KYMCO MXU 500i 2018 Operating and installation instructions

KYMCO Repair Manual MXU 500i/700i
KYMCO MXU 700i and MXU 500i Service Information
Models Covered:
2018 KYMCO MXU 700i
2018 KYMCO MXU 500i
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KYMCO Repair Manual MXU 500i/700i
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.
This manual was written using the latest information available at the time of publication.
Illustrations in this manual are shown to help you with the basics of performing the jobs
listed. The pictures in this manual may not depict the actual vehicle you’re working on,
however the procedures will be similar.
Inexperienced technicians without the correct tools and knowledge may not be able to
perform these jobs as intended. Caution needs to be taken for the vehicle and its operator
as serious injury can occur. Always read a procedure in its entirety before attempting any
repairs.
Many thumbnail images can be clicked on to show larger images.
Topics that are explained in greater detail are referenced and linked to.
This manual features a 2018 KYMCO MXU 700i with a 500i engine chapter.
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1.Quick Reference MXU 500i/700i
Quick Reference
This chapter provides a quick reference source of technical specifications and information
for the KYMCO MXU 700i and MXU 500i models.
Break In Procedure......................................................................................................................1-2
General Information.....................................................................................................................1-3
VIN and Engine Number Location............................................................................................1-24
Special Tools..............................................................................................................................1-25
Specifications.............................................................................................................................1-26
Torque Specifications ...............................................................................................................1-37
Troubleshooting.........................................................................................................................1-44
Diagnostic Trouble Codes (DTCs)............................................................................................1-53
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1.Quick Reference MXU 500i/700i
Break In Procedure
A new ATV and an overhauled ATV engine require a "break-in" period. The first 10 hours
(or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in
period will help assure maximum life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle.
Varying the engine RPM during the break-in period allows the components to "load" (aiding
the mating process) and then "unload" (allowing components to cool). Although it is
essential to place some stress on the engine components during break-in, care should be
taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during
the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle the engine several minutes until
the engine has reached normal operating temperature. Do not idle the engine for
excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle is recommended; however, brief
full-throttle accelerations and variations in driving speeds contribute to good engine
break-in.
After the completion of the break-in period, the engine oil and oil filter should be changed.
Other maintenance after break-in should include checking of all prescribed adjustments
and tightening of all fasteners.
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1.Quick Reference MXU 500i/700i
General Information
Break In Procedure
A new ATV and an overhauled ATV engine require a "break-in" period. The first 10 hours
(or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in
period will help assure maximum life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle.
Varying the engine RPM during the break-in period allows the components to "load" (aiding
the mating process) and then "unload" (allowing components to cool). Although it is
essential to place some stress on the engine components during break-in. care should be
taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during
the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle the engine several minutes until
the engine has reached normal operating temperature. Do not idle the engine for
excessively long periods of time
During the break-in period, a maximum of 1/2 throttle is recommended: however, brief full-
throttle accelerations and variations in driving speeds contribute to good engine break-in.
After the completion of the break-in period, the engine oil and oil filter should be changed
Other maintenance after break-in should include checking of all pre- scribed adjustments
and tightening of all fasteners.
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas,
oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gas
containing up to 10% ethanol, 5% methane, or 5% MTBE are acceptable gas.
When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since
ethanol will prevent the accumulation of moisture in the fuel system.
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1.Quick Reference MXU 500i/700i
FILLING THE GAS TANK
WARNING: Always fill the gas tank in a well-ventilated area Never add fuel to the ATV gas
tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas
tank.
WARNING: Do not overflow gasoline when filling the gas tank. A fire hazard could
materialize. Always allow the engine to cool before filling the gas tank.
Since gasoline expands as its temperature rises, the gas tank must be filled to its rated
capacity only. Expansion room must be maintained in the tank particularly if the tank is filled
with cold gasoline and then moved to a warm area.
RECOMMENDED OIL
CAUTION: Any oil used in place of the recommended oil could cause serious engine
damage. Do not use oils which contain graphite or molybdenum additives. These oils can
adversely affect clutch operation. Also, not recommended are racing, vegetable,
non-detergent, and castor-based oils.
Engine Oil (Recommended) SAE 5W-30
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE
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1.Quick Reference MXU 500i/700i
LUBRICANT
The recommended lubricant is KYMCO Gear Lube or an equivalent gear lube which is SAE
approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the
KYMCO ATV front differentials and rear drives.
CAUTION:Any lubricant used in place of the recommended lubricant could cause serious
front differential/rear drive damage.
Genuine Parts
When replacement of parts is necessary, use only genuine KYMCO ATV parts. They are
precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated
Parts Manual for the correct part number, quantity, and description.
Preparation For Storage
CAUTION: Prior to storing the ATV. it must be properly serviced to prevent rusting and
component deterioration.
KYMCO recommends the following procedure to prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the
entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine
or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air
filter housing cover and air filter. Start the engine and allow it to idle; then using KYMCO
Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period
of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover.
CAUTION: If the interior of the air filter housing is dirty, clean the area before starting the
engine.
4. Empty the fuel in the fuel tank.
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1.Quick Reference MXU 500i/700i
5. Plug the exhaust outlet on the muffler with a clean cloth.
6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components
together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap
screws, and bolts are tightened to specifications.
8. Disconnect the battery cables; then remove the battery, clean the battery posts and
cables, and store in a clean, dry area.
9. Store the ATV indoors in a level position.
CAUTION: Avoid storing outside in direct sunlight and avoid using a plastic cover as
moisture will collect on the ATV causing rusting.
Preparation After Storage
Taking the ATV out of storage and correctly preparing it will assure many miles and hours
of trouble-free riding. KYMCO recommends the following procedure to prepare the ATV.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the muffler.
3. Check all control cables for signs of wear or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Charge the battery; then install. Connect the battery cables.
Caution: The ignition switch must be in the OFF position prior to installing the battery or
damage may occur to the ignition system. Connect the positive battery cable first, then the
negative.
6. Check the entire brake systems (fluid level, pads, etc.), all controls, lights, and headlight
aim; adjust or replace as necessary.
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1.Quick Reference MXU 500i/700i
7. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap
screws, and bolts are tightened to specifications.
8. Check tire pressure, Inflate to recommended pressure as necessary.
9. Make sure the steering moves freely and does not bind.
10.Check the spark plug. Clean or replace as necessary.
General Service Instructions
Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.
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1.Quick Reference MXU 500i/700i
When tightening bolts or nuts, begin with larger-diameter and move to smaller ones.
Tighten bolts evenly and tighten to the specified torque diagonally.
Use genuine parts and lubricants.
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