Introduction to the Service Manual
This service manual, published by Cyclepedia Press LLC, offers detailed instructions for the maintenance, service, and repair of 2010-2012 KYMCO MXU 500 4x4 and MXU 500i ATV models. It features comprehensive photographs, wiring diagrams, and complete specifications, alongside step-by-step procedures developed by experienced ATV technicians.
The manual covers various aspects of the ATV, ensuring that users have the necessary information to perform accurate and effective service operations. Please note that printed versions of this manual are in black and white.
Image: Front cover of the Cyclepedia Press LLC service manual for KYMCO MXU 500 ATVs.
Applicable Models
This service manual is specifically designed for the following KYMCO MXU 500 ATV models:
- 2010 KYMCO MXU 500 4x4 IRS
- 2011 KYMCO MXU 500 4x4 IRS
- 2012 KYMCO MXU 500 4x4 IRS
- 2010 KYMCO MXU 500 LE 4x4 IRS
- 2011 KYMCO MXU 500 LE 4x4 IRS
- 2012 KYMCO MXU 500i IRS LE
- 2012 KYMCO MXU 500i
General Information and Preparations
This section provides foundational knowledge and essential procedures required before commencing service work.
- Serial Number Locations: Guidance on locating important identification numbers on the ATV.
- Service Precautions: Important safety guidelines and warnings to observe during all service operations.
- Torque Values: A comprehensive list of specified torque settings for various fasteners.
- Special Tools: Information on specialized tools required for specific procedures.
- Lubrication Points: Identification of all lubrication points and recommended lubricants.
- Cable and Harness Routing: Correct routing diagrams for cables and wiring harnesses.
- Wiring Diagram: Detailed electrical wiring schematics for the ATV.
Maintenance and Adjustments
This section details routine maintenance tasks and adjustment procedures to ensure optimal ATV performance and longevity.
- Inspection-Adjustment: Procedures for inspecting various components and performing necessary adjustments.
- Lubrication System: Maintenance and service of the ATV's lubrication system.
- Fuel System: Service procedures for the fuel delivery system.
- Cooling System: Maintenance and repair of the engine cooling system.
Engine and Related Components
Detailed instructions for servicing the engine and its primary components.
- Engine Removal: Step-by-step guide for safely removing the engine from the chassis.
- Cylinder Head / Valves: Procedures for inspection, service, and reassembly of the cylinder head and valve train.
- Cylinder-Piston: Service and inspection of the cylinder and piston assembly.
- Left Crankcase/Crankshaft/Balance Shaft: Detailed instructions for servicing these internal engine components.
Drivetrain and Transmission
This section covers the components responsible for power transfer to the wheels.
- Drive And Driven Pulleys: Service and adjustment of the CVT system pulleys.
- Final Reduction: Maintenance and repair of the final drive reduction gears.
- Drive Train: General service procedures for the entire drivetrain.
- Rear Wheel /Axle/Shock Absorber/Swing Arm: Instructions for servicing the rear wheel, axle, shock absorber, and swing arm assembly.
Chassis, Suspension, and Brakes
Information regarding the ATV's structural components, steering, and braking systems.
- Frame Covers-Exhaust Muffler: Removal, installation, and inspection of frame covers and the exhaust system.
- Brake System: Comprehensive service and repair procedures for the braking system.
- Suspension/Steering System: Maintenance, adjustment, and repair of the front and rear suspension, and the steering components.
Electrical Systems
This section details the electrical components and their service requirements.
- Battery-Charging System AC Generator: Service and testing of the battery and charging system components.
- Ignition System: Troubleshooting and repair of the ignition system.
- Starting System: Service procedures for the electric starting system.
- Lights / Switches: Inspection, troubleshooting, and replacement of lighting and switch components.
Troubleshooting
A dedicated section providing diagnostic information and procedures to identify and resolve common issues with the KYMCO MXU 500 ATV.
Specifications
This manual includes complete specifications for the KYMCO MXU 500 ATV models, covering dimensions, weights, fluid capacities, and other critical data necessary for proper service and repair. For detailed specifications, please refer to the relevant sections within the manual.
- Print Length: 449 pages
- Item Weight: 2.28 pounds
- Dimensions: 8.5 x 1.02 x 11 inches
- ISBN-13: 979-8309490257
Additional Information
This service manual focuses exclusively on technical service and repair procedures. Information regarding product warranty, customer support contacts, or operational instructions for the ATV is not included within this technical service guide. For such details, please consult your ATV's owner's manual or contact an authorized KYMCO dealer.
Image: Back cover of the service manual, displaying the ISBN barcode and publisher information.
