KYMCO MXU 500i - User Manual

This document is a repair manual for the KYMCO MXU 500i and MXU 700i All-Terrain Vehicles (ATVs), specifically covering the 2013 models. It is designed to assist trained mechanics in performing service and repair tasks on these vehicles. The manual emphasizes that proper training and tools are essential, and inexperienced technicians should seek professional help to avoid serious injury or damage.

The manual is structured into several chapters, each focusing on a specific system or set of components of the ATV.

Quick Reference

This chapter provides a concise overview of technical specifications and essential information.

Break-In Procedure: Details the recommended steps for the initial operation of a new or overhauled vehicle to ensure proper component seating and longevity.
General Information: Covers fundamental aspects of the ATV, likely including general safety guidelines, identification numbers, and basic operational principles.
VIN and Warning Stickers: Explains the location and meaning of the Vehicle Identification Number (VIN) and various warning labels, which are crucial for safety and identification.
Special Tools: Lists and describes any specialized tools required for specific repair or maintenance procedures, highlighting the need for appropriate equipment.
Specifications: Provides detailed technical data for various components, such as dimensions, weights, fluid capacities, and performance parameters.
Torque Specifications: Offers precise torque values for fasteners throughout the ATV, ensuring components are tightened correctly to prevent loosening or damage.
Troubleshooting: Presents a guide to diagnose common issues, outlining symptoms and potential causes to help mechanics identify problems efficiently.
Diagnostic Trouble Codes: Explains the meaning of specific diagnostic codes generated by the vehicle's electronic control unit (ECU), aiding in the diagnosis of electronic system malfunctions.

Periodic Maintenance

This chapter outlines routine maintenance procedures essential for reliable operation and extended service life.

Periodic Maintenance Chart: A schedule detailing recommended inspection and service intervals for various components.
Air Filter Servicing: Instructions for inspecting, cleaning, or replacing the air filter to ensure proper engine breathing and prevent contamination.
Brake Fluid: Procedures for checking brake fluid levels, inspecting its condition, and replacing it as needed to maintain braking performance.
Brake Inspection: Guidelines for inspecting brake pads, discs, calipers, and lines for wear, damage, or leaks.
Compression Check: Steps to measure engine compression, which helps assess engine health and identify potential issues like worn piston rings or valve problems.
Engine Idle Speed: Instructions for checking and adjusting the engine's idle speed to ensure smooth operation.
Engine Oil: Procedures for checking engine oil levels, changing the oil, and replacing the oil filter.
Final Drive / Differential Oil: Maintenance steps for the final drive and differential oils, including checking levels and replacement.
Spark Arrestor: Instructions for cleaning or inspecting the spark arrestor in the exhaust system, important for fire prevention.
Spark Plug: Procedures for inspecting, cleaning, and replacing spark plugs to ensure efficient ignition.
Throttle Free Play: Steps to check and adjust the throttle cable free play for proper throttle response.
Tires: Guidelines for inspecting tire pressure, tread wear, and overall condition.
Suspension and Steering: Maintenance and inspection procedures for suspension components (shocks, A-arms) and steering linkages (tie-rods, knuckles).
Valve Clearance: Instructions for checking and adjusting valve clearances, crucial for optimal engine performance and longevity.

Fuel System

This chapter details the components and servicing of the fuel system.

Airbox: Covers the airbox assembly, which houses the air filter and directs air to the engine.
Check Engine Lamp (CELP): Explains the function of the Check Engine Lamp and how to interpret its signals.
Component Location: Provides diagrams and descriptions of where various fuel system components are located.
Diagnostic Tool: Describes the use of diagnostic tools for interfacing with the ECU and retrieving fuel system data.
Fuel Injection Sensors: Covers the inspection and testing of various sensors critical to the fuel injection system, such as throttle position sensor, manifold absolute pressure sensor, etc.
Fuel Injector: Procedures for inspecting, cleaning, or replacing fuel injectors.
Fuel Pump: Details the fuel pump assembly, including removal, inspection, and installation.
Throttle Body Removal: Steps for safely removing the throttle body from the engine.
Throttle Body Components: Describes the individual components of the throttle body and their functions.

External Components

This chapter focuses on the removal, installation, and servicing of the ATV's exterior parts.

Drive Selector: Covers the mechanism for selecting drive modes (e.g., 2WD, 4WD).
Exhaust System: Procedures for inspecting, removing, and installing exhaust components.
Front Bumper: Instructions for removing and installing the front bumper.
Front Cover: Details the front plastic covers and their removal/installation.
Front Fender: Procedures for servicing the front fenders.
Fuel Tank: Covers the fuel tank, including removal, inspection, and installation.
Instrument Cover: Instructions for accessing and servicing the instrument panel.
Mudguards and Footrests: Details the maintenance of mudguards and footrests.
Lights: Procedures for inspecting, replacing, and adjusting various lights (headlights, taillights, turn signals).
Racks: Covers the front and rear cargo racks, including removal and installation.
Rear Fender: Procedures for servicing the rear fenders.
Seat: Instructions for removing and installing the seat.
Side Covers: Details the side plastic covers and their removal/installation.
Skid Plate: Covers the skid plate, which protects the underside of the ATV.

Engine MXU700i / 5. Engine MXU 500i

These chapters provide detailed information on the engine components, with separate sections for the 700i and 500i models due to potential differences.

