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KYMCO MXU400 User Manual

KYMCO MXU400
158 pages
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FOREWORD
This
KYMCO
Service
Manual
contains
service,
maintenance,
and
troubleshoo
tin
g
information
for
th
e
2008
KYMCO MXU400
ATV.
The
compl
ete
manual
is
des
i
gned
to
aid
service
personnel
in
service-oriented
applicat
ions.
This manual is divided into sections. Each section covers a specific ATV component or system and,
in addition to the standard service procedures, includes disassembling, inspecting, and assembling
instructions. When using this manual as a guide, the technician should use discretion as to how
much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each
component or system KYMCO. This manual will assist the service technician in becoming more
aware of and efficient with servicing procedures. Such efficiency not only helps build consumer
confidence but also saves time and labor.
All KYMCO ATV publications and decals display the words Warning, Caution, Note, and At This
Point to emphasize important information.
The symbol identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even
death. The symbol identifies unsafe practices which may result in ATV-related
damage. Follow the directive because it deals with the possibility of damaging part or parts of the
ATV. The symbol   NOTE: identifies supplementary information worthy of particular attention. The
symbol AT THIS POINT directs the tech- nician to certain and specific procedures to promote
efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct.
Some photographs used in this manual are used for clarity purposes only and are not designed to
depict actual conditions. Because KYMCO Inc. constantly refines and improves its products, no
retroactive obligation is incurred.
All materials and specifications are subject to change without notice. Keep this manual accessible
in the shop area for reference.
Overseas Service D
e
pa
r
tm
e
nt
KYMCO
Inc.
©
2008
KYMCO
Inc.
March
2008
®™
Trademarks
of
KYMCO
Inc.,
Taiwan

Table of Contents

Questions and Answers:

KYMCO MXU400 Specifications

General IconGeneral
BrandKYMCO
ModelMXU400
CategoryOffroad Vehicle
LanguageEnglish

Summary

Foreword

Section 1 - General Information/Specifications

General Specifications

Details chassis and general specifications for the ATV.

Torque Specifications

Provides torque values for various components.

Break-In Procedure

Outlines the recommended break-in process for the ATV.

Gasoline - Oil - Lubricant

Details recommended fluids and fuel.

Preparation For Storage

Steps for preparing the ATV for storage.

Preparation After Storage

Steps for retrieving ATV from storage.

Section 2 - Periodic Maintenance

Periodic Maintenance Chart

Schedule for routine maintenance tasks.

Battery Maintenance

Maintenance procedures for the ATV battery.

Fuses

Location and replacement of fuses.

Air Filter Cleaning and Inspection

Cleaning and inspection of the air filter.

Valve/Tappet Clearance

Checking valve clearance using a feeler gauge or adjuster.

Testing Engine Compression

Procedure for testing engine compression.

Spark Plug Inspection

Inspection and replacement of the spark plug.

Muffler/Spark Arrester Cleaning

Cleaning the spark arrester.

Adjusting Throttle Cable

Procedure for adjusting throttle cable free-play.

Engine/Transmission Oil Change

Procedures for changing engine oil and filter.

Front/Rear Differential Lubricant Change

Changing differential and drive lubricants.

Tires Inspection

Tire inspection and maintenance.

Steering Components Inspection

Inspection of steering system parts.

Suspension Components Inspection

Inspection of suspension components.

Hydraulic Brake Systems

Checking and bleeding brake systems.

Checking/Replacing V-Belt

Inspection and replacement of the V-belt.

Section 3 - Engine/Transmission

Engine/Transmission Specifications

Technical specifications for engine/transmission.

Engine/Transmission Troubleshooting

Common engine/transmission problems and remedies.

Removing Engine/Transmission

Top-Side Components

Procedures for servicing top engine components.

Left-Side Components

Procedures for servicing left engine components.

Right-Side Components

Procedures for servicing right engine components.

Center Crankcase Components

Procedures for servicing center crankcase.

Top-Side Components Servicing

Removing Top-Side Components

Steps to remove top engine parts.

Valve Cover/Rocker Arms Servicing

Servicing valve cover and rocker arms.

Cylinder Head/Camshaft Servicing

Servicing cylinder head and camshaft.

Cylinder Servicing

Servicing the cylinder.

Piston Servicing

Servicing the piston.

Left-Side Components Servicing

Removing Left-Side Components

Steps to remove left engine components.

Cover/Stator Assembly Servicing

Servicing the cover and stator assembly.

Rotor/Flywheel Servicing

Servicing the rotor and flywheel.

Starter Motor Servicing

Servicing the starter motor.

Right-Side Components Servicing

Removing Right-Side Components

Steps to remove right engine components.

V-Belt Cover Servicing

Servicing the V-belt cover.

Driven Pulley Servicing

Servicing the driven pulley.

Clutch Cover Servicing

Servicing the clutch cover.

