MXU500 Cap01 (info Generali)
User Manual: MXU500 cap01 (info generali)
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GENERAL INFORMATION MXU 500 1 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER---------------------------------------------------------SPECIFICATIONS ---------------------------------------------------------SERVICE PRECAUTIONS -----------------------------------------------TORQUE VALUES --------------------------------------------------------SPECIAL TOOLS ----------------------------------------------------------LUBRICATION POINTS -------------------------------------------------CABLE & HARNESS ROUTING ---------------------------------------TROUBLESHOOTING----------------------------------------------------- 1- 1 1- 2 1- 3 1-11 1-15 1-19 1-21 1-35 1-0 1. GENERAL INFORMATION MXU 500 SERIAL NUMBER (1) Location of Frame Serial Number (1) Location of Engine Serial Number 1-1 1. GENERAL INFORMATION MXU 500 SPECIFICATIONS LAA0 MXU 500 2203 mm (88.12 in) 1223 mm (48.92 in) 1240 mm (49.6 in) 1293 mm (51.72 in) O.H.C. 498.5 cm3 (30.48 cu-in) Fuel used 92# nonleaded gasoline Carburetor Ignition System Electrical Equipment Battery Capacity Clutch type Clutch operation system Primary reduction system Secondary reduction system High reduction ratio Low reduction ratio Reverse ratio FR/RR tire rolling circumference Front Tire pressure Rear Left Turning angle Right Brake system type Front Rear Front Suspension type Rear Frame type Drive Train Engine Moving Device 154 kg (338.8 lbs) 134 kg (294.8 lbs) 288 kg (633.6 lbs) 164 kg (360.8 lbs) 144 kg (316.8 lbs) 308 kg (648 lbs) 25X8-12 25X10-12 235 mm (9.4 in) 3350 mm (134 in) Electric/Recoil Starting system starter Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive 92X75 mm Bore x stroke (3.68X3 in) Compression ratio 10.5:1 15 kgf/cm² Compression pressure (1500kPa, 213 psi) Intake valve Opens 5° BTDC (at 1mm lift) Closes 45° ABDC Exhaust valve Opens 45° BBDC (at 1mm lift) Closes 5° ATDC Valve clearance Intake 0.1 mm (0.004 in) (cold) Exhaust 0.1 mm (0.004 in) Idle speed (rpm) 1500 rpm Cooling type Liquid cooled Fuel System Front wheel Dry weight Rear wheel Total Front wheel Curb weight Rear wheel Total Front wheel Tires Rear wheel Ground clearance Min. turning radius Forced pressure & Wet sump Oil pump type Trochoid Oil filter type Full-flow filtration 3.6 L (3.17 lmp qt, Oil capacity 3.82 Us qt) 3 L (2.64 lmp qt, Oil exchanging capacity 3.18 Us qt) After draining and oil 3.2 L (2.82 lmp qt, filter cartridge change 3.39 Us qt) Air cleaner type & No Wet type element 17 L (3.57 lmp gal, Fuel capacity 4.42 US gal Type CVK Main ON ROAD #128 jet OFF ROAD #130 Slow jet #40 Choke jet #90 Full transistor digital Type ignition Ignition timing 5°/1500 rpm Spark plug CR7E (NGK) 0.6～0.7mm Spark plug gap (0.024～0.028 in) Lubrication type Lubrication System Model No. Name & Type Overall length Overall width Overall height Wheel base Engine type Displacement 12V18AH Wet, centrifugal automatic Automatic (V-belt) V-belt Shaft drive 3.76 6.464 5.31 1995/1995 mm (79.8/79.8 in) 0.28 kg/cm² (28 Kpa, 3.2 psi) 36° 36° Disk brake Disk brake Double wishbone Link suspension Double cradle 1-2 1. GENERAL INFORMATION 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. 1-3 MXU 500 1. GENERAL INFORMATION MXU 500 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. 1-4 1. GENERAL INFORMATION 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. 1-5 MXU 500 Confirm Capacity 1. GENERAL INFORMATION 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. MXU 500 Snapping! 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. 1-6 1. GENERAL INFORMATION MXU 500 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. 1-7 No Contact ! 