KYMCO MXU 500 User manual

MXU 500
By KWANG YANG Motor Co., Ltd.
First Edition, May 2006
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100LAA001

MXU 500
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the MXU 500.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which are
subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 4 through 12 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 13 through 16 is
the removal/ installation of chassis.
Section 17 through 21 states the testing
and measuring methods of electrical
equipment.
Most sections start 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.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
FRAME COVERS /EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
COOLING SYSTEM 6
ENGINE REMOVAL 7
CYLINDER HEAD/VALVES 8
CYLINDER/PISTON 9
DRIVE PULLEY/DRIVEN PULLEY/
CLUTCH 10
FINAL REDUCTION/
TRANSMISSION SYSTEM 11
LEFT CRANKCASE/CRANKSHAFT/
BALANCE SHAFT 12
DRIVE TRAIN 13
FRONT WHEEL/FRONT SUSPENSION
/
STTEERING SYSTEM 14
REAR WHEEL/AXLE/SHOCK
ABSORBER/SWING ARM 15
BRAKE SYSTEM 16
BATTERY/CHARGING SYSTEM 17
IGNITION SYSTEM 18
STARTER SYSTEM 19
LIGHTS/ SWITCHES 20
WIRING DIAGRAMS 21
The information and contents included in
this manual may be different from the
vehicle in case specifications are changed.
KYMCO reserves the right to make
changes at any time without notice and
without incurring any obligation.
CHASSIS
ELECTRICAL
E
Q
UIPMENT
ENGINE

1. GENERAL INFORMATION
1-0
MXU500
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER---------------------------------------------------------- 1- 1
SPECIFICATIONS ---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS ------------------------------------------------ 1- 3
TORQUE VALUES --------------------------------------------------------- 1-11
SPECIAL TOOLS ----------------------------------------------------------- 1-15
LUBRICATION POINTS -------------------------------------------------- 1-19
CABLE & HARNESS ROUTING ---------------------------------------- 1-21
TROUBLESHOOTING----------------------------------------------------- 1-35
1

1. GENERAL INFORMATION
1-1
MXU500
SERIAL NUMBER
(1) Location of Engine Serial Numbe
r
(1) Location of Frame Serial Numbe
r

1. GENERAL INFORMATION
1-2
MXU500
SPECIFICATIONS
Model No. LAA0
Name & Type MXU 500
Overall length 2203 mm (88.12 in)
Overall width 1223 mm (48.92 in)
Overall height 1240 mm (49.6 in)
Wheel base 1293 mm (51.72 in)
Engine type O.H.C.
Displacement 498.5 cm3
(30.48 cu-in)
Fuel used 92# nonleaded gasoline
Front wheel 154 kg (338.8 lbs)
Rear wheel 134 kg (294.8 lbs)
Dry weight
Total 288 kg (633.6 lbs)
Front wheel 164 kg (360.8 lbs)
Rear wheel 144 kg (316.8 lbs)
Curb weight
Total 308 kg (648 lbs)
Front wheel 25X8-12
Tires Rear wheel 25X10-12
Ground clearance 235 mm (9.4 in)
Min. turning radius 3350 mm (134 in)
Starting system Electric/Recoil
starter
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke 92X75 mm
(3.68X3 in)
Compression ratio 10.5:1
Compression pressure 15 kgf/cm²
(1500kPa, 213 psi)
Opens 5°BTDCIntake valve
(at 1mm lift) Closes 45°ABDC
Opens 45°BBDCExhaust valve
(at 1mm lift) Closes 5°ATDC
Intake 0.1 mm (0.004 in)Valve clearance
(cold) Exhaust 0.1 mm (0.004 in)
Idle speed (rpm) 1500 rpm
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 (3.17 lmp qt,
3.82 Us qt)
Oil exchanging capacity 3 L (2.64 lmp qt,
3.18 Us qt)
After draining and oil
filter cartridge change
3.2 L (2.82 lmp qt,
3.39 Us qt)
Air cleaner type & No Wet type element
Fuel capacity 17 L (3.57 lmp gal,
4.42USgal
Type CVK
ON ROAD #128Main
jet OFF ROAD #130
Slow jet #40
Choke jet #90
Type Full transistor digital
ignition
Ignition timing 5°/1500 rpm
Spark plug CR7E (NGK)
Spark plug gap 0.6～0.7mm
(0.024～0.028 in)
Battery Capacity 12V18AH
Clutch type Wet, centrifugal
automatic
Clutch operation system Automatic (V-belt)
Primary reduction system V-belt
Secondary reduction
system Shaft drive
High reduction ratio 3.76
Low reduction ratio 6.464
Reverse ratio 5.31
FR/RR tire rolling
circumference
1995/1995 mm
(79.8/79.8 in)
Front
Tire pressure
Rear
0.28 kg/cm²
(28 Kpa, 3.2 psi)
Left 36°
Turning angle
Right 36°
Front Disk brake
Brake system type Rear Disk brake
Front Double wishbone
Suspension type Rear Link suspension
Frame type Double cradle
Engine
I
g
nition S
y
stem
Drive Train Moving Device
Lubrication System Fuel S
y
stem
Carbureto
r
Electrical Equipment

