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KYMCO 2006 MXU 500 Off-Road, Owner'S Manual

Get ready to conquer any off-road terrain with the KYMCO 2006 MXU 500 Off-Road ATV. For detailed information on operating and maintaining your vehicle, download the Owner's Manual for free at manualshive.com. This comprehensive manual will ensure you get the most out of your ATV adventure.

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19

. STARTER SYSTEM

     

19-7

  MXU 500

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.
The coil is normal if the starter MAG switch

clicks.

If you do not hear the switch click. Inspect

the relay switch and starter MAG using the

procedure below.

GROUND LINE INSPECTION

Disconnect the starter relay switch connector.

Check for continuity between the Green wire

terminal and ground.

There should be continuity.

VOLTAGE INSPECTION

Connect the starter MAG connector.

Turn the ignition switch ON.

Measure the starter MAG Yellow/Red wire

terminal and ground.

If the battery voltage appears only when the

rear brake lever is squeezed fully (or the gear

change switch in neutral) and starter switch is

pushed, the circuit is normal.

                                                Starter MAG

                                                  Starter Relay

                                                        Starter MAG

Starter Relay

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 3: ...16 should never operate this vehicle Anyone who operates this vehicle should get proper instruction FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only This machine i...

Page 4: ...this manual can result in SERIOUS INJURY or DEATH Indicates a strong possibility that serious injury or death may result if instructions are not followed CAUTION Indicates a possibility that equipment...

Page 5: ...s information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maint...

Page 6: ...utton 26 Engine stop switch 27 Passing signal switch 27 RIGHT HANDLEBAR SWITCH 28 2WD 4WD select switch 28 RECOIL STARTER 29 CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS SAFETY INFORMATIO...

Page 7: ...TCH 40 OWNER S MANUAL STORAGE COMPARTMENT 41 ACCESSORY SOCKET 42 PRE OPERATION CHECKS 43 DRIVE SELECT LEVER 44 Drive select lever adjustment 46 FRONT AND REAR BRAKES 48 FUEL 49 DRIVE SHAFT BOOTS 50 EN...

Page 8: ...96 JUDGEMENT 73 GOOD Speed limiter 80 Load Limits 81 No modifications 83 FOR OFF ROAD USE ONLY 90 DURING OPERATION 92 CLIMBING UPHILL 98 OPERATION 58 STARTING A COLD ENGINE 58 Using the recoil starte...

Page 9: ...AIR CLEANER HOUSING DRAIN TUBE 135 IDLE SPEED ADJUSTMENT 136 THROTTLE LEVER ADJUSTMENT 137 VALVE CLEARANCE ADJUSTMENT 138 FRONT BRAKE PADS INSPECTION 138 REAR BRAKE PADS INSPECTION 139 ENGINE OIL FIN...

Page 10: ...RD 162 Page COOLING SYSTEM INSPECTION 141 Engine overheating 143 BATTERY 146 Battery remove 147 Battery installation 147 FUSE REPLACEMENT 148 HEADLIGHT BEAM ADJUSTMENT 149 DRIVE SHAFT BOOTS 149 CABLE...

Page 11: ...understand this information before riding They contain important information for safe and proper operation of your ATV The labels should be considered as permanent parts of the vehicle If a label com...

Page 12: ...45 Kg 100 lbs on 1 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH WARNING 2 Before shifting you must stop the machine and return the throt...

Page 13: ...ils MAXIMUM TOWING CAPACITY 454kg 1000lbs TONGUE WEIGHT 16kg 35 lbs WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC...

Page 14: ...ructions Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one...

Page 15: ...safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the...

Page 16: ...ide or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always follow proper procedures for going down hills and for braking on hil...

Page 17: ...ther sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF p...

Page 18: ...the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your machine in an area...

Page 19: ...wing illustration DESCRIPTION AND MACHINE IDENTIFICATION 1 Key identification number IDENTIFICATION NUMBER RECORDS Record the key identification number frame serial number engine serial number and mod...

Page 20: ...SERIAL NUMBER The engine serial number is stamped on the left crankcase 1 Engine serial number 1 FRAME SERIAL NUMBER The frame serial number is stamped on the front and rear of the frame 1 Frame seria...

Page 21: ...01 Rear brake lever 03 Front brake lever 02 Headlights Position lights 11 PARTS LOCATION 01 02 02 03...

Page 22: ...ights Brake lights 05 2WD 4WD select switch Headlight dimmer switch Starter button Engine Stop Switch 08 Spark arrester 09 Trailer hitch 10 Throttle lever 06 Instrument and indicators 07 06 04 04 08 0...

Page 23: ...3 11 Reservoir water tank 12 Front brake fluid reservoir 13 Fuel valve Brake pedal fluid reservoir 17 Seat lock lever 18 Oil level inspection window 14 Recoil starter 15 Seat 16 13 15 16 17 14 11 12 1...

Page 24: ...14 19 Battery Fuse 21 Tool kit 23 Rear brake fluid reservoir 24 Accessory socket seat 25 Exhaust system 20 22 Accelerating pump lever Drive select lever 19 23 20 21 24 25 22...

Page 25: ...32 Fuel fill cap 33 Choke knob 34 Rear brake pedal 35 Flag pole bracket 28 Front cargo rack 29 Ignition switch 30 Left footpeg 15 32 33 34 31 27 NOTE The machine you have purchased may differ slightly...

Page 26: ...key can not be removed The engine can be started OFF All electrical circuits are switched off The key can be removed in this position All electrical circuits are switched on The ignition switch is ON...

Page 27: ...3 Coolant temperature warning indicator Set button Mode button 10 2 3 4 7 1 Multi function display The display includes the following functions Speedometer Odometer Tripmeter Digital clock 2WD 4WD in...

Page 28: ...dicator light L This indicator light comes on when the drive select lever is in the L position 6 High range indicator light H This indicator light comes on when the drive select lever is in the H posi...

Page 29: ...l gauge 4 Odometer Tripmeter 5 Digital clock 4 1 2 3 5 19 A B TRIP ODO mile km PM 2WD 4WD 1 Speedometer Shows riding speed in km h or mph Press and hold MODE button for more than 2 seconds to select m...

Page 30: ...mate fuel supply available in a graduated display The normal operating fuel range is with the section between the segment F and segment E When the segment E or the fuel indicator 3 flashes fuel will b...

Page 31: ...There are two tripmeters tripmerer A and tripmeter B Press and hold SET button for more than 2 seconds to select ODO TRIP A or TRIP B Press and hold MODE button for more than 2 seconds to select mph o...

Page 32: ...ds to select tripmeter A or tripmeter B 22 A B TRIP mile km A B TRIP mile km PM 2WD 4WD SET MODE P R N H L A B TRIP mile km PM 2WD 4WD SET MODE P R N H L A TRIP mile km 2 Press and hold both the MODE...

Page 33: ...more than 2 seconds to select ODO mode 3 Press and hold both the MODE button and SET button in the same time for more than 2 seconds The clock will be set in the adjust mode with the hour display fla...

Page 34: ...o set the hour press the SET button until the desired hour 5 Press the MODE button the minute display will start flashing 24 ODO mile km 2WD 4WD SET MODE P R N H L ODO mile km 2WD 4WD SET MODE P R N H...

Page 35: ...te press the SET button until the desired minute 7 To end the adjustment Press both the MODE button and SET button in the same time 25 ODO mile km 2WD 4WD SET MODE P R N H L ODO mile km 2WD 4WD SET MO...

Page 36: ...position to switch on the high beam Turn the switch to the position to switch off the headlight Stater button To starter the engine press the starter button with the transmission in neutral the igniti...

Page 37: ...d it should normally remain in the RUN position 3 3 Engine stop switch If you stop your ATV by turning the engine stop switch OFF be sure to turn the ignition switch OFF to prevent battery discharge N...

Page 38: ...ve mode that is suitable for your riding The 2WD 4WD select switch is located above the throttle lever To select the drive mode push the 2WD 4WD select switch to the desired position To check your pre...

Page 39: ...when the battery is low See using the recoil starter 1 Pull the grip up briskly and fully 2 After the engine starts put the grip back to original position and seal the hole 1 Recoil starter 1 NOTE Do...

Page 40: ...unction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the o...

Page 41: ...ENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident...

Page 42: ...nt brakes are operated by squeezing the front brake lever REAR BRAKE LEVER The rear brake is operated by squeezing the rear brake lever near left handgrip BRAKE PEDAL Operating the brake pedal applies...

Page 43: ...AL HAZARD Improper use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a...

Page 44: ...ver adjustment and operation 1 Drive select lever R Reverse P Park L Low H High N Neutral 1 L H P R N Apply the rear brake and shift the shift lever into P position before turning off the engine when...

Page 45: ...until it clicks Insert the breather tube into the meter cover hole To refuel refer to 1 Fuel tank cap 2 Breather tube 3 Meter cover hole 1 2 3 FUEL VALVE The fuel valve supplies fuel from the fuel ta...

Page 46: ...e with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refueling return...

Page 47: ...for proper operation 1 Fully open 2 Half open A ON position B OFF position 3 Closed Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life of the engine Pushin...

Page 48: ...tarting a cold engine start ambient temperature below 15 C 0 F requires a richer air fuel mixture When the pump lever is pressed the pump send the necessary amount of fuel to the fuel pipe for correct...

Page 49: ...the seat with the grommets on the frame and press the seat down until it locks Make sure that the seat is securely fitted NOTE SEAT To remove the seat pull the seat lock lever upward and pull up the s...

Page 50: ...local regulations before riding 1 Flag pole bracket TRAILER HITCH page 81 The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball as specified by the tra...

Page 51: ...easy reference Store your owner s manual 1 in the storage compartment 2 at the right side of the front fender 1 1 Owner s manual 2 Storage compartment To open the compartment remove the lid 3 The owne...

Page 52: ...socket when washing your ATV CAUTION To use the accessory socket 1 Turn the ignition switch ON then start the engine 2 Turn the headlights OFF 3 Open the accessory socket cap 2 and then insert the acc...

Page 53: ...138 140 44 47 FUEL Check fuel level Fill with fuel if necessary 49 50 Check oil level Fill with oil if necessary Check for leakage ENGINE OIL FINAL GEAR AND DIFFERENTIAL GEAR OIL 51 52 118 128 THROTTL...

Page 54: ...hedules described in the Owner s Manual WARNING DRIVE SELECT LEVER Check operation of the lever before start the engine 1 Make sure moving the shift lever into the N position of the shift guide 2 Turn...

Page 55: ...operly adjusted drive select lever WHAT CAN HAPPEN You may lose the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N position and neutral indica...

Page 56: ...e the engine stop 2 Remove 3 fasteners 1 then remove the left side cover 2 2 1 Fasteners 2 Left side cover 3 Loosen the locknuts 3 of rod 4 Shift the gear to neutral by moving the shift lever and or t...

Page 57: ...4 Turn the rod clockwise or counterclockwise until the drive select lever 5 into the N position of the shift guide and tighten the locknuts 5 Drive select lever N Neutral 5 N 47...

Page 58: ...If the brakes do not provide proper braking performance inspect the brakes for wear See page 138 140 FRONT AND REAR BRAKES POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You...

Page 59: ...gasoline with a pump octane number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will...

Page 60: ...OID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do...

Page 61: ...ctionmodifiers Passengercarmotor oils oftenlabeled EnergyConserving containanti frictionadditiveswhichwill causestarterclutchslippage resultingin reducedcomponentlifeandpoorengine performance CAUTION...

Page 62: ...l Periodic oil change 0 1 L 3 56 Imp oz 3 33 US oz Total amount 0 15 L 5 33 Imp oz 5 US oz DIFFERENTIAL GEAR OIL See page 127 128 Make sure the differential gear oil at the specified level Add oil as...

Page 63: ...Repair as necessary for proper operation THROTTLE LEVER Check to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as necessar...

Page 64: ...mbinations are not recommended 2 The tires should be set to the recommended pressure Recommended tire pressure Front 25 32 kpa 0 25 0 32 kgf cm 3 5 4 5 psi Rear Check and adjust tire pressures when th...

Page 65: ...3 92 psi 2 Maximum 4 Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst How to measure tire pressure Use the low pres...

Page 66: ...ary with engine temperature The coolant level is satisfactory if it is between the FULL and LOW marks on the tank If the coolant level is at or below the LOW level add tap water soft water to bring th...

Page 67: ...WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the...

Page 68: ...ING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in...

Page 69: ...e the accelerating pump if the cold engine start ambient temperature below 15 0 0 C 0 F Using the accelerating pump Remove the seat then press the accelerating pump lever twice page 39 1 1 Acceleratin...

Page 70: ...ine start position 0 0 0 0 0 0 0 0 7 Completely close the throttle lever and start the engine by pushing the start switch 1 Fully open 3 Closed 2 Half open a Choke knob The engine can be started in an...

Page 71: ...tempt 8 If the engine is started with the choke knob in position 1 the choke knob should be returned to position 2 to warm up the engine If the engine is started with the choke knob in position 2 keep...

Page 72: ...ngine To see whether or not the engine is warm check if it responds to the throttle normally with the choke knob turned off CAUTION To start the engine without the electric starter 1 Follow steps 1 th...

Page 73: ...the specified idling speed Otherwise the transmission may be damaged CAUTION DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING 1 Drive select lever R Reverse P Park L Low H High N Neutral 1 L H P R N N...

Page 74: ...e no obstacles or people behind you When it is safe to proceed go slowly NOTE Shifting neutral to reverse and reverse to park 1 Bring the machine to a complete stop and return the throttle lever to th...

Page 75: ...operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid...

Page 76: ...to the park position Turn the fuel valve to OFF and apply the parking brake The front brake lever has three locked position that allow it to be used as a parking brake To set the parking brake 3 1 2 1...

