KYMCO MXU 500 ATV Swingarm Solid Rear Axle Service Manual Printed by Cyclepedia

Description

The CYCLEPEDIA PRESS LLC KYMCO MXU 500 ATV service manual features detailed, photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran dealer trained ATV technician.  Note: Printed manuals are in black and white.

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KYMCO MXU 500 ATVs covered by this service manual:

2007 KYMCO MXU 500 Swingarm/Solid Axle
2008 KYMCO MXU 500 Swingarm/Solid Axle
2009 KYMCO MXU 500 Swingarm/Solid Axle

The KYMCO MXU 500 ATV manual covers the following topics:

Serial Number Locations
Specifications
Service Precautions
Torque Values
Special Tools
Lubrication Points
Cable and Harness Routing
Wiring Diagram
Troubleshooting

Frame Covers-Exhaust Muffler

Service Information
Troubleshooting
Fasterner Removal and Reinstallation
Frame Covers
Exhaust Muffler Removal

Inspection-Adjustment

Service Information
Maintenance Schedule
Fuel Line/Throttle Operation
Air Cleaner
Spark Plug
Front Drive Gear Oil
Spark Arrester
Drive Shaft Boots
Valve Clearance
Carburetor Idle Speed
Cylinder Compression
Engine Oil
Rear Drive Gear Oil
Rear Parking Brake Adjustment
Brake Fluid/Headlight Aim
Drive Belt/Brake Pads Inspection
Steering System Inspection
Toe-In Adjustment
Wheels/Tires
Drive Select Lever Adjustment
Cable Inspection and Lubrication
Suspension
Cooling System

Lubrication System

Lubrication System Diagram
Service Information
Troubleshooting
Engine Oil & Oil Filter
Oil Pump

Fuel System

Service Information
Troubleshooting
Fuel Tank
Fuel Valve
Carburetor Removal/Choke Inspection/Installation
Carburetor Disassembly/Inspection/Assembly
Air Cleaner Housing
Pair Solenoid Valve

Cooling System

System Flow Pattern
Service Information
Troubleshooting
Cooling System Testing
Coolant Replacement
Fan Motor
Fan Motor Switch
Radiator
Radiator Reserve Tank
Thermostat
Water Pump
Water Temperature Sensor

Engine Removal

Service Information
Engine Removal

Cylinder Head / Valves

Service Information
Troubleshooting
Cylinder Compression Test
Cylinder Head Removal/Installation
Cylinder Head Cover Disassembly/Assembly
Cylinder Head Cover Removal/Installation
Camshaft Removal/Inspection/Installation
Rocker Arms Removal/Inspection/Installation
Cylinder Head Disassembly/Inspection/Assembly
Cam Chain Removal/Inspection/Installation

Cylinder-Piston

Schematic Drawing
Troubleshooting
Service Information
Cylinder and Piston Removal/Inspection/Installation

Drive And Driven Pulleys

Schematic Drawing
Service Information
Troubleshooting
Clutch Disassembly/Inspection/Assembly
Drive Pulley Disassembly/Inspection/Assembly
Driven Pulley Disassembly/Inspection/Assembly
Left Crankcase Cover Removal/Installation
Drive Pulley, Drive V-Belt and Driven Pulley Removal/Inspection/Installation
Clutch Removal/Installation

Final Reduction

Service Information
Right Crankcase Removal/Installation
Bearing Replacement in the Right Crankcase
Countershaft Disassembly/Assembly/Inspection
Secondary Drive/Driven Bevel Gear Removal/Inspection/Installation
Secondary Gear Shims Adjustment
Transmission Removal/Inspection/Installation
Upper Shift Fork Disassembly/Assembly
Drive Shaft Disassembly/Assembly/Inspection

Left Crankcase/Crankshaft/Balance Shaft

Service Information
Troubleshooting
Crankshaft and Balance Shaft Removal/Inspection/Installation
Bearing/Oil Seal Replacement in the Left Crankcase

Brake System

Service Information
Brake Pad Replacement
Combination Brake Fluid Change/Air Bleed (On Road)
Rear Brake/Parking Brake Caliper Disassembly/Inspection/Assembly (on Road)
Rear Brake/Parking Brake Caliper Removal/Installation (On Road)
Relay Valve Removal/Disassembly/Inspection/Assembly/Installation (On Road)
Front Brake Discs Removal/Inspection/Installation
Front Brake Fluid Change / Air Bleed (Off Road)
Brake Master Cylinders Removal/Inspection/Installation
Front Brake Calipers Removal/Installation
Brake Master Cylinder Disassembly/Inspection/Assembly
Rear Brake Disc Removal/Inspection/Installation
Rear Brake Fluid Change/Air Bleed
Brake Caliper Disassembly/Inspection/Assembly
Rear Brake Calipers Removal/Installation

Suspension/Steering System

Troubleshooting
Front Arms Disassembly/Inspection/Assembly
Service Information
Front Arms Inspection/Removal/Installation
Front Wheel Hub Removal/Inspection/Installation
Steering Knuckle Disassembly/Assembly
Steering Knuckle Removal/Inspection/Installation
Tie Rod Removal/Inspection/Installation
Front Wheel Removal/Inspection/Installation
Front Shock Absorber Removal/Inspection/Installation
Handlebar Removal/Inspection/Installation
Steering Column Removal/Inspection/Installation

Drive Train

Service Information
Front Drive Shaft Removal/Inspection/Installation
Front Drive Shaft Disassembly/Inspection/Assembly
Front Drive Removal/Inspection/Installation
Front Drive Disassembly/Inspection/Assembly
Front Drive Shim Adjustment
Rear Drive Removal/Inspection/Installation
Rear Drive Disassembly/Inspection/Assembly
Rear Drive Shim Adjustment
Front Propeller Shaft Disassembly/Inspection/Assembly
Rear Propeller Shaft Disassembly/Inspection/Assembly

Rear Wheel /Axle/Shock Absorber/Swing Arm

Service Information
Rear Axle Housing Disassembly/Assembly
Troubleshooting
Rear Axle Housing Removal/Inspection/Installation
Rear Axle Removal/Inspection/Installation
Rear Shock Absorber Removal/Inspection/Installation
Rear Swing Arm Disassembly/Inspection/Assembly
Rear Swing Arm Removal/Installation
Rear Wheel Removal/Inspection/Installation
Rear Wheel Hub Removal/Inspection/Installation

Battery-Charging System AC Generator

Charging System Layout/Charging Circuit
Service Information
Troubleshooting
Battery
Charging System Inspection
Alternator Charging Coil
Regulator/Rectifier
Alternator Stator Removal/Inspection/Installation

Ignition System

Ignition System Layout
Ignition Circuit
Service Information
Troubleshooting
Ignition Coil Inspection
Ignition Control Module

Starting System

Service Information
Troubleshooting
Starting System Layout
Starting Circuit
Starter Motor
Starter Relay Switch/Starter Mag
Recoil Starter Removal/Inspection/Assembly
Recoil Starter Handle Replace
Recoil Starter Disassembly/Inspection/Assembly
Starter Pulley Removal/Inspection/Installation
Starter Clutch Removal/Inspection/Installation

Lights / Switches

Service Information
Bulb Removal
Horn (On Road Only)
Ignition Switch
Handlebar Switch
Gear Indicator Switch
Speed Sensor
2WD/4WD Selecting System
Fuel Unit