLY Compressor Nut Nut Wrench DISASSEMBLY Remove the driven pulley (refer to the “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section in this chapter). Use the special tool to remove the nut.
Page 217 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Remove the O-rings and dust seals from the Dust Seal Dust Seal movable driven face. O-ring O-ring Grooves INSPECTION Check the driven pulley for smooth operation. If any scratches or damage is found then replace as a set.
Page 218 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Dust Seal Dust Seal ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Apply grease to lips of the new dust seals and install into the movable driven face.
Page 219 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Install spring collar. Spring Compressor Use the special tool to install spring and Compressor Nut Nut Wrench spring seat, then install and tighten the nut to the specified torque. Torque: 7.5 kgf-m (75 N-m, 54 lbf-ft)
Page 220 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 One-way Clutch Bearing CLUTCH REMOVAL/INSTALLATION REMOVAL Remove the fan guide (refer to the “DRIVE PULLEY AND DRIVEN PULLEY REMOVAL/INSTALLATION” section in this chapter). Remove the nine bolts and then remove the clutch housing assembly and one-way clutch bearing.
Page 221 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 (USA type: Nut/Collar) Y-type Holder Use the special tool to hold clutch carrier assembly. Special tool: Y-type holder A120E00056 Not USA type: Use the special tool to remove the nut and washer. Special tool:...
Page 222 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Collar INSTALLATION Apply clean engine oil to the clutch carrier assembly and collar, then install the collar and clutch carrier assembly. Clutch Carrier Assembly (Not USA type: Washer) Install the washer (Not USA type).
Page 223 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Dowel Pins Install the dowel pins and gasket. Gasket Nut/Washer One-way Clutch Bearing Apply molybdenum disulfide grease to the one-way clutch bearing, then install it. Install the clutch housing and tighten the bolts to the specified torque in a crisscross pattern in 2-3 steps.
Page 224 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 CLUTCH DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the clutch housing and clutch carrier assembly (refer to the “CLUTCH REMOVAL/INSTALLATION” section in this chapter). Remove the one-way clutch bearing from the clutch housing. One-way Clutch Bearing Oil Seal Clutch housing removal (not USA type): Remove the oil seal.
Page 225 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Clutch Housing Clutch housing removal (USA type): Remove the clutch housing. Oil Seal Remove the oil seal, then remove the bearing. Bearing 10-22...
Page 226 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 INSPECTION Check the clutch housing for heat damage, wear or damage. Check the one-way clutch bearing for chafing, wear or damage. Replace the one-way clutch assembly and clutch housing as a set. Check the clutch shoe for heat damage.
Page 227 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Check operation (not USA type): Install the one-way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly. When turning the clutch housing clockwise, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty.
Page 228 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Snap Ring ASSEMBLY Clutch housing installation (not USA type): Apply clean engine oil, then install the new bearing. Install the snap ring. Bearing Oil Seal Install the clutch housing. Install the snap ring. Apply lightweight lithium-soap base grease to the new oil seal lip, then install the new oil seal.
Page 229 10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MXU 500 Oil Seal Apply lightweight lithium-soap base grease to the new oil seal lip, then install the new oil seal. Clutch Housing Install the clutch housing. One-way clutch bearing installation: Install the one-way clutch bearing into the clutch housing.
Page 230: Final Reduction
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM __________________________________________________________________________________ FINAL REDUCTION/TRANSMISSION SYSTEM SERVICE INFORMATION------------------------------------------------ 11- 2 TROUBLESHOOTING----------------------------------------------------- 11- 2 SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/INSTALLATION -------------------------------- 11- 3 SECONDARY GEAR SHIMS ADJUSTMENT ------------------------ 11- 8 RIGHT CRANKCASE REMOVAL/INSTALLATION---------------- 11-10 BEARING REPLACEMENT IN THE RIGHT CRANKCASE ------- 11-12...
Page 231 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 11-1...
Page 232: Transmission System
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The bevel gear and output shaft can be serviced with the engine installed in the frame. SPECIAL TOOL Y-type holder A120E00056 Bearing puller A120E00037 Bearing drive A120E00014 Nut wrench...
Page 233 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/INSTAL LATION REMOVAL Drain engine oil into a clean container. (Refer to the “ENGINE OIL” section in the chapter Move the engine assembly forward (refer to the “ENGINE REMOVAL” section in the chapter 6) or remove the rear propeller (refer to the “REAR PROPELLER SHAFT...
Page 234 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Front Drive Shaft Install the front drive shaft. Hold universal joint nut by using a suitable bar, then remove the rear propeller shaft nut. Universal Joint Remove the rear middle joint. Rear Middle Joint...
Page 235 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Secondary Drive Bevel Gear/Shim Using a chisel, unlock the nut. Hold the driven pulley by using the special tool (refer to the “DRIVE PULLEY, DRIVE V-BELT AND DRIVEN PULLEY REMOVAL/INSPECTION/INSTALLATIO N” section in the chapter 10), then remove the nut.
Page 236 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Inspect the rear middle joint splines for wear or damage. Inspect the output shaft splines for wear or damage. Secondary Drive Bevel Gear/Shim INSTALLATION Install the shim and secondary drive bevel gear. Holder the driven pulley by using the special tool, then install and tighten the nut to the specified torque.
Page 237 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Front Drive Shaft Install the output shaft, secondary driven bevel gear and shim Install the rear middle joint. Install the front drive shaft. Hold universal joint nut by using a suitable bar, then install and tighten the rear middle joint nut to the specified torque.
Page 238 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM SECONDARY GEAR SHIMS ADJUSTMENT Set a dial gauge on the driven bevel gear as shown. Measure the backlash by turning the rear propeller shaft in each direction, reading the total backlash on the dial gauge. If the...
Page 239 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: ● Remove the driven bevel gear. ● Clean and degrease several teeth of the drive and driven bevel gears.
Page 240 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM RIGHT CRANKCASE REMOVAL/INSTALLATION REMOVAL Remove the cam chain (refer to the “CAM CHAIN REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 8) Remove the secondary drive and driven bevel gear (refer to the “SECONDARY DRIVE/DRIVEN BEVEL GEAR REMOVAL/INSPECTION/ INSTALLATION”...
Page 241 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Remove the fifteen bolts from right crankcase. Remove the two dowel pins. INSTALLATION Apply a light but through coating of liquid gasket (Threebond 1215 or equivalent) to all crankcase mating surfaces except the oil passage area.
Page 242: Bearing Replacement In The Right Crankcase
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Install and tighten the bolts in a crisscross pattern in 2 or 3 steps Torque: 1.2 kgf-m (12 N-m, 8.6 lbf-ft) Apply oil Washer Plug Stopper Install the stopper, spring, washer and plug. Tighten the stopper plug to the specified torque.
Page 243 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Bearing Drive Install the new balance shaft/countershaft/primary drive shaft bearing by using the special tool. Special tool: Bearing driver A120E00014 Set Plate DRIVE SHAFT BEARING REPLACEMENT Remove the four bolts and two set plates.
Page 244 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Rear Side Bearing OUTPUT SHAFT FRONT/REAR BEARING REPLACEMENT The output shaft bearings can be replaced when the crankcase is assembly. Front Side Bearing REAR SIDE BEARING Remove the oil seal. Remove the nut by using the special tool.
Page 245 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Install and tighten the nut to the specified torque by using the special tool. Torque: 11 kgf-m (110 N-m, 79.2 lb-ft) Special tool: Nut wrench A120E00066 Apply clean engine oil to the new oil seal lip then install the oil seal.
Page 246 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Install the snap ring. Apply clean engine oil to the new oil seal lip then install the new seal. Snap Ring Oil Seal 11-16...
Page 247: Transmission Removal/Inspection/Installation
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Shift Arm TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the bolt and then remove the shift arm. Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in this chapter) Bolt Shift Shaft Remove the shift shaft.
Page 248 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Upper Shift Fork Lower Shift Fork Remove the upper shift fork. Remove the lower shift fork. Remove the shift cam. Shift Cam Countershaft Assembly Remove the countershaft and driveshaft as an assembly. Disassemble the countershaft and the driveshaft.