Page 77: ...r other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline p...

Page 78: ...genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could...

Page 79: ...ent Keep the following points in mind Never exceed the weight limit shown An overloaded ATV can be unstable Maximum load Rear cargo rack 85 kg 187 lbs Front cargo rack 45 kg 100 lbs Trailer Maximum to...

Page 80: ...he front and at the front of the rear Center the load from side to side cargo rack cargo rack Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load...

Page 81: ...71 Riding Your ATV...

Page 82: ...ctice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of...

Page 83: ...ce until you are totally familiar with the machine s handling and performance characteristics POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is...

Page 84: ...ow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child u...

Page 85: ...of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your...

Page 86: ...s POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perceptio...

Page 87: ...AT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The lo...

Page 88: ...ly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger on the The is to allow th...

Page 89: ...rating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneve...

Page 90: ...ident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders inexperienced with this model this mo...

Page 91: ...reduce these limits Loading and Operational Guidelines This ATV is not designed to carry or tow a trailer If you decide to add accessories to allow you to carry cargo or tow a trailer use common sense...

Page 92: ...MCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and usin...

Page 93: ...ccessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction If you have question consult an...

Page 94: ...ine in a place where pedestrians or children are not likely to touch it POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burne...

Page 95: ...HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATV are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go...

Page 96: ...TIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or high...

Page 97: ...Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning o...

Page 98: ...ss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned a...

Page 99: ...flag pole bracket as a trailer hitch POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO...

Page 100: ...FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only Do not ride in areas posted no trespassing Do not ride on private property without getting permission 90...

Page 101: ...ill be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position and shift the drive s...

Page 102: ...g operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg your foot or leg may come into contact...

Page 103: ...achine or overturn POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts su...

Page 104: ...collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds...

Page 105: ...Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body...

Page 106: ...he tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways contr...

Page 107: ...such as ice since all control may be lost POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause th...

Page 108: ...to lose control POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID T...

Page 109: ...cribed in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the thr...

Page 110: ...Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cau...

Page 111: ...e or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or r...

Page 112: ...ling backwards Apply the front brake 4WD Apply both front and rear brakes gradually When fully stopped shift to the parking position P Dismount on uphill side or to a side if pointed straight uphill T...

Page 113: ...ront brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the hill using the front brake lever to control spee...

Page 114: ...loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When de...

Page 115: ...u start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hi...

Page 116: ...down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wi...

Page 117: ...107 Shift your weight to the uphill side of the ATV OK...

Page 118: ...he ATV as loss of control and damage to the ATV may result POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overtu...

Page 119: ...wly and carefully Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads or lining POTEN...

Page 120: ...t you have regained proper braking ability PARKING Always choose a level place to park After bringing your ATV to a stop hold the brakes while you shift into neutral Then set the parking brake and tur...

Page 121: ...turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 94 95 If your ATV starts to slide sideways Steer in the direction of the slide if y...

Page 122: ...p over dismount on the uphill side See pages 106 107 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the...

Page 123: ...gine when performing maintenance unless otherwise specified PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient c...

Page 124: ...ting this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situation could lead to an ac...

Page 125: ...e for cracks or damage Replace if necessary Check valve clearance Adjust if necessary Check condition Adjust gap and clean Replace if necessary Clean More often in wet or dusty areas Replace if necess...

Page 126: ...ecessary Check operation Correct if necessary Check bearing assembly for looseness damage Replace if damaged Check operation Replace if damaged Check toe in Adjust if necessary Coolant Exhaust system...

Page 127: ...IAL EVERY ROUTINE Lubricate every 6 months Check all chassis fittings and fasteners Correct if necessary Knuckle shafts Steering shaft Fittings and Fasteners 1 6 12 MONTH It is recommended that these...

Page 128: ...heck the oil level through the inspection window D The oil level should be between the maximum H and minimum L marks If the level is low add oil to raise it to the proper level Wait a few minutes unti...

Page 129: ...it C Place a container under the engine D Remove the oil fill cap 1 and oil filter cap 2 to drain the oil Be sure no foreign material enters the crankcase CAUTION When removing the oil filter cap the...

Page 130: ...ightening torque Oil filter cap engine 14 7 N m 1 5 kgf m 11 lbf ft CAUTION H Fill the engine with oil and install the oil fill cap Recommended oil see page 158 Oil quantity Periodic oil change 3 L 2...

Page 131: ...ce the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and drain plug 2 to drain the oil Be sure no forei...

Page 132: ...then remove right side cover 4 F Remove the oil filter cartridge 5 with an oil cartridge wrench 3 Fasteners 4 Right side cover 3 122 Skip steps E to I if the oil filter cartridge is not being replace...

Page 133: ...ll the new oil filter cartridge with an oil cartridge wrench and then tighten it to the specified torque 123 Make sure the O ring is seated properly NOTE Tightening torque Oil filter cartridge 10 N m...

Page 134: ...m 2 5 kgf m 18 lbf ft Recommended oil see page 158 Oil quantity see page 158 Be sure no foreign material enters the crankcase CAUTION L Start the engine and warm it up for several minutes While warmin...

Page 135: ...ground to assure complete and rapid draining Final gear oil replacement 1 Remove the two bolts 1 on the skid plate 2 right left side and two bolts 3 under the skid plate remove skid plate 2 To drain t...

Page 136: ...il level check hole 6 Install the oil filler cap and oil level check bolt Tightening torque Drain plug 20 N m 2 kgf m 15 lbf ft 126 Recommended oil SAE 80 Oil quantity Periodic oil change 0 13 L 4 63...

Page 137: ...e oil with the differential gear case warm and the ATV on level ground to assure complete and rapid draining Differential gear oil replacement 1 To drain the oil first place an oil drain pan under the...

Page 138: ...level check hole 6 Install the oil filler bolt washer and oil level check bolt washer Tightening torque Drain plug 32 N m 3 2 kgf m 23 lbf ft 128 Recommended oil SAE 90 Oil quantity Periodic oil chang...

Page 139: ...mportant engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an in...

Page 140: ...re the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 2 Remove the three bolts 1 the spark arrester 2 and the gasket 3 from the muffler 130 1 1 Bolts 2 Spark a...

Page 141: ...gasket in the muffler and tighten the three bolts securely 131 POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Coul...

Page 142: ...d in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner 1 Remove the seat 2 Unlatch the six retainer c...

Page 143: ...air cleaner holder 8 7 Remove the inner air cleaner 9 and air cleaner screen 10 from the air cleaner guide 11 8 Remove the air cleaner screen from the inner air cleaner 6 6 Screw washer 7 8 9 10 11 7...

Page 144: ...il saturated then squeeze out the excess oil 11 Reassemble by reversing the disassembly sequence POTENTIAL HAZARD Using gasoline or low flash point solvents for cleaning ATV parts WHAT CAN HAPPEN A fi...

Page 145: ...ugh water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the drain tube 1 Remove the drain tube 1 by remov...

Page 146: ...n Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 3 Connect the tachometer and set the idle to the specified idling speed by adjusting t...

Page 147: ...turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear that could caus...

Page 148: ...gularly This adjustment however should be left to a professional KYMCO service technician FRONT BRAKE PADS INSPECTION A wear indicator is provided on each brake The indicators allows checking of brake...

Page 149: ...limit line ask a KYMCO dealer to replace the pads BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection window POTENTIAL HAZARD Brake fluid contacting t...

Page 150: ...1 Lower level mark Hand brake lever L 1 1 1 Lower level mark Foot brake pedal 2 Upper level mark Foot brake pedal 140 2...

Page 151: ...d it must be bled See your authorized KYMCO dealer for this service page 138 139 To prevent damage to the brake system use only fluid from a sealed container Never allow contaminants dirt water etc to...

Page 152: ...e specified level 4 If your ATV overheats see for details page 143 Hard water or salt water is harmful to the engine You may use distilled water if rou can not get soft water CAUTION 1 If water is add...

Page 153: ...dealer when changing the coolant WARNING Engine overheating If your ATV overheat wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Restart the engine If th...

Page 154: ...hen reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Be sure the tapered side of the wheel nuts 1 face the wheel rim 2 Be sure the tapered side of the wheel n...

Page 155: ...EN A wheel may come loose possibly leading to an accident HOW TO AVOID THE HAZARD Carefully follow the instructions in this Owner s Manual when installing WARNING The arrow mark on the tire must point...

Page 156: ...s this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care NOTE When the ATV is to be stored for an extended period remove the ba...

Page 157: ...ery first then disconnect the positive terminal lead 3 5 Remove the battery 1 Install in the reverse order of removal 2 After installing the battery check to see if the battery cables are routed corre...

Page 158: ...lder 6 Close the fuse box cap and install seat page 39 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 148 POTENTIAL HAZARD Using an improper fuse WHA...

Page 159: ...witch at position and start the engine Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting screws CAUTION 1 Adjusting screws 1 149 DRIVE SHAFT BOOTS Check the pro...

Page 160: ...become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner...

Page 161: ...ve the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead t...

Page 162: ...ilter element and fuel tank Check fuel flow No fuel Fuel valve Clean fuel valve Turn the fuel valve to OFF Turn the fuel valve to RES Supply fuel 1 Fuel Remove the fuel hose from the fuel valve Check...

Page 163: ...les 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmissio...

Page 164: ...es which may mar the paint or protective finish When finished start the engine and let it idle for several minutes POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes m...

Page 165: ...and carburetor Be sure to drain the fuel in a well ventilated area not in a garage POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite HOW...

Page 166: ...o the cylinder Operate the starter for a few seconds to distribute the oil then reinstall the spark plug POTENTIAL HAZARD Prolonged contact of fuel with the skin Breathing fuel vapor WHAT CAN HAPPEN T...

Page 167: ...ll fuel tank Engine Type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system 157 308 kg 678 lbs Liquid cooled 4 stroke OHC Single cylinder 498 5 cm 30...

Page 168: ...mount Final gear oil Periodic oil change Total amount Differential gear oil Periodic oil change Total amount API Service SJ type or higher SEA 80 3 L 2 64 lmp qt 3 18 US qt 3 6 L 3 17 lmp qt 3 82 US q...

Page 169: ...l Type Tank capacity Reserve amount UNLEADED FUEL 17 L 3 57 lmp gal 4 42 US gal 2 3 L 0 48 lmp gal 0 6 US gal Carburetor Type CVK Spark plug Type Gap CR7E NGK 0 6 0 7 mm 0 024 0 028 in Clutch Type Wet...

Page 170: ...spring Oil damper Coil spring Oil damper Electrical Ignition system Generator system Battery type Tire Type Size Front Rear Bulb voltage wattage quantity Headlight Brake light Taillight Position light...

Page 171: ...or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after...

Page 172: ...ccordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENACE INTERVAL DATE OF SERVIC...

Page 173: ...44 Drive select lever adjustment 46 DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING 63 DRIVE SHAFT BOOTS 50 149 DURING OPERATION 92 INDEX A B ACCELERATING PUMP LEVER 38 ACCESSORIES 68 81 82 ACCESSOR...

Page 174: ...tch 26 High beam indicator 17 High range indicator light 18 E F ENGINE BREAK IN 65 ENGINE OIL 51 118 ENGINE OVERHEATING 143 ENGINE SERIAL NUMBER 10 ENGINE STOP SWITCH 27 EXHAUST SYSTEM 84 FINALGEAR OI...

Page 175: ...RIODIC MAINTENANCE LUBRICATION 115 PERIODIC MAINTENANCE AND ADJUSTMENT 113 PREFACE C PRE OPERATION CHECKS 43 79 41 K L M N KEY IDENTIFICATION NUMBER 9 LIGHTS 53 LOADING 69 81 Low range indicator light...

Page 176: ...CATIONS 157 SPEED LIMITER 31 80 Speedometer 19 Starter button 26 STARTING A COLD ENGINE 58 STARTING A WARM ENGINE 62 STORAGE 155 SWITCHES 53 Page T W V THROTTLE LEVER 30 53 THROTTLE LEVER ADJUSTMENT 1...

Page 177: ...reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 LDB5 OFF U00 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kao...

Page 178: ......

Page 179: ......

Page 180: ...nstruction At speeds too fast for your skills or the conditions On public roads a collision can occur with another vehicle With a passenger passengers affect balance and steering control ALWAYS Use pr...

Page 181: ...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 T100LAA...

Page 182: ...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...

Page 183: ..._____________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFO...

Page 184: ...1 GENERAL INFORMATION 1 1 MXU 500 SERIAL NUMBER 1 Location of Engine Serial Number 1 Location of Frame Serial Number...

Page 185: ...n Idle speed rpm 1500 rpm Cooling type Liquid cooled Lubrication type Forced pressure Wet sump Oil pump type Trochoid Oil filter type Full flow filtration Oil capacity 3 6 L 3 17 lmp qt 3 82 Us qt Oil...

Page 186: ...tening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants When servicing the motorcycle be sure t...

Page 187: ...mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting...

Page 188: ...cified capacity After operation terminal caps shall be installed securely When taking out the connector the lock on the connector shall be released before operation Hold the connector body when connec...

Page 189: ...d terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation Insert the terminal completely Check the terminal cover for proper coverage Do not mak...

Page 190: ...ke sure that it is not interfering with any moving or sliding parts When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp ed...

Page 191: ...tact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken shea...

Page 192: ...with adjacent or surrounding parts in all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions...

Page 193: ...ols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmi...

Page 194: ...t and nut 0 3 3 2 2 0 4 4 2 9 0 9 9 6 5 1 2 12 9 2 7 27 20 4 40 29 Torque specifications listed below are for important fasteners ENGINE Item Q ty Thread dia mm Torque kgf m N m lbf ft Remarks MAINTEN...