1. GENERAL INFORMATION
1-3
MXU500
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when reassembling.
When tightening 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 to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-4
MXU500
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the 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 connecting points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive (+)
terminal must be connected first.
After connection, apply grease to the battery
terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-5
MXU500
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified 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 connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confir
m
Capacity

1. GENERAL INFORMATION
1-6
MXU500
The connector shall be inserted
completely.
If the double connector has a lock, lock it
at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged 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 make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the designated
locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!

1. GENERAL INFORMATION
1-7
MXU500
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or its
clamp.
After clamping, check each harness to 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 edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !

1. GENERAL INFORMATION
1-8
MXU500
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with electrical
tape or tube if they contact 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 sheath,
repair by wrapping it with protective tape or
replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight!
Do not press or
squeeze the wire.

1. GENERAL INFORMATION
1-9
MXU500
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere 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 instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do you understand
the instrument? Is the
instrument set
correctly?
Remove Rust !

1. GENERAL INFORMATION
1-10
MXU500
Symbols:
The following symbols 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.
: Transmission Gear Oil (90#)
: Caution
: Warning
En
g
ine Oil
Grease
Gear Oil

1. GENERAL INFORMATION
1-11
MXU500
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque
kgf-m (N-m, lbf-ft) Item Torque kgf-m (N-m, lbf-ft)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
0.5 (5, 3.6)
1 (10, 7.2)
2.2 (22, 16)
3.5 (35, 25)
5.5 (55, 40)
7 (70, 50)
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
0.3 (3, 2.2)
0.4 (4, 2.9)
0.9 (9, 6.5)
1.2 (12, 9)
2.7 (27, 20)
4 (40, 29)
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.
(mm)
Torque
kgf-m (N-m, lbf-ft) Remarks
MAINTENANCE:
Spark plug
Tappet ADJ nut
Engine oil filter cap
Engine oil filter cartridge
Engine drain plug
LUBRICATION SYSTEM:
Oil pump screw
Oil pipe bolt
COOLING SYSTEM:
Water pump bolt
Fan motor bolt
Fan motor switch
1
4
1
1
1
1
2
2
4
1
10
5
30
20
12
4
16
6
5
16
1.2 (12, 8.6)
0.9 (9, 6.5)
1.5 (15, 11)
1 (10, 7.2)
2.5 (25, 18)
0.3 (3, 2)
3.5 (35, 25.2)
1.3 (13, 9)
0.53 (5, 2.8)
1.8 (17, 13)
Apply oil
Apply oil
Apply oil
(Cont’d)

