KYMCO MXU 500i, MXU 700i Repair Manual

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 abov e. If y ou do no t have t he pr oper t raini ng or to ols t o per form 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. Illus trati ons i n this manual are s how n to hel p y ou wi th th e basics o f
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 adjustmen ts . Th ese pr eventive maintenance procedures, i f
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