Page 195: ...nkcase bolt Drive bevel gear nut Driven bevel gear nut Stopper lever bolt Stopper lever boss nut Shift came stopper plug Output shaft bearing nut Drive shaft bearing bolt STARTER SYSTEM Starter pulley...

Page 196: ...ve Front propeller shaft bolt Front drive gear case mounting bolt Shifting fork shaft plug Front drive gear case bolt 2WD 4WD shift motor mounting bolt 2WD 4WD shift motor mounting bolt Rear drive Rea...

Page 197: ...mounting bolt nut BRAKE SYSTEM Front brake disc bolt Rear brake disc bolt Brake caliper mounting bolt Brake hose oil bolt Master cylinder holder bolt Brake pad mounting bolt Bleed valve nut Delay valv...

Page 198: ...00036 Bearing puller A120E00037 Valve spring compressor Refer to the CYLINDER HEAD DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 8 A120E00040 Universal holder Refer to the DRIVE PULLEY DRIVE...

Page 199: ...120E00059 Flywheel puller Refer to the STARTER CLUTCH REMOVAL INSPECTION INSTALLATION section in the chapter 19 A120E00060 Oil filter cartridge wrench Refer to the Refer to the ENGINE OIL section in t...

Page 200: ...chapter 15 A120F00012 Left pivot lock nut wrench Refer to the REAR SWING ARM REMOVAL INSTALLATION section in the chapter 15 A120F00013 Joint yoke puller Refer to the FRONT DRIVE DISASSEMBLY INSPECTIO...

Page 201: ...manual Pinion bearing lock nut wrench Refer to the REAR DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 13 A120F00020 Pinion puller Refer to the REAR DRIVE DISASSEMBLY INSPECTION ASSEMBL...

Page 202: ...inside wall Connecting rod piston pin hole Connecting rod big end Clutch Crankshaft Balance shaft Crankshaft one way clutch movable part Recoil starter pulley Oil pump drive chain Starter reduction g...

Page 203: ...me 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 Steering...

Page 204: ...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 Remove the rear cooling...

Page 205: ...ear parking brake cable ON ROAD 12 Brake light switch wire A Pass the brake light switch wire and left handlebar switch wire through the band B Passe the throttle cable chock cable brake light switch...

Page 206: ...adiator hose 5 Over flow hose Reserve tank 16 Headlight connector 6 Ignition switch connector Left front signal light 7 Air bleed hose connectors ON ROAD 8 2WD 4WD switch connector 17 Air bleed hose 9...

Page 207: ...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 B Pass the harne...

Page 208: ...nsor wire 3 Crankcase breather hose 9 Speed sensor 4 Harness wire 10 Engine ground cable 5 Crankcase breather hose joint 11 Fuel hose 6 Starter motor cable 12 AICV air supply hose A Pass the starter m...

Page 209: ...il 14 Fan motor switch 6 Water hose 15 Headlight connector 7 Water bypass hose Left front turn signal light connectors ON ROAD 8 Delay valve ON ROAD 16 Air bleed hose 8 Brake fluid joint OFF ROAD 17 F...

Page 210: ...per 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 5 Water bypass hose 11 Thermostat 6 Air bleed hose Pass...

Page 211: ...28 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...

Page 212: ...ON ROAD 7 Rear brake hose Brake pedal 4 Rear brake hose Brake lever A Pass the speed sensor wire through the guide B Pass the rear brake hose Brake pedal through the guide C Pass the rear brake hose...

Page 213: ...5 Over flow hose reserve tank 14 Horn ON ROAD 6 Siphon hose 15 Fuel flow hose 7 Harness wire 16 Water bypass hose 8 Coolant filler hose 17 Combined brake hose ON ROAD 9 Headlight connector 18 water ho...

Page 214: ...31 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...

Page 215: ...se 12 AICV vacuum hose Note 6 AICV air supply hose 13 A C G wire 7 AICV air supply hose Note 14 Crankcase breather housing A Pass the harness wire through the guide B Pass the A C G wire through the g...

Page 216: ...e ON ROAD 12 Rear caliper Brake pedal 6 Gear position light switch 13 Speed sensor 7 Brake fluid filler hose A Pass the harness wire through the band B Pass the gear position light switch wire starter...

Page 217: ...tors 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 7 Positive terminal lead 8 Ne...

Page 218: ...piston and piston rings Leaking cylinder head gasket Air leaking through intake pipe Leaking intake manifold Incorrect ignition timing Incorrectly adjusted air screw Flooded carburetor Clogged air cle...

Page 219: ...d up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cause...

Page 220: ...Faulty ignition unit Faulty A C generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch Remove spark plug and install it into spark plug cap to test spark by connecting...

Page 221: ...and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fuel suppl...

Page 222: ...or rectifier coupler red wire and battery wire to engine ground and test voltage Inspection Adjustment Inspection Adjustment Symptom Symptom Probable Cause Probable Cause Normal voltage Battery has vo...

Page 223: ...rol unit Faulty ignition coil Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Nor...

Page 224: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 225: ...2 FRAME COVERS EXHAUST MUFFLER 2 1 MXU 500...

Page 226: ...bles and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler mounting bolt 3 5 kgf m 35 Nm 25 lbf ft Exhaust pipe mounting nut 3 5 kgf m 35 Nm 25 lbf ft Exhaust muffler band...

Page 227: ...ull 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 Push in the head of center piece until it become...

Page 228: ...he seat lock lever upward and pull up the seat at the rear 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 FRONT CARGO...

Page 229: ...r front fender Remove the two mounting bolts from front cargo rack remove the front cargo rack Installation is in the reverse order of removal FRONT CARRIER COVER REMOVAL INSTALLATION Remove the four...

Page 230: ...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 REAR CARGO RACK REMO...

Page 231: ...cargo rack Installation is in the reverse order of removal RIGHT LEFT FOOTBOARD REMOVAL INSTALLATION Remove the nine fasteners two screws nuts and four bolts then remove the right footboard Remove the...

Page 232: ...order of removal FRONT CENTER COVER REMOVAL INSTALLATION Remove the two fasteners and then remove front cover Installation is in the reverse order of removal METER COVER REMOVAL INSTALLATION Disconnec...

Page 233: ...nd then remove drive select grip Remove the two fasteners from fuel tank cover left side Remove the two fasteners from fuel tank cover right side Remove the two fasteners from fuel tank cover front si...

Page 234: ...t connectors Remove the two fasteners from front fender right and left side front fender then remove the front fender Installation is in the reverse order of removal REAR FENDER REMOVAL INSTALLATION R...

Page 235: ...ignition control module and 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 Installation is in th...

Page 236: ...OVAL 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...

Page 237: ...MUFFLER 2 13 MXU 500 EXHAUST MUFFLER REMOVAL Loosen the exhaust pipe band bolt Remove two muffler mounting bolts Remove the muffler and gasket from the exhaust pipe Remove the exhaust pipe joint nuts...

Page 238: ...aust pipe and tighten the joint nuts Torque Exhaust pipe mounting nut 3 5 kgf m 35 N m 14 lbf ft Install the muffler and tighten the mounting bolts Torque Exhaust muffler mounting bolt 3 5 kgf m 35 N...

Page 239: ...N 3 4 SPEED LIMITER AIR CLEANER 3 5 AIR FILTER FOR DRIVE BELT 3 7 SECONDARY AIR SUPPLY SYSTEM 3 8 SPARK PLUG 3 9 VALVE CLEARANCE 3 11 CARBURETOR IDLE SPEED 3 12 CLINDER COMPRESSION ENGINE OIL 3 13 REA...

Page 240: ...free play 3 5 mm 0 12 0 2 in Spark plug gap 0 6 0 7 mm 0 024 0 028 in Spark plug Standard CR7E NGK Valve clearance IN 0 1 mm 0 004 in EX 0 1 mm 0 004 in Idle speed 1500r 100 rpm Engine oil capacity A...

Page 241: ...m 18 lbf ft Rear drive gear oil drain bolt 2 kgf m 20 N m 15 lbf ft Rear drive gear oil level check bolt 2 kgf m 20 N m 15 lbf ft Rear drive gear oil filler cap 1 5 kgf m 15 N m 11 lbf ft Front drive...

Page 242: ...ese 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 This information appli...

Page 243: ...de the rubber sleeve 1 back to expose the throttle cable adjuster 2 2 Loosen the lock nut 3 then turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the lock nut and rein...

Page 244: ...the ATV Speed limiter length A 13 mm 0 52 in Adjustment 1 Loosen the lock nut 1 2 Turn the adjuster 2 in or out until the specified speed limiter length is obtained Turning in Speed limiter length is...

Page 245: ...ove the air cleaner screen from the inner air cleaner CLEAN AIR FILTER ELEMENT Wash the element gently but throughly in solvent Squeeze the excess solvent out of the element and let dry Apply the engi...

Page 246: ...FOR DRIVE BELT To clean the air filter Remove front center cover refer to the FRAME COVERS section in the chapter 2 Remove a fastener from air inlet hose Remove air filter Tap the element lightly to...

Page 247: ...ver there is negative pressure pulse in the exhaust system This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxi...

Page 248: ...ver removing the carbon deposits be sure to observe the operational color of the spark plug s porcelain tip This color tells you whether or not the standard spark plug is suitable for your type of usa...

Page 249: ...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 specificat...

Page 250: ...TER PULLEY REMOVAL INSPECTION INSTALLATION section in the chapter 8 Turn the crankshaft clockwise and align the T mark on the flywheel with the index mark on the right crankcase cover The punch marks...

Page 251: ...0 9 kgf m 9 N m 6 5 lbf ft After tightening the lock nut recheck the valve clearance Install the removed parts in the reverse order of removal CARBURETOR IDLE SPEED Warm up the engine before this oper...

Page 252: ...ombustion chamber and the piston head ENGINE OIL OIL LEVEL Place the machine on a level place Warm up the engine for several minutes and stop it Check the oil level through the inspection window The o...

Page 253: ...ed Reinstall the O ring oil strainer compression spring and oil filter cap Tighten the oil filter cap to specification Torque 1 5 kgf m 15 N m 11 lbf ft 7 Fill the engine with oil and install the oil...

Page 254: ...l minutes and stop it 3 Place a container under the engine 4 Remove the oil fill cap 1 5 Remove the drain plug 2 to drain the oil 6 Remove the three fasteners 3 and then remove right side cover 4 Be s...

Page 255: ...kgf m 10 N m 7 2 lbf ft 10 Install right side cover 11 Reinstall the drain plug and tighten the drain plug to the specified torque Torque 2 5 kgf m 25 N m 18 lbf ft 12 Add the specified amount of rec...

Page 256: ...e warm and the ATV on level ground to assure complete and rapid draining Rear drive gear oil replacement 1 Remove the two bolts 1 on the skid plate 2 right left side and two bolts 3 under the skid pla...

Page 257: ...ear case warm and the ATV on level ground to assure complete and rapid draining Front drive gear oil replacement 1 To drain the oil first place an oil drain pan under the oil drain plug 1 2 Remove the...

Page 258: ...il level check bolt to the specified torque Torque Oil filler cap 3 5 kgf m 35 N m 25 5 lbf ft Oil level check bolt 1 kgf m 10 N m 7 2 lbf ft SPARK ARRESTER Be sure the exhaust pipe and muffler are co...

Page 259: ...he spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary 4 Install the spark arrester and the gasket in the muffler and t...

Page 260: ...th Service limit A 30 8 mm 1 232 in Replace the drive belt if out of specification Refer to the DRIVE PULLEY DRIVE V BELT AND DRIVEN PULLEY REMOVAL INSPECTION INSTALLATION section in the chapter 10 fo...

Page 261: ...he lower level mark through the inspection window HEADLIGHT AIM Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adju...

Page 262: ...essive play Check the tie rod ends Turn the handlebar to the left and or right until it stops completely then slightly move the handlebar from left to right Replace the tie rod ends if tie rod end has...

Page 263: ...ds ends This reference point will be needed during adjustment Loosen the lock nuts tie rod end of both tie rods The same number of turns should be given to both tie rods right and left until the speci...

Page 264: ...heck the tire pressure TIRE PRESSURE 1 Rider Front 0 28 kgf cm 28 Kpa 3 2 psi Rear 0 28 kgf cm 28 Kpa 3 2 psi TIRE SIZE Front 25X8 12 Rear 25X10 12 Check the front axle nut for looseness Front Axle Nu...

Page 265: ...ar or damage Tire wear limit 4 mm 0 16 in WHEEL INSPECTION Inspect the wheel Replace if damage or bends Always balance the wheel when a tire or wheel has been changed or replaced Rear Axle Nut x Never...

Page 266: ...andard position 2 Minimum Soft position 1 Maximum Hard position 5 DRIVE SELECT LEVER ADJUSTMENT 1 Turn the ignition switch is ON and make sure the engine stop 2 Remove 3 fasteners 1 then remove the le...

Page 267: ...lock nuts 3 of rod 4 4 Remove the bolt and nut from the rod end shift arm side 5 Shift the drive select lever to neutral along the shift guide 6 Shift the gear to neutral by moving the shift arm The n...

Page 268: ...parts of each lever ADJUSTING THE REAR BRAKE LIIGHT SWITCH BRAKE PEDAL 1 Loosen the lock nut 2 Turn the adjusting nut clockwise or counterclockwise until the rear brake light comes on at the proper ti...

Page 269: ...nd fill the tank to the FULL level line with 1 1 mixture of distilled water and antifreeze coolant mixture preparation refer to the chapter 6 COOLING SYSTEM Check to see if there are any coolant leaks...

Page 270: ...r cracks or deterioration and replace if necessary Check that all hose clamps are tight Check the radiator air passages for clogs or damage Straighten any bent fins and remove insects mud or other obs...