Page 249 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Primary Drive Shaft Remove the primary drive shaft. Spring Remove the bolt/washer, then remove the stopper lever and spring. Stopper Lever Bolt/Washer INSPECTION Guide bar Measure the guide bar runout. Out of specification → Replace.
Page 250 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Pawl Cam Follower Upper shift fork Inspect the shift fork cam follower and shift fork pawl. Scoring/beads/wear → Replace a set. Inspection the spring. Cracks or damage→ Replace a set.. Spring Cam Follower Lower shift fork Inspect the shift fork cam follower and shift fork pawl.
Page 251 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Spring Stopper lever Check the stopper lever pawl for bends, damage or wear. Inspect the spring for cracks or damage. Stopper Lever Pawl Check the shift cam groove and shift cam gear. Wear or damage → Replace.
Page 252 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Stopper Lever Shaft INSTALLATION Make sure the shaft nut specified torque in the V-belt compartment while holds the stopper lever shaft. Torque: 3 kgf-m (30 N-m, 21.6 lbf-ft) Stopper Lever Hook the spring onto the hook part of the stopper lever, squeeze the spring in to the groove of the left crankcase.
Page 253 .FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Primary Drive Shaft Countershaft Assembly Apply clean engine oil to the countershaft assembly, driveshaft assembly and primary drive shaft. Install the primary drive shaft. Install the countershaft and drive shaft assemblies as a set into the left crankcase.
Page 254 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Guide Bar Apply clean engine oil to the guide bar, install the guide bar. Align The Marks Install the shift shaft. Align the mark on the shift shaft gear with the mark on the shift cam gear.
Page 255: Upper Shift Fork Disassembly/Assembly
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Snap Ring/Washer Spring UPPER SHIFT FORK DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the upper shift fork (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the snap ring, washer and fork. Fork Washer Cam Pawl Remove the spring, cam pawl and washer.
Page 256: Drive Shaft Disassembly/Assembly/Inspection
.FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM Reverse Gear DRIVE SHAFT DISASSEMBLY/ASSEMBLY/ INSPECTION DISASSEMBLY Remove the drive shaft assembly (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the washer (thick) and reverse gear. Washer (Thick) Washer (Thin) Remove the washer (thin).
Page 257: Countershaft Disassembly/Assembly/Inspection
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 500 Washer Washer COUNTERSHAFT DISASSEMBLY/ASSEMBLY/ INSPECTION DISASSEMBLY Remove the countershaft assembly (refer to the “TRANSMISSION REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the washer and high drive gear. High Drive Gear High/Low Gear Clutch Remove the high/low gear clutch dog...
Page 258 .FINAL REDUCTION/ MXU 500 TRANSMISSION SYSTEM ASSEMBLY/INSPECTION Washer Washer Washer Clip Countershaft Stopper Wheel Reverse Drive Gear High Drive Gear Washer High/Low Gear Clutch dog Clip Low Drive Gear Clip Reverse Gear Clutch dog Inspect the gear teeth. Clip Blue discoloration/pitting/wear → Replace.
Page 259 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 __________________________________________________________________________________ LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT SERVICE INFORMATION------------------------------------------------ 12- 2 TROUBLESHOOTING----------------------------------------------------- 12- 2 CRANK SHAFT AND BALANCE SHAFT REMOVAL/INSPECTION/INSTALLATION -------------------------- 12- 3 BEARING/OIL SEAL REPLACEMENT IN THE LEFT CRANKCASE---------------------------------------------------------------- 12- 6 12-0...
Page 260: Left Crankcase/Crankshaft
.LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 12-1...
Page 261 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. −Cylinder head ( Chapter 8) −Cylinder/piston ( Chapter 9)
Page 262 .LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Balance Shaft Crankshaft CRANKSHAFT AND BALANCE SHAFT REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the right crankcase (refer to the “RIGHT CRANKCASE REMOVAL/INSTALLATION” section in the chapter 11). Remove the crankshaft and balance shaft together. INSPECTION Balance shaft Inspect the balance shaft gear teeth.
Page 263 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Measure the connecting rod small end free play (A). Out of specification: 0.8 ~ 1 mm (0.032 ~ 0.04 in) → Replace the crankshaft. Measure the crankshaft run out (B). Service Limit (replace if over): 0.1 mm (0.004 in)
Page 264: Balance Shaft
.LEFT CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Mark (on the Balance Shaft) INSTALLATION Install the balance shaft and crankshaft into the left crankcase. Align the mark on the balance shaft with the mark on the crankshaft. Mark (on the Crankshaft) 12-5...
Page 265 .LEFT CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MXU 500 Bearing Puller Primary Drive Shaft Bearing BEARING/OIL SEAL REPLACEMENT IN THE LEFT CRANKCASE BALANCE SHAFT/COUNTERSHAFT/ PRIMARY DRIVE SHAFT/BALANCE SHAFT BEARING REPLACEMENT Remove the balance shaft/countershaft/primary drive shaft /drive shaft bearing by using the special tool.
Page 266: Drive Train
. DRIVE TRAIN MXU 500 __________________________________________________________________________________ DRIVE TRAIN SERVICE INFORMATION------------------------------------------------ 13- 2 TROUBLESHOOTING----------------------------------------------------- 13- 2 FRONT DRIVE SHAFT REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 13- 3 FRONT DRIVE SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY------------------------------------------------------------------ 13- 5 FRONT DRIVE REMOVAL/INSPECTION/INSTALLATION--------- 13-11 FRONT DRIVE DISASSEMBLY/INSPECTION/ASSEMBLY------ 13-14 FRONT DRIVE SHIM ASJUSTMENT ---------------------------------- 13-32...
Page 267 . DRIVE TRAIN MXU 500 FRONT DRIVE REAR DRIVE 13-1...
Page 268: Drive Train
. DRIVE TRAIN MXU 500 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.
Page 269 . DRIVE TRAIN MXU 500 FRONT DRIVE SHAFT REOMVAL/INSPECTION/ INSTALLATION REMOVAL Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14). Front Drive Shaft Remove the front drive shaft from front drive assembly. If it is difficult to remove the front drive shaft by hand, use the special tools.
Page 270: Installation
. DRIVE TRAIN MXU 500 Inspect the free play by using a push-and- pull motion (thrust movement). Excessive play → Replace the joint assembly. INSTALLATION Install a new circlip into its groove in the splines. Circlip Apply lightweight lithium-soap base grease to the splines of the drive shafts and install the drive shaft to the front drive gear case.
Page 271: Front Drive Shaft Disassembly/Inspection
. DRIVE TRAIN MXU 500 FRONT DRIVE SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front drive shaft (refer to the “FRONT DRIVE SHAFT REOMVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the boot band of the case side joint. Band Slide the boot toward the center of the front drive shaft and remove the circlip from the case side joint.
Page 272 . DRIVE TRAIN MXU 500 Wipe off any grease and remove the snap ring from the groove on the front drive shaft. Snap Ring Remove the cage and boot from the front drive shaft. Do not disassemble the wheel side joint.
Page 273 . DRIVE TRAIN MXU 500 Inspect the front drive shaft spline for wear or damage. If any damages are found, replace them with a new one. Inspect the front drive shaft for bends. If any damages are found, replace them with a new one.
Page 274 . DRIVE TRAIN MXU 500 Fit a boot on the drive shaft end, fitting the small diameter side of the boot to the shaft groove, fix its end with a new band. Band Cage Install the cage on the shaft.
Page 275 . DRIVE TRAIN MXU 500 Apply molybdenum disulfide grease to the entire surface of the cage and the inside of the case side joint/wheel side joint. Position Case side joint Wheel side joint Grease Quantity 85 g (2.8 oz) 45 g (1.5 oz)
Page 276 . DRIVE TRAIN MXU 500 After fitting the boot on the case side joint, insert a screw driver into the boot on the case side joint and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure.
Page 277: Front Drive Removal/Inspection/Installation
. DRIVE TRAIN MXU 500 FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Drain the front drive gear oil (refer to the “FRONT DRIVE GEAR OIL” in the chapter 3). Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14).
Page 278 . DRIVE TRAIN MXU 500 Remove the three bolts from front propeller shaft. Front Propeller Shaft Remove two front drive case mounting bolts/nuts from frame, then remove the case out of the frame. INSPECTION Check the breather rubber case for wear or damage.
Page 279 . DRIVE TRAIN MXU 500 INSTALLATION Install the front drive case into the frame. Install and tighten the two mounting bolts/nuts to the specified torque. Torque: 4 kgf-m (40 N-m, 29 lbf-ft) Install the front propeller shaft. Install and tighten the three new bolts to specified torque.
Page 280: Front Drive Disassembly/Inspection/Assembly
. DRIVE TRAIN MXU 500 FRONT DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY Remove the front drive case assembly (refer to the “FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the three bolts and then remove the 2WD/4WD shifting motor assembly. Shifting Motor Assembly Remove the 2WD/4WD shifting pinion and O-ring by hand.
