KYMCO MXU 500i User Manual

KYMCO MXU 500i/700i Repair Manual
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KYMCO MXU 700i and MXU 500i Service Information
Models Covered:
2013 KYMCO MXU 700i
2013 KYMCO MXU 500i
Using this manual
This manual has been designed to assist trained mechanics in servicing the
models listed above. If you do not have the proper training or tools to perform a
particular task it is best if you seek out a service professional.

KYMCO MXU 500i Specifications

General

Brand	KYMCO
Model	MXU 500i
Category	Offroad Vehicle
Language	English

Summary

Quick Reference

Break In Procedure

Details the recommended procedure for breaking in a new KYMCO MXU 700i/500i.

Specifications

Torque Specifications

Provides essential torque specifications for various components of the MXU models.

Troubleshooting

Guides users through common troubleshooting steps for issues encountered with the ATVs.

Diagnostic Trouble Codes

Lists and explains diagnostic trouble codes (DTCs) for the KYMCO MXU 700i/500i.

Periodic Maintenance

Periodic Maintenance Chart

Outlines a schedule for routine maintenance tasks for the KYMCO MXU 700i/500i.

Compression Check

Engine Oil

Valve Clearance

Engine MXU700i

Engine Specifications

Camshaft Removal

Process for removing the camshaft.

Clutch

Details on clutch inspection, removal, and installation.

Crankcase Splitting

Instructions for splitting the engine crankcase.

Crankcase Assembly

Procedure for assembling the engine crankcase.

Transmission Assembly

Procedure for assembling the transmission.

Engine MXU 500i

Camshaft

Camshaft Installation

Procedure for installing the camshaft.

Cylinder Head

Details on cylinder head removal, inspection, and installation.

Valves

Servicing and adjustment of engine valves.

Cylinder and Piston

Procedure for cylinder and piston inspection and replacement.

Flywheel

Oil Pump

Cam Chain

Engine Removal

Step-by-step instructions for removing the engine.

Engine Installation

Procedure for reinstalling the engine.

Output Shaft

Crankcase

Details on the crankcase, including inspection and servicing.

Crankshaft

Procedure for inspecting and servicing the crankshaft.

Transmission Removal

Step-by-step guide for removing the transmission.

Transmission Shafts

Details on transmission shafts and their servicing.

Transmission Installation

Procedure for assembling the transmission.

Crankcase Bearings

Information on crankcase bearings and their replacement.

CVT Continuously Variable Transmission MXU500i

CVT Continuously Variable Transmission MXU700i

CVT Removal

Step-by-step instructions for removing the CVT unit.

CVT Installation

Procedure for installing the CVT unit.

Clutch Removal

Instructions for removing the CVT clutch assembly.

Clutch Installation

Procedure for installing the CVT clutch assembly.

Final Drive

Differential Removal

Procedure for removing the final drive differential.

Differential Installation

Procedure for installing the final drive differential.

Differential Disassembly

Instructions for disassembling the final drive differential.

Differential Assembly

Procedure for assembling the final drive differential.

Final Drive Gear Disassembly

Instructions for disassembling the final drive gear.

Final Drive Gear Assembly

Procedure for assembling the final drive gear.

Electrical Systems

Electrical Specifications

Battery

Charging System

Troubleshooting and testing of the charging system.

Ignition System

Starter Motor

Starting System

Troubleshooting and servicing of the starting system.

Wiring Diagrams

Presents wiring diagrams for electrical system troubleshooting.