Page 271: ...ke 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 2 Loosen the lock...

Page 272: ...ained Tighten the lock nut Parking brake cable end length L 53 2 mm 2 12 0 08 in 5 Slowly turn the adjusting bolt on the caliper clockwise until resistance is felt then turn adjusting bolt 1 8 counter...

Page 273: ...3 INSPECTION ADJUSTMENT 3 34 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...

Page 274: ...____________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM _____________________________________________________________...

Page 275: ...4 LUBRICATION SYSTEM 4 1 MXU 500 LUBRICATION SYSTEM DIAGRAM...

Page 276: ...ly 3 6 liter 3 17 lmp qt 3 82 Us qt Engine oil capacity At draining and oil filter cartridge change 3 2 liter 2 82 lmp qt 3 39 Us qt Recommended engine oil KYMCO 4 stroke oil or equivalent motor oil A...

Page 277: ...oil leak Faulty water pump mechanical seal x Non recommended oil used Faulty head gasket Water leak in crankcase Oil contamination x Deteriorated oil No oil pressure x Faulty oil filter x Oil level t...

Page 278: ...N SYSTEM 4 4 MXU 500 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 Check Hole...

Page 279: ...ion in the chapter 19 Remove the two bolts and oil pump drive chain guide Remove the two bolts and oil separator cover Remove snap ring Remove the oil pump driven gear then remove the oil pump drive c...

Page 280: ...wo bolts and then remove the oil pump INSPECTION Oil pump drive chain guide Inspect the drive chain slipper surface of the drive chain guide for wear or damage INSTALLATION Install the oil pump Holder...

Page 281: ...and tighten the two bolts securely Install two dowel pins Install the holder then install a bolt but do not tighten Install the driven gear and drive chain Install the snap ring Driven Gear Drive Cha...

Page 282: ...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 Oil Separator...

Page 283: ...ASSEMBLY INSPECTION ASSEMBLY DISASSEMBLY Remove the oil pump shaft Remove the screw and oil pump cover Remove the dowel pin oil pump outer rotor and inner rotor Oil Pump Shaft Outer Rotor Oil Pump Bod...

Page 284: ...to the oil pump body Measure the tip clearance Service limit 0 2 mm 0 008 in Measure the pump body clearance Service limit 0 25 mm 0 01 in Measure the side clearance with the straight edge and feeler...

Page 285: ...Install the inner rotor into the outer rotor Install the oil pump shaft Install the dowel pin onto the oil pump body Install the oil pump cover onto the oil pump body by aligning the dowel pin Install...

Page 286: ...the right crankcase cover refer to the ALTERNATOR STATOR REMOVAL INSPECTION INSTALLATION in the chapter 17 Remove the oil seal Remove the snap ring Remove the bearing by using the special tool Specia...

Page 287: ...4 LUBRICATION SYSTEM 4 13 MXU 500 ASSEMBLY Install a new bearing by using the special tool Special tool Oil seal bearing drive A120E00014 Install a new oil seal Bearing Drive Snap Ring Oil Seal...

Page 288: ...pter 11 Remove the pressure relief valve and O ring from the right crankcase INSPECTION Check the operation of the pressure relief valve by pushing on the piston INSTALLATION Apply oil to a new O ring...

Page 289: ...the two bolts washers on the oil pipe oil pipe and washers under oil pipe INSTALLATIION Install the inner washers on the right crankcase Install the oil pipe with the thick side face upward Oil Pipe W...

Page 290: ...500 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 Oil Pipe Washers under oil pipe...

Page 291: ..._______________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM _________________________...

Page 292: ...5 FUEL SYSTEM 5 1 MXU 500...

Page 293: ...O rings and diaphragm must be removed first to avoid damage Then clean with compressed air x When the machine is not used for over one month drain the residual gasoline from the float chamber to avoi...

Page 294: ...ration x Float level too low x Intake air leak Engine idles roughly stalls or runs poorly x Clogged fuel tank cap breather hole x Excessively used choke x Kinked or restricted fuel line x Ignition mal...

Page 295: ...o nuts from the fuel tank then remove the fuel tank INSTALLATION Fuel tank installation is in the reverse order of removal FUEL VALVE REMOVAL Remove the screw and then remove control switch Disconnect...

Page 296: ...he rubber gasket from the fuel valve body INSPECTION Inspect the fuel valve body for dirt and clog Clean if necessary Replace the rubber gasket with new ones if they are damaged or deteriorated Replac...

Page 297: ...procedures Connect all fuel tube Install the fuel filter with the arrow mark facing forward x Aligning the tab on the control shaft with the outlet duct in the fuel valve body x Aligning the tab on th...

Page 298: ...ING section in this chapter Disconnect the over flow hose Loosen the carburetor clamp screw then remove carburetor from intake pipe Remove a screw then remove the throttle valve cover Disconnect the t...

Page 299: ...ing for bends wear or damage INSTALLATION Installation is in the reverse order of removal Cutout Lug Lug Cutout Make sure the lug on the carburetor into the cutout on the intake pipe Make sure the lug...

Page 300: ...to drain the gasoline from the float chamber Remove the four screws and top cap Remove the spring and piston valve Fuel Drain Plug Spring Top Cap Piston Valve x Keep sparks and flames away from the wo...

Page 301: ...ing Remove the casting enrichment valve and O ring Remove the three screws and accelerating pump cover and then take out the spring Remove the accelerating pump and O ring Casting Enrichment Valve Cov...

Page 302: ...and float chamber Pull float pin outs then remove the float and float valve Remove the slow jet Remove choke jet Remove main jet Remove the needle jet holder Float Float Valve Float Chamber Float Val...

Page 303: ...lot screw spring washer and O ring Pilot Screw Needle Jet 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 o...

Page 304: ...body dry using compressed air After cleaning reassemble the carburetor with new seals Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled ca...

Page 305: ...t for foreign substance clogging or damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination Check the operation of the float valve Check the piston v...

Page 306: ...e spring coasting enrichment valve and accelerating pump and cover coasting enricher and accelerating pump for damage Check jet needle needle jet slow jet needle jet holder main jet choke jet and pilo...

Page 307: ...the part with a new carburetor Check the float level after checking the float valve valve seat and float Set the carburetor so that the float valve end just contacts the float arm lip Make sure the f...

Page 308: ...hoke jet 15 Main jet 16 Needle jet holder 17 Needle jet 18 Slow jet 19 Float valve 20 Float 21 Float pin 22 Pilot screw Assemble the parts taking consideration of their function Before assembling wash...

Page 309: ...n to the float chamber groove securely Assemble the accelerating pump diaphragm and new O ring Small Convex O ring Accelerating Pump Cover Accelerating Pump Diaphragm O ring Install the accelerating p...

Page 310: ...the chapter 2 Loosen the carburetor to air cleaner connecting tube band screw Remove the clip and disconnect the crankcase breather hose from the crankcase Remove the mounting bolts and then remove t...

Page 311: ...VALVE REMOVAL INSTALLATION Disconnect air supply hose and vacuum hose from the air solenoid valve then remove the air solenoid valve from frame Installation is in the reverse order of removal Vacuum...

Page 312: ...____________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM _________________________________________...

Page 313: ...6 COOLING SYSTEM 6 1 MXU 500 SYSTEM FLOW PATTERN...

Page 314: ...te inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage x This section covers service of the cooling system x Add coolant at...

Page 315: ...1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1 054 50 1 086 1 084 1 082 1 080 1 077 1 074 1 071 1 068 1 065 1 062 1 059 55 1 095 1 093 1 091 1 088 1 085...

Page 316: ...x Thermostat stuck closed x Insufficient coolant x Passages blocked in radiator hoses or water jacket x Faulty cooling fan motor x Faulty fan motor switch x Faulty water pump Engine temperature too l...

Page 317: ...r replace components if the system will not hold the specified pressure for at least six seconds COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rest or...

Page 318: ...bypass hose from water pump or remove the drain plug and drain the coolant from the system Remove the reserve tank cap and drain the coolant from the reserve tank Reconnect the bypass hose securely R...

Page 319: ...g up to the filler neck Bleed air from the system as follow 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle three to four times to bleed air from the system 3 Stop the engine an...

Page 320: ...Remove the nut and thermostat housing stay from the frame Remove the bolts housing stay and thermostat housing cover Remove the O ring from the housing cover Remove the thermostat Thermostat O ring T...

Page 321: ...rature or if it respond at temperatures other than those specified Thermostat begin to open 80 84q C 176 183q F Valve lift 8 mm 0 3 in minimum at 95q C 203q F INSTALLATION Install the thermostat into...

Page 322: ...oove 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 Fill the system with recommended coolant and bl...

Page 323: ...l seal is defective and water pump body should be replaced REMOVAL Drain the coolant refer to the COOLANT REPLACEMENT section in this chapter Loosen the hose bands and disconnect the lower radiator ho...

Page 324: ...pped portion of the water pump Install the water pump into the crankcase while aligning the water pump shaft groove with oil pump shaft end Align the mounting bolt holes in the water pump and crankcas...

Page 325: ...pecified toque Torque 1 3 kgf m 13 N m 9 lbf ft Connect the water hoses and bypass hose then tighten the hose bands Fill the system with recommended coolant and bleed the air refer to the COOLANT REPL...

Page 326: ...ater hose water filler hose bleed hose and upper water hose from the radiator Disconnect the fan switch connectors Remove the two mounting bolts under radiator and two mounting bolts on the radiator t...

Page 327: ...operate If the switch operating temperature is not within the specified range replace the switch with a new one OFFoON Over 88 92q C ONoOFF Lower 88 92q C INSTALLATION Fit the O ring Tighten the cooli...

Page 328: ...FRAME COVERS section in the chapter 2 Disconnect the fan motor connector Remove the four mounting bolts and then remove the fan motor INSPECTION Check the fan motor to operate using an available batt...

Page 329: ...cted If the resistance measured is out of specification replace the temperature gauge with a new one Temperature Standard resistance 50 C 123 9 478 9 100 C 26 29 3 After the water temperature sensor h...

Page 330: ...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 Disconnect the siphon hose INSTALLATION Install...

Page 331: ..._______________________________________________________________________________ __________________________________________________________________________________ _____________________________________...

Page 332: ...equire engine removal for serviced with the engine installed in the frame Oil pump Chapter 4 Water pump Chapter 6 Cylinder head Chapter 8 Cylinder Piston Chapter 9 Drive and driven pulleys clutch Chap...

Page 333: ...efer to the CARBURETOR REMOVAL CHOKE INSPECTION INSTALLATION and AIR CLEANER HOUSING sectionsinthe chapter5 Disconnect the lower water hose and bypass hose from water pump cover Cut the rubber band of...

Page 334: ...t Remove the spark plug cap and disconnect the AICV air supply hose from cylinder head Remove the bolt nut from drive select rod Remove the mounting nuts from the drive select lever guide then remove...

Page 335: ...intake pipe Slide the rubber sleeve back to expose the starter motor wire nut Remove the starter motor cable nut for disconnect the starter motor cable Remove the bolt and then disconnect the engine g...

Page 336: ...ct the gear indicator light switch connector Disconnect the speed sensor connector Remove the bolts and then remove the front propeller shaft from the engine assembly Gear Indicator Light Switch Conne...

Page 337: ...engine hangers then remove the engine hangers Remove the rear lower engine mounting bolt nut Remove the upper engine mounting bolt nut Rise the engine front side and move the engine forward then remov...

Page 338: ...h rubber hammer and remove the rear propeller shaft from the engine assembly Lower the cylinder head and rise the engine rear side then move the engine from the frame left side Rear Propeller Shaft Ta...

Page 339: ...frame Apply lightweight lithium soap base grease to the rear propeller shaft splines Install the rear propeller shaft into the engine assembly Apply grease Rear Propeller Shaft Rear Propeller Shaft Ap...

Page 340: ...ngers and four engine hanger nuts loosely Install the front lower engine mounting bolt and nut loosely Tighten the four engine hanger nuts to the specified torque Torque 3 5 kgf m 35 N m 25 lbf ft Tig...

Page 341: ...ront propeller shaft into the engine assembly Install and tighten the three new bolts to specified torque Torque 4 5 kgf m 45 N m 32 5 lbf ft Install the front cooling duct Apply grease Front Propelle...

Page 342: ...ter hoses wire and cable properly refer to the CABLE HARNESS ROUTING section in the chapter 1 Adjusting the following items Engine oil refer to the ENGINE OIL section in the chapter 3 Engine coolant r...

Page 343: ..._______________________________________________________________ CYLINDER HEAD VALVES __________________________________________________________________________________ SCHEMATIC DRAWING 8 1 SERVICE IN...

Page 344: ...8 CYLINDER HEAD VALVES 8 1 MXU 500 SCHEMATIC DRAWING...

Page 345: ...install them in the reverse order of removal SPECIFICATIONS Unit mm in Item Standard Service Limit IN 0 1 mm 0 004 in Valve clearance cold EX 0 1 mm 0 004 in Cylinder head compression pressure 15 kg...

Page 346: ...spring compressor A120E00040 TROUBLESHOOTING x The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed White smoke f...

Page 347: ...crank the engine with the starter motor until the gauge reading stops rising The maximum reading is usually reached 4 7 seconds Compression pressure 15 kg cm2 1500 kPa 213 psi Low compression can be c...

Page 348: ...ubber washers and cylinder head cover Remove the cylinder head cover packing INSTALLATION Apply fluid gasket threebond 1215 to the mating surface of the cylinder head cover then install the packing In...

Page 349: ...YLINDER HEAD COVER DISASSEMBLY ASSEMBLY DISASSEMBLY Remove the three bolts and breather separator Remove the gasket ASSEMBLY Assembly is in the reverse order of disassembly Torque Breather separator b...