1. GENERAL INFORMATION Route harnesses so they are neither pulled tight nor have excessive slack. MXU 500 Do not pull too tight! 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 press or squeeze the wire. 1-8 1. GENERAL INFORMATION MXU 500 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. Do you understand the instrument? Is the instrument set correctly? Be careful not to drop any parts. When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting. Remove Rust ! 1-9 1. GENERAL INFORMATION MXU 500 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. Engine Oil Grease Gear Oil : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. : Transmission Gear Oil (90#) : Caution : Warning 1-10 1. GENERAL INFORMATION MXU 500 TORQUE VALUES STANDARD TORQUE VALUES 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) Item Torque kgf-m (N-m, lbf-ft) 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 Q‘ty Thread dia. (mm) MAINTENANCE: Spark plug Tappet ADJ nut Engine oil filter cap Engine oil filter cartridge Engine drain plug 1 4 1 1 1 10 5 30 20 12 1.2 (12, 8.6) 0.9 (9, 6.5) 1.5 (15, 11) 1 (10, 7.2) 2.5 (25, 18) LUBRICATION SYSTEM: Oil pump screw Oil pipe bolt 1 2 4 16 0.3 (3, 2) 3.5 (35, 25.2) COOLING SYSTEM: Water pump bolt Fan motor bolt Fan motor switch 2 4 1 6 5 16 1.3 (13, 9) 0.53 (5, 2.8) 1.8 (17, 13) Item Torque kgf-m (N-m, lbf-ft) Remarks Apply oil Apply oil Apply oil (Cont’d) 1-11 1. GENERAL INFORMATION MXU 500 Q‘ty Thread dia. (mm) 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 4 9 2 4 3 2 1 2 2 2 10 8 6 6 6 6 10 18 8 6 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) CYLINDER: Cylinder bolt 2 6 1 (10, 7.2) DRIVE/DRIVEN PULLEY: Drive pulley nut Wet clutch nut Driven pulley nut Driven pulley assembly plate nut 1 1 1 1 20 25 16 36 14 (140, 100.8) 14 (140, 100.8) 10 (100, 72) 7.5 (75, 54) Apply oil 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 19 1 1 1 1 1 1 4 6 20 20 8 12 20 85 8 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) Apply oil Apply oil Apply oil STARTER SYSTEM: Starter pulley nut 1 14 5.5 (55, 40) Item Torque kgf-m (N-m, lbf-ft) Remarks Apply oil Apply oil Apply oil Apply oil Apply oil 1-12 1. GENERAL INFORMATION MXU 500 FRAME Item Q‘ty Thread dia. (mm) Torque Kgf-m (N-m, lbf-ft) 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 1 1 1 1 1 1 4 2 2 8 30 8 14 18 6 10 18 16 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) EXHAUST MUFFLER: Exhaust muffler mounting bolt Exhaust pipe mounting nut Exhaust muffler band bolt 2 2 1 8 8 8 3.5 (35, 25) 3.5 (35, 25) 2.1 (21, 15) ENGINE ASSEMBLY: Engine mounting bolt/nut Engine hanger nut 3 4 10 8 6 (60, 43.5) 3.5 (35, 25) 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 3 2 1 9 1 2 8 2 6 10 10 8 8 8 6 10 10 8 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) Remarks Castle nut Castle nut Apply threebond: 1215 Apply threebond: 1215 Apply threebond: 1215 Apply threebond: 1215 Apply threebond: 1215 (Cont’d) 1-13 1. GENERAL INFORMATION Item Q‘ty MXU 500 Thread dia. (mm) Torque Kgf-m (N-m, lbf-ft) STEERING SYSTEM: Handlebar holder bolt Steering bracket Steering column nut Tie-rod ball joint nut 4 2 1 4 8 8 14 10 2.5 (25, 18) 2.2 (22, 16) 7 (70, 50) 2.1 (21, 16) WHEEL: Front wheel nut Rear wheel nut 8 8 10 10 6.5 (65, 46) 6.5 (65, 46) 6 4 4 10 12 10 4.5 (45, 32) 3 (30, 22) 4 (40, 29) 4 1 1 1 8 10 30 30 30 10 4 (40, 29) 11.8 (118, 85) 1.1 (11, 8) 11.8 (118, 85) 5.5 (55, 40) 8 4 8 10 4 8 5 2 1 8 8 8 10 6 8 6 6 20 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) 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 Remarks Castle nut Castle nut OFF ROAD: 4 Q’ty ON ROAD only ON ROAD only 1-14 1. GENERAL INFORMATION MXU 500 SPECIAL TOOLS Tool Name Oil seal and bearing installer Tool No. Illustration (Note: the special tools may differ slightly from those shown in the figure of this manual.) 