1. GENERAL INFORMATION
1-12
MXU500
Item Q‘ty Thread dia.
(mm)
Torque
kgf-m (N-m, lbf-ft) Remarks
CYLINDER HEAD:
Cylinder head bolt
Cylinder head bolt
Cylinder head nut
Cylinder head cover
Breather separator bolt
Cam chain tensioner bolt
Tensioner sealing bolt
Rocker arm shaft
Chain guide pivot bolt
Water joint bolt
CYLINDER:
Cylinder bolt
DRIVE/DRIVEN PULLEY:
Drive pulley nut
Wet clutch nut
Driven pulley nut
Driven pulley assembly plate nut
TRANSMISSION:
Crankcase bolt
Drive bevel gear nut
Driven bevel gear nut
Stopper lever bolt
Stopper lever boss nut
Shift came stopper plug
Output shaft bearing nut
Drive shaft bearing bolt
STARTER SYSTEM:
Starter pulley nut
4
9
2
4
3
2
1
2
2
2
2
1
1
1
1
19
1
1
1
1
1
1
4
1
10
8
6
6
6
6
10
18
8
6
6
20
25
16
36
6
20
20
8
12
20
85
8
14
4.8 (48, 34.6)
2.3 (23, 17)
1 (10, 7)
1 (10, 7)
1.3 (13, 9)
1.2 (12, 8.6)
1 (10, 7)
4.5 (45, 32.4)
2 (20, 15)
1.2 (12, 8.6)
1 (10, 7.2)
14 (140, 100.8)
14 (140, 100.8)
10 (100, 72)
7.5 (75, 54)
1.2 (12, 8.6)
14 (140, 100.8)
14 (140, 100.8)
2.5 (25, 18)
3 (30, 21.6))
4.8 (48, 35)
11 (110, 79.2)
3 (30, 21.6)
5.5 (55, 40)
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil

1. GENERAL INFORMATION
1-13
MXU500
FRAME
Item Q‘ty Thread
dia.
(mm)
Torque
K
g
f-
m
(
N-m,
lbf-ft)
Remarks
MAINTENANCE:
Rear drive gear oil drain bolt
Rear drive gear oil filler cap
Rear drive gear oil level check bolt
Front drive gear oil drain bolt
Front drive gear oil filler cap
Front drive gear oil level check bolt
Tie-rod adjusting nut
Front wheel hub nut
Rear wheel hub nut
EXHAUST MUFFLER:
Exhaust muffler mounting bolt
Exhaust pipe mounting nut
Exhaust muffler band bolt
ENGINE ASSEMBLY:
Engine mounting bolt/nut
Engine hanger nut
DRIVE TRAIN:
Front drive:
Front propeller shaft bolt
Front drive gear case mounting bolt
Shifting fork shaft plug
Front drive gear case bolt
2WD/4WD shift motor mounting bolt
2WD/4WD shift motor mounting bolt
Rear drive:
Rear drive gear case mounting nut
Rear drive gear case bolt
Rear drive gear case bolt
1
1
1
1
1
1
4
2
2
2
2
1
3
4
3
2
1
9
1
2
8
2
6
8
30
8
14
18
6
10
18
16
8
8
8
10
8
10
10
8
8
8
6
10
10
8
2 (20, 15)
1.5 (15, 11)
2 (20, 15)
3.2 (32, 23)
3.5 (35 25.5)
1 (10, 7.2)
3.5 (35 25.5)
7 (70, 50)
10 (100, 72)
3.5 (35, 25)
3.5 (35, 25)
2.1 (21, 15)
6 (60, 43.5)
3.5 (35, 25)
4.5 (45, 32.4)
4 (40, 29)
1.5 (15, 11)
2.3 (23, 16.5)
2.3 (23, 16.5)
1.2 (12, 8.5)
5.5 (55, 40)
5 (49, 36)
2.5 (25, 19)
Castle nut
Castle nut
Apply threebond: 1215
Apply threebond: 1215
Apply threebond: 1215
Apply threebond: 1215
Apply threebond: 1215
(Cont’d)