Page 350: ...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 chapter 3 Remove the cam chain tensioner lif...

Page 351: ...Loosen and remove the four camshaft holder bolts washers in a crisscross pattern in several steps then remove the camshaft holders Remove the camshafts Bolts Camshaft Holder Camshaft Holder Camshaft H...

Page 352: ...Inspect the camshaft surface of each camshaft holder for scoring scratches or evidence of insufficient lubrication Check the stop pin spring on the exhaust camshaft holder for damage Replace the stop...

Page 353: ...ches blue discoloration Measure the cam lobe height Service Limits IN 37 11 mm 1 4844 in EX 36 86 mm 1 4744 in If any defects are found replace the camshaft with a new one then inspect lubrication sys...

Page 354: ...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 in chapter 3 Apply molybdenum disulfide oil t...

Page 355: ...ct locations Timing Marks Punch Marks Install each camshafts to the correct locations IN no decompressor cam EX has a decompressor cam Make sure the timing marks on the cam sprockets are flush with th...

Page 356: ...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 Tighten the bolts to the specified torque i...

Page 357: ...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 Tighten the bolts to t...

Page 358: ...on system Measure each rocker arm shaft O D Measure the I D of each rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 1 mm 0 004 in Inspect the rocker...

Page 359: ...ALLATION 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...

Page 360: ...e the two bolts and intake pipe Remove the five bolts then remove the pair reed valve cover and holder Remove the two nuts then remove the pair reed valve and gasket Remove the two bolts water joint g...

Page 361: ...8 CYLINDER HEAD VALVES 8 18 MXU 500 Remove the two nuts under the cylinder head Remove the bolt and then remove the cylinder head Remove the dowel pins and gasket Gasket Dowel Pins...

Page 362: ...Apply engine oil to the cylinder head bolt 9 threads Install the bolt 9 but do not tighten it Install the camshafts intake camshaft holder and exhaust camshaft holder refer to the CAMSHAFT REMOVAL IN...

Page 363: ...o 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 Tighten the bolts to the specified torque in...

Page 364: ...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 Arrow Mark Tighten the...

Page 365: ...10 N m 7 lbf ft Install the water stop collar gasket and water joint Install and tighten the two bolts to the specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Install gasket and pair reed valve Ins...

Page 366: ...8 CYLINDER HEAD VALVES 8 23 MXU 500 Install the new O ring onto the intake pipe Install the intake pipe and tighten the two bolts securely O ring Intake Pipe...

Page 367: ...ve the valve spring cotters retainers springs spring seats oil seals and valves using a valve spring compressor Special tool Valve Spring Compressor A120E00040 x Be sure to compress the valve springs...

Page 368: ...he corresponding guide I D to obtain the stem to guide clearance Service limits IN 0 08 mm 0 0032 in EX 0 1 mm 0 004 in Cylinder head Check the spark plug hole and valve areas for cracks Check the cyl...

Page 369: ...Install the valve spring seats and oil seal Lubricate each valve with engine oil and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using th...

Page 370: ...8 CYLINDER HEAD VALVES 8 27 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...

Page 371: ...apter 9 Remove the oil pump drive chain refer to OIL PUMP REMOVAL INSTALLATION section in the chapter 4 Remove the cam chain from the right crankcase Remove the two bolts and cam chain guides INSPECTI...

Page 372: ...29 MXU 500 INSTALLATION 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...

Page 373: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 374: ...9 CYLINDER PISTON 9 1 MXU 500 SCHEMATIC DRAWING...

Page 375: ...measuring position 10 mm from bottom of skirt Piston to cylinder clearance 0 01 0 0004 0 045 0 0018 0 1 0 004 Piston pin hole I D 22 002 0 8801 22 008 0 8803 22 04 0 8816 Piston pin O D 21 994 0 8798...

Page 376: ...t Remove the water hose from the cylinder Remove the two cylinder bolts washers Remove the dowel pins Remove the cylinder and gasket Remove the piston pin clip Press the piston pin out of the piston a...

Page 377: ...out catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to groove clearance Service Limits Top 0 08 mm 0 003 in 2nd 0 065 mm 0 0026 i...

Page 378: ...3 676 in at A 10 mm Calculate the cylinder to piston clearance Measure the piston pin hole Take the maximum reading to determine the I D Service Limit 22 04 mm 0 8816 in Measure the piston pin O D at...

Page 379: ...at three levels in an X and Y axis Take the maximum reading to determine the cylinder wear Service Limit 92 1 mm 3 684 in Calculate the piston to cylinder clearance Take a maximum reading to determine...

Page 380: ...in INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing up Do not confuse the top and second rings To install the oil ring install the oil...

Page 381: ...on pin hole Install the piston with the IN mark face intake side and piston pin Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase Install the new pin clip In...

Page 382: ...l the two cylinder bolts washers and after the cylinder head and holders has installed refer to the CYLINDER HEAD REMOVAL INSTALLATION section in the chapter 8 then tighten the two cylinder bolts to s...

Page 383: ..._ __________________________________________________________________________________ DRIVE PULLEY DRIVEN PULLEY CLUTCH _________________________________________________________________________________...

Page 384: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 1 MXU 500 SCHEMATIC DRAWING...

Page 385: ...29 9 1 196 30 1 1 204 29 5 1 18 TORQUE VALUES Drive pulley nut 14 kgf m 140 N m 100 8 lbf ft Apply oil to the threads Clutch nut 14 kgf m 140 N m 100 8 lbf ft Driven pulley nut 10 kgf m 100 N m 72 lbf...

Page 386: ...er to the FRAME COVERS section in the chapter 2 Remove the ten bolts remove the left crankcase cover and rubber gasket Remove the two dowel pins INSTALLATION Install the rubber gasket onto the left cr...

Page 387: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 4 MXU 500 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 Bolts...

Page 388: ...the driven pulley then remove the nut Special tool Y type holder A120E00056 Remove the driven pulley and V belt Remove the driven pulley washer Remove the drive pulley face Drive Pulley Nut Washer Dri...

Page 389: ...t the drive belt for cracks scaling 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 INSTALLATION Install the fan gui...

Page 390: ...en the nut to the specified torque Torque 10 kgf m 100 N m 72 lbf ft Apply oil to the threads Special tools Y type holder A120E00056 Apply lubricant to the drive face boss inner surface then install t...

Page 391: ...Use the special tool to hold drive pulley then tighten the nut to the specified torque Torque 14 kgf m 140 N m 100 8 lbf ft Apply oil to the threads Special tool Drive pulley holder A120E00058 Make su...

Page 392: ...ECTION ASSEMBLY DISASSEMBLY Remove the drive pulley refer to DRIVE PULLEY AND DRIVEN PULLEY REMOVAL INSTALLATION section Remove the drive face boss Remove the ramp plate and four slide pieces Remove t...

Page 393: ...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 Check...

Page 394: ...Y Clean the movable drive face drive pulley face weight rollers slide pieces ramp plate and drive face boss Install the weight rollers Remove any excess grease The direction of all weight rollers is t...

Page 395: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 12 MXU 500 Install the slide pieces and ramp plate Install the drive face boss Drive Face Boss Ramp Plate Slide Pieces...

Page 396: ...collar on the movable driven face Remove the four guide pins rollers then remove the movable driven face Install the block and bolts then tighten the bolts Attach the block nut wrench and spring compr...

Page 397: ...ration If any scratches or damage is found then replace as a set Check the torque cam grooves for wear or damage Check guide pins and rollers for wear or damage If any scratches or damage is found the...

Page 398: ...als and install into the movable driven face Coat new O rings with grease and install them into the movable driven face grooves Install the movable driven face onto the driven face Install the guide r...

Page 399: ...cial tool Driven pulley spring compressor A120E00059 Attach the block nut nut wrench and spring compressor to the driven pulley assembly Place the block in a vise and secure it Tighten the spring comp...

Page 400: ...LLATION section in this chapter Remove the nine bolts and then remove the clutch housing assembly and one way clutch bearing Remove the two dowel pins and gasket Using a chisel unlock the nut Working...

Page 401: ...tool Y type holder A120E00056 Not USA type Use the special tool to remove the nut and washer Special tool Lock nut wrench A120E00067 USA type Remove the nut and collar Remove the clutch carrier assem...

Page 402: ...er assembly Install the washer Not USA type Install the collar USA type Use the special tools to install and tighten the nut to the specified torque Torque 14 kgf m 140 N m 100 8 lbf ft Special tool Y...

Page 403: ...olybdenum 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 Torque 1 kgf m 10...

Page 404: ...assembly refer to the CLUTCH REMOVAL INSTALLATION section in this chapter Remove the one way clutch bearing from the clutch housing Clutch housing removal not USA type Remove the oil seal Remove the...

Page 405: ...10 DRIVE PULLEY DRIVEN PULLEY CLUTCH 10 22 MXU 500 Clutch housing removal USA type Remove the clutch housing Remove the oil seal then remove the bearing Clutch Housing Bearing Oil Seal...

Page 406: ...Check the one way clutch bearing for chafing wear or damage Check the clutch shoe for heat damage Measure the clutch shoe thickness Service limit A 1 mm 0 04 in Only USA type Turn the crankshaft bear...

Page 407: ...Replace it Check operation USA type Install the one way clutch bearing and collar to the clutch housing and hold the collar When turning the clutch housing clockwise the clutch housing should turn fre...

Page 408: ...n install the new bearing Install the snap ring 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 Clutch...

Page 409: ...tall the new oil seal Install the clutch housing One way clutch bearing installation Install the one way clutch bearing into the clutch housing Oil Seal Clutch Housing The one way clutch bearing shoul...

Page 410: ...______________________________________________________ FINAL REDUCTION TRANSMISSION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION 11 2 T...

Page 411: ...11 FINAL REDUCTION TRANSMISSION SYSTEM 11 1 MXU 500...

Page 412: ...6 lbf ft Apply engine oil Drive bevel gear nut 14 kgf m 140 N m 100 8 lbf ft Apply engine oil Driven bevel gear nut 14 kgf m 140 N m 100 8 lbf ft Apply engine oil Stopper lever boss nut 3 kgf m 30 N m...

Page 413: ...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 DISASSEMBLY INSPECTION ASSEMBLY section in the chap...

Page 414: ...using a suitable bar then remove the rear propeller shaft nut Remove the rear middle joint Tap the output shaft by using a rubber hammer then remove the output shaft secondary driven bevel gear and s...

Page 415: ...o the DRIVE PULLEY DRIVE V BELT AND DRIVEN PULLEY REMOVAL INSPECTION INSTALLATIO N section in the chapter 10 then remove the nut Special tool Y type holder A120E00056 Remove the secondary drive bevel...

Page 416: ...s for wear or damage 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 Torque 14...

Page 417: ...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 Torque 14...

Page 418: ...ear backlash Standard 0 03 0 15 mm 0 001 0 006 in Secondary Drive Bevel Gear Shim Drive Driven bevel gear shims A 0 6 mm 0 024 in B 0 65 mm 0 026 in C 0 7 mm 0 028 in D 0 75 mm 0 03 in E 0 8 mm 0 032...

Page 419: ...correct example 2 then to complete installation 1 Incorrect contact at tooth top 2 Correct 3 Incorrect contact at tooth root If tooth contact is found to be incorrect examples 1 and 3 the shim thickn...

Page 420: ...L 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 section in this chapt...

Page 421: ...o 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 Install the right crankcase and t...

Page 422: ...topper plug to the specified torque Torque 4 8 kgf m 48 N m 35 lbf ft BEARING REPLACEMENT IN THE RIGHT CRANKCASE BALANCE SHAFT COUNTERSHAFT PRIMARY DRIVE SHAFT BEARING REPLACEMENT Remove the balance s...

Page 423: ...he special tool Special tool Bearing driver A120E00014 DRIVE SHAFT BEARING REPLACEMENT Remove the four bolts and two set plates Remove the bearing Install the new bearing by using the special tool Spe...

Page 424: ...al Remove the nut by using the special tool Special tool Nut wrench A120E00066 Remove the bearing by using the special tool Special tool Bearing Puller A120E00037 Install the new bearing Oil Seal Nut...

Page 425: ...rench A120E00066 Apply clean engine oil to the new oil seal lip then install the oil seal FRONT SIDE BEARING Remove the oil seal Remove the snap ring Remove the bearing by using the special tool Speci...

Page 426: ...11 FINAL REDUCTION TRANSMISSION SYSTEM 11 16 MXU 500 Install the snap ring Apply clean engine oil to the new oil seal lip then install the new seal Snap Ring Oil Seal...

Page 427: ...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 Remove the shift sha...

Page 428: ...hift cam Remove the countershaft and driveshaft as an assembly Disassemble the countershaft and the driveshaft Driveshaft Assembly Countershaft Assembly Upper Shift Fork Lower Shift Fork Shift Cam Kee...

Page 429: ...Remove the bolt washer then remove the stopper lever and spring INSPECTION Guide bar Measure the guide bar runout Out of specification Replace Service Limit Less than 0 03 mm 0 0012 in Primary Drive S...

Page 430: ...ork pawl Scoring beads wear Replace a set Inspection the spring Cracks or damage Replace a set Lower shift fork Inspect the shift fork cam follower and shift fork pawl Scoring beads wear Replace Prima...

Page 431: ...l for bends damage or wear Inspect the spring for cracks or damage Check the shift cam groove and shift cam gear Wear or damage Replace Inspect shift shaft gear Damage Replace Inspect shift shaft Dama...

Page 432: ...m 30 N m 21 6 lbf ft Hook the spring onto the hook part of the stopper lever squeeze the spring in to the groove of the left crankcase Install the washer and a new bolt Tighten the bolt to the specifi...