Page 281 . DRIVE TRAIN MXU 500 Shim Remove the shim from right gear case. Front Drive Assembly Remove the front drive assembly from the left gear case. ● Do not attempt to disassembly the front drive assembly. ● The front drive is available only as an assembly.
Page 282 . DRIVE TRAIN MXU 500 Bearing Bearing Remove the bearings from the front drive assembly by using a commercially available bearing puller. ● If there is no abnormal condition, the bearing removal is not necessary ● The removed bearing must be replaced with a new one.
Page 283 . DRIVE TRAIN MXU 500 Remove the snap ring out of its groove and slide it towards the shifting sleeve. Snap Ring Remove the universal joint yoke assembly by using the special tool. Special tool: Joint yoke remover A120F00016 Snap Ring...
Page 284 . DRIVE TRAIN MXU 500 Snap Ring Bearing Remove the snap ring. Remove the bearing by using the special tool. Special tool: Yoke bearing puller A120F00018 ● If there is no abnormal condition, the bearing removal is not necessary ● The removed bearing must be replaced with a new one.
Page 285 . DRIVE TRAIN MXU 500 Bearing Pull the pinion bearing from the shaft with a commercially available bearing puller. ● If there is no abnormal condition, the bearing removal is not necessary ● The removed bearing must be replaced with a new one.
Page 286 . DRIVE TRAIN MXU 500 ● Tap the C-ring out by using the special tool. Special Tool ● Insert a screwdriver into the hole on the special tool, then pull it out. Bearing Remove the bearings by tapping the universal joint with a copper hammer.
Page 287 . DRIVE TRAIN MXU 500 Oil Seal Oil Seal INSPECTION Inspect the gear case and oil seals for wear or damage. If any wear or damage is found, replace the oil seal with a new one. Fork Inspect the shifting fork and its rack-and- pinion for wear and damage.
Page 288 . DRIVE TRAIN MXU 500 Inspect the right gear case and oil seal for wear or damage. If any wear or damage is found, replace the oil seal with a new one. Check the right gear case bearing for wear or damage.
Page 289 . DRIVE TRAIN MXU 500 Inspect the splines of universal joint for wear or damage. If any defects are found, replace the universal joint yoke with a new one. Inspect the universal joint, wear and damage. If any defects are found, replace the bearings and universal joint as a set.
Page 290 . DRIVE TRAIN MXU 500 ASSEMBLY Before reassembly, thoroughly clean all parts in cleaning solvent. 13-24...
Page 291 . DRIVE TRAIN MXU 500 Install the new bearings to the front drive. Apply lightweight lithium-soap base grease to the new oil seal lips. Install the new oil seals into the gear cases by using the special tool. Special tool: Oil seal &...
Page 292 . DRIVE TRAIN MXU 500 Bearing Install the new bevel pinion gear pilot bearing into the right gear case by using a proper shaft. Pinion Gear/Bearing Snap Ring Install the pinion gear assembly and fix the bearing race with the snap ring.
Page 293 . DRIVE TRAIN MXU 500 Snap Ring Install the new bearing into the right gear case by using the special tool and fix it with the snap ring. Special tool: Oil seal & bearing installer A120E00014 Dust Seal Install the new oil seal into the right gear case.
Page 294 . DRIVE TRAIN MXU 500 After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. Before install the universal joint yoke assembly, place the snap ring between the shifting sleeve and splines of universal joint.
Page 295 . DRIVE TRAIN MXU 500 Fix the universal joint yoke with the snap ring. Snap Ring Rack Fork Shaft Install the 2WD/4WD shifting fork, springs and shifting rack as shown. Apply sealant (three bond: 1215) to the shifting fork shaft plug and tighten it to the specified torque.
Page 296 . DRIVE TRAIN MXU 500 Front Drive Assembly Install the front drive to the right gear case. Install the dowel pin and apply a sealant (threebond: 1215) to the mating surface of the case. After the backlash and tooth contact have been checked or adjusted, apply a sealant to the mating surface of the case.
Page 297 . DRIVE TRAIN MXU 500 O-ring Coat a new O-ring with lightweight lithium- soap base grease and install the 2WD/4WD shifting pinion. Shifting Pinion Apply three bond: 1215 to the M8 bolt. Install the 2D/4WD shifting motor and tighten its mounting bolts to the specified torque.
Page 298: Front Drive Shim Asjustment
. DRIVE TRAIN MXU 500 Pinion Gear Wooden Piece or Plastic piece FRONT DRIVE SHIM ADJUSTMENT BACKLASH Install the removed left and right side shims and front drive assembly. Assemble the gear case (refer to the “FRONT DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in this chapter).
Page 299 . DRIVE TRAIN MXU 500 If the backlash it too small, replace the right side shim(s) with a thicker one. If the backlash too large, replace the right side shim(s) with a thinner one. If the right side shim was changed with a 0.1 mm thicker shim, replace the left side...
Page 300 . DRIVE TRAIN MXU 500 Remove the gear case. Measure the thickness of compressed solder with the micrometer. Shim thickness Select the proper size of shim(s) from the right chart, according as the compressed 0.7 mm (0.0276 in) solder thickness.
Page 301 . DRIVE TRAIN MXU 500 TOOTH CONTACT After backlash adjustment and left side shim selection are carried out, the tooth contact must be checked. Pay attention to the following points: ● Remove the drive ring gear. ● Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or...
Page 302: Rear Drive Removal/Inspection/Installation
. DRIVE TRAIN MXU 500 REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the left rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 15). Remove the four mounting nuts from the right rear axle housing.
Page 303 . DRIVE TRAIN MXU 500 INSPECTION Check the breather rubber case for wear or damage. Also, check that the joint of the rubber case fits tightly. Turn the pinion gear and check that the gear turns smoothly and quietly without binding.
Page 304 . DRIVE TRAIN MXU 500 Apply Grease Compression Spring Install the compression spring into the pinion gear. Apply lightweight lithium-soap base grease to the pinion gear splines and inner. Apply Grease Rear Propeller Shaft Install the rear propeller shaft to the rear drive assembly.
Page 305 . DRIVE TRAIN MXU 500 Rear Propeller Shaft Rear Drive Assembly Install and tighten the four mounting nuts to the specified torque in a crisscross pattern in 2 or 3 steps. Torque: 5.5 kgf-m (55 Nm, 40 lbf-ft) 13-39...
Page 306: Rear Drive Disassembly/Inspection/Assembly
. DRIVE TRAIN MXU 500 O-ring (Case) REAR DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the rear drive assembly (refer to the “REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the O-rings from the gear case and cover grooves. O-ring (Cover) Remove the eight cover bolts in a crisscross pattern in several steps.
Page 307 . DRIVE TRAIN MXU 500 Oil Seal Bearing Remove the oil seal, then remove the bearing from the cover by using a proper pipe. ● If there is no abnormal condition, the oil seal or bearing removal is not necessary ●...
Page 308 . DRIVE TRAIN MXU 500 Shim Remove the left ring gear shim. Oil Seal Bearing Remove the oil seal, then remove the bearing from the case by using a proper pipe. ● If there is no abnormal condition, the oil seal or bearing removal is not necessary ●...
Page 309 . DRIVE TRAIN MXU 500 Remove the oil seal. ● If there is no abnormal condition, the oil seal removal is not necessary ● The removed oil seal must be replaced with a new one. Oil Seal Remove the bearing lock nut by using special tool.
Page 310 . DRIVE TRAIN MXU 500 Snap Ring/Bearing Remove the snap ring. Remove the pinion gear pilot bearing by using the special tools. Special tool: Bearing puller A120E00037 Bearing Pull the pinion bearing from the shaft with a commercially available bearing puller.
Page 311 . DRIVE TRAIN MXU 500 Oil Seal Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft. Inspect the pinion gear for wear or damage. If the pinion gear is damaged, inspect the ring gear.
Page 312 . DRIVE TRAIN MXU 500 Inspect the ring gear for wear or damage. If the ring gear is damaged, inspect the pinion gear also. If any defects are found, replace the bearings and ring gear with the new ones. ASSEMBLY Before reassembly, thoroughly clean all parts in cleaning solvent.
Page 313 . DRIVE TRAIN MXU 500 Bearing Install the shim(s) onto the pinion gear shaft, then install the new bearing onto the pinion shaft by using a proper pipe. Shim(s) Snap Ring/Bearing Install the new bevel pinion gear pilot bearing into the gear case by using a proper shaft.
Page 314 . DRIVE TRAIN MXU 500 Apply lightweight lithium-soap base grease to the new oil seal lips. Install the new oil seal into the gear case by using a proper pipe. Install the new water proof plate by using a proper pipe.
Page 315 . DRIVE TRAIN MXU 500 Install the removed left shim to the gear Shim case. Ring Gear Install ring gear to the gear case. Shim Install the removed right shim to the ring gear. 13-49...
Page 316 . DRIVE TRAIN MXU 500 Apply a sealant (three bond: 1215) to the mating surface of the case, then install the gear cover. After the backlash and tooth contact have been checked or adjusted, apply a sealant to the mating surface of the case.
Page 317: Rear Drive Shim Adjustment
. DRIVE TRAIN MXU 500 REAR DRIVE SHIM Wooden Piece or Plastic piece Pinion Gear ADJUSTMENT BACKLASH Install the removed left and right side shims and rear drive assembly. Assemble the gear case (refer to the “REAR DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in this chapter).
Page 318 . DRIVE TRAIN MXU 500 If the backlash is not within specification, the shim must be changed and the backlash should be re-checked until correct. Right/Left Shim thickness Refer to the chart at the right for the A 1.55 mm (0.062 in) appropriate shim thickness.
