inspection/adjustment - ATV Quad Complete Service

3. INSPECTION/ADJUSTMENT
MXU 500
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INSPECTION/ADJUSTMENT
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SERVICE INFORMATION-----------------------------------------------MAINTENANCE SCHEDULE-------------------------------------------FUEL LINE/THROTTLE OPERATION --------------------------------SPEED LIMITER/AIR CLEANER --------------------------------------AIR FILTER FOR DRIVE BELT ----------------------------------------SECONDARY AIR SUPPLY SYSTEM --------------------------------SPARK PLUG---------------------------------------------------------------VALVE CLEARANCE ----------------------------------------------------CARBURETOR IDLE SPEED -------------------------------------------CLINDER COMPRESSION/ENGINE OIL ----------------------------REAR DRIVE GEAR OIL ------------------------------------------------FRONT DRIVE GEAR OIL-----------------------------------------------SPARK ARRESTER -------------------------------------------------------DRIVE SHAFT BOOTS ---------------------------------------------------DRIVE BELT/BRAKE PADS INSPECTION --------------------------BRAKE FLUID INSPECTION/HEADLIGHT AIM ------------------STEERING SYSTEM INSPECTION------------------------------------TOE-IN ADJUSTMENT --------------------------------------------------WHEELS/TIRES -----------------------------------------------------------FRONT SHOCK ABSORBER/REAR SHOCK ABSORBER/
DRIVE SELECT LEVER ADJUSTMENT -----------------------------CABLE INSPECTION AND LUBRICATION/ADJUSTING THE
REAR BRAKE LIGHT SWITCH (BRAKE PEDAL) -----------------COOLING SYSTEM-------------------------------------------------------PARKING BRAKE ADJUSTMENT (ON ROAD) ---------------------
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3-13
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3-0
3. INSPECTION/ADJUSTMENT
MXU 500
SERVICE INFORMATION
GENERAL
! WARNING
•Before running the engine, make sure that the working area is well-ventilated. Never run the
engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may
cause death to people.
•Gasoline is extremely flammable and is explosive under some conditions. The working area
must be well-ventilated and do not smoke or allow flames or sparks near the working area or
fuel storage area.
SPECIFICATIONS
Throttle grip free play
Spark plug gap
: 3~5 mm (0.12~0.2 in)
: 0.6~0.7 mm (0.024~0.028 in)
Spark plug: Standard : CR7E (NGK)
Valve clearance
: IN: 0.1 mm (0.004 in)
EX: 0.1 mm (0.004 in)
Idle speed
: 1500±100 rpm
Engine oil capacity
At disassembly : 3.6 liter (3.17 lmp qt, 3.82 Us qt)
At change
: 3 liter (2.64 lmp qt, 3.18 Us qt)
After draining and oil filter cartridge change: 3.2 liter (2.82 lmp qt, 3.39 Us qt)
Front drive gear oil
Recommended oil:
At disassembly:
At change:
SAE 90
300 cc (10.6 lmp oz, 10.1 Us oz)
300 cc (10.6 lmp qt, 10.1 Us qt)
Rear drive gear oil
Recommended oil:
At disassembly:
At change:
SAE 80
150 cc (5.33 lmp oz, 5 Us oz)
130 cc (4.63 lmp qt, 4.33 Us qt)
Cylinder compression: 15 kg/cm² (1500 kPa, 213 psi)
Ignition timing: 5°±1°/1500 rpm
3-1
3. INSPECTION/ADJUSTMENT
MXU 500
Tire pressure
Front
Rear
1 Rider
0.28 kgf/cm² (28 Kpa, 3.2 psi)
0.28 kgf/cm² (28 Kpa, 3.2 psi)
Tire size:
Front : 25X8-12
Rear : 25X10-12
TORQUE VALUES
Spark plug
Tappet ADJ nut
Engine oil filter cap
Engine oil filter cartridge
Engine oil drain plug
Rear drive gear oil drain bolt
Rear drive gear oil level check bolt
Rear drive gear oil filler cap
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
1.2kgf-m (12 N-m, 8.6 lbf-ft)
0.9 kgf-m (9 N-m, 6.5 lbf-ft)
1.5 kgf-m (15 N-m, 11 lbf-ft)
1 kgf-m (10 N-m, 7.2 lbf-ft)
2.5 kgf-m (25 N-m, 18 lbf-ft)
2 kgf-m (20 N-m, 15 lbf-ft)
2 kgf-m (20 N-m, 15 lbf-ft)
1.5 kgf-m (15 N-m, 11 lbf-ft)
3.2 kgf-m (32 N-m, 23 lbf-ft)
3.5 kgf-m (35 N-m, 25.5 lbf-ft)
1 kgf-m (10 N-m, 7.2 lbf-ft)
3.5 kgf-m (35 N-m, 25.2 lbf-ft)
7 kgf-m (70 N-m, 50 lbf-ft)
10 kgf-m (100 N-m, 72 lbf-ft)
SPECIAL TOOLS
Valve adjusting wrench
Oil cartridge wrench
A120E00036
A120E00061
3-2
3. INSPECTION/ADJUSTMENT
MXU 500
MAINTENANCE SCHEDULE
This chapter includes all information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, if 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 ad well as new vehicles that are
being prepared for sale. All service technicians should be familiar with this entire chapter.