Page 433: ...gine oil to the shift cam then install the shift cam Apply clean engine oil to the gearshift fork sliding surface and gearshift fork pawl Install the lower gearshift fork into the clutch dog countersh...

Page 434: ...ply clean engine oil to the guide bar install the guide bar Install the shift shaft Check the transmission operation Unsmooth operation Repair Guide Bar Shift Shaft Align The Marks Align the mark on t...

Page 435: ...ction in this chapter Remove the snap ring washer and fork Remove the spring cam pawl and washer ASSEMBLY Install the washer and cam pawl Install the spring Install the fork Install the washer and sna...

Page 436: ...bly refer to the TRANSMISSION REMOVAL INSPECTION INSTALLATION section in this chapter Remove the washer thick and reverse gear Remove the washer thin ASSEMBLY INSPECTION Inspect the gear teeth Blue di...

Page 437: ...e the washer and high drive gear Remove the high low gear clutch dog Remove the clip then remove the washer and low drive gear Remove the clip then remove the stopper wheel Remove the clip then remove...

Page 438: ...teeth Blue discoloration pitting wear Replace Inspect the mated dogs Rounded edges cracks missing portions Replace Washer High Drive Gear Washer High Low Gear Clutch dog Clip Washer Low Drive Gear Co...

Page 439: ..._______________________ __________________________________________________________________________________ __________________________________________________________________________________ LEFT CRANK...

Page 440: ...12 LEFT CRANKCASE CRANKSHAFT BALANCE SHAFT 12 1 MXU 500...

Page 441: ...nder head Chapter 8 Cylinder piston Chapter 9 Drive and driven pulleys Chapter 10 A C generator Chapter 17 Starter clutch Chapter 19 Oil pump Chapter 4 SPECIFICATIONS Unit mm in Item Standard Service...

Page 442: ...NSTALLATION section in the chapter 11 Remove the crankshaft and balance shaft together INSPECTION Balance shaft Inspect the balance shaft gear teeth Burrs chips roughness wear Replace Crankshaft inspe...

Page 443: ...0 004 in Measure the connecting rod big end side clearance C Service Limit replace if over Not USA type 0 6 mm 0 024 in USA type 0 8 mm 0 032 in Measure the crank width D Out of specification 72 72 05...

Page 444: ...AFT BALANCE SHAFT 12 5 MXU 500 INSTALLATION Install the balance shaft and crankshaft into the left crankcase Mark on the Balance Shaft Align the mark on the balance shaft with the mark on the cranksha...

Page 445: ...shaft countershaft primary drive shaft drive shaft bearing by using the special tool Special tool Bearing puller A120E00037 Install the new bearing by using the special tool Special tool Bearing driv...

Page 446: ...___ DRIVE TRAIN __________________________________________________________________________________ SERVICE INFORMATION 13 2 TROUBLESHOOTING 13 2 FRONT DRIVE SHAFT REMOVAL INSPECTION INSTALLATION 13 3...

Page 447: ...13 DRIVE TRAIN 13 1 MXU 500 FRONT DRIVE REAR DRIVE...

Page 448: ...bolt M8 2 3 kgf m 23 N m 16 5 lbf ft Apply threebond 1215 2WD 4WD shift motor mounting bolt M6 1 2 kgf m 12 N m 8 5 lbf ft Rear drive gear case mounting nut 5 5 kgf m 55 Nm 40 lbf ft Rear drive gear c...

Page 449: ...assembly INSPECTION Inspect the boots circlip and boot bands for wear or damage If any damages are found replace them with new ones Inspect the double off set joint spline for wear or damage If any d...

Page 450: ...irclip into its groove in the splines Apply lightweight lithium soap base grease to the splines of the drive shafts and install the drive shaft to the front drive gear case Case Side Joint Circlip Be...

Page 451: ...efer to the FRONT DRIVE SHAFT REOMVAL INSPECTION INSTALLATION section in this chapter Remove the boot band of the case side joint Slide the boot toward the center of the front drive shaft and remove t...

Page 452: ...circlip and snap ring for wear or damage If any damages are found replace them with new ones Inspect the cage and inner surface of case side joint for pitting wear or damage If any damages are found r...

Page 453: ...EMBLY Do not attempt to straighten a bent shaft this may dangerously weaken the shaft Circlip Case Side Joint Snap Ring Cage Circlip Band Boot Band Band Boot Band Front Drive Shaft Wash all parts exce...

Page 454: ...small diameter side of the boot to the shaft groove fix its end with a new band Install the cage on the shaft Install the snap ring to the groove on the drive shaft Band Snap Ring Large Diameter Side...

Page 455: ...e case side joint and fit a circlip in the groove of the case side joint Circlip Position Grease Case side joint Wheel side joint Quantity 85 g 2 8 oz 45 g 1 5 oz The tube of joint molybdenum disulfid...

Page 456: ...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 Fix the boot on the case side joint with a new boot band taking c...

Page 457: ...INSTALLATION section in the chapter 14 Remove the front upper arms and front lower arms refer to the FRONT ARMS INSPECTION REMOVAL INSTALLATION section in the chapter 14 Remove the drive shafts refer...

Page 458: ...ront 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 Also check that the j...

Page 459: ...olts 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 Torque 4 5 kgf m 45 N m 32 4 lbf ft Conn...

Page 460: ...he three bolts and then remove the 2WD 4WD shifting motor assembly Remove the 2WD 4WD shifting pinion and O ring by hand Remove the nine bolts from left gear case in a crisscross pattern Pry the case...

Page 461: ...m right gear case Remove the front drive assembly from the left gear case Remove the shim from the left gear case Shim Front Drive Assembly Do not attempt to disassembly the front drive assembly The f...

Page 462: ...fork shaft plug Remove the 2WD 4WD shifting fork spring and shifting rack by removing shaft If there is no abnormal condition the bearing removal is not necessary The removed bearing must be replaced...

Page 463: ...universal joint yoke assembly by using the special tool Special tool Joint yoke remover A120F00016 Remove the snap ring Remove the oil seal out of the right gear case Snap Ring If there is no abnormal...

Page 464: ...e bearing puller A120F00018 Remove the shifting sleeve Remove the snap ring Remove the pinion gear together with the bearing Snap Ring Bearing Snap Ring Pinion Gear Bearing Shifting Sleeve If there is...

Page 465: ...7 Remove the C rings from the universal joint by using the special tool Special tool C ring remover A120F00022 Bearing If there is no abnormal condition the bearing removal is not necessary The remove...

Page 466: ...rewdriver into the hole on the special tool then pull it out Remove the bearings by tapping the universal joint with a copper hammer Bearing Bearing If there is no abnormal condition the bearing remov...

Page 467: ...und replace the shifting fork and its rack and pinion with the new ones If the shifting fork is damaged inspect the groove of the shifting sleeve Check the outer race play and smooth rotation of the b...

Page 468: ...r case bearing for wear or damage If any wear or damage is found replace the bearing with a new one Check the outer race play and smooth rotation of the bearing by hand while it is on the front drive...

Page 469: ...sal 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 Insert the universal joint to the new bearing and c...

Page 470: ...13 DRIVE TRAIN 13 24 MXU 500 ASSEMBLY Before reassembly thoroughly clean all parts in cleaning solvent...

Page 471: ...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 bearing installer A120E00014 In...

Page 472: ...on gear pilot bearing into the right gear case by using a proper shaft Install the pinion gear assembly and fix the bearing race with the snap ring Install the shifting sleeve to the pinion gear shaft...

Page 473: ...0014 Install the new oil seal into the right gear case Apply 4 5 g 0 13 0 17 oz of lightweight lithium soap base grease to the outside of seal lip groove Apply lightweight lithium soap base grease to...

Page 474: ...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...

Page 475: ...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 Torque 1 5 kgf m 15 N m 11 lbf ft Inst...

Page 476: ...them to the specified torque in a crisscross pattern in 2 or 3 steps Torque 2 3 kgf m 23 N m 16 5 lbf ft Front Drive Assembly After the backlash and tooth contact have been checked or adjusted apply a...

Page 477: ...se and install the 2WD 4WD 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 Torque M8 2 3 kgf m 23 N m 16 5...

Page 478: ...f the three measurements If the backlash is not within specification the shim must be changed and the backlash should be re checked until correct Refer to the chart at the right for the appropriate sh...

Page 479: ...few pieces of solder O D 1 2 2 5 mm L 6 mm on the bearing outer race as shown Assemble the gear case and tighten its bolts to the specified torque in a crisscross pattern in 2 or 3 steps Torque 2 3 k...

Page 480: ...solder thickness After selecting the proper size of shim s check or adjust the backlash and tooth contact Shim thickness 0 7 mm 0 0276 in 0 75 mm 0 0295 in 0 8 mm 0 0315 in 0 85 mm 0 0335 in 0 9 mm 0...

Page 481: ...ing gear and compare the coated teeth to the examples shown in 1 2 and 3 If tooth contact is found to be correct example 2 go to the FRONT DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in this chapter...

Page 482: ...NSPECTION INSTALLATION section in the chapter 15 Remove the four mounting nuts from the right rear axle housing Remove the rear drive assembly and rear propeller shaft together Remove the rear propell...

Page 483: ...ion gear and check that the gear turns smoothly and quietly without binding If the gears do not turn smoothly or quietly the gears and or bearing may be damaged or faulty Replace the final gear case a...

Page 484: ...es and inner Install the rear propeller shaft to the rear drive assembly Install the rear propeller shaft and rear drive assembly to the engine and right rear axle housing Apply Grease Apply Grease Co...

Page 485: ...IVE TRAIN 13 39 MXU 500 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 Rear Drive Assembly Rear Propeller S...

Page 486: ...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 Remove the eight cover bolts in a crisscross patt...

Page 487: ...g from the cover by using a proper pipe Remove the right ring gear shim Remove the ring gear Oil Seal Bearing Ring Gear Shim If there is no abnormal condition the oil seal or bearing removal is not ne...

Page 488: ...ring from the case by using a proper pipe Remove the water proof plate by using a commercially available puller Shim Water Proof Plate Oil Seal Bearing If there is no abnormal condition the oil seal o...

Page 489: ...nut wrench A120F00020 Install the special tool onto the pinion gear shaft and gear case Special tool Pinion puller set A120F00021 Pull the pinion assembly out from the case Oil Seal If there is no ab...

Page 490: ...with a commercially available bearing puller Remove the pinion shim s INSPECTION Inspect the gear case cover and oil seals for wear or damage If any wear or damage is found replace the oil seal with...

Page 491: ...ion gear is damaged inspect the ring gear If any defects are found replace the bearing and gear with the new ones Inspect the splines of pinion gear shaft for wear or damage If any defects are found r...

Page 492: ...e 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 thoroug...

Page 493: ...pe Install the new bevel pinion gear pilot bearing into the gear case by using a proper shaft Install the snap ring Install the pinion gear assembly by using a proper pipe Install the bearing lock nut...

Page 494: ...w water proof plate by using a proper pipe Install the new bearings into the gear case and cover by using a proper pipe Apply lightweight lithium soap base grease to the new oil seal lips Install the...

Page 495: ...13 DRIVE TRAIN 13 49 MXU 500 Install the removed left shim to the gear case Install ring gear to the gear case Install the removed right shim to the ring gear Shim Shim Ring Gear...

Page 496: ...bf ft Apply lightweight lithium soap base grease to the new oil rings Install the new oil rings into the gear case and cover O ring Cover O ring Case After the backlash and tooth contact have been che...

Page 497: ...ash readings at three places while turning the ring gear slightly in each direction and securely holding the pinion gear by using commercially tool Read the total backlash on the dial gauge Standard 0...

Page 498: ...he gear case cover Right Left Shim thickness A 1 55 mm 0 062 in B 1 5 mm 0 0 06 in C 1 45 mm 0 058 in Adjust the backlash by referring to the chart at the right and using the thickness of the removed...

Page 499: ...t the proper size of shim s from the right chart according as the compressed solder thickness After selecting the proper size of shim s install it on the ring back side Do not apply a sealant to the c...

Page 500: ...r Remove the ring gear and compare the coated teeth to the examples shown in 1 2 and 3 If tooth contact is found to be correct example 2 go to the REAR DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in...

Page 501: ...usted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the...

Page 502: ...er shaft refer to the FRONT DRIVE REMOVAL INSPECTION INSTALLATION section in this chapter Slide the spring rings back then remove the boot universal joint yoke shaft and compression spring Remove the...

Page 503: ...or tears If any damage is found replace the boot with a new one Inspect the splines of universal joint for wear or damage If any defects are found replace the universal joint yoke with a new one Joint...

Page 504: ...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 If excessive play is noted replace the bearings dust seal and uni...

Page 505: ...nt movement smoothly If a large resistance is felt to movement tap the bearing with a plastic mallet lightly Apply lightweight lithium soap base grease to the shaft splines and inner Apply lightweight...

Page 506: ...60 MXU 500 Fix the boot and spring ring taking care not distort the boot Universal Joint Yoke Spring Compression Spring Boot The dust boot should be fastened with the spring ring at the grooves in th...

Page 507: ...INSPECTION ASSEMBLY DISASSEMBLY Remove the front propeller shaft refer to the REAR DRIVE REMOVAL INSPECTION INSTALLATION section in this chapter Slide the spring ring back then remove the boot Remove...

Page 508: ...or tears If any damage is found replace the boot with a new one Inspect the splines of universal joint for wear or damage If any defects are found replace the universal joint yoke with a new one Joint...

Page 509: ...als 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 If excessive play is noted replace the bearings dust seals and...

Page 510: ...the joint movement smoothly If a large resistance is felt to movement tap the bearing with a plastic mallet lightly Fix the boot and spring ring taking care not distort the boot Boot The dust boot sho...

