KYMCO MXU 400 Manuals

Manuals and User Guides for KYMCO MXU 400. We have 2 KYMCO MXU 400 manuals available for free PDF download: Service Manual, Owner's Manual

KYMCO MXU 400 Service Manual (158 pages)

Brand: KYMCO | Category: Offroad Vehicle | Size: 18.16 MB

1 Section 1 - General Information/ Specifications

5
Section 2 - Periodic Maintenance

11
- Periodic Maintenance Chart
  12
- Battery
  13
  - Torque Specifications
    13
- Lubrication Points
  13
- Periodic Maintenance
  13
- Air Filter
  14
- Fuses
  14
- Valve/Tappet Clearance (Feeler Gauge Procedure)
  16
- Valve/Tappet Clearance (Valve Adjuster Procedure)
  16
- Testing Engine Compression
  17
- Muffler/Spark Arrester
  18
- Spark Plug
  18
- Adjusting Engine RPM (Idle)
  19
- Adjusting Throttle Cable
  19
- Engine/Transmission Oil - Filter - Strainer
  19
- Front Differential/Rear Drive Lubricant
  21
- Driveshaft/Coupling
  22
- Ignition Timing
  22
- Nuts/Bolts/Cap Screws
  22
- Steering Components
  22
- Suspension/Shock Absorbers/Bushings
  22
- Tires
  22
- Lights
  23
- Electrical Connections
  25
- Frame/Welds/Racks
  25
- Hydraulic Brake Systems
  25
- Shift Lever
  25
- Burnishing Brake Pads
  27
- Checking/Replacing V-Belt
  27
Table of Contents

37
- Removing Top-Side Components
  39
- Top-Side Components
  39
- Servicing Top-Side Components
  43
- Installing Top-Side Components
  51
- Left-Side Components
  55
- Removing Left-Side Components
  56
- Installing Left-Side Components
  58
- Removing Right-Side Components
  59
- Right-Side Components
  59
- Installing Right-Side Components
  63
  - Driven Pulley Assembly
    63
- Servicing Right-Side Components
  63
- Center Crankcase Components
  66
- Disassembling Crankcase Half
  67
- Separating Crankcase Halves
  67
- Servicing Center Crankcase Components
  69
  - Crankshaft Assembly
    70
- Assembling Crankcase Half
  72
- Installing Engine/Transmission
  74
- Joining Crankcase Halves
  74
Section 4 - Fuel/Lubrication/Cooling

79
- Fuel/Lubrication/Cooling
  79
- Carburetor
  80
- Carburetor Schematic
  80
- Carburetor Specifications
  80
- Engine RPM (Idle)
  86
- Gas Tank
  86
- Throttle Cable Free-Play
  86
- Oil Filter/Oil Pump
  88
- Testing Oil Pump Pressure
  88
- Oil Cooler
  89
- Troubleshooting
  90
Section 5 - Electrical System

91
- Electrical System
  91
- Accessory Receptacle/Connector
  92
- Battery
  92
- RPM Limiter
  92
- Specifications
  92
- Testing Electrical Components
  92
- Brakelight Switch (Pressure)
  93
- Oil Temperature and Cooling Fan Switches
  93
- Fan Motor
  94
- Fuses
  95
- Ignition Coil
  95
- Ignition Switch
  96
- Speed Sensor
  96
- Front Drive Selector Switch
  97
- Handlebar Control Switches
  97
- Front Drive Selector Actuator
  98
- Gear Shift Position Switch
  98
- Starter Relay
  99
- Stator Coil
  99
- CDI Unit
  100
- Starter Motor
  100
- Headlights
  101
- Neutral Start/Front Drive Actuator/Start-In-Gear/ 2WD Relays
  101
- Regulator/Rectifier
  101
- Taillights - Brakelights
  101
- Back-Up Lights
  102
- Running Lights
  102
- Ignition Timing
  103
- Troubleshooting
  103
Section 6 - Drive System

105
- Drive System
  106
- Front Drive Actuator
  106
- Suspension
  106
- Front Differential
  107
- Drive Axles
  118
- Rear Gear Case
  122
- Hub
  123
- Hydraulic Brake Caliper
  124
- Troubleshooting Brake System
  126
- Troubleshooting Drive System
  126
Section 7 - Suspension

127
- Front A-Arms
  128
- Shock Absorbers
  128
- Suspension
  128
- Rear A-Arms
  129
- Wheels and Tires
  130
- Troubleshooting
  132
Section 8 - Steering/Frame

133
- Steering Post/Tie Rods
  134
- Steering/Frame
  134
- Handlebar Grip
  135
- Steering Knuckles
  136
- Measuring/Adjusting Toe-In
  137
- Front Bumper Assembly
  138
- Front Rack
  138
- Front Body Panel/Fender
  139
- Exhaust System
  140
- Rear Body Panel/Rack
  141
- Troubleshooting
  143
  - Controls/Indicators
    145
    