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 chapter 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) 1-15 1. GENERAL INFORMATION Tool Name Tool No. MXU 500 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) 1-16 1. GENERAL INFORMATION Tool Name Crankshaft bearing puller Tool No. MXU 500 Illustration (Note: the special tools may differ slightly from those shown in the figure of this manual.) 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) 1-17 1. GENERAL INFORMATION Tool Name Tool No. MXU 500 Illustration (Note: the special tools may differ slightly from those shown in the figure of this manual.) Pinion bearing lock nut wrench (Refer to the “REAR DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 13.) A120F00020 Pinion puller (Refer to the “REAR DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 13.) A120F00021 C-ring remover (Refer to the “FRONT DRIVE DISASSEMBLY/INSPECTION/ ASSEMBLY” section in the chapter 13) A120F00022 1-18 1. GENERAL INFORMATION MXU 500 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Clutch Crankshaft Balance shaft Crankshaft one-way clutch movable part Recoil starter pulley Oil pump drive chain Starter reduction gear Starter one-way clutch O-ring face •Genuine KYMCO Engine Oil (SAE5W-50) •API SJ Engine Oil Oil seal lip Output shaft Bevel gear Drive shaft Countershaft Main shaft Transmission gear shaft bearing part Front drive gear and bearing part Gear oil: SAE 90# Rear drive gear and bearing part Gear oil: SAE 80# 1-19 1. GENERAL INFORMATION MXU 500 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. abnormal noise and rise the durability of the ATV. Throttle Cable This will avoid Steering Column Upper Front Swing Arm Bush Front Swing Arm Bush Steering Column Lower 1-20 1. GENERAL INFORMATION MXU 500 CABLE & HARNESS ROUTING ＊ Remove the fuel tank and fuel valve together (refer to the “FUEL TANK” section in the chapter 5). ＊ Remove the front cooling duct (refer to the “ENGINE REMOVAL” section in the chapter 7). ＊ Remove the rear cooling duct (refer to the “ENGINE REMOVAL” section in the chapter 7). 1-21 1. GENERAL INFORMATION (1) Throttle cable (2) Instrument connector (3) Ignition switch wire (4) Accessory socket connectors (5) Left handlebar switch (6) Rear parking brake cable (ON ROAD) MXU 500 (7) Brake light switch wire (8) Rear brake hose (Brake lever) (9) 2WD/4WD switch wire (10) Choke cable (11) Front brake hose (12) Brake light switch wire (A) Pass the brake light switch wire and left handlebar switch wire through the band. (B) Passe the throttle cable, chock cable, brake light switch wires, 2WD/4WD switch wire, front brake hose, rear brake hose, instrument connector wire, accessory socket connector wire, rear parking brake cable (ON ROAD), left handlebar switch wire and ignition switch wire through the guide. (C) Pass the 2WD/4WD switch wire through the band. 1-22 1. GENERAL INFORMATION (1) Fan EMI filter (2) Headlight connector Right front signal light connectors (ON ROAD) (3) Harness wire (4) Siphon hose (5) Over flow hose (Reserve tank) (6) Ignition switch connector (7) Air bleed hose (8) 2WD/4WD switch connector (9) Fuel tank flow hose (connect the fuel tank cover, Note) (10) Air bleed hose (11) Ignition coil MXU 500 (12) Ignition coil wire (13) 2WD /4WD start switch /2WD/4WD motor connectors (14) Left handlebar switch connectors (15) Upper radiator hose (16) Headlight connector Left front signal light connectors (ON ROAD) (17) Air bleed hose (18) LO beam relay (19) HI beam relay (20) 2WD/4WD change ECU (A) Pass the air bleed hose through the guide. Note: The fuel tank flow hose may locate the frame right side for some model. 