KYMCO MXU 500i Operating instructions

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.

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.
While the instructions, photographs and illustrations in this manual have been
reviewed for accuracy it is up to the individual performing the procedures to
use good judgement when performing any procedures described. Every
precaution has been taken in the manufacture of this manual however the
publisher assumes no responsibility for errors and omissions. Furthermore, no
liability or responsibility is assumed for damages to property or injury to
persons resulting from the use of the information contained in this guide. Use
of this information to perform service procedures is done entirely at your own
risk.

1.Quick Reference
This chapter provides a quick reference source of technical specifications and
information for the KYMCO MXU 700i and MXU 500i models.
1.Break In Procedure...................................................................... 1-2
2.General Information..................................................................... 1-3
3.VIN and Warning Stickers ........................................................... 1-26
4.Special Tools................................................................................ 1-27
5.Specifications............................................................................... 1-28
6.Torque Specifications ................................................................. 1-40
7.Troubleshooting........................................................................... 1-48
8.Diagnostic Trouble Codes .......................................................... 1-59

2.Periodic Maintenance
This chapter covers the location and servicing of the periodic maintenance
items for the KYMCO MXU 700i and MXU 500i models.
This chapter includes all information necessary to perform recommended
inspections and adjustments. These preventive maintenance procedures, if
followed, will ensure more reliable vehicle operation and a longer service life.
The need for costly overhaul work will be greatly reduced. This information
applies to vehicles already in service as well as new vehicles that are being
prepared for sale. All service technicians should be familiar with this entire
chapter.
1.Periodic Maintenance Chart ...................................................... 2-3
2.Air Filter Servicing ..................................................................... 2-6
3.Brake Fluid .................................................................................. 2-19
4.Brake Inspection ........................................................................ 2-26
5.Compression Check .................................................................. 2-31
6.Engine Idle Speed ...................................................................... 2-34
7.Engine Oil ................................................................................... 2-35
8.Final Drive / Differential Oil ....................................................... 2-46
9.Spark Arrestor ............................................................................ 2-58
10.Spark Plug ................................................................................ 2-63
11.Throttle Free Play ..................................................................... 2-69
12.Tires .......................................................................................... 2-74
13.Suspension and Steering ........................................................ 2-78
14.Valve Clearance ........................................................................ 2-88

3.Fuel System
This chapter covers the location and servicing of the fuel system components.
1.Airbox .......................................................................................... 3-4
2.Check Engine Lamp (CELP) ...................................................... 3-10
3.Component Location ................................................................. 3-15
4.Diagnostic Tool .......................................................................... 3-21
5.Fuel Injection Sensors ............................................................... 3-37
6.Fuel Injector ................................................................................ 3-51
7.Fuel Pump ................................................................................... 3-66
8.Throttle Body Removal .............................................................. 3-82
9.Throttle Body Components ....................................................... 3-100

4.External Components
This chapter covers the location and servicing of the external components.
1.Drive Selector ............................................................................. 4-5
2.Exhaust System ......................................................................... 4-14
3.Front Bumper ............................................................................. 4-24
4.Front Cover ................................................................................. 4-29
5.Front Fender ............................................................................... 4-33
6.Fuel Tank .................................................................................... 4-45
7.Instrument Cover ....................................................................... 4-63
8.Mudguards and Footrests ......................................................... 4-72
9.Lights .......................................................................................... 4-77
10.Racks ........................................................................................ 4-85
11.Rear Fender .............................................................................. 4-98
12.Seat ........................................................................................... 4-108
13.Side Covers .............................................................................. 4-112
14.Skid Plate .................................................................................. 4-116

5.Engine MXU700i
This chapter covers the location and servicing of the engine components for
the KYMCO MXU 700i models. For the MXU 500i models see the Engine MXU
500i topic
1.Engine Specifications ................................................................ 5-11
2.Engine Removal ......................................................................... 5-19
3.Engine Installation ..................................................................... 5-29
4.Rocker Cover .............................................................................. 5-39
5.Camshaft Removal ..................................................................... 5-64
6.Camshaft Installation ................................................................. 5-75
7.Cylinder Head ............................................................................. 5-82
8.Valves .......................................................................................... 5-99
9.Cam Chain .................................................................................. 5-112
10.Cylinder and Piston ................................................................. 5-117
11.Generator Cover ....................................................................... 5-139
12.Flywheel .................................................................................... 5-157
13.Clutch ........................................................................................ 5-170
14.Oil Pump ................................................................................... 5-186
15.Crankcase Splitting .................................................................. 5-210
16.Crankcase Assembly ............................................................... 5-221
17.Crankcase Bearings ................................................................. 5-230
18.Crankshaft ................................................................................ 5-234
19.Transmission Removal ............................................................ 5-241
20.Transmission Shafts ................................................................ 5-254
21.Transmission Assembly .......................................................... 5-270
22.Output Shaft ............................................................................. 5-282

