KYMCO MXU 550i 2021 Manuals

Manuals and User Guides for KYMCO MXU 550i 2021. We have 1 KYMCO MXU 550i 2021 manual available for free PDF download: Repair Manual

KYMCO MXU 550i 2021 Repair Manual (956 pages)

Brand: KYMCO | Category: Offroad Vehicle | Size: 40 MB

Using this Manual
2
Table of Contents
3
Quick Reference
3
Break in Procedure
4
General Information
5
Gasoline - Oil - Lubricant
5
Recommended Gasoline
5
Recommended Oil
6
Genuine Parts
7
Preparation for Storage
7
Preparation after Storage
8
VIN and Engine Number Location
26
Special Tools
27
Specifications
28
Lubrication Specifications
30
Cooling System Specifications
34
Torque Specifications
37
General Torque Specifications
43
Troubleshooting
44
Electrical Troubleshooting
48
Brake Troubleshooting
50
Suspension and Steering
51
Diagnostic Trouble Codes (Dtcs)
53
Periodic Maintenance
56
Periodic Maintenance Chart
57
Air Filter Servicing
59
Installation
64
Airbox Drain
67
Brake Fluid
69
Brake Inspection
75
Master Cylinder
75
Brake Pads
76
Brake Discs
77
Rear Brake Light Switch
78
Compression Check
79
Engine Idle Speed
81
Engine Oil
82
Final Drive Oil
92
Spark Arrestor
102
Installation
104
Spark Plug
106
Throttle Free Play
112
Throttle Limiter
115
Tires
116
Air Pressure
117
Tire Tread Depth
118
Suspension and Steering Inspection
119
Toe-In Check
123
Valve Clearance
128
Fuel System
133
General Service Information
133
Troubleshooting
134
Engine Fail to Start
134
Airbox
136
Installation
138
Check Engine Lamp (CELP)
141
Display Indicators
141
Self-Diagnostic Procedures
143
Self-Diagnosis Reset Procedure
144
Component Location
145
Right Side
145
Throttle Body
147
Diagnostic Tool
150
Fuel Injection Sensors
163
Input Voltage Inspection
168
Throttle Position Sensor
169
Resistance Inspection
170
Data Analysis
170
Fuel Injector
175
Installation
179
Fuel Pump
184
Fuel Line Inspection
184
Fuel Level Gauge Inspection
190
Fuel Pump Relay
192
Continuity Test
192
Throttle Body Removal and Installation
198
Intake Pipe
204
Throttle Body Components
213
T-MAP Sensor
213
TPS Sensor
216
General Instructions
223
Lubrication System
223
High Oil Pressure
224
Oil Contamination
224
Compression too High
226
Engine Specifications
227
MXU 550I
227
Cylinder Head Cover
229
Installation
235
Camshaft
238
Cam Chain Tensioner
241
Rocker Arms
248
Camshaft Installation
256
Cylinder Head
270
Installation
276
Valves
281
Cylinder and Piston
292
Cylinder Bore
300
Piston Diameter
302
Piston-To-Cylinder Clearance
303
Piston Ring-To-Groove Clearance
303
Piston Ring End Gap
304
Connecting Rod Small End
306
Recoil Starter Cover
314
Installation
318
Generator Cover
322
Flywheel
334
Starter Clutch
338
Installation
343
Oil Pump
349
Installation
362
Cam Chain
368
Engine Removal
373
Engine Installation
382
Output Shaft and Bevel Gear
391
Seals and Bearings
400
Installation
412
Crankcase
421
Oil Relief Valve
427
Crankshaft
437
Installation
440
Transmission Removal
441
Transmission Shafts
453
Transmission Installation
467
Installation
470
Crankcase Bearings
478
Cooling System
481
Troubleshooting
482
Coolant
483
Pressure Testing
491
Radiator
493
Radiator Fan
499
Installation
499
Thermostat
504
Water Pump
510
Mechanical Seal Inspection
510
CVT Continuously Variable Transmission
521
General Instructions
521
Troubleshooting
522
CVT Cooling Ducts
523
Belt Case Cover
528
CVT Removal
536