1-23 1. GENERAL INFORMATION (1) Fuel tank flow hose (connect the fuel tank cover, Note) (2) Hazard connector (ON ROAD) (3) Harness wire (4) Throttle cable MXU 500 (5) Crankcase breather hose (6) Over flow (carburetor) (7) Water temperature sensor wire (8) Choke cable (A) Pass the harness wire through the band. (B) Pass the harness wire through the band. Note: The fuel tank flow hose may locate the frame right side for some model. 1-24 1. GENERAL INFORMATION (1) Over flow (carburetor) (2) Crankcase breather hose (3) Crankcase breather hose (4) Harness wire (5) Crankcase breather hose joint (6) Starter motor cable MXU 500 (7) Gear position light switch (8) Speed sensor wire (9) Speed sensor (10) Engine ground cable (11) Fuel hose (12) AICV air supply hose (A) Pass the starter motor cable, engine ground cable and gear position light wire through the band. (B) Pass the speed sensor wire through the band. 1-25 1. GENERAL INFORMATION (1) Upper radiator hose (2) Ignition coil wire (3) Air bleed hose (4) Air bleed hose (5) Ignition coil (6) Water hose (7) Water bypass hose (8) Delay valve (ON ROAD) (8) Brake fluid joint (OFF ROAD) (9) Rear brake hose (Brake lever) MXU 500 (10) Rear parking brake cable (ON ROAD) (11) Front brake hose (12) 2WD /4WD start switch//2WD/4WD motor connectors (13) Thermostat (14) Fan motor switch (15) Headlight connector Left front turn signal light connectors (ON ROAD) (16) Air bleed hose (17) Front brake hose (A) Pass the rear parking cable (ON ROAD) and rear brake hose through the guide. (B) Pass the rear parking cable (ON ROAD) and rear brake hose through the guide. (C) Pass the front brake hose through the guide. 1-26 1. GENERAL INFORMATION (1) Air bleed hose (2) Upper radiator hose (3) Air bleed hose (4) AICV control solenoid valve (5) Water bypass hose (6) Air bleed hose MXU 500 (7) Water joint (8) Rear brake hose (Brake lever) (9) Rear parking brake cable (ON ROAD) (10) Water hose (11) Thermostat Pass the rear parking brake and rear brake hose through the guide (A), (B) and (C). 1-27 1. GENERAL INFORMATION (1) Rear brake hose (Brake pedal) (2) Rear parking brake cable (ON ROAD) MXU 500 (3) Rear brake hose (Brake lever) ● Pass the rear parking brake cable (ON ROAD) and rear brake hose (Brake lever) through the guide (A), (B), (C), band (D) and guide (E). 1-28 1. GENERAL INFORMATION (1) Rear caliper (Brake pedal) (2) Rear caliper (Brake lever) (3) Rear parking brake cable (ON ROAD) (4) Rear brake hose (Brake lever) MXU 500 (5) Speed sensor (6) Speed sensor wire (7) Rear brake hose (Brake pedal) (A) Pass the speed sensor wire through the guide. (B) Pass the rear brake hose (Brake pedal) through the guide. (C) Pass the rear brake hose (Brake pedal) and rear brake hose (Brake lever) through the guide. (D) Pass the rear brake hose (Brake pedal) and rear brake hose (Brake lever) through the guide. 1-29 1. GENERAL INFORMATION (1) Regulator/Rectifier (2) Hazard connector (ON ROAD) (3) Flasher relay (ON ROAD) (4) Instrument wire (5) Over flow hose (reserve tank) (6) Siphon hose (7) Harness wire (8) Coolant filler hose (9) Headlight connector Right front turn signal light connectors (ON ROAD) MXU 500 (10) Fan motor connector (11) Low radiator hose (12) EMI filter (13) Front brake hose (14) Horn (ON ROAD) (15) Fuel flow hose (16) Water bypass hose (17) Combined brake hose ( ON ROAD) (18) water hose (A) Pass the harness wire through the band. (B) Pass the front brake hose through the guide. (C) Pass the fuel flow hose and water bypass hose through the guide. 1-30 1. GENERAL INFORMATION (1) Low radiator hose (2) Water bypass hose (3) Combined brake hose (ON ROAD) (4) Front brake hose (A) Pass the front brake hose (combined) and water bypass hose through the guide. (B) Pass the front brake hose through the guide. 