5.Engine MXU 500i
This chapter covers the location and servicing of the engine components for
the KYMCO MXU 500i. For the engine in the MXU 700i see the Engine
MXU700i topic.
1.Cylinder Head Cover.................................................................... 5-8
2.Camshaft ..................................................................................... 5-18
3.Camshaft Installation ................................................................. 5-39
4.Cylinder Head ............................................................................. 5-55
5.Valves .......................................................................................... 5-69
6.Cylinder and Piston ................................................................... 5-82
7.Recoil Starter Cover ................................................................... 5-109
8.Generator Cover ......................................................................... 5-117
9.Flywheel ...................................................................................... 5-129
10.Oil Pump ................................................................................... 5-145
11.Cam Chain ................................................................................ 5-169
12.Engine Removal ....................................................................... 5-176
13.Engine Installation ................................................................... 5-186
14.Output Shaft ............................................................................. 5-197
15.Crankcase ................................................................................. 5-231
16.Crankshaft ................................................................................ 5-250
17.Transmission Removal ............................................................ 5-255
18.Transmission Shafts ................................................................ 5-268
19.Transmission Installation ........................................................ 5-283
20.Crankcase Bearings ................................................................. 5-295

6.Cooling System
This chapter covers the location and servicing of the external components for
the KYMCO MXU 700i and MXU 500i models.
1.Coolant ........................................................................................ 6-4
2.Pressure Testing ........................................................................ 6-13
3.Radiator ...................................................................................... 6-16
4.Thermostat .................................................................................. 6-30
5.Water Pump ................................................................................ 6-37
7. CVT Continuously Variable Transmission
MXU500i
This chapter covers the location and servicing of the CVT components for the
KYMCO MXU 500i models.
1.Cooling Ducts ............................................................................. 7-3
2.Belt Case Cover .......................................................................... 7-11
3.CVT Removal .............................................................................. 7-20
4.CVT Installation .......................................................................... 7-36
5.Clutch Removal .......................................................................... 7-52
6.Clutch Installation ...................................................................... 7-68

7. CVT Continuously Variable Transmission
MXU700i
This chapter covers the location and servicing of the CVT components for the
KYMCO MXU 700i models.
1.CVT Cooling Ducts ..................................................................... 7-3
2.CVT Removal .............................................................................. 7-11
3.CVT Installation .......................................................................... 7-31
4.Clutch Removal .......................................................................... 7-51
5.Clutch Installation ...................................................................... 7-64
8.Final Drive
This chapter covers the location and servicing of the final drive components for
the KYMCO MXU 700i and MXU 500i models.
1.Drive Shafts ................................................................................ 8-3
2.Differential Removal .................................................................. 8-19
3.Differential Installation .............................................................. 8-23
4.Differential Disassembly ........................................................... 8-27
5.Differential Assembly ................................................................ 8-61
6.Rear Final Drive Gear ................................................................. 8-78
7.Final Drive Gear Disassembly ................................................... 8-82
8.Final Drive Gear Assembly ........................................................ 8-111

9.Brake System
This chapter covers the location and servicing of the front brake components
for the KYMCO MXU 700i and MXU 500i models.
1.Brake Discs ................................................................................. 9-3
2.Brake Pedal ................................................................................. 9-10
3.Front Brake Calipers .................................................................. 9-30
4.Rear Brake Calipers ................................................................... 9-43
5.Master Cylinders ........................................................................ 9-67
10.Wheels
This chapter covers the location and servicing of the wheel components for the
KYMCO MXU 700i and MXU 500i models.
1.Wheels ........................................................................................ 10-1
2.Wheel Bearings .......................................................................... 10-19
11.Steering
This chapter covers the location and servicing of the steering components for
the KYMCO MXU 700i and MXU 500i models.
1.Handlebar ................................................................................... 11-1
2.Steering Knuckles ...................................................................... 11-2
3.Steering Shaft ............................................................................. 11-3
4.Tie-Rods ...................................................................................... 11-4

12.Front Suspension
This chapter covers the location and servicing of the front suspension
components for the KYMCO MXU 700i and MXU 500i models.
A-arms ............................................................................................ 12-2
Front Shock Absorbers ................................................................ 12-11
13.Rear Suspension
This chapter provides the rear suspension specifications for the KYMCO MXU
700i and MXU 500i models.
Shock Absorbers .......................................................................... 13-2
Suspension Arms .......................................................................... 13-6
14.Electrical Systems
This chapter covers the location and servicing of the electrical systems for the
KYMCO MXU 700i and MXU 500i models.
1.Electrical Specifications ............................................................ 14-19
2.Battery ......................................................................................... 14-21
3.Charging System ........................................................................ 14-26
4.Fuses ........................................................................................... 14-40
5.Ignition System .......................................................................... 14-46
6.Lights .......................................................................................... 14-64
7.Starter Motor ............................................................................... 14-72
8.Starting System .......................................................................... 14-78
9.Switches ..................................................................................... 14-87
10.Wiring Diagrams ....................................................................... 14-101