KYMCO MXU 500 IRS Bedienungsanleitung

MXU 500 IRS

By KWANG YANG Motor Co., Ltd.

First Edition, Dec. 2008

unauthorized use without the written permission of

KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T100-LAA0CD-IT

MXU 500 IRS

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the MXU 500 IRS.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which are

subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 4 through 12 give instructions

for disassembly, assembly and adjustment

of engine parts. Section 13 through 16 is

the removal/ installation of chassis.

Section 17 through 21 states the testing

and measuring methods of electrical

equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages give

detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

Quality Technology Division

Education Department

TABLE OF CONTENTS

GENERAL INFORMATION

FRAME COVERS /EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

FUEL SYSTEM

COOLING SYSTEM

ENGINE REMOVAL

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE PULLEY/DRIVEN PULLEY/

CLUTCH

FINAL REDUCTION/

TRANSMISSION SYSTEM

LEFT CRANKCASE/CRANKSHAFT/

BALANCE SHAFT

DRIVE TRAIN

FRONT WHEEL/FRONT SUSPENSION

STTEERING SYSTEM

REAR WHEEL/AXLE/SHOCK

ABSORBER/SWING ARM

BRAKE SYSTEM

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTER SYSTEM

LIGHTS/ SWITCHES

WIRING DIAGRAMS

The information and contents included in

this manual may be different from the

vehicle in case specifications are changed.

KYMCO reserves the right to make

changes at any time without notice and

without incurring any obligation.

CHASSIS

ELECTRICAL

UIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

MXU 500 IRS

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

SERIAL NUMBER---------------------------------------------------------- 1- 1

SPECIFICATIONS---------------------------------------------------------- 1- 2

SERVICE PRECAUTIONS------------------------------------------------ 1- 3

TORQUE VALUES --------------------------------------------------------- 1-11

SPECIAL TOOLS ----------------------------------------------------------- 1-15

LUBRICATION POINTS -------------------------------------------------- 1-19

1. GENERAL INFORMATION

1-1

MXU 500 IRS

SERIAL NUMBER

(1) Location of Engine Serial Numbe

(1) Location of Frame Serial Numbe

1. GENERAL INFORMATION

1-2

MXU 500 IRS

SPECIFICATIONS

Model No. LAA0CA/LAA0CD

Name & Type MXU 500 IRS

Overall length 2203 mm

Overall width 1223 mm

Overall height 1243 mm

Wheel base 1297 mm

Engine type D.O.H.C.

Displacement 498.5 CC

Fuel used 92# nonleaded gasoline

Front wheel 162 kg

Rear wheel 155kg

Dry weight Total 317kg /318kg

Front wheel 170 kg

Rear wheel 164 kg

Curb weight Total 334kg /335kg

Front wheel 25X8R-12

Tires Rear wheel 25X10R-12

Ground clearance 241 mm

Min. turning radius

Starting system Electric/Recoil

starter

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement DOHC.,chain drive

Bore x stroke 92X75 mm

Compression ratio 10.5:1

Compression pressure 15 kg/cm²

Opens 5°BTDCIntake valve

(at 1mm lift) Closes 45°ABDC

Opens 45°BBDCExhaust valve

(at 1mm lift) Closes 5°ATDC

Intake 0.1 mmValve clearance

(cold) Exhaust 0.1 mm

Idle speed (rpm) 1500 ±100rpm

Cooling type Liquid cooled

Lubrication type Forced pressure &

Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 3.6 L

Oil exchanging capacity 3.0 L

Air cleaner type & No Wet type element

Fuel capacity 17 L

Type KYMCO CVK

ON ROAD #128Main

jet OFF ROAD #126

VENTURE DIA 38mm

Type Full transistor digital

ignition

Ignition timing 5°/1500 rpm

Spark plug CR7E (NGK)

Spark plug gap 0.6～0.7mm

Battery Capacity 12V18AH

Clutch type Wet, centrifugal

automatic

Clutch operation system Automatic (V-belt)

Primary reduction system V-belt

Secondary reduction

system Shaft drive

Forward drive high radio 8.770~30.067

Forward drive low radio 16.279~55.814

Reverse drive ratio 13.381~45.878

FR/RR tire rolling

circumference 1995/1995 mm

Front 0.35 kgf/cm²

(35 Kpa, 5.0 psi)

Tire pressure

Rear 0.32 kgf/cm²

(32Kpa, 4.5psi)

Left 41°

Turning angle Right 41°

Front Disk brake

Brake system type Rear Disk brake

Front

Dual A-Arm

Suspension type Rear

Dual A-Arm

Engine

nition S

stem

Drive Train Moving Device

Lubrication System Fuel S

stem

Carbureto

Electrical Equipment

1. GENERAL INFORMATION

1-3

MXU 500 IRS

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. GENERAL INFORMATION

1-4

MXU 500 IRS

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. GENERAL INFORMATION

1-5

MXU 500 IRS

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.

Confir

Capacity

1. GENERAL INFORMATION

1-6

MXU 500 IRS

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.

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.

Snapping!

1. GENERAL INFORMATION

1-7

MXU 500 IRS

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.

o Contact !

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