3-3
3. INSPECTION/ADJUSTMENT
FUEL LINE
MXU 500
Fuel tubes
Check the fuel tubes and replace any parts,
which show signs of deterioration, damage
or leakage.
* Do not smoke or allow flames or sparks
in your working area.
Fuel Filter
THROTTLE OPERATION
Check the throttle to swing for smooth
movement.
Measure the throttle to swing free play.
Free Play (A): 3~5 mm (0.12~0.2 in)
To adjust throttle free play:
1. Slide the rubber sleeve (1) back to expose
the throttle cable adjuster (2).
2. Loosen the lock nut (3), then turn the
adjuster to obtain the correct free play.
(3~5 mm or 0.12~0.2 in)
3. Tighten the lock nut and reinstall the
sleeve.
Other checks:
Check the throttle cable for kinks and signs
of wear that could cause stretching or
failure. Lubricate the throttle cable with a
commercially available lubricant to prevent
premature wear and corrosion.
3-4
3. INSPECTION/ADJUSTMENT
SPEED LIMITER
The speed limiter keeps the throttle from
fully opening, even when the throttle lever
is pushed to the maximum. Screwing in the
adjuster limits the maximum engine power
available and decreases the maximum speed
of the ATV.
Speed limiter length (A): 13 mm (0.52 in)
Adjustment
1. Loosen the lock nut (1).
2. Turn the adjuster (2) in or out until the
specified speed limiter length is obtained.
Turning in:
Speed limiter length is decreased.
Turning out:
Speed limiter length is increased.
3. Tighten the lock nut.
AIR CLEANER
AIR CLEANER REPLACEMENT
1. Remove the seat (refer to the “FRAME
COVERS” section in the chapter 2).
3. Unlatch the six retainer clips (1) and
remove the air cleaner housing cover (2).
3-5
MXU 500
3. INSPECTION/ADJUSTMENT
MXU 500
3. Loosen the screw (3) and remove the air
cleaner assembly (4) from the air cleaner
housing.
4. Unscrew the clamp (5)
5. Remove the outer air cleaner (7).
6. Remove the screw/washers (6) and
remove the air cleaner assembly from the
air cleaner holder (8).
7. Remove the inner air cleaner (9) and air
cleaner screen (10) from the air cleaner
guide (11).
8. Remove the air cleaner screen from the
inner air cleaner.
CLEAN AIR FILTER ELEMENT
(7)
(8)
(9)
(10)
(11)
Wash the element gently, but throughly in
solvent.
* Use parts cleaning solvent only. Never
use gasoline or low flash point solvents
which may lead to a fire or explosion.
Squeeze the excess solvent out of the
element and let dry.
* Do not twist or wring out the foam
element. This could damage the foam
material.
Apply the engine oil.
Squeeze out the excess oil.
* The element should be wet but not
dripping.
More frequent replacement is required when
riding in unusually dusty or rainy areas.
3-6
3. INSPECTION/ADJUSTMENT
MXU 500
AIR CLEANER HOUSING DRAIN
1. Remove the drain tube (1) by removing
the clip (3).
2. Drain the deposits.
3. Reinstall the drain tube, securing it with
the clip.
AIR FILTER FOR DRIVE BELT
Fastener
To clean the air filter:
Remove front center cover (refer to the
“FRAME COVERS” section in the chapter
2).
Remove a fastener from air inlet hose.
Remove air filter.
Air Filter
Tap the element lightly to remove most of
the dust and dirt.
Blow out the remaining dirt with
compressed air.
Installation is in the reverse order of
removal.
If necessary replace the air filter.
3-7
Air Filter
3. INSPECTION/ADJUSTMENT
MXU 500
SECONDARY AIR SUPPLY
SYSTEM
This model is equipped with a built-in
secondary air supply system. The pulse
secondary air supply system is located on
the cylinder head.
The secondary air supply system introduces
filtered air into exhaust gases in the exhaust
port. The secondary air is drawn into the
exhaust port whenever there is negative
pressure pulse in the exhaust system. This
charged secondary air promotes burning of
the unburned exhaust gases and changes a
considerable amount of hydrocarbons and
carbon monoxide into relatively harmless
carbon dioxide and water.