1. GENERAL INFORMATION
1-14
MXU500
Item Q‘ty Thread
dia.
(mm)
Torque
K
g
f-
m
(
N-m,
lbf-ft)
Remarks
STEERING SYSTEM:
Handlebar holder bolt
Steering bracket
Steering column nut
Tie-rod ball joint nut
WHEEL:
Front wheel nut
Rear wheel nut
SUSPENSION:
Front:
Front swing arm bolt/nut
Knuckle ball joint nut
Front shock absorber mount bolt/nut
Rear:
Rear shock absorber mount bolt/nut
Right pivot bolt
Left pivot bolt
Left pivot lock nut
Axle housing mounting bolt/nut
BRAKE SYSTEM:
Front brake disc bolt
Rear brake disc bolt
Brake caliper mounting bolt
Brake hose oil bolt
Master cylinder holder bolt
Brake pad mounting bolt
Bleed valve nut
Delay valve mounting bolt
Delay valve plug
4
2
1
4
8
8
6
4
4
4
1
1
1
8
8
4
8
10
4
8
5
2
1
8
8
14
10
10
10
10
12
10
10
30
30
30
10
8
8
8
10
6
8
6
6
20
2.5 (25, 18)
2.2 (22, 16)
7 (70, 50)
2.1 (21, 16)
6.5 (65, 46)
6.5 (65, 46)
4.5 (45, 32)
3 (30, 22)
4 (40, 29)
4 (40, 29)
11.8 (118, 85)
1.1 (11, 8)
11.8 (118, 85)
5.5 (55, 40)
3.5 (35, 25.2)
3.5 (35, 25.2)
3.2 (32, 24)
3.5 (35, 25)
1.2 (12, 8.6)
1.8 (18, 13)
0.6 (6, 4.32)
1.2 (12, 8.6)
5 (50, 36)
Castle nut
Castle nut
OFF ROAD: 4 Q’ty
ON ROAD only
ON ROAD only

1. GENERAL INFORMATION
1-15
MXU500
SPECIAL TOOLS
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Oil seal and bearing
installer A120E00014
Valve adjuster
(Refer to the “VALVE
CLEARANCE” section in the
chapter 3.)
A120E00036
Bearing puller A120E00037
Valve spring compressor
(Refer to the “CYLINDER HEAD
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the
cha
p
ter 8.
)
A120E00040
Universal holder
(Refer to the “DRIVE PULLEY,
DRIVE V-BELT AND DRIVEN
PULLEYREMOVAL/
INSPECTION/
INSTALLATION” section and
“CLUTCH REMOVAL/
INSTALLATION” section in the
chapter 10.)
A120E00056
Drive pulley holder
(Refer to the “DRIVE PULLEY,
DRIVE V-BELT AND DRIVEN
PULLEYREMOVAL/
INSPECTION/
INSTALLATION” section in the
chapter 10.)
A120E00058
(Cont’d)

1. GENERAL INFORMATION
1-16
MXU500
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Driven pulley holder
(Refer to the “DRIVEN PULLEY
DISASSEMBLY/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
(Refer to the “(Refer to the
“ENGINE OIL” section in the
chapter 3.)
A120E00061
Output shaft bearing nut
wrench
(Refer to the “(Refer to the
“BEARING REPLACEMENT
IN THE RIGHT
CRANKCASE” section in the
chapter 11.)
A120E00066
Lock nut wrench
(Refer to the “CLUTCH
REMOVAL/INSTALLATION”
section in the chapter 10)
A120E00067
(Cont’d)

1. GENERAL INFORMATION
1-17
MXU500
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Crankshaft bearing puller A120E00068
Ball joint remover
(Refer to the “STEERING
KNUCKLE REMOVAL/
INSPECTION/
INSTALLATION” section in the
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/INSPECTION/
ASSEMBLY” section in the
chapter 13)
A120F00016
Drive shaft puller
(Refer to the “FRONT DRIVE
SHAFT REOMVAL/
INSPECTION/
INSTALLATION” section in the
chapter 13)
A120F00017
Yoke bearing puller
(Refer to the “FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the
chapter 13)
A120F00018
(Cont’d)