Engine Specifications: Specific technical data for each engine model.
Engine Removal/Installation: Comprehensive steps for safely removing and installing the engine.
Rocker Cover: Procedures for removing and installing the rocker cover.
Camshaft Removal/Installation: Detailed steps for servicing the camshaft.
Cylinder Head: Covers the cylinder head assembly, including disassembly, inspection, and reassembly.
Valves: Procedures for inspecting, removing, and installing valves.
Cam Chain: Details the cam chain and its tensioner, including inspection and replacement.
Cylinder and Piston: Covers the cylinder barrel and piston assembly, including inspection for wear and replacement.
Generator Cover: Procedures for removing and installing the generator cover.
Flywheel: Details the flywheel, including removal and installation.
Clutch: Covers the clutch assembly, including disassembly, inspection, and reassembly.
Oil Pump: Procedures for servicing the oil pump.
Crankcase Splitting/Assembly: Detailed steps for separating and reassembling the crankcase halves.
Crankcase Bearings: Covers the inspection and replacement of crankcase bearings.
Crankshaft: Procedures for inspecting and servicing the crankshaft.
Transmission Removal/Installation: Steps for removing and installing the transmission.
Transmission Shafts: Details the individual shafts within the transmission.
Output Shaft: Covers the output shaft assembly.
Recoil Starter Cover (MXU 500i): Specific to the 500i, covers the recoil starter mechanism.

Cooling System

This chapter covers the components responsible for engine cooling.

Coolant: Procedures for checking coolant levels, draining, and refilling the cooling system.
Pressure Testing: Instructions for pressure testing the cooling system to detect leaks.
Radiator: Covers the radiator, including removal, inspection, and installation.
Thermostat: Procedures for inspecting and replacing the thermostat.
Water Pump: Details the water pump assembly, including removal, inspection, and installation.

CVT Continuously Variable Transmission MXU500i / MXU700i

These chapters provide specific information for the Continuously Variable Transmission (CVT) for both models.

CVT Cooling Ducts: Covers the ducts that provide cooling air to the CVT.
Belt Case Cover: Procedures for removing and installing the CVT belt case cover.
CVT Removal/Installation: Detailed steps for removing and installing the entire CVT assembly.
Clutch Removal/Installation: Procedures for servicing the CVT clutch components.

Final Drive

This chapter covers the final drive components common to both MXU 700i and MXU 500i models.

Drive Shafts: Procedures for inspecting, removing, and installing drive shafts.
Differential Removal/Installation: Steps for removing and installing the differential unit.
Differential Disassembly/Assembly: Detailed instructions for disassembling and reassembling the differential.
Rear Final Drive Gear: Covers the rear final drive gear assembly.
Final Drive Gear Disassembly/Assembly: Procedures for servicing the final drive gears.

Brake System

This chapter details the braking components for both models.

Brake Discs: Procedures for inspecting and replacing brake discs.
Brake Pedal: Covers the brake pedal assembly and its adjustment.
Front Brake Calipers: Procedures for servicing the front brake calipers, including pad replacement and bleeding.
Rear Brake Calipers: Procedures for servicing the rear brake calipers.
Master Cylinders: Covers the brake master cylinders, including inspection and rebuilding.

Wheels

This chapter focuses on the wheel components.

Wheels: Procedures for removing, installing, and inspecting wheels.
Wheel Bearings: Instructions for inspecting and replacing wheel bearings.

Steering

This chapter covers the steering components.

Handlebar: Procedures for removing and installing the handlebar.
Steering Knuckles: Covers the steering knuckles and their bearings.
Steering Shaft: Procedures for inspecting and servicing the steering shaft.
Tie-Rods: Instructions for inspecting and replacing tie-rods.

Front Suspension

This chapter details the front suspension components.

A-arms: Procedures for inspecting, removing, and installing A-arms.
Front Shock Absorbers: Instructions for inspecting and servicing front shock absorbers.

Rear Suspension

This chapter covers the rear suspension components.

Shock Absorbers: Procedures for inspecting and servicing rear shock absorbers.
Suspension Arms: Instructions for inspecting, removing, and installing rear suspension arms.

Electrical Systems

This chapter provides comprehensive information on the ATV's electrical systems.

Electrical Specifications: Detailed electrical data, including voltage, current, and resistance values.
Battery: Procedures for inspecting, testing, charging, and replacing the battery.
Charging System: Covers the alternator, rectifier/regulator, and wiring, including testing procedures.
Fuses: Location and replacement of fuses.
Ignition System: Details the ignition coil, spark plug, and associated wiring, including testing procedures.
Lights: Wiring and troubleshooting for all lighting components.
Starter Motor: Procedures for inspecting, removing, and installing the starter motor.
Starting System: Covers the entire starting circuit, including the starter relay and switches.
Switches: Testing and replacement of various electrical switches.
Wiring Diagrams: Comprehensive wiring schematics to aid in electrical troubleshooting.

Usage Features:

The manual is designed for ease of use by trained mechanics. It includes:

Illustrations: Visual aids to help understand procedures, even if the exact vehicle model shown differs slightly.
Cross-referencing: Topics explained in greater detail are referenced and linked, allowing for easy navigation.
Clickable Thumbnails: Many images can be enlarged for better detail.
Step-by-step procedures: Instructions are broken down into manageable steps.
Safety warnings: Emphasizes caution for the vehicle and operator to prevent injury.

Maintenance Features:

The manual provides comprehensive guidance for maintaining the KYMCO MXU 500i and 700i ATVs, including:

Preventive Maintenance: Detailed schedules and procedures to ensure reliable vehicle operation and a longer service life, reducing the need for costly overhauls.
Diagnostic Information: Tools and codes to help identify and resolve issues efficiently.
Component-specific guides: Each major system and component has its own dedicated section with detailed servicing instructions.
Specifications and Torque Values: Essential data for correct assembly and adjustment.

The manual serves as a critical resource for anyone performing service on these KYMCO ATV models, ensuring that repairs are conducted safely and effectively according to manufacturer guidelines.