    Throttle Control
    146
    
    Lcd Gauge
    147

KYMCO MXU 400 Owner's Manual (90 pages)

Brand: KYMCO | Category: Offroad Vehicle | Size: 8.07 MB

Introduction
3
Table of Contents
4
Safety
5
ATV Safety Alert
7
Decal
8
Location
8
Hangtag of EPA
8
Warning Information
9
Warning Labels
10
Location of Parts and Controls
12
Warnings
13
Prevention
24
Overview
24
Gloves
24
Boots/Ankle Protection
24
Helmet
25
Eye Protection
25
Long Parts and Long Sleeved Shirt
25
Condition of the ATV
26
Tires and Wheels
27
Controls and Cables
27
Brakes
27
Throttle
27
Lights and Electric
28
Oil and Fuel
28
Chassis
28
Miscellaneous Items
28
First Aid and Survival
29
Tools
29
Identification
29
Cellular Phone
29
Active Riding
30
Basic Operating Maneuvers
30
Mounting the ATV
30
Starting the Engine
30
Starting a Cold Engine
31
Braking/Stopping
32
Shifting
32
How to Handle the ATV
33
Dismounting the ATV
33
Parking
33
Starting
34
Leaning, Weight Shift, and Balance
34
Wide Turns
35
Sharp Turns
35
Quick Turns
36
K-Turns
37
Riding Uphill
38
Riding Downhill
39
Sidehilling/Traversing
39
Swerving
40
Crossing Obstacles
41
Tips
42
Parking on a Hill
42
Stalling on a Hill
42
Reversing
42
Crossing Roads
43
Driving in Cold Weather
43
Stopping the ATV
44
Stopping the Engine
44
Sound Judgement
45
Environment
46
Weather
46
Night Riding
46
Paved Surfaces
46
Trail Riding
47
Trail Signs
47
Riding Companions
48
Hikers
48
Other Vehicles
48
Animals and Nature
48
Equipment
49
ATV Maintenance
49
Cargo Limitations
49
Load Capacity Ratings Chart
50
Speedrack
50
Max Load Capacity
50
Tongue Weight
50
Alcohol and Drug Consumption
51
The Effects of Alcohol
51
Physical Condition
52
Reckless Riding
52
Group Behavior
52
Sipde
52
Supervision
53
Inexperienced/Untrained Riders
53
Experiences/Trained Riders
53
Preface
55
Parts and Accessories
55
Specifications
56
General Information
57
ATV Identification Numbers
57
Ignition Switch Key
57
Control Locations and Functions
57
Gas Tank Valve
58
2WD/4WD Selector Switch
58
Hand Brake Lever/Brake Lever Lock
59
Headlight HI/LO Switch
59
Emergency Stop Switch
60
Starter Button
60
Turn Signal Switch
60
Throttle Lever
60
Auxiliary Brake Pedal
61
Speedometer/Lcd
61
Primer - Cold Start
62
Gas/Vent Hoses
62
Carburetor Float Bowl Drain
63
Oil Level Stick
63
Seat Latch
63
Safety Flag Bracket
64
Rack Loading
64
Trailering and Towing
64
Transporting ATV
65
Gasoline-Oil-Lubricant
65
Recommended Gasoline
65
Recommended Engine/Transmission Oil
65
Recommended Front Differential/Rear Drive Lubricant
66
Filling Gas Tank
66
Break-In Procedure
66
General Maintenance
68
Maintenance Schedule
69
Oil Cooler
70
Shock Absorbers
70
General Lubrication
70
Cables
70
Front Differential and Rear Drive Gear Lubricant
71
Hydraulic Hand Brake
72
Brake Fluid
72
Auxiliary Brake
73
Brake Lever Lock
73
Brake Hoses
73
Brake Pads
73
Protective Rubber Boots
74
Tie Rod Boots
74
Drive Axle Boots
74
Battery
75
Spark Plug
76
Engine Idle RPM Adjustment
77
Throttle Cable Adjustment
77
Air Filter
78
Air Filter Housing Drain
78
Draining V-Belt Cover
79
Tires
79
Tire Tread Condition
79
Tire Replacement
79
Tubeless Tire Repair
80
Wheel Removal
80
Muffler/Spark Arrester
80
Light Bulb Replacement
80
Checking/Adjusting Headlight Aim
81
Headlight
81
Taillight/Brakelight
81
Fuses
82
Electrical Output Terminals
82
Storage Compartments
82
Preparation for Storage
83
Preparation after Storage
84
Index
87
Identification Numbers Record
88

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KYMCO MXU 400 Manuals

KYMCO MXU 400 Service Manual (158 pages)

Table of Contents

1 Section 1 - General Information/ Specifications

Section 2 - Periodic Maintenance

Table of Contents

Section 4 - Fuel/Lubrication/Cooling

Section 5 - Electrical System

Section 6 - Drive System

Section 7 - Suspension

Section 8 - Steering/Frame

KYMCO MXU 400 Owner's Manual (90 pages)

Table of Contents

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