KYMCO MXU 500 IRS Manual Download Page 3

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. GENERAL INFORMATION

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MXU 500 IRS

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GENERAL INFORMATION

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SERIAL NUMBER---------------------------------------------------------- 1- 1

SPECIFICATIONS ---------------------------------------------------------- 1- 2

SERVICE PRECAUTIONS ------------------------------------------------ 1- 3

TORQUE VALUES --------------------------------------------------------- 1-11

SPECIAL TOOLS ----------------------------------------------------------- 1-15

LUBRICATION POINTS -------------------------------------------------- 1-19

Summary of Contents for MXU 500 IRS

Page 1: ...IRS By KWANG YANG Motor Co Ltd First Edition Dec 2008 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T100 LA...

Page 2: ...with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD Quality Technology Division Education...

Page 3: ..._______________________________________________ __________________________________________________________________________________ _____________________________________________________________________...

Page 4: ...1 GENERAL INFORMATION 1 1 MXU 500 IRS SERIAL NUMBER 1 Location of Engine Serial Number 1 Location of Frame Serial Number...

Page 5: ...Idle speed rpm 1500 100rpm 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 Oil exchanging capacity 3...

Page 6: ...ghtening 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...

Page 7: ...he 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 connecti...

Page 8: ...pecified 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 conn...

Page 9: ...ged 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 m...

Page 10: ...make 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...

Page 11: ...ontact 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 sh...

Page 12: ...re 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 instructio...

Page 13: ...mbols 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 Trans...

Page 14: ...1 GENERAL INFORMATION 1 11 MXU 500 IRS TORQUE VALUES ENGINE...

Page 15: ...1 GENERAL INFORMATION 1 12 MXU 500 IRS...

Page 16: ...1 GENERAL INFORMATION 1 13 MXU 500 IRS FRAME Cont d...

Page 17: ...1 GENERAL INFORMATION 1 14 MXU 500 IRS...

Page 18: ...0E00036 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 DRIV...

Page 19: ...Y INSPECTION ASSEMBLY section in the chapter 10 A120E00059 Flywheel puller Refer to the STARTER CLUTCH REMOVAL INSPECTION INSTALLATION section in the chapter 19 A120E00060 Oil filter cartridge wrench...

Page 20: ...he 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 INSPECT...

Page 21: ...puller Refer to the REAR DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 13 A120F00021 C ring remover Refer to the FRONT DRIVE DISASSEMBLY INSPECTION ASSEMBLY section in the chapter 13 A...

Page 22: ...Cylinder 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 re...

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