Check the AICV (air injection control valve)
hoses between the AICV control solenoid
valve and cylinder head for deterioration,
damage or loose connections. Make sure the
hoses are not cracked.
If the hoses show any signs of heat damage,
inspect the AICV check valve in the AICV
reed valve cover damage.
3-8
3. INSPECTION/ADJUSTMENT
SPARK PLUG
MXU 500
Ignition Coil Cap
Disconnect the spark plug cap and clean
around the spark plug.
* Clean around the spark plug base with
compressed air before removing, and be
sure that no debris is allowed to enter the
combustion chamber.
Spark Plug
Remove the spark plug using a equipped
spark plug wrench or an equivalent tool.
Inspect or replace as described in the
maintenance schedule.
INSPECTION
Remove the carbon deposits from the spark
plug with a small wire brush or a spark plug
cleaning machine.
The spark plug should be replaced
periodically. Whenever removing the
carbon deposits, be sure to observe the
operational color of the spark plug's
porcelain tip. This color tells you whether or
not the standard spark plug is suitable for
your type of usage. A normal operating
spark plug should be light brown or tan
color. If the spark plug is very white or
glazed appearing, then it has been operating
much too hot. This spark plug should be
replaced with the colder plug.
Recommended spark plug: NGK: CR7E
3-9
3. INSPECTION/ADJUSTMENT
MXU 500
Measure the spark plug gap between the
center and side electrodes with the feeler
gauge.
If necessary, adjust the gap by bending the
side electrode carefully.
Spark plug gap:
0.6-0.7 mm (0.024-0.028 in)
Install the spark plug in the cylinder head
and hand tighten, then torque to the
specification.
Torque: 1.2 kgf-m (12 N-m, 8.6 lbf-ft)
Install the spark plug cap.
Install the removed parts in the reverse
order of removal.
3-10
3. INSPECTION/ADJUSTMENT
VALVE CLEARANCE
*
MXU 500
Timing Hole Cap/O-ring
Inspect and adjust the valve clearance
while the engine is cold (Below
35°C/95°F).
To adjust:
Remove the right floorboard (refer to the
“FRAME COVERS” section in the chapter
2).
Remove the cylinder head cover (refer to
the “CYLINDER HEAD COVER
REMOVAL/INSTALLATION” section in
the chapter 8).
Crankshaft Hole Cap/O-ring
Remove the timing hole cap and O-ring.
Index Mark
Remove the recoil starter and O-rings (refer
to the “STARTER PULLEY
REMOVAL/INSPECTION/
INSTALLATION” section in the chapter
8).
Turn the crankshaft clockwise and align the
“T” mark on the flywheel with the index
mark on the right crankcase cover.
“T” Mark
Punch Marks
The punch marks on the camshaft should
face upward as shown.
If the punch marks on the camshaft are
facing downward, turn the crankshaft
clockwise one full turn (360°) and the
punch marks are facing upward.
3-11
3. INSPECTION/ADJUSTMENT
Adjust by loosening the valve adjusting
screw lock-nut and turning the adjusting
screw until there is a slight drag on the
thickness gauge.
MXU 500
Wrench Thickness
Gauge Valve Adjusting
Valve clearance (when cold):
IN.: 0.1 mm (0.004 in)
EX.: 0.1 mm (0.004 in)
Apply oil to the valve adjusting screw locknut threads and seating surface.
Hold the adjusting screw and tighten the
lock nut.
Special tool:
Valve adjusting wrench
Lock Nut
A120E00036
Torque: 0.9 kgf-m (9 N-m, 6.5 lbf-ft)
After tightening the lock nut, recheck the
valve clearance.
Install the removed parts in the reverse
order of removal.
CARBURETOR IDLE SPEED
*
The engine must be warm for accurate
idle speed inspection and adjustment.
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed: 1500±100 rpm
When the engine misses or run erratic,
adjust the pilot screw (refer to the
“CARBURETOR
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the chapter 5).
Throttle Stop Screw
3-12
3. INSPECTION/ADJUSTMENT
MXU 500
Compression Gauge
CYLINDER COMPRESSION
Warm up the engine before compression
test.
Remove the spark plug.
Insert a compression gauge.
Open the throttle valve fully and push the
starter button to test the compression.
Cylinder compression:
15 kg/cm² (1500 kPa, 213 psi)
If the compression is low, check for the
following:
- Leaky valves
- Valve clearance too small
- Leaking cylinder head gasket
- Worn piston rings
- Worn piston/cylinder
If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.
Upper Level
ENGINE OIL
OIL LEVEL
Place the machine on a level place.
Warm up the engine for several minutes and
stop it.
*Run the engine for 2~3 minutes and
check the oil level after the engine is
stopped for 2~3 minutes.