1-31 MXU 500 1. GENERAL INFORMATION (1) Harness wire (2) Over flow (carburetor) (3) Crankcase breather hose (4) Fuel unit connectors (5) Fuel hose (6) AICV air supply hose (7) AICV air supply hose (Note) MXU 500 (8) Water hose (9) Low radiator hose (10) Water bypass hose (11) Combined brake hose (ON ROAD) (12) AICV vacuum hose (Note) (13) A.C.G. wire (14) Crankcase breather housing (A) Pass the harness wire through the guide. (B) Pass the A.C.G. wire through the guide. (C) Pass the combined brake hose (ON ROAD) and water bypass hose through the guide. (D) Pass the combined brake hose (ON ROAD) through the guide. Note: Pass the AICV air supply hose and AICV vacuum hose through the guide (B). 1-32 1. GENERAL INFORMATION (1) Starter motor cable (2) Engine ground cable (3) Clutch diode (4) Harness wire (5) Combined brake hose (ON ROAD) (6) Gear position light switch (7) Brake fluid filler hose MXU 500 (8) Brake light switch (9) Speed sensor wire (10) Rear brake hose (Brake pedal) (11) Rear brake hose (Brake pedal) (12) Rear caliper (Brake pedal) (13) Speed sensor (A) Pass the harness wire through the band. (B) Pass the gear position light switch wire, starter motor cable and engine ground cable through the band. (C) Pass the speed sensor wire and brake light switch wire through the guide. (D) Pass the rear brake hose (Brake pedal) through the guide. (E) Pass the speed sensor wire through the guide. 1-33 1. GENERAL INFORMATION MXU 500 (1) Taillight/Brake light/Rear turn signal light connectors (OFF ROAD) (1) Taillight/Brake light/Rear turn signal light connectors (ON ROAD) (2) License light connector (ON ROAD) (3) Fuse box (4) Ignition unit (5) Starter MAG (6) Starter relay (7) Positive terminal lead (8) Negative terminal lead (9) Frame ground wire ● Pass the harness wire through the guide (A) and (B). 1-34 1. GENERAL INFORMATION MXU 500 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Fuel reaches carburetor Fuel does not reach carburetor Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Clogged fuel tank cap breather hole Clogged fuel filter Clogged fuel valve passage Weak or no spark Faulty spark plug Fouled spark plug Faulty ignition unit Faulty change gear control unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition switch Weak or dead battery Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps Test cylinder compression Normal compression Low or no compression Faulty starter clutch Valve clearance too small Valve stuck open Worn cylinder, piston and piston rings Leaking cylinder head gasket Start engine by following normal starting procedure Engine does not fire Engine fires but does not start Air leaking through intake pipe Leaking intake manifold Incorrect ignition timing Incorrectly adjusted air screw Dry spark plug Wet spark plug Flooded carburetor Clogged air cleaner Throttle valve excessively open Remove spark plug and inspect again 1-35 1. GENERAL INFORMATION MXU 500 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Engine speed increases Engine speed does not increase sufficiently Check ignition timing (using a timing light) Correct timing Incorrect timing Correct Incorrect Clogged air cleaner Restricted fuel flow Clogged fuel tank cap breather hole Clogged exhaust muffler Carburetor fuel level too low Faulty ignition unit Faulty pulser coil Check valve clearance Test cylinder compression Normal compression Abnormal compression Improper valve clearance adjustment Excessively worn valve seat (protruded valve stem) Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing Check carburetor for clogging Not clogged Clogged Clean and unclog Remove spark plug and inspect Plug not fouled or discolored Plug fouled or discolored Correct