KYMCO MXU 450i, Service Manual

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7-3
7
KC297
8. Remove the lower shock absorber eyelet from the
upper A-arm.
9. Remove the cap screws securing the A-arms to the
frame.
10. Remove the circlip from the ball joint; then
remove the ball joint from the A-arm.
CLEANING AND INSPECTING
„
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
1. Clean all A-arm components using a pressure
washer.
2. Clean the ball joint mounting hole of all residual
Loctite, grease, oil, or dirt for installing purposes.
3. Inspect the A-arm for bends, cracks, and worn
bushings.
4. Inspect the ball joint mounting holes for cracks or
damage.
5. Inspect the frame mounts for signs of damage,
wear, or weldment damage.
INSTALLING
1. Apply green Loctite #609 to the entire outside
diameter of the ball joint; then install the ball joint
into the A-arm and secure with the circlip.
2. Install the A-arm assemblies into the frame
mounts and secure with the cap screws. Only fin-
ger-tighten at this time.
3. Secure the lower eyelet of the shock absorber to
the upper A-arm. Tighten nut to 35 ft-lb.
4. Secure the A-arm assemblies to the frame mounts
(from step 2). Tighten the cap screws to 35 ft-lb.
5. Install the knuckle assembly onto the ball joints
and secure with cap screws. Tighten to 35 ft-lb.
6. Apply grease to the hub and drive axle splines;
then install the hub assembly onto the drive axle.
7. Secure the hub assembly with the nut. Tighten
only until snug.
8. Secure the brake caliper to the knuckle with the
two patch-lock cap screws. Tighten to 20 ft-lb.
9. Secure the hub nut (from step 7) to the shaft/axle.
Tighten to 200 ft-lb.
10. Install a new cotter pin and spread the pin to
secure the nut.
11. Install the wheel and tighten to 40 ft-lb.
12. Remove the ATV from the support stand.
Rear A-Arms
REMOVING
1. Secure the ATV on a support stand to elevate the
wheels
.
2. Pump up the hand brake; then engage the brake
lever lock.
3. Remove the wheel.
4. Remove the cotter pin securing the hex nut; then
remove the hex nut. Release the brake lever lock.
5. Remove the caliper (right side only).
„
NOTE: Do not allow the brake caliper to hang
from the hose.
6. Remove the cap screws and lock nut securing the
shock absorber to the frame and lower A-arm; then
remove the shock absorber.
! CAUTION
Do not tighten the nut beyond the 35 ft-lb specifica-
tion or the shock eyelet or mount WILL be damaged.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.