Page 511: ...EM __________________________________________________________________________________ SERVICE INFORMATION 14 2 TROUBLESHOOTING 14 3 FRONT WHEEL REMOVAL INSPECTION INSTALLATION 14 4 FRONT WHEEL HUB REM...

Page 512: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 1 MXU 500...

Page 513: ...gle 180 TORQUE VALUES Steering column nut 7 kgf m 70 N m 50 lbf ft Front swing arm nut 4 5 kgf m 45 N m 32 lbf ft Front wheel nut 6 5 kgf m 65 N m 46 lbf ft Front wheel hub nut 7 kgf m 70 N m 50 lbf f...

Page 514: ...ive wheel bearing play x Bent spoke plate x Faulty tire Steers to one side or does not track straight x Improperly tightened axle nut x Uneven front shock absorbers Soft front shock absorber x Bent fr...

Page 515: ...el hub nut cap together INSPECTION Measure the wheel run out Replace wheel or check bearing play if out of specification Rim run out limits Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in INSTALLATION When...

Page 516: ...VAL INSPECTION INSTALLATION section in this chapter Elevate the front wheels by placing a suitable stand under the frame Remove the cotter pin Apply the front brake and then remove nut washer and fron...

Page 517: ...gf m 70 N m 50 lbf ft Install the cotter pin and band ends of cotter pin Apply grease onto the wheel hub splines Always use a new cotter pin Do not apply oil to the seat of the nut Do not loosen the w...

Page 518: ...sembly Inspect the shock absorber Oil leaks Replace the shock absorber assembly Inspect the spring of the shock absorber by move the spring up and down Fatigue Replace the shock absorber assembly Insp...

Page 519: ...heel hub refer to the FRONT WHEEL HUB REMOVAL INSPECTION INSTALLATION section in this chapter Remove the three bolts and brake disc protection plate Remove the cotter pin and nut from the tie rod end...

Page 520: ...rning the pressure bolt Tighten the pressure bolt with a wrench Release the ball joints of the steering knuckle using the special tool according to the following instructions Special tool Ball join re...

Page 521: ...mages are found replace the knuckle end with a new one Inspect the brake disc protection plate for damage If any damages are found replace the brake disc protection plate with a new one Inspect the du...

Page 522: ...e 3 kgf m 30 N m 22 lbf ft Install the all cotter pins and band ends of cotter pins Install the tie rod onto the steering knuckle and tighten the nut to the specified torque Torque 2 1 kgf m 21 N m 16...

Page 523: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 12 MXU 500 Install the brake disc protection plate and then tighten the three bolts securely Plate...

Page 524: ...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 appropri...

Page 525: ...al noise and smooth rotation If there is anything unusual replace the bearing with a new one Remove the bearings using the appropriate bar then remove the spacer ASSEMBLY Apply lightweight lithium soa...

Page 526: ...tall the spacer into the steering knuckle Install the new outer bearing by using the special tool Special tool Oil seal and bearing driver A120E00014 Install the new dust seals by using the special to...

Page 527: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 16 MXU 500 Install the steering knuckle end by using a appropriate pipe Install the snap ring Pipe Snap Ring...

Page 528: ...otter pin and nut from the upper arm end Remove the cotter pin and nut from the steering knuckle end Remove the upper arm and steering knuckle ends refer to the STEERING KNUCKLE REMOVAL INSPECTION INS...

Page 529: ...t of the frame If bent cracked or damaged repair or replace the frame Check the tightening torque of the front lower arm securing nuts Torque 4 5 kgf m 45 N m 32 lbf ft Check the front lower arm side...

Page 530: ...from the front upper arm then remove the front upper arm Remove the mounting two bolts nuts from the front lower arm then remove the front lower arm INSTALLATION Install the front lower arm front upp...

Page 531: ...BLY Upper arm Remove the snap ring Remove the upper arm end by using a appropriate collar Lower arm Remove the bolt and then remove the front protector INSPECTION Inspect the upper arm end boot for we...

Page 532: ...damage Replace Inspect bushes Wear damage Replace Inspect the front protector for damage If any damages are found replace the front protector with a new one ASSEMBLY Install the upper arm end by usin...

Page 533: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 22 MXU 500 Install the snap ring Install the front protector then install and tighten the bolt securely Snap Ring Front Protector...

Page 534: ...ckle 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 INSPECTION Inspect the tie rod Bend...

Page 535: ...face of the tie rod is parallel to the rod end shaft and then tighten the lock nut Torque 3 5 kgf m 35 N m 25 5 lbf ft Set the other rod end steering knuckle side in an angle as shown right hand tie r...

Page 536: ...ring column side 2 1 kgf m 21 N m 16 lbf ft Install the all cotter pins and band ends of cotter pins Be sure that the rod end on the indentation surface side is connected to the steering knuckle Do no...

Page 537: ...itch wire from the handlebar Remove the two screws and then remove the left handlebar switch from the handlebar Remove the two screws and then remove the throttle lever assembly Remove the nut then re...

Page 538: ...move the 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 f...

Page 539: ...brake master cylinder on the handlebar and install the master cylinder holder with the UP mark facing up aligning the punch mark on the handlebar with the holder joint seam First tighten the upper bo...

Page 540: ...L FRONT SUSPENSION STEERING SYSTEM 14 29 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 scr...

Page 541: ...tion in the chapter 2 Remove the tie rods refer to the TIE ROD REMOVAL INSPECTION INSTALLATION section in this chapter Remove the handlebar refer to the HANDLEBAR REMOVAL INSPECTION INSTALLATION secti...

Page 542: ...NG SYSTEM 14 31 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 Remove the dust seal Remove the snap rin...

Page 543: ...ing brackets and oil seal Wear damage Replace INSTALLATION Install the steering column and collar then tighten the nut under the frame body Torque 7 kgf m 70 N m 50 lbf ft Install the cotter pin and b...

Page 544: ...SUSPENSION STEERING SYSTEM 14 33 MXU 500 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 Steering...

Page 545: ...___________________________________________________ REAR WHEEL AXLE SHOCK ABSORBER SWING ARM __________________________________________________________________________________ SERVICE INFORMATION 15 2...

Page 546: ...15 REAR WHEEL AXLE SHOCK ABSORBER SWING ARM 15 1 MXU 500...

Page 547: ...pper mount bolt 4 kgf m 40 N m 29 lbf ft Rear shock absorber lower mount bolt 4 kgf m 40 N m 29 lbf ft Rear wheel hub nut 10 kgf m 100 N m 72 lbf ft Right pivot bolt 11 8 kgf m 118 N m 85 lbf ft Left...

Page 548: ...and wheel hub nut cap together INSPECTION Measure the wheel run out Replace wheel or check bearing play if out of specification Rim run out limits Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in INSTALLAT...

Page 549: ...MOVAL INSPECTION INSTALLATION section in this chapter Elevate the rear wheels by placing a suitable stand under the frame Remove the cotter pin Apply the rear brake and then remove nut and rear wheel...

Page 550: ...s of cotter pin 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 grease Always use a new cotter pin Do...

Page 551: ...leaks Replace the shock absorber assembly Inspect the spring of the shock absorber by move the spring up and down Fatigue Replace the shock absorber assembly Inspect bushes collar and dust seals Wear...

Page 552: ...ide INSPECTION Check the axle splines for wear or damage Set the axle in V blocks and measure the runout with a dial indicator Axle runout is 1 2 the total indicator reading Service limit 3 mm 0 12 in...

Page 553: ...N section in this chapter Remove the bolt from skid plate under the left axle housing Remove the four nuts bolts from the left housing attaching the rear swing arm Remove the four nuts from the left h...

Page 554: ...he rear axle housing for distortion or damages If any damages are found replace the rear axle housing Inspect the dust seal lips for wear or damage If any damages are found replace a new one Inspect t...

Page 555: ...ssembly onto the right rear axle housing refer to the REAR DRIVE CASE ASSEMBLY REMOVAL INSPECTION INSTALLATION section in the chapter 13 Install the left rear axle housing onto the rear drive case ass...

Page 556: ...ar 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 Remove the dust seal from th...

Page 557: ...he axle housing and lips of the new dust seal before install them Install the new bearings by using the special tool Special tool Oil seal bearing driver A120E00014 Install the snap ring Install a new...

Page 558: ...al 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 lip...

Page 559: ...EL AXLE SHOCK ABSORBER SWING ARM 15 14 MXU 500 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 Dust Seal...

Page 560: ...MOVAL INSPECTION INSTALLATION section in this chapter Remove the swing arm pivot bolt cap Remove the right pivot bolt Remove the bolt and band then remove the rear brake fluid hoses from swing arm Rem...

Page 561: ...m 11 N m 8 lbf ft Move the swing arm up and down several times to seat the pivot bearings Retighten the pivot bolts to the same torque Install the left pivot lock nut Tighten the lock nut while holdi...

Page 562: ...from swing arm Inspect the skid plate for damage If any damages are found replace the skid plate with a new one Inspect the swing arm for distortion or damage If any damage are found replace the swing...

Page 563: ...outer races and bearing plates if any damages are found replace the them with new ones Remove the swing arm bearings outer races and bearing plates by using a proper pipe Bearing Bearing Outer Race Be...

Page 564: ...by using the special tool Special tool Oil seal bearing driver A120E00014 Apply lightweight lithium soap base grease to the swing arm bearings and lips of dust seals then install them into the swing...

Page 565: ...16 10 FRONT BRAKE FLUID CHANGE AIR BLEED OFF ROAD 16 11 REAR BRAKE FLUID CHANG AIR BLEED 16 14 COMBINATION BRAKE FLUID CHANG AIR BLEED ON ROAD 16 17 BRAKE MASTER CYLINDERS REMOVAL INSPECTION INSTALLAT...

Page 566: ...16 BRAKE SYSTEM 16 1 MXU 500...

Page 567: ...rking with brake fluid use shop towels to cover and protect painted rubber and plastic parts Wipe off any splash of brake fluid with a clean towel Do not wipe the machine with a towel contaminated by...

Page 568: ...brake performance Brake noise x Air in brake system x Contaminated brake pad surface x Deteriorated brake fluid x Excessive brake disk run out x Contaminated brake pads and brake disk x Incorrectly i...

Page 569: ...n the chapter 14 Remove the two brake pad pins from the brake caliper Remove the two mounting bolts from brake caliper and then remove brake caliper Compress the brake caliper holder and remove brake...

Page 570: ...ll the brake pad mounting pins 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 RE...

Page 571: ...e the same Rear brake combined Remove the rear wheel refer to the REAR WHEEL REMOVAL INSPECTION INSTALLATION section in the chapter 15 Remove the two brake pad pins from the brake caliper Remove the t...

Page 572: ...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 pa...

Page 573: ...16 BRAKE SYSTEM 16 8 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...

Page 574: ...section in the chapter 14 Remove the four bolts and then remove the brake disc INSPECTION Measure the brake disc thickness Service Limit 3 mm 0 12 in Measure the brake disk run out Service Limit 0 3 m...

Page 575: ...ection in the chapter 15 Remove the four bolts and then remove the brake disc INSPECTION Measure the brake disc thickness Service Limit 3 mm 0 12 in Measure the brake disk run out Service Limit 0 3 mm...

Page 576: ...nnect a transparent hose to the brake caliper bleed valve right and calipers and then loosen the bleed valve nuts Use a syringe to draw the brake fluid out through the hose Then tighten the bleed valv...

Page 577: ...f m 6 Nm 4 32 lbf ft Connect a transparent hose to the left 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 tr...

Page 578: ...the right caliper bleed valve nut to bleed air from the brake system 3 Fully apply the brake lever after continuously pull it several times Then loosen the left caliper bleed valve nut to bleed air fr...

Page 579: ...out through the hose Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose Then tighten the bleed valve nut To...

Page 580: ...epeat these steps until the brake system is free of air BRAKE PEDAL OFF ROAD Brake fluid change Place the machine on the level ground and set the handlebar upright Remove the brake fluid reservoir cap...

Page 581: ...mended Brake Fluid DOT 4 Brake system bleeding 1 Connect a transparent hose to the bleed valve 2 Fully apply the brake pedal after continuously depress it several times Then loosen the caliper bleed v...

Page 582: ...servoir cap 2 Remove the brake fluid reservoir cap front brake lever 3 Connect a transparent hose to the delay valve bleed valve and then loosen the bleed valve nut Use a syringe to draw the brake flu...

Page 583: ...he hose Then tighten the bleed valve nuts Torque 0 6 kgf m 6 Nm 4 32 lbf ft 6 Connect a transparent hose to the rear brake caliper bleed valve combined and then loosen the bleed valve nut Use a syring...

Page 584: ...o it until there is no air bubbles in the transparent hose Then tighten the bleed valve nut Torque 0 6 kgf m 6 Nm 4 32 lbf ft Recommended Brake Fluid DOT 4 9 Fill the brake reservoir brake pedal with...

Page 585: ...e 0 6 kgf m 6 Nm 4 32 lbf ft Recommended Brake Fluid DOT 4 11 Loosen the rear caliper combined bleed valve nut Connect the transparent hose to the bleed valve Use the syringe to draw brake fluid into...

Page 586: ...lly apply the brake pedal after continuously depress it several times and fully apply the front brake lever after continuously pull it several times Then loosen the rear caliper bleed valve nut to ble...

Page 587: ...il the brake system is free of air Then tighten the bleed valve nuts Torque 0 6 kgf m 6 Nm 4 32 lbf ft Bleed Valve Bleed Valve When bleeding air from the brake system the brake fluid level should be k...

Page 588: ...FLUID CHANGE AIR BLEED ON ROAD in this chapter Remove the bolt nut and then remove the brake lever Remove fluid hose bolt two washers and then disconnect the fluid hose Remove the two master cylinder...