Page 319 . DRIVE TRAIN MXU 500 Install and tighten its bolts to the specified torque in a crisscross pattern in 2 or 3 steps. Torque: 10-mm bolt: 5 kgf-m (49 N-m, 36 lbf-ft) 8-mm bolt: 2.5 kgf-m (25 N-m, 19 lbf-ft) ●...
Page 320 . DRIVE TRAIN MXU 500 TOOTH CONTACT After backlash adjustment and right side shim selection are carried out, the tooth contact must be checked. Pay attention to the following points: ● Remove the ring gear. ● Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or...
Page 321 . DRIVE TRAIN MXU 500 Make sure to check the backlash and Pinion Gear Shim thickness shim thickness after the tooth contact has A 2.05 mm (0.052 in) been adjusted, since it may have B 2 mm (0.08 in) changed. Adjust the tooth contact and backlash until they are both within C 1.95 mm (0.078 in)
Page 322: Front Propeller Shaft Disassembly/Inspection/ Assembly
. DRIVE TRAIN MXU 500 FRONT PROPELLER SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front propeller shaft (refer to the “FRONT DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). ” Front Propeller Shaft Compression Spring Boot Slide the spring rings back, then remove the boot, universal joint yoke, shaft and compression spring.
Page 323 . DRIVE TRAIN MXU 500 Bearings Remove the bearings by tapping the universal joint with a copper hammer. ● If there is no abnormal condition, the dust seal or bearing removal is not necessary. ● The removed dust seal and bearing must be replaced with new ones.
Page 324 . DRIVE TRAIN MXU 500 Inspect the universal joint, wear and damage. If any defects are found, replace the bearings, dust seal and universal joint as a set. Insert the universal joint to the new bearing and check the play by turning the universal joint, as shown.
Page 325 . DRIVE TRAIN MXU 500 Snap Ring ASSEMBLY Install the universal joint, new dust seal and new bearings. Install the snap rings. After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly.
Page 326 . DRIVE TRAIN MXU 500 Compression Spring Boot Fix the boot and spring ring, taking care not distort the boot. The dust boot should be fastened with the spring ring at the grooves in the propeller shaft. Universal Joint Yoke...
Page 327: Rear Propeller Shaft Disassembly/Inspection/ Assembly
. DRIVE TRAIN MXU 500 REAR PROPELLER SHAFT DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front propeller shaft (refer to the “REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Boot Slide the spring ring back, then remove the boot. Spring Snap Ring Remove the snap rings from the universal joint.
Page 328 . DRIVE TRAIN MXU 500 Bearings Remove the bearings by tapping the universal joint with a copper hammer. ● If there is no abnormal condition, the dust seal or bearing removal is not necessary. ● The removed dust seal and bearing must be replaced with new ones.
Page 329 . DRIVE TRAIN MXU 500 Inspect the universal joint, wear and damage. If any defects are found, replace the bearings, dust seals and universal joint as a set. Insert the universal joint to the new bearing and check the play by turning the universal joint, as shown.
Page 330 . DRIVE TRAIN MXU 500 After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. Boot Fix the boot and spring ring, taking care not distort the boot.
Page 331 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 __________________________________________________________________________________ FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM SERVICE INFORMATION------------------------------------------------ 14- 2 TROUBLESHOOTING----------------------------------------------------- 14- 3 FRONT WHEEL REMOVAL/INSPECTION/INSTALLATION ---- 14- 4 FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 5 FRONT SHOCK ABSORBER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 14- 7...
Page 332 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 14-1...
Page 333 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake disk •...
Page 334: Troubleshooting
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •Insufficient tire pressure • Bent rim • Excessive wheel bearing play • Bent spoke plate • Faulty tire • Improperly tightened axle nut Steers to one side or does not track straight •...
Page 335: Front Wheel/Front Suspension/ Stteering System
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove four nuts from front wheel. Elevate the front wheels by placing a suitable stand under the frame. Support the machine securely so there is no danger of it falling over.
Page 336 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Cotter Pin FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove the front wheel ( refer to the “ FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Elevate the front wheels by placing a suitable stand under the frame.
Page 337 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 INSTALLATION Install the wheel hub, washer and nut. Cotter Pin Apply grease onto the wheel hub splines. Apply the front brake and then tighten the nut to the specified torque. Torque: 7 kgf-m (70 N-m, 50 lbf-ft) Install the cotter pin and band ends of cotter pin.
Page 338 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 FRONT SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION REMOVAL Remove the front shock absorber upper mount and lower mount bolts/nuts, then remove the front shock absorber. Shock Absorber INSPECTION Bush Collar/Bush/Dust Seals Inspect the shock absorber rod.
Page 339: Front Wheel Hub Removal/Inspection
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION REMOVAL Elevate the front wheels by placing a suitable stand under the frame. Support the machine securely so there is no danger of it falling over. Remove the front wheel hub (refer to the “FRONT WHEEL HUB...
Page 340 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Tie-rod Release the tie-rod ball joint/upper arm ball joint off the knuckle, using the special tool according to the following instructions. Special tool: Ball join remover A120F00012 Apply grease to the ball joint remover at the point shown.
Page 341 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Knuckle End Boot INSPECTION Inspect the knuckle end boot for wear or damage. If any damages are found, replace the knuckle end with a new one. Inspect the brake disc protection plate for damage.
Page 342: Installation
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 INSTALLATION Apply lightweight lithium-soap base grease to the bearings of the steering knuckle and lips of the dust seal before install the steering knuckle. Install the steering knuckle onto the upper and lower front arms and tighten the nuts to the specified torque.
Page 343 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Install the brake disc protection plate and then tighten the three bolts securely. Plate 14-12...
Page 344: Steering Knuckle Removal/Inspection
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Snap Ring STEERING KNUCKLE DISASSEMBLY/ASSEMBLY DISASSEMBLY Remove the steering knuckle (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the knuckle end by using the appropriate collar. Collar Dust Seal Remove the dust seals.
Page 345 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Inspect the inner race play of the bearing by Play hand while it is in the steering knuckle. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Play If there is anything unusual, replace the bearing with a new one.
Page 346 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Spacer Install the new inner bearing by using the special tool. Special tool: Oil seal and bearing driver A120E00014 Install the spacer into the steering knuckle. Make sure the long side of the spacer...
Page 347 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Install the steering knuckle end by using a appropriate pipe. Pipe Snap Ring Install the snap ring. 14-16...
Page 348: Front Arms Inspection/Removal/Installation
FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 FRONT ARMS INSPECTION/REMOVAL/ INSTALLATION INSPECTION Remove the brake disc protection plate (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Remove the front shock absorber (refer to the “FRONT SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION”...
Page 349 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Check the front upper arm vertical movement by moving it up and down. If vertical movement is tight, binding or roughs, replace the inner bushes as a set. Check the front lower arm bracket of the frame.
Page 350 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Front Upper Arm REMOVAL Remove the bolt on the hose clamp and then remove the brake hose from front upper arm. Remove the mounting bolt/nut from the front upper arm, then remove the front upper arm.
Page 351: Front Arms Disassembly/Inspection/Assembly
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 FRONT ARMS DISASSEMBLY/INSPECTION/ Snap Ring ASSEMBLY DISASSEMBLY Upper arm Remove the snap ring. Remove the upper arm end by using a appropriate collar. Front Protector Lower arm Remove the bolt and then remove the front protector.
Page 352 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Inspect the front upper arm. Cracks/bends/damage →Replace. Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Inspect bushes. Wear/damage →Replace. Front Protector Inspect the front lower arm. Cracks/bends/damage →Replace.
Page 353 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Snap Ring Install the snap ring. Front Protector Install the front protector, then install and tighten the bolt securely. 14-22...