and not contaminated Incorrect or contaminated Fouled spark plug Incorrect heat range plug Remove oil dipstick and check oil level and condition Oil level too high Oil level too low Oil not changed Remove cylinder head oil pipe bolt and inspect Valve train lubricated properly Valve train not lubricated properly Check if engine overheats Engine does not overheats Engine overheats Rapidly accelerate or run at high speed Engine does not knock Engine knocks Clogged oil line Faulty oil pump Coolant level too low Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon build-up in combustion chamber Ignition timing too early Excessive carbon build-up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early 1-36 1. GENERAL INFORMATION MXU 500 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Correct timing Incorrect timing Correctly adjusted Incorrectly adjusted Faulty ignition unit Faulty pulser coil Check carburetor air screw adjustment Mixture too rich (turn screw out) Mixture too lean (turn screw in) Check carburetor gasket for air leaks No air leak Air leaks Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark 1-37 Weak or intermittent spark Deteriorated O-ring Carburetor not securely tightened Damaged insulator rubber Faulty or fouled spark plug Faulty ignition unit Faulty A.C. generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch 1. GENERAL INFORMATION MXU 500 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Correct timing Incorrect timing Correctly adjusted Incorrectly adjusted Faulty ignition unit Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Worn valve seat Check fuel pump for fuel supply Fuel flows freely Fuel flow restricted Check carburetor jets for clogging Empty fuel tank Clogged fuel tube or filter Clogged Fuel tank cap breather hole Not clogged Clogged Clean and unclog Correct Incorrect Cam timing gear aligning marks not aligned Not weakened Weak spring Check valve timing Check valve spring tension Faulty spring 1-38 1. GENERAL INFORMATION MXU 500 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Voltage does not increase Dead battery Faulty battery Normal Resistance too high Faulty A.C. generator coil Broken yellow wire Shorted pink and yellow wires Normal voltage No voltage Broken red wire Normal Abnormal Faulty regulator/rectifier Poorly connected coupler Normal voltage Measure resistance between AC generator coil terminals Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine ground and test voltage Check regulator/rectifier coupler for loose connection Faulty A.C. generator Overcharging Inspection/Adjustment Connect battery (+) wire to regulator/rectifier coupler green wire and battery (-) wire to engine ground and test voltage Symptom Probable Cause Battery has voltage with ignition switch “ON” Battery has no voltage with ignition switch “ON” Normal Abnormal Broken green wire Check regulator/rectifier coupler for loose connection Poorly connected coupler Faulty regulator/rectifier 1-39 1. GENERAL INFORMATION MXU 500 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Weak or no spark Good spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose Loose spark plug cap Good Good Poorly connected coupler Normal Abnormal Check ignition unit coupler for looseness Measure resistance between terminals of ignition unit coupler Check related parts Normal Abnormal Faulty ignition switch Weak battery Faulty pulser coil Faulty ignition coil Faulty charging system Broken wire harness Poorly connected coupler Check ignition unit with a ignition unit tester Normal Abnormal Faulty ignition unit Faulty change gear control unit Check ignition coil with a ignition unit tester Abnormal Faulty ignition coil 1-40
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