Page 589: ...hydraulic brake system refer to the REAR BRAKE FLUID CHANGE AIR BLEED section or COMBINATION BRAKE FLUID CHANGE AIR BLEED ON ROAD section in this chapter Remove the joint then disconnect the fluid hos...

Page 590: ...rear master cylinder Install the brake light switch Place the right and left brake master cylinder on the handlebar and install the master cylinder holder with the UP mark facing up aligning the punc...

Page 591: ...m soap base grease to the bolt then install and tighten the bolt and nut securely Fill the brake reservoir with the specified brake fluid and bleed air from the brake system refer to the FRONT BRAKE F...

Page 592: ...gf m 35 Nm 25 lbf ft Apply lightweight lithium soap base grease to the dust boot in the master cylinder then install the brake arm Apply lightweight lithium soap base grease to the bolt then install a...

Page 593: ...VAL INSTALLATION section in this chapter Remove the piston dust boot and snap ring from the brake master cylinder Remove the spring and piston together Brake pedal master cylinder Remove the brake mas...

Page 594: ...ther INSPECTION Check the cylinder inside wall for scratch corrosion or other abnormal condition If any abnormal condition is found replace the master cylinder Check the spring and piston for scratch...

Page 595: ...t Install the snap ring 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 u...

Page 596: ...washers and then disconnect the all fluid hoses Remove the two mounting bolts and remove the relay valve DISASSEMBLY Remove the bolt Remove the spring Do not splash brake fluid onto any rubber plastic...

Page 597: ...Install the spring Replace a new O ring then install and tighten the bolt to the specified torque Torque 5 kgf m 50 N m 36 lbf ft O ring Piston Spring Delay Valve Body Wash the delay valve components...

Page 598: ...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 Torque 3 5 kgf m 35 Nm 25 lbf ft Fill the specified brake...

Page 599: ...om the caliper Remove the brake pads refer to the BRAKE PADS REPLACEMENT section in this chapter Remove the brake caliper INSTALLATION Install the brake fluid hose with the attaching bolt and two new...

Page 600: ...e the brake pads refer to the BRAKE PADS REPLACEMENT section in this chapter Remove the brake caliper INSTALLATION Install the brake fluid hose with the attaching bolt and two new sealing washers then...

Page 601: ...ke pads refer to the BRAKE PADS REPLACEMENT section in this chapter Remove the brake caliper INSTALLATION Install the brake fluid hose with the attaching bolt and two new sealing washers then tighten...

Page 602: ...L INSTALLATION section or REAR BRAKE CALIPERS REMOVAL INSTALLATION section in this chapter Remove the brake pad spring plate Remove the piston from the brake caliper If necessary use compressed air to...

Page 603: ...the caliper bracket INSPECTION Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages If any abnormal condition is noted replace the caliper Inspect the dust boot...

Page 604: ...ke 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 Never use different types of fluid or...

Page 605: ...n this chapter Remove the brake pad spring plate Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a sh...

Page 606: ...em with a new ones Remove the caliper bracket Remove the dust boot Remove the dust seal and piston seal Loosen the lock nut while hold the adjusting bolt Remove the adjusting bolt Remove the parking b...

Page 607: ...ion or damage If any damage is found replace it with a new one Remove the drive bolt and dust boot Inspect the drive shaft and shaft guide for wear or damage Remove the two bolts and parking brake cas...

Page 608: ...43 MXU 500 Remove the O ring Inspect the O ring for wear or damage If any damages are found replace it with a new one INSTALLATION Apply silicone grease to the new O ring then install the new O ring O...

Page 609: ...securely Apply silicone grease to the new piston seal and new dust seal then install them Install the piston Apply silicone grease to the brake shaft then install it Apply silicone grease to the dust...

Page 610: ...s not touch piston Install the parking brake arm and spring Install the adjusting bolt and lock nut Dust Boot Piston Adjusting Bolt Lock Nut Parking Brake Arm Spring Brake Fluid Inlet hole Align the p...

Page 611: ...stall it Install the spring plate Install the parking brake caliper refer to the REAR BRAKE PARKING BRAKE CALIPER EMOVAL INSTALLATION ON ROAD section in this chapter Adjust the parking brake refer to...

Page 612: ...___________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM _________________________...

Page 613: ...17 BATTERY CHARGING SYSTEM 17 1 MXU 500 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT IC 12V 18AH BATTERY...

Page 614: ...f one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte level goes down quickl...

Page 615: ...seals again x For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery SPECIFICATIONS ITE...

Page 616: ...ition Install the battery Check the battery current leakage Specified current leakage 0 5 Ma max Check the alternator charging coil Standard 0 1 0 3 20 C 68 F Measure and record the battery voltage us...

Page 617: ...ery first then disconnect the positive terminal lead 3 5 Remove the battery Battery installation 1 Install in the reverse order of removal 2 After installing the battery check to see if the battery ca...

Page 618: ...ignition switch OFF disconnect the negative cable from the battery Connect the ammeter probe to the negative cable and the ammeter probe to the battery terminal With the ignition switch OFF check for...

Page 619: ...ve and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multi meter when the engine runs at 5000 min 1 rpm Standard...

Page 620: ...s continuity to ground REGULATOR RECTIFIER WIRE HARNESS INSPECTION Disconnect the regulator rectifier connectors Check the connectors for loose contacts of corroded terminals Battery line Measure the...

Page 621: ...en 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 20 C 68 F Check for continui...

Page 622: ...MXU 500 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 Rectif...

Page 623: ...section in the chapter 3 Disconnect the alternator stator connectors Remove the starter pulley refer to the STARTER PULLEY REMOVAL INSPECTION INSTALLATI ON section in the chapter 19 Remove the oil fil...

Page 624: ...the two dowel pins and gasket Remove the two pulse coil mount bolts Remove the three stator mount bolts grommet and the stator from the right crankcase cover INSPECTION Check the stator and pulse coil...

Page 625: ...y Install the pulse coil and tighten mount bolts to the specified torque Torque 1 2 kgf m 12 N m 9 lbf ft Clean the mating surfaces of the right crankcase and cover Install the dowel pins and gasket I...

Page 626: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGN...

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 629: ...the ignition control module Always turn off the ignition switch before servicing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the...

Page 630: ...TAGE Short circuit in engine stop switch or ignition switch wire Faulty engine stop switch or ignition switch Loose or poorly connected ignition control module connectors Open circuit or poor connecti...

Page 631: ...rk plug cap and ground the spark plugs to the cylinder as done in the spark test Turn the ignition switch to ON and engine stop switch ON Turn the engine stop switch in RUN OFF ROAD Connect the multi...

Page 632: ...Disconnect the spark plug cap from the spark plug page 18 4 Disconnect the ignition coil primary connectors Remove the two bolts and the ignition coil Installation is in the reverse order of removal...

Page 633: ...W G GR L Y G W B Y G B W G GR 6 7 M 6 7 M 6 7 M L Y 0 785 K Continue G W 0 778 K 0 785 k B Y G Continue 0 785 K Due to the semiconductor in circuit it is necessary to use a specified tester for accur...

Page 634: ..._________________________________________________________________________ STARTER SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT 19 1...

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 637: ...the starter motor may be damaged x See section 20 for following components Ignition switch Starter switch Brake light switch SPECIAL TOOL Flywheel puller A120E00060 TORQUE Starter pulley nut 5 5 kgf...

Page 638: ...following page Abnormal Starter motor does not turn Normal Abnormal Normal Check for loose or poorly connected starter MAG terminals Abnormal Check for loose or poorly connected or broken starter moto...

Page 639: ...ch x Loose or poor contact of connector x Open circuit in wire harness x Faulty starter MAG x Loose or poor starter relay connector contact Battery voltage registers No voltage Check the starter MAG v...

Page 640: ...TALLATION section in the chapter 5 Turn the ignition switch turned to OFF Remove the two mounting bolts and starter motor Release the rubber cap and remove the terminal nut to disconnect the starter m...

Page 641: ...relay switch and starter MAG using the procedure below GROUND LINE INSPECTION Disconnect the starter relay switch connector Check for continuity between the Green wire terminal and ground There should...

Page 642: ...bles 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 There should be continuity between the cable te...

Page 643: ...CTION INSTALLATION REMOVAL Remove the six bolts then remove the recoil starter assembly Remove the two dowel pins INSTALLATION Install the dowel pins Recoil Starter Dowel Pins Dowel Pins The recoil st...

Page 644: ...19 STARTER SYSTEM 19 10 MXU 500 Install the recoil starter assembly Install and tighten the six bolts diagonally Recoil Starter...

Page 645: ...ssembly refer to the RECOIL STARTER REMOVAL INSPECTION INSTALLATION section in this chapter Remove the cap on the handle Replace the handle Cap Knot Knot Collar Handle Before untying the knot above th...

Page 646: ...RECOIL STARTER REMOVAL INSPECTION INSTALLATION section in this chapter Remove the handle refer to the RECOIL STARTER HANDLE REPLACE section in this chapter Untying the knot then turn the reel clockwi...

Page 647: ...ope and check that the ratchet is pushed out Inspect the rope reel and drive pawl for wear or damage Inspect the pawl spring for fatigue Coil Spring Reel Wear hand and eye protection when removing the...

Page 648: ...the rope through the reel and make a knot above the reel Coil Spring Reel Knot Rope Hook Coil Spring Wear hand and eye protection when installing the spring since the spring may quickly unwind and ca...

Page 649: ...he hook part of the reel turn the reel counterclockwise three or four times with the rope Coil Spring Reel Wear hand and eye protection when installing the reel since the spring may quickly unwind and...

Page 650: ...rn the reel clockwise with the rope slowly Apply molybdenum disulfide grease to the washer and friction plate Install the pawl spring friction plate washer Install and tighten the new bolt securely Ap...

Page 651: ...19 STARTER SYSTEM 19 17 MXU 500 Pull the rope and check that the ratchet is pushed out...

Page 652: ...bly refer to the RECOIL STARTER REMOVAL INSPECTION INSTALLATION section in this chapter Remove the starter pulley nut by using a suitable bar INSPECTION Inspect the starter pulley for cracks or pittin...

Page 653: ...9 STARTER SYSTEM 19 19 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...

Page 654: ...se cover refer to the ALTERNATOR STATOR REMOVAL INSPECTION INSTALLATION section in the chapter 17 Remove the flywheel driven gear by using the special tool Special tool Flywheel puller A120E00060 Remo...

Page 655: ...gear should not turn counterclockwise Remove the starter driven gear by turning the driven gear Check the starter driven gear teeth for wear or damage Measure the starter driven gear boss O D Service...

Page 656: ...gear Install the starter reduction gear to the right crankcase Install the woodruff key in the crankshaft key groove Apply molybdenum oil solution to the starter driven gear bushing Install the start...

Page 657: ...SYSTEM 19 23 MXU 500 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 Reduction Gear Dr...

Page 658: ..._________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS SWITHCES ________...

Page 659: ...g 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...

Page 660: ...a new one Install the bulb aligning the bulb socket groove with the bulb tab and set the lock clip Connect headlight wire connector Install the rubber boot Install the front fender in the reverse ord...

Page 661: ...the bulb Install the bulb in the reverse order of removal TURN SIGNAL LIGHT ON ROAD FRONT Remove the rubber boot from the turn signal light case Remove the bulb socket by turning it counterclockwise R...

Page 662: ...r of removal LICENCE LIGHT BULB ON ROAD Remove the two screws and licence light cover Remove the bulb Install the bulb in the reverse order of removal HORN ON ROAD REMOVAL Disconnect the horn wire lea...

Page 663: ...ame pipe Remove the meter cover refer to the FRAME COVER section in the chapter 2 Remove the ignition switch from the cover while pushing in the two stoppers Install a new ignition switch by aligning...

Page 664: ...20 LIGHTS SWITCHES 20 6 MXU 500 ON ROAD Start Switch Light Switch Horn Switch Winker Switch Hazard Switch 2WD 4WD Select Button...

Page 665: ...20 LIGHTS SWITCHES 20 7 MXU 500 OFF ROAD Engine Stop Switch Start Switch Dimmer Switch Passing Switch 2WD 4WD Select Button...

Page 666: ...r light switch connector Remove the bolt then remove the gear indicator light switch and washer Install the washer and a new switch with a new O ring apply engine oil to O ring Shift the drive select...

Page 667: ...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 If th...

Page 668: ...un Cont d Faulty 2WD 4WD motor Faulty 2WD 4WD change ECU Improper 2WD 4WD motor connector connection Faulty 2WD 4WD selecting button Faulty 2WD 4WD change ECU Turn on the ignition switch Listen for a...

Page 669: ...T DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 13 Connect the 12 V battery to the 2WD 4WD motor lead wires as shown If the motor does not run replace the motor assembly with a new one...

Page 670: ...the 2WD 4WD change ECU when the 2WD 4WD selecting button is pushed 2WD switch and 4WD switch Remove the 2WD 4WD motor refer to the FRONT DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 1...

Page 671: ...r 2 Remove the fuel unit connectors Remove the four bolts then remove the fuel unit from fuel tank INSPECTION Measure the resistance between the Yellow White and Blue White terminals of the fuel unit...

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...

Page 676: ...W B W R 1 R R W BR BR B B BR BR B BR L B 1 B 2 R R W Y B G SB O Y B G SB O W G R W W BR L R LG R W R 1 W B 2 W B 1 L G R W L B G L G W 2 G Y BR L G SB G SB B L 18 20 22 21 19 1 2 3 4 5 6 7 8 9 10 11...

Page 677: ...B 2 R R W Y B G SB O Y B G SB O W G R W W BR L R LG R W R 1 W B 2 W B 1 L G R W L B G L G W 2 G Y BR L G SB G SB B L 18 22 21 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 23 24 25 26 27 29 30 31 32 28 3...

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