Page 354 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 TIE-ROD REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the cotter pin and nut from tie-rod end steering knuckle side (refer to the “STEERING KNUCKLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the cotter pin and nut from tie-rod end steering column side.
Page 355 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Adjustment steps: (The following procedures are done on both tie-rods, right and left.) Loosen the lock nuts. Adjust the tie-rod length by tuning both tie- rod ends. Tie rod length: 379.75±0.25 mm (15.19±0.01 in)
Page 356 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 INSTALLATION Install the tie-rod and onto the steering knuckle and steering column, then tighten the nuts. Torque: Steering knuckle side: 2.1 kgf-m (21 N-m, 16 lbf-ft) Steering column side: 2.1 kgf-m (21 N-m, 16 lbf-ft)
Page 357: Handlebar Removal/Inspection/Installation
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Master Cylinder HANDLEBAR REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the frame cover (refer to the “FRAME COVERS” section in the chapter Remove the two bolts and then remove left master cylinder from the handlebar. Remove the band and then remove the brake light switch wire from the handlebar.
Page 358 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Remove the four bolts, then remove the handlebar holders Handlebar Holders INSPECTION Inspect the handlebar. Cracks/bends/damage →Replace. INSTALLATION Install handlebar and handlebar holder, then tighten the four bolts. Torque: 2.5 kgf-m (25 N-m, 18 lbf-ft) Align the mark on the handlebar with the lower handlebar holder surface.
Page 359 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 • Be sure the handlebar holder mark face to front. • First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side. Install the handlebar switch by aligning the...
Page 360 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Install the throttle assembly by aligning the upper holder lip with the mark in the handlebar and then install the lower holder and tighten the two screws securely. 14-29...
Page 361: Steering Column
FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 STEERING COLUMN REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove frame covers (refer to the “FRAME COVERS” section in the chapter Remove the tie-rods (refer to the “TIE- ROD REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the handlebar (refer to the “HANDLEBAR...
Page 362 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Remove the cotter pin and nut from the steering column under the frame body, then remove steering column. Remove the collar and dust seal. Collar Dust Seal Dust Seal Remove the dust seal.
Page 363 FRONT WHEEL/FRONT SUSPENSION/ STEERING SYSTEM MXU 500 Replace the bearing by using the special Bearing Driver tool. Special tool: Oil seal and bearing driver A120E00014 Bearing Driver INSPECTION Inspect the steering column. Bends/damage →Replace. Do not attempt to straighten a bent steering column, this may dangerously weaken the steering column.
Page 364 FRONT WHEEL/FRONT SUSPENSION STEERING SYSTEM MXU 500 Steering Bracket Cable Holder Install the dust seal, steering brackets and cable holder. Install and tighten the two bolts to the specified torque. Torque: 2.2 kgf-m (22 N-m, 16 lbf-ft) 14-33...
Page 365: Rear Wheel/Axle/Shock
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 __________________________________________________________________________________ REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM SERVICE INFORMATION------------------------------------------------ 15- 2 TROUBLESHOOTING----------------------------------------------------- 15- 2 REAR WHEEL REMOVAL/INSPECTION/INSTALLATION ------ 15- 3 REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 15- 4 REAR SHOCK ABSORBER REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 15- 6...
Page 366 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 15-1...
Page 367: Absorber/Swing Arm
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake disk •...
Page 368: Rear Wheel Removal/Inspection/Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove four nuts from rear wheel. Elevate the rear wheels by placing a suitable stand under the frame. Support the machine securely so there is no danger of it falling over.
Page 369 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Nut/Washer REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION REMOVAL Place the machine on a level place. Remove the rear wheel ( refer to the “REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION” section in this chapter) Elevate the rear wheels by placing a suitable stand under the frame.
Page 370 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Apply grease INSTALLATION Install the wheel hub and nut. Apply lightweight lithium-soap base grease onto the wheel hub splines, rear axle splines and dust seal lips of the axle housing. Apply grease Apply the front brake and then tighten the nut to the specified torque.
Page 371 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Shock Absorber REAR SHOCK ABSORBER REMOVAL/INSPECTIION/ INSTALLATION REMOVAL Remove the rear shock absorber upper mount nut and washer. Remove the lower mount bolt/nut, then remove the rear shock absorber. INSPECTION Collar/Bush/Dust Seals Rubber Bush Inspect the shock absorber rod.
Page 372: Rear Wheel Hub Removal/Inspection
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR AXLE REMOVAL/INSPECTION/ INSTALLATION Rear Axle REMOVAL Remove the rear wheel hubs (refer to the “REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the rear axle from axle housing right side. Tap the axle and with a rubber hammer, this will avoid damage the axle thread.
Page 373: Rear Axle Housing Removal/Inspection/Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the rear axle (refer to the “REAR AXLE REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the bolt from skid plate under the left axle housing. Skid Plate Remove the four nuts/bolts from the left housing (attaching the rear swing arm).
Page 374 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Remove the rear drive case assembly (refer to the “REAR DRIVE REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 13). Remove the four nuts/bolts from right housing. Remove the shock absorber lower mounting bolt/nut, then remove the right rear axle housing.
Page 375 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 INSTALLATION Install the right rear axle housing and four bolts onto the rear swing arm. Install and tighten the four nuts to the specified torque in a crisscross pattern in 2 or 3 steps.
Page 376 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR AXLE HOUSING DISASSEMBLY/ASSEMBLY DISASSEMBLY/ASSEMBLY Remove the rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Left rear axle housing Remove the rear axle collar from axle housing.
Page 377 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Apply lightweight lithium-soap base grease to the new bearings of the axle housing and lips of the new dust seal before install them. Lightweight lithium-soap base grease Snap Ring Install the new bearings by using the special tool.
Page 378 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Right rear axle housing Dust Seal Snap Ring Remove the dust seal from the axle housing. Remove the snap ring from the axle housing. Remove the bearing using the proper shaft. Apply lightweight lithium-soap base grease to the new bearings of the axle housing and lips of the new dust seal before install them.
Page 379 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Dust Seal Snap Ring Install the new bearing by using the special tool. Special tool: Oil seal & bearing driver A120E00014 Install the snap ring. Install a new dust seal. 15-14...
Page 380: Rear Swing Arm Removal/Installation
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 REAR SWING ARM REMOVAL/INSTALLATION REMOVAL Remove the rear axle housing (refer to the “REAR AXLE HOUSING REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the swing arm pivot bolt cap. Remove the right pivot bolt.
Page 381 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Lock Nut Wrench INSTALLATION Install the right pivot bolt and the left pivot adjusting bolt. Tighten the right pivot bolt to the specified torque. Actual: 11.8 kgf-m (118 N-m, 85 lbf-ft) Tighten the left pivot adjusting bolt to the specified torque.
Page 382: Rear Swing Arm Disassembly/Inspection
REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Skid Plate REAR SWING ARM DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY/INSPECTION Remove the three bolts and then remove the skid plate from swing arm. Inspect the skid plate for damage. If any damages are found, replace the skid plate with a new one.
Page 383 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Bearing Bearing Remove the bearings. Bearing Bearing Plate Inspect the swing arm bearings, outer races and bearing plates, if any damages are found, replace the them with new ones. Outer Race Remove the swing arm bearings outer races and bearing plates by using a proper pipe.
Page 384 REAR WHEEL/AXLE/SHOCK ABSORBER/SWING ARM MXU 500 Bearing Plate ASSEMBLY Install the new swing arm bearing outer race and its new plate to the swing arm by using the special tool. Special tool: Oil seal & bearing driver A120E00014 When installing the bearing plate, make sure that the bulge of bearing plate faces inside.
Page 385: Brake System
. BRAKE SYSTEM MXU 500 __________________________________________________________________________________ BRAKE SYSTEM SERVICE INFORMATION------------------------------------------------ 16- 2 TROUBLESHOOTING----------------------------------------------------- 16- 3 BRAKE PADS REPLACEMENT----------------------------------------- 16- 4 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 16- 9 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION ------------------------------------------------------------ 16-10 FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD)----- 16-11...
