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MXU 500
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the
MXU 500
.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which are
subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 4 through 12 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 13 through 16 is
the removal/ installation of chassis.
Section 17 through 21 states the testing
and measuring methods of electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages give
detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
FRAME COVERS /EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
FUEL SYSTEM
5
COOLING SYSTEM
6
ENGINE REMOVAL
7
CYLINDER HEAD/VALVES
8
CYLINDER/PISTON
9
DRIVE PULLEY/DRIVEN PULLEY/
CLUTCH
10
FINAL REDUCTION/
TRANSMISSION SYSTEM
11
LEFT CRANKCASE/CRANKSHAFT/
BALANCE SHAFT
12
DRIVE TRAIN
13
FRONT WHEEL/FRONT SUSPENSION/
STTEERING SYSTEM
14
REAR WHEEL/AXLE/SHOCK
ABSORBER/SWING ARM
15
BRAKE SYSTEM
16
BATTERY/CHARGING SYSTEM
17
IGNITION SYSTEM
18
STARTER SYSTEM
19
LIGHTS/ SWITCHES
20
WIRING DIAGRAMS
21
The information and contents included in
this manual may be different from the
vehicle in case specifications are changed.
KYMCO reserves the right to make
changes at any time without notice and
without incurring any obligation.
CHASSIS
ELECTRICAL
E
Q
UIPMENT
ENGINE
Summary of Contents for 2006 MXU 500 Off-Road
Page 1: ...OWNER S MANUAL KWANG YANG MOTOR CO LTD MXU 500 OFF ROAD Issued 03 09 2006...
Page 2: ......
Page 81: ...71 Riding Your ATV...
Page 117: ...107 Shift your weight to the uphill side of the ATV OK...
Page 178: ......
Page 179: ......
Page 225: ...2 FRAME COVERS EXHAUST MUFFLER 2 1 MXU 500...
Page 275: ...4 LUBRICATION SYSTEM 4 1 MXU 500 LUBRICATION SYSTEM DIAGRAM...
Page 292: ...5 FUEL SYSTEM 5 1 MXU 500...
Page 313: ...6 COOLING SYSTEM 6 1 MXU 500 SYSTEM FLOW PATTERN...
Page 344: ...8 CYLINDER HEAD VALVES 8 1 MXU 500 SCHEMATIC DRAWING...
Page 374: ...9 CYLINDER PISTON 9 1 MXU 500 SCHEMATIC DRAWING...
Page 384: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 1 MXU 500 SCHEMATIC DRAWING...
Page 411: ...11 FINAL REDUCTION TRANSMISSION SYSTEM 11 1 MXU 500...
Page 440: ...12 LEFT CRANKCASE CRANKSHAFT BALANCE SHAFT 12 1 MXU 500...
Page 447: ...13 DRIVE TRAIN 13 1 MXU 500 FRONT DRIVE REAR DRIVE...
Page 512: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 1 MXU 500...
Page 546: ...15 REAR WHEEL AXLE SHOCK ABSORBER SWING ARM 15 1 MXU 500...
Page 566: ...16 BRAKE SYSTEM 16 1 MXU 500...
Page 627: ...18 IGNITION SYSTEM 18 1 MXU 500 IGNITION SYSTEM LAYOUT...
Page 628: ...18 IGNITION SYSTEM 18 2 MXU 500 IGNITION CIRCUIT ON ROAD OFF ROAD...
Page 635: ...19 STARTER SYSTEM 19 1 MXU 500 STARTING SYSTEM LAYOUT...
Page 636: ...19 STARTER SYSTEM 19 2 MXU 500 STARTING CIRCUIT ON ROAD OFF ROAD...
Page 651: ...19 STARTER SYSTEM 19 17 MXU 500 Pull the rope and check that the ratchet is pushed out...
Page 672: ...21 WIRING DIAGRAMS 21 0 MXU 500 21 21...
Page 673: ...21 WIRING DIAGRAMS 21 1 MXU 500...
Page 674: ...21 WIRING DIAGRAMS 21 0 MXU 500 21 21...
Page 675: ...21 WIRING DIAGRAMS 21 1 MXU 500...