Drive Pulley Disassembly
541
Driven Pulley Disassembly
544
CVT Installation
550
Driven Pulley
550
Drive Pulley
555
Clutch Removal
563
Clutch Installation
577
Final Drive
585
Troubleshooting
586
Drive Shafts
587
Boot Inspection
587
Installation
599
Differential Removal and Installation
600
Differential Disassembly
607
Pinion Housing
610
Bearing Replacement
616
Pinion Gear
628
Differential Assembly
636
Rear Final Drive Gear
651
Installation
652
Final Drive Gear Disassembly
655
Final Drive Gear Assembly
680
Brake System
691
Poor Brake Performance
692
Brake Noise
692
Brake Discs
693
Installation
696
Brake Pedal and Master Cylinder
698
Installation
713
Front Brake Calipers
716
Brake Pad Replacement
717
Rear Brake Calipers
728
Brake Pad Installation
738
Master Cylinders
749
Brake Levers
753
Installation
754
Troubleshooting
759
Front Wheel Removal
760
Front Wheel Hub Removal
761
Front Wheel Hub Installation
762
Front Wheel Installation
764
Wheel Inspection
766
Rear Wheel Removal
767
Rear Wheel Hub Removal
768
Rear Wheel Hub Installation
769
Rear Wheel Installation
772
Wheel Bearings
774
Brake Master Cylinders
781
Installation
790
Master Cylinders
798
Steering Knuckles
799
Steering Shaft
803
Installation
828
Front Suspension
856
Bushing Replacement
859
Front Shock Absorbers
865
Rear Suspension
869
Troubleshooting
869
Rear Shock Absorbers
870
Electrical System
887
Charging System and Battery
887
Caution
887
General Instructions
888
Troubleshooting
889
Ignition System
890
General Instructions
890
Troubleshooting
890
Starting System
891
General Instructions
891
Troubleshooting
891
Lights, Switches, and Fuel Pump
892
General Instructions
892
Troubleshooting
892
Electrical Specifications
893
Battery
894
General Information
894
Removal
894
Testing
897
Voltage
897
Current Leakage
897
Charging System Testing
898
Battery Charging
898
Installation
899
Charging System
901
Battery
901
Charging Voltage
901
Stator Coil
902
Coil Resistance
902
Regulator/Rectifier
903
Inspection
903
Removal
905
Installation
907
Fuses and Relays
909
Fuse Box
909
Main Fuse
911
Relays
912
Ignition System
914
Electrical Connections
914
Troubleshooting
915
Spark Check
915
Ignition Coil
916
Primary Resistance
916
Spark Plug Cap Resistance
917
Ignition Coil Peak Voltage
917
Removal
918
Installation
920
Ignition Pulse Generator / Crank Position Sensor
921
Resistance
921
Peak Voltage
922
Ignition Advance Check
922
Ecu
923
ECU Input Voltage
923
Removal
926
Installation
928
Lights
929
Headlight Aim
929
Headlights
930
Bulb Replacement
930
Removal
931
Installation
932
Taillights
933
Removal
933
Installation
934
Starter Motor
935
Inspection
935
Removal
936
Installation
937
Starting System
940
System Diagram
940
Troubleshooting
940
Starter Motor
941
Starter Relay (Starter Mag)
941
Operation Inspection
941
Fuse
942
Voltage Inspection
943
Continuity Inspection
944
Removal
944
Installation
945
Switches
947
Ignition Switch
947
Left Handlebar Switches
948
Light Switch
949
Engine Start Switch
949
Engine Kill Switch
950
Gear Position Switch
950
Speed Sensor
951
Replacement
952
2WD/4WD Actuator and Switch
953
2WD/4WD Switch
953
2WD/4WD Actuator Inspection
955
Brake Light Switches
956

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KYMCO MXU 550i 2021 Manuals

KYMCO MXU 550i 2021 Repair Manual (956 pages)

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