Page 386 . BRAKE SYSTEM MXU 500 16-1...
Page 387 . BRAKE SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake pads and brake disk. • Drain the brake fluid from the hydraulic brake system before disassembly. • Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads.
Page 388 . BRAKE SYSTEM MXU 500 TROUBLESHOOTING Loose brake lever Tight brake lever • Air in hydraulic brake system •Seized piston • Brake fluid level too low •Clogged hydraulic brake system • Hydraulic brake system leakage •Smooth or worn brake pad...
Page 389 . BRAKE SYSTEM MXU 500 BRAKE PADS REPLACEMENT FRONT BRAKE PADS Remove the front wheel. ( refer to the “ FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION ” section in the chapter 14 ). Remove the two brake pad pins from the brake caliper.
Page 390 . BRAKE SYSTEM MXU 500 A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins. Install the brake caliper mounting bolts to the specified torque.
Page 391 . BRAKE SYSTEM MXU 500 REAR BRAKE PADS (ON ROAD) Rear brake Remove the rear wheel. ( refer to the “ REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION ” section in the chapter 15 ). The replacement of rear brake and front brake pads are the same.
Page 392 . BRAKE SYSTEM MXU 500 Compress the brake caliper holder and remove brake pads. A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads.
Page 393 . BRAKE SYSTEM MXU 500 Install the brake caliper mounting bolts to the specified torque. Torque: 3.2 kgf-m (32 Nm, 25 lbf-ft) Tighten the brake pad mounting pins. Torque: 1.8 kgf-m (18 Nm, 13 lbf-ft) 16-8...
Page 394 . BRAKE SYSTEM MXU 500 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the front wheel hub (refer to the “FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 14). Remove the four bolts and then remove the brake disc. INSPECTION Measure the brake disc thickness.
Page 395 . BRAKE SYSTEM MXU 500 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the rear wheel hub (refer to the “REAR WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 15). Remove the four bolts and then remove the brake disc. Brake Disc INSPECTION Measure the brake disc thickness.
Page 396 . BRAKE SYSTEM MXU 500 FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD) BRAKE FLUID CHANGE Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
Page 397 . BRAKE SYSTEM MXU 500 Connect a transparent hose to the right caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.
Page 398 . BRAKE SYSTEM MXU 500 BRAKE SYSTEM BLEEDING 1. Connect a transparent hose to the bleed valves (right and left caliper). 2. Fully apply the brake lever after continuously pull it several times. Then, loosen the right caliper bleed valve nut to bleed air from the brake system.
Page 399 . BRAKE SYSTEM MXU 500 REAR BRAKE FLUID CHANGE/AIR BLEED BRAKE LEVER Brake fluid change Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. Reservoir Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
Page 400 . BRAKE SYSTEM MXU 500 Brake system bleeding Bleed Valve 1. Connect a transparent hose to the bleed valve. 2. Fully apply the brake lever after continuously pull it several times. Then, loosen the caliper bleed valve nut to bleed air from the brake system.
Page 401 . BRAKE SYSTEM MXU 500 Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Fill the brake reservoir with brake fluid and...
Page 402 . BRAKE SYSTEM MXU 500 COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD) BRAKE FLUID CHANGE Place the machine on the level ground and set the handlebar upright. 1. Remove the two screws from the brake fluid reservoir cap. 2. Remove the brake fluid reservoir cap (front brake lever).
Page 403 . BRAKE SYSTEM MXU 500 Reservoir 4. Remove the brake fluid reservoir cap (brake pedal). Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. 5. Connect a transparent hose to the front...
Page 404 . BRAKE SYSTEM MXU 500 Reservoir 7. Fill the brake reservoir (front brake lever) with brake fluid. Bleed Valve 8. Loosen the delay valve bleed valve nut. Connect the transparent hose to the bleed valve. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.
Page 405 . BRAKE SYSTEM MXU 500 10. Connect a transparent hose to the right caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose.
Page 406 . BRAKE SYSTEM MXU 500 Bleed Valve DELAY VALVE BLEEDING 1. Connect a transparent hose to the bleed valve (delay valve). 2. Fully apply the front brake lever after continuously pull it several times. Then, loosen the bleed valve nut (delay valve) to bleed air between the front brake master cylinder and the delay valve.
Page 407 . BRAKE SYSTEM MXU 500 6. Repeat these steps until the brake system is free of air. Then tighten the bleed valve nuts. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) When bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height (brake pedal).
Page 408 . BRAKE SYSTEM MXU 500 BRAKE MASTER CYLINDERS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Front/rear master cylinder Remove the brake reservoir cap and drain the brake fluid from the hydraulic brake system (refer to the “FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD” section or “REAR BRAKE Brake Lever FLUID CHANGE/AIR BLEED”...
Page 409 . BRAKE SYSTEM MXU 500 Rear Brake Master Cylinder Push the hole under the front brake master cylinder and then remove the brake light switch. Remove the screw and then remove the brake light switch from the rear brake master cylinder.
Page 410 . BRAKE SYSTEM MXU 500 Remove fluid hose bolt/two washers and then disconnect the fluid hose. When removing the brake fluid hose bolt, be sure to place towels under the hose and plug the hose end to avoid brake fluid leakage and contamination.
Page 411 . BRAKE SYSTEM MXU 500 ON ROAD TYPE: Refer to the “REAR PARKING SYSTEM” section in this chapter to install the left master cylinder holder. Install the brake fluid hose with the attaching bolt and two new sealing washers, then tighten the bolt to the specified torque.
Page 412 . BRAKE SYSTEM MXU 500 Brake pedal master cylinder Install and tighten the two mounting bolts to the specified torque. Torque: 1.2 kg-m (12 Nm, 8.6 lbf-ft) Install the brake fluid hose (ON ROAD: two brake fluid hose) with the attaching bolt and...
Page 413 . BRAKE SYSTEM MXU 500 BRAKE MASTER CYLINDER DISASSEMBLY/INSPECTION/ Snap Ring ASSEMBLY DISASSEMBLY Front/rear brake master cylinder Remove the brake master cylinder (refer to the “BRAKE MASTER CYLINDERS REMOVAL/INSTALLATION” section in this chapter). Remove the piston dust boot and snap ring from the brake master cylinder.
Page 414 . BRAKE SYSTEM MXU 500 Dust Boot Snap Ring Remove the dust boot. Remove the snap ring, then remove the piston and spring together. INSPECTION Check the cylinder inside wall for scratch, corrosion or other abnormal condition. If any abnormal condition is found, replace the master cylinder.
Page 415: Assembly
. BRAKE SYSTEM MXU 500 ASSEMBLY ● Wash the master cylinder components with new brake fluid before reassembly. ● Do not wipe the brake fluid off with a rag after washing the components. ● When washing the components, use the specified brake fluid (DOT 4).
Page 416: Installation
. BRAKE SYSTEM MXU 500 RELAY VALVE REMOVAL/DISASSEMBLY/INSP ECTION/ASSEMBLY/ INSTALLATION (ON ROAD) REMOVAL Drain brake fluid (refer to the “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter). Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts.
Page 417 . BRAKE SYSTEM MXU 500 Spring Delay Valve Body Push the piston out with a screwdriver. INSPECTION Check the delay valve body inside wall for scratch, corrosion or other abnormal condition. If any abnormal condition is found, replace the delay valve.
Page 418: Installation
. BRAKE SYSTEM MXU 500 INSTALLATION Install and tighten the mounting bolts to the specified torque. Torque: 1.2 kgf-m (12 Nm, 8.6 lbf-ft) Install the all brake fluid hoses with the attaching bolts and new sealing washers, then tighten the bolts to the specified torque.
Page 419: Installation
. BRAKE SYSTEM MXU 500 FRONT BRAKE CALIPERS REMOVAL/INSTALLATION REMOVAL Drain the brake fluid from the hydraulic brake system (refer to the “FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD)” section or “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter).
Page 420: Installation
. BRAKE SYSTEM MXU 500 Caliper (Brake Lever) REAR BRAKE CALIPERS REMOVAL/INSTALLATION Drain the brake fluid from the hydraulic brake system (refer to the “REAR BRAKE FLUID CHANGE/AIR BLEED” section in this chapter). Remove the brake fluid hose bolt and two washers from the caliper.
Page 421: Rear Brake/Parking Brake Caliper Removal
. BRAKE SYSTEM MXU 500 Parking Brake Cable REAR BRAKE/PARKING BRAKE CALIPER REMOVAL/INSTALLATION (ON ROAD) Drain the brake fluid from the hydraulic brake system (refer to the “COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD)” section in this chapter). Disconnect the parking brake cable from the caliper.
Page 422: Brake Caliper Disassembly/Inspection/Assembly
. BRAKE SYSTEM MXU 500 BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front or rear brake caliper (refer to the “FRONT BRAKE CALIPERS REMOVAL/INSTALLATION” section or “REAR BRAKE CALIPERS REMOVAL/INSTALLATION” section in this chapter). Remove the brake pad spring plate.
Page 423 . BRAKE SYSTEM MXU 500 Push the piston dust seal inward to remove. Dust Seal Inner Oil Seal Pushing the piston oil seal outward to remove it. Clean the seals groove with brake fluid. Be careful not to damage the piston surface.