Center Crankcase Components Servicing

Separating Crankcase Halves

Procedure for separating crankcase halves.

Disassembling Crankcase Half

Disassembling a crankcase half.

Servicing Center Crankcase Components

Checking Gear Backlash

Checking gear backlash.

Correcting Gear Backlash

Correcting gear backlash.

Checking Gear Tooth Contact

Checking gear tooth contact.

Joining Crankcase Halves

Installing Engine/Transmission

Section 4 - Fuel/Lubrication/Cooling

Carburetor Specifications

Specifications for the carburetor.

Carburetor Servicing

Cleaning, inspecting, and assembling the carburetor.

Gas Tank Servicing

Servicing the gas tank.

Section 5 - Electrical System

Battery Maintenance

Battery information and maintenance.

Fuses Testing

Testing and replacing fuses.

Ignition Coil Testing

Testing the ignition coil.

Speed Sensor Testing

Testing the speed sensor.

Ignition Switch Testing

Testing the ignition switch.

Handlebar Control Switches Testing

Testing handlebar control switches.

Front Drive Selector Switch Testing

Testing the front drive selector switch.

Front Drive Selector Actuator Testing

Testing the front drive actuator.

Gear Shift Position Switch Testing

Testing the gear shift position switch.

Stator Coil Testing

Testing the stator coil.

Starter Relay Testing

Testing the starter relay.

Starter Motor Testing

Testing the starter motor.

Regulator/Rectifier Testing

Testing the regulator/rectifier.

Headlights Testing

Testing headlights.

Taillights - Brakelights Testing

Testing taillights and brakelights.

Running Lights Testing

Testing running lights.

Back-Up Lights Testing

Testing back-up lights.

Electrical System Troubleshooting

Troubleshooting electrical system issues.

Section 6 - Drive System

Front Drive Actuator Servicing

Servicing the front drive actuator.

Front Differential Servicing

Servicing the front differential.

Drive Axles Servicing

Servicing the drive axles.

Hub Servicing

Servicing the hub.

Hydraulic Brake Caliper Servicing

Servicing the hydraulic brake caliper.

Troubleshooting Drive System

Common drive system problems and remedies.

Troubleshooting Brake System

Common brake system problems and remedies.

Drive Axles Servicing

Removing Rear Drive Axles

Steps to remove rear drive axles.

Installing Rear Drive Axle

Steps to install rear drive axle.

Installing Front Drive Axle

Steps to install front drive axle.

Hub Servicing

Hub Removing

Steps to remove the hub.

Hub Cleaning and Inspecting

Cleaning and inspecting hub components.

Hub Installing

Steps to install the hub.

Hydraulic Brake Caliper Servicing

Caliper Removing/Disassembling

Steps to remove and disassemble caliper.

Caliper Cleaning and Inspecting

Cleaning and inspecting caliper components.

Caliper Assembling/Installing

Assembling and installing the caliper.

Section 7 - Suspension

Shock Absorbers Servicing

Servicing shock absorbers.

Front A-Arms Servicing

Servicing front A-arms.

Rear A-Arms Servicing

Servicing rear A-arms.

Wheels and Tires Servicing

Servicing wheels and tires.

Suspension Troubleshooting

Troubleshooting suspension issues.

Tire Inflation Pressure

Wheel Removing

Steps to remove wheels.

Wheel/Tire Cleaning and Inspecting

Cleaning and inspecting wheels and tires.

Wheel Installing

Steps to install wheels.

Tire Checking/Inflating

Checking and inflating tires.

Section 8 - Steering/Frame

Steering Post/Tie Rods Servicing

Servicing steering post and tie rods.

Handlebar Grip Servicing

Servicing handlebar grips.

Steering Knuckles Servicing

Servicing steering knuckles.

Measuring/Adjusting Toe-In

Measuring and adjusting front wheel toe-in.

Front Rack Servicing

Servicing the front rack.

Front Bumper Assembly Servicing

Servicing the front bumper assembly.

Front Body Panel/Fender Servicing

Servicing front body panels and fenders.

Exhaust System Servicing

Servicing the exhaust system.

Rear Body Panel/Rack Servicing

Servicing rear body panels and racks.

Steering/Frame Troubleshooting

Troubleshooting steering and frame issues.

Hand Brake Lever/Master Cylinder Assembly Servicing

REMOVING

Steps to remove brake lever/master cylinder.

INSPECTING

Inspecting brake lever/master cylinder parts.

INSTALLING

Steps to install brake lever/master cylinder.

Throttle Control Servicing

REMOVING

Steps to remove throttle control.

INSTALLING

Steps to install throttle control.

ADJUSTING

Adjusting throttle cable free-play.

LCD Gauge Replacement

REPLACING

Procedure for replacing the LCD gauge.

INSTALLING

Steps to install the new LCD gauge.

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