Page 424 . BRAKE SYSTEM MXU 500 ASSEMBLY ● Wash the brake caliper components with new brake fluid before reassembly. ● Do not wipe the brake fluid off with a rag after washing the components. ● When washing the components, use the specified brake fluid (DOT 4).
Page 425: Rear Brake/Parking Brake Caliper
. BRAKE SYSTEM MXU 500 REAR BRAKE/PARKING BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY (ON ROAD) DISASSEMBLY/INSPECTION Remove parking brake caliper (refer to the “REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION ” section in this chapter). (ON ROAD Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper.
Page 426 . BRAKE SYSTEM MXU 500 Dust Boot Inspect the dust boots for deterioration or damage. If any damages are found, replace them with a new ones. Remove the caliper bracket. Remove the dust boot. Caliper Bracket Remove the dust seal and piston seal.
Page 427 . BRAKE SYSTEM MXU 500 Dust Boot Drive Bolt Inspect the dust boot for deterioration or damage. If any damage is found, replace it with a new one. Remove the drive bolt and dust boot. Brake Shaft Shaft Guide Inspect the drive shaft and shaft guide for wear or damage.
Page 428 . BRAKE SYSTEM MXU 500 O-ring Remove the O-ring. O-ring Inspect the O-ring for wear or damage. If any damages are found, replace it with a new one. O-ring INSTALLATION Apply silicone grease to the new O-ring, then install the new O-ring.
Page 429 . BRAKE SYSTEM MXU 500 Parking Brake Case Install the parking brake case and two bolts. Tighten the bolts securely. Piston Seal/Dust Seal Apply silicone grease to the new piston seal and new dust seal, then install them. Install the piston.
Page 430 . BRAKE SYSTEM MXU 500 Dust Boot Press the piston and turn the brake shaft counterclockwise to expand boot, then the brake shaft does not touch piston. Piston Parking Brake Arm Spring Install the parking brake arm and spring. Align the parking brake arm with the brake fluid inlet hole as shown.
Page 431 . BRAKE SYSTEM MXU 500 Dust Boot Install the dust boots. Apply silicone grease to caliper bracket, then install it. Caliper Bracket Install the spring plate. Spring Plate Install the parking brake caliper (refer to the “REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION ”...
Page 432: Battery/Charging System
. BATTERY/CHARGING SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT/CHARGING CIRCUIT ----------- 17- 1 SERVICE INFORMATION------------------------------------------------ 17- 2 TROUBLESHOOTING----------------------------------------------------- 17- 4 BATTERY -------------------------------------------------------------------- 17- 5 CHARGING SYSTEM INSPECTION ----------------------------------- 17- 6 ALTERNATOR CHARGING COIL-------------------------------------- 17- 7...
Page 433 . BATTERY/CHARGING SYSTEM MXU 500 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT 12V 18AH BATTERY 17-1...
Page 434 . BATTERY/CHARGING SYSTEM MXU 500 SERVICE INFORMATION GENERAL CAUTION • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
Page 435 . BATTERY/CHARGING SYSTEM MXU 500 BATTERY CHARGING • This model comes with a maintenance free (MF) battery. Remember the following about MF batteries. ─ Use only the electrolyte that comes with the battery. ─ Use all of the electrolyte ─ Seal the battery properly ─...
Page 436: Troubleshooting
. BATTERY/CHARGING SYSTEM MXU 500 TROUBLESHOOTING Battery is damaged or weak Remove the battery. •Faulty battery Incorrect Check the battery condition. Correct Disconnect the regulator/rectifier Incorrect connectors and recheck the battery Install the battery. Check the battery current leakage. current leakage.
Page 437: Battery
. BATTERY/CHARGING SYSTEM MXU 500 BATTERY REMOVAL/INSTALLATION Battery removal 1. Make sure the ignition switch is OFF. 2. Remove the seat (refer to the “FRAME COVERS” section in the chapter 2) 3. Release the rings and remove the rubber band (1).
Page 438: Charging System Inspection
. BATTERY/CHARGING SYSTEM MXU 500 BATTERY CHARGING Remove the battery (see page 17-5). Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. Turn the power ON/OFF at the charger, not at the battery terminals.
Page 439: Alternator Charging Coil
. BATTERY/CHARGING SYSTEM MXU 500 CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.
Page 440: Regulator/Rectifier
. BATTERY/CHARGING SYSTEM MXU 500 Measure the resistance between each Yellow wire terminals. Standard: 0.1 0.3 Ω (20ºC/68ºF) Check for continuity between each Yellow wire terminal of the alternator side connector and ground. There should be no continuity. Replace the alternator stator if resistance is out of specification, or if any wire has continuity to ground.
Page 441 . BATTERY/CHARGING SYSTEM MXU 500 Ground line Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Charging coil line Measure the resistance between each Yellow wire terminals. Standard: 0.1 0.3 Ω (20ºC/68ºF) Check for continuity between each Yellow wire terminal and ground.
Page 442 . BATTERY/CHARGING SYSTEM MXU 500 Regulator/Rectifier Connector REMOVAL/INSTALLATION Disconnect the regulator/rectifier connectors. Remove the two bolts and then remove the regulator/rectifier. Installation is in the reverse order of removal. Regulator/Rectifier 17-10...
Page 443: Alternator Stator Removal/Inspection/ Installation
. BATTERY/CHARGING SYSTEM MXU 500 ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION REMOVAL Drain the engine oil (refer to the “ENGINE OIL” section in the chapter 3). Disconnect the alternator stator connectors. Alternator Stator Connectors Oil Filler Plug Remove the starter pulley (refer to the “STARTER PULLEY...
Page 444 . BATTERY/CHARGING SYSTEM MXU 500 Dowel Pins Remove the two dowel pins and gasket. Gasket Remove the two pulse coil mount bolts. Remove the three stator mount bolts, grommet and the stator from the right crankcase cover. Stator Pulse Coil INSPECTION Check the stator and pulse coil for damage.
Page 445 . BATTERY/CHARGING SYSTEM MXU 500 INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1.2 kgf-m (12 N-m, 9 lbf-ft) Apply sealant to the grommet seating surface and install it to the cover groove properly.
Page 446: Ignition System
. IGNITION SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT------------------------------------------- 18-1 IGNITION CIRCUIT ------------------------------------------------------- 18-2 SERVICE INFORMATION------------------------------------------------ 18-3 TROUBLESHOOTING----------------------------------------------------- 18-4 IGNITION COIL INSPECTION ------------------------------------------ 18-5 IGNITION CONTROL MODULE ---------------------------------------- 18-6 18-0...
Page 447 . IGNITION SYSTEM MXU 500 IGNITION SYSTEM LAYOUT 18-1...
Page 448 . IGNITION SYSTEM MXU 500 IGNITION CIRCUIT (ON ROAD) (OFF ROAD) 18-2...
Page 449 . IGNITION SYSTEM MXU 500 SERVICE INFORMATION GENERAL INSTRUCTIONS ● Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. ● When servicing the ignition system, always follow the steps in the troubleshooting on page 18-3.
Page 450 . IGNITION SYSTEM MXU 500 TROUBLESHOOTING LOW PEAK VOLTAGE ● Cranking speed is too low (battery is undercharged). ● Poorly connected connectors or an open circuit in the ignition system. ● Faulty ignition-coil. ● Faulty ignition control module. NO PEAK VOLTAGE ●...
Page 451: Ignition Coil Inspection
. IGNITION SYSTEM MXU 500 IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Check cylinder compression and check that the spark plugs is installed correctly in the cylinder. Disconnect the spark plug cap from the spark plug. Spark Plug Cap...
Page 452 . IGNITION SYSTEM MXU 500 IGNITION PULSE GENERATOR INSPECTION Disconnect the ignition pulse generator connector. Measure the ignition pulse generator resistance between the Green/White wire and Blue/Yellow wire. Standard: 489±20% Ω (20ºC/68ºF) Ignition Pulse Generator Connector IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug cap from the spark plug (page 18-4).
Page 453 . IGNITION SYSTEM MXU 500 Due to the semiconductor in circuit, it RESISTANCE INSPECTION is necessary to use a specified tester for accurate testing. Use of an improper Measure the resistance between the terminals. tester in an improper range may give false readings.
Page 454: Starter System
. STARTER SYSTEM MXU 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTER SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19- 1 STARTING CIRCUIT ------------------------------------------------------ 19- 2 SERVICE INFORMATION------------------------------------------------ 19- 3 TROUBLESHOOTING----------------------------------------------------- 19- 3 STARTER MOTOR --------------------------------------------------------- 19- 6 STARTER RELAY SWITCH/STARTER MAG ----------------------- 19- 7...
Page 455 . STARTER SYSTEM MXU 500 STARTING SYSTEM LAYOUT 19-1...
Page 456 . STARTER SYSTEM MXU 500 STARTING CIRCUIT (ON ROAD) (OFF ROAD) 19-2...
Page 457 . STARTER SYSTEM MXU 500 SERVICE INFORMATION GENERAL • Always turn the ignition switch to “OFF” before servicing the starter motor. The motor could suddenly start, causing serious injury. • The starter motor can be serviced with the engine in the frame.
Page 458 . STARTER SYSTEM MXU 500 (From previous page) Check for loose or poorly •Poorly connected terminal Abnormal connected starter MAG terminals. Normal •Poorly connected starter motor cable. Check for loose or poorly Abnormal connected or broken starter •Open circuit in starter motor cable.
Page 459 . STARTER SYSTEM MXU 500 (From previous page) Check the starter MAG •Faulty engine stop switch (OFF ROAD). No voltage voltage (page 19-7). •Faulty starter switch. •Loose or poor contact of connector. Battery voltage registers •Open circuit in wire harness.
Page 460: Starter Motor
. STARTER SYSTEM MXU 500 Starter Motor Cable STARTER MOTOR INSPECTION Disconnect the starter motor cable from the starter MAG. Turn the ignition switch to “ON”. Connect the starter motor cable directly to the battery positive terminal. If the starter motor does not turn, the starter motor is faulty.
Page 461: Starter Relay Switch/Starter Mag
. STARTER SYSTEM MXU 500 Starter MAG STARTER RELAY SWITCH/STARTER MAG INSPECTION Turn the ignition switch to “ON”. Squeeze the brake lever or pedal fully. The coil is normal if the starter relay switch clicks. Squeeze and hold the brake lever or pedal fully then push the starter switch.
Page 462 . STARTER SYSTEM MXU 500 Starter MAG CONTINUTY INSPECTION Disconnect the starter MAG switch connector and cables. Connect a fully charged 12 V battery positive wire to the relay switch Yellow/Red wire terminal and negative wire to the Yellow/Green wire terminal.
Page 463: Recoil Starter Removal/Inspection/ Installation
. STARTER SYSTEM MXU 500 Recoil Starter RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION The recoil starter can not start the engine when the battery is removal. REMOVAL Remove the six bolts, then remove the recoil starter assembly. Remove the two dowel pins.
Page 464 . STARTER SYSTEM MXU 500 Recoil Starter Install the recoil starter assembly. Install and tighten the six bolts diagonally. 19-10...
Page 465: Recoil Starter Handle Replace
. STARTER SYSTEM MXU 500 RECOIL STARTER HANDLE REPLACE Remove the recoil starter assembly (refer to the “RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the cap on the handle. Knot Replace the handle. Before untying the knot above the...
Page 466: Recoil Starter Disassembly/Inspection/ Assembly
. STARTER SYSTEM MXU 500 RECOIL STARTER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the recoil starter assembly (refer to the “RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the handle (refer to the “RECOIL STARTER HANDLE REPLACE” section Knot in this chapter).
Page 467 . STARTER SYSTEM MXU 500 Coil Spring Remove the reel, then remove the coil spring. Wear hand and eye protection when removing the reel, since the spring may quickly unwind and cause and injury. Reel INSPECTION Pull the rope and check that the ratchet is pushed out.
Page 468 . STARTER SYSTEM MXU 500 Coil Spring Inspect the coil spring for fatigue. Hook ASSEMBLY Apply molybdenum disulfide grease to the coil spring, then install the coil spring. ● Wear hand and eye protection when installing the spring, since the spring may quickly unwind and cause and injury.
Page 469 . STARTER SYSTEM MXU 500 Coil Spring Install the reel. ● Wear hand and eye protection when installing the reel, since the spring may quickly unwind and cause and injury. ● Engage the part of the reel with coil spring end.
Page 470 . STARTER SYSTEM MXU 500 Unhook the rope, then turn the reel clockwise with the rope slowly. Apply Grease Apply Grease Apply molybdenum disulfide grease to the washer and friction plate. Spring Bolt/Washer/Plate/Spring Install the pawl spring, friction plate/washer. Install and tighten the new bolt securely.
Page 471 . STARTER SYSTEM MXU 500 Pull the rope and check that the ratchet is pushed out. 19-17...
Page 472: Starter Pulley Removal/Inspection/ Installation
. STARTER SYSTEM MXU 500 STARTER PULLEY REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the recoil starter assembly (refer to the “RECOIL STARTER REMOVAL/INSPECTION/ INSTALLATION” section in this chapter). Remove the starter pulley nut by using a suitable bar. Nut/Washer INSPECTION Inspect the starter pulley for cracks or pitting.
Page 473 . STARTER SYSTEM MXU 500 INSTALLATION Install the starter pulley and washer. Install and tighten the nut to the specified torque by using suitable bar. Torque: 5.5 kgf-m (55 N-m, 40 lbf-ft) Nut/Washer 19-19...
Page 474: Starter Clutch Removal/Inspection/ Installation
. STARTER SYSTEM MXU 500 Flywheel Puller STARTER CLUTCH REMOVAL/INSPECTION/ INSTALLATION REMVOAL Remove the right crankcase cover (refer to the “ALTERNATOR STATOR REMOVAL/INSPECTION/ INSTALLATION” section in the chapter 17). Remove the flywheel/driven gear by using the special tool. Flywheel/Driven Gear...
Page 475 . STARTER SYSTEM MXU 500 INSPECTION Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise. Remove the starter driven gear by turning the driven gear.
Page 476 . STARTER SYSTEM MXU 500 Reduction Gear INSTALLATION Apply oil to the starter reduction gear. Install the starter reduction gear to the right crankcase. Woodruff Key Install the woodruff key in the crankshaft key groove. Apply molybdenum oil solution to the starter driven gear bushing.
Page 477 . STARTER SYSTEM MXU 500 Reduction Gear Driven Gear Clean any oil from the tappered portion of the flywheel I.D. Install the flywheel/driven gear onto the crankshaft, aligning the key way with woodruff key. Flywheel 19-23...
Page 478: 20. Lights/Switches
20. LIGHTS/SWITCHES MXU 500 __________________________________________________________________________________ LIGHTS/SWITHCES SERVICE INFORMATION------------------------------------------------ 20- 1 BULBS REMOVAL--------------------------------------------------------- 20- 2 HORN (ON ROAD) --------------------------------------------------------- 20- 4 IGNITION SWITCH -------------------------------------------------------- 20- 5 HANDLEBAR SWITCH --------------------------------------------------- 20- 5 GEAR INDICATOR SWITCH -------------------------------------------- 20- 8 SPEED SENSOR ------------------------------------------------------------ 20- 9...
Page 479: Service Information
20. LIGHTS/SWITCHES MXU 500 SERVICE INFORMATION ● A continuity test can be made with the switches installed on the vehicle. ● All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. ● To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be made without removing the pat from the vehicle.
Page 480: Bulbs Removal
20. LIGHTS/SWITCHES MXU 500 Headlight Connector BULBS REMOVAL HEADLIGHT Disconnect the headlight wire connector. Remove the rubber boot from the headlight case. Rubber Boot Lock Clip Relax the lock clip to remove the bulb and replace with a new one.
Page 481 20. LIGHTS/SWITCHES MXU 500 Bulb TAIL/BRAKE LIGHT Bulb Socket Remove the bulb socket by turning it counterclockwise. Remove the bulb. Install the bulb in the reverse order of removal. Rubber Boot TURN SIGNAL LIGHT (ON ROAD) FRONT Remove the rubber boot from the turn signal light case.
Page 482: Horn (On Road)
20. LIGHTS/SWITCHES MXU 500 Bulb REAR Remove the bulb socket by turning it counterclockwise. Remove the bulb. Install the bulb in the reverse order of removal. Bulb Socket LICENCE LIGHT BULB (ON ROAD) Remove the two screws and licence light cover.
Page 483: Ignition Switch
20. LIGHTS/SWITCHES MXU 500 IGNITION SWITCH INSPECTION Disconnect the ignition switch connectors. (Refer to the “FRAME COVER” section in the chapter 2.) Check for continuity between the switch side connector terminals in each switch position. Continuity should exist between the color...
Page 484 20. LIGHTS/SWITCHES MXU 500 Hazard Switch (ON ROAD) Winker Switch Horn Switch Light Switch Start Switch 2WD/4WD Select Button 20-6...
Page 485 20. LIGHTS/SWITCHES MXU 500 Dimmer Switch (OFF ROAD) Start Switch Engine Stop Switch Passing Switch 2WD/4WD Select Button 20-7...
Page 486 20. LIGHTS/SWITCHES MXU 500 GEAR INDICATOR LIGHT SWITCHES INSPECTION Disconnect the gear indicator light switch wire connector. Check for continuity between the switch side connector terminal and engine ground. Gear Indicator Light Switch REPLACEMENT Disconnect the gear indicator light switch connector.
Page 487: Speed Sensor
20. LIGHTS/SWITCHES MXU 500 SPEED SENSOR Disconnect the connector. Remove the bolt then remove the speed sensor. If the speedometer, odometer or trip meter does not function properly. Inspect the connection of speed sensor connector. If the connection is all right, replace the speedometer with a new one.
Page 488: 2Wd/4Wd Selecting System
20. LIGHTS/SWITCHES MXU 500 2WD/4WD SELECTING SYSTEM The 2WD/4WD selecting system consists of the following components: ● 2WD/4WD selecting button ● 2WD switch ● 4WD switch ● 2WD/4WD change ECU ● 2WD/4WD motor ● Battery TROUBLSHOOTING Does not shift to 2WD/4WD (2WD/4WD motor will not run.)
Page 489 20. LIGHTS/SWITCHES MXU 500 Check the 2WD switch or 4WD switch. Faulty 2WD/ switch or 4WD Incorrect (See page 12) switch Correct Open circuit in wire harness The 2WD/4WD motor runs, but does not shift to 2WD/4WD. Check the front drive sliding dog (refer to the “FRONT DRIVE...
Page 490 20. LIGHTS/SWITCHES MXU 500 2WD/4WD change ECU Make sure the 2WD/4WD selecting button is correct (see page 20-11). Disconnect the 2WD/4WD motor connector. Turn on the ignition switch. Listen for a click from the 2WD/4WD change ECU when the 2WD/4WD selecting button is pushed.
Page 491: Fuel Unit
20. LIGHTS/SWITCHES MXU 500 Apply three bond: 1215 to the 2WD/4WD switches and tighten them to the specified torque. Torque: 2.2 kgf-m (22 N-m, 16 lbf-ft) FUEL UNIT REMOVAL Remove the fuel tank cover (refer to the “FRAME COVERS” section in the chapter Remove the fuel unit connectors.
Page 492 . WIRING DIAGRAMS MXU 500 21-0...
Page 493 . WIRING DIAGRAMS MXU 500 21-1...

KYMCO MXU 500 User Manual

Preface

2. Frame Covers/Exhaust Muffler

3 Inspection/Adjustment

4. Lubrication System

5 Fuel System

6 Cooling System

Cylinder Head/Valves

Drive Pulley/Driven Pulley/Clutch

Transmission System 11

Drive Train

Front Wheel/Front Suspension Steering System

15. Rear Wheel/Axle/Shock Absorber/Swing Arm

16 Brake System

17. Battery/Charging System

Quick Links

Chapters

Troubleshooting

Related Manuals for KYMCO MXU 500

Summary of Contents for KYMCO MXU 500