Lower Level
Check the oil level through the inspection
window.
The oil level should be between the
maximum (H) and minimum (L) marks. If
the level is low, add oil to raise it to the
proper level.
Recommended engine oil:
KYMCO 4-stroke oil or equivalent motor
oil API service classification: SJ
Viscosity: SAE 5W50
* Other viscosities shown in the chart may
be used when the average temperature in
your riding area is within the indicated
range.
3-13
Inspection Window
3. INSPECTION/ADJUSTMENT
MXU 500
ENGINE OIL REPLACEMENT AND
OIL FILTER CLEANING
1. Place the machine on a level place.
2. Warm up the engine for several minutes
and stop it.
3. Place a container under the engine.
4. Remove the oil filler cap (1).
* Be sure no foreign material enters the
crankcase.
5. Remove the oil filter cap (2) to drain the
oil.
* The engine oil will drain more easily
while the engine is warm.
6. Clean the oil strainer with solvent.
Inspect the O-ring and replace if
damaged. Reinstall the O-ring, oil
strainer, compression spring and oil filter
cap. Tighten the oil filter cap to
specification.
Compression Spring
O-ring
Torque: 1.5 kgf-m (15 N-m, 11 lbf-ft)
7. Fill the engine with oil and install the oil
filler cap.
Oil Strainer
Oil Filter Cap
Engine oil capacity
At disassembly:
3.6 liter (3.17 lmp qt, 3.82 Us qt)
At change:
3 liter (2.64 lmp qt, 3.18 Us qt)
After draining and oil filter cartridge
change:
3.2 liter (2.82 lmp qt, 3.39 Us qt)
3-14
3. INSPECTION/ADJUSTMENT
ENGINE OIL REPLACEMENT (WITH
OR WITHOUT OIL FILTER
CARTRIDGE REPLACEMENT)
1. Place the machine on a level place.
2. Warm up the engine for several minutes
and stop it.
3. Place a container under the engine.
4. Remove the oil fill cap (1).
* Be sure no foreign material enters the
crankcase.
5. Remove the drain plug (2) to drain the
oil.
* The engine oil will drain more easily
while the engine is warm.
* Skip steps 6 to 10 if the oil filter
cartridge is not being replaced.
6. Remove the three fasteners (3) and then
remove right side cover (4).
3-15
MXU 500
3. INSPECTION/ADJUSTMENT
MXU 500
7. Remove the oil filter cartridge (5) with an
oil cartridge wrench.
Special tool:
Oil cartridge wrench
A120E00061
8. Apply a light coat of clean engine oil to
the O-ring (6) of the new oil filter
cartridge.
* Make sure the O-ring is seated properly.
9. Install the new oil filter cartridge with an
oil cartridge wrench, and then tighten it
to the specified torque.
Torque: 1 kgf-m (10 N-m, 7.2 lbf-ft)
10. Install right side cover.
11. Reinstall the drain plug and tighten the
drain plug to the specified torque.
Torque: 2.5 kgf-m (25 N-m, 18 lbf-ft)
12. Add the specified amount of
recommended engine oil, and then
install the engine oil filler cap and
tighten it.
Engine oil capacity
At disassembly:
3.6 liter (3.17 lmp qt, 3.82 Us qt)
At change:
3 liter (2.64 lmp qt, 3.18 Us qt)
After draining and oil filter cartridge
change:
3.2 liter (2.82 lmp qt, 3.39 Us qt)
* Be sure no foreign material enters the
crankcase.
3-16
3. INSPECTION/ADJUSTMENT
13. Start the engine and warm it up for
several minutes. While warming up,
check for oil leakage. If oil leakage is
found, turn the engine off immediately
and check for the cause.
14. Turn the engine off, and then check the
oil level through the inspection window
(7) and correct it if necessary.
REAR DRIVE GEAR OIL
Change the oil in the rear drive gear case
when specified by the Maintenance
Schedule. Change the oil with the rear drive
gear case warm, and the ATV on level
ground to assure complete and rapid
draining.
Rear drive gear oil replacement
1. Remove the two bolts (1) on the skid
plate (2) right/left side and two bolts (3)
under the skid plate, remove skid plate.
2. To drain the oil, first place an oil drain
pan under the oil drain plug (4).
3. Remove the oil filler cap (5), then remove
the drain plug.
4. After the oil has completely drained,
reinstall the drain plug.
Torque: 2 kgf-m (20 N-m, 15 lbf-ft)
5. Fill the gear case with the recommended
oil.
Recommended oil: SAE 80
Oil quantity:
Periodic oil change:
0.13 L (4.63 lmp oz, 4.33 US oz)
Remove the oil level check bolt (6).
Make sure the oil level reaches the oil
level check hole.
3-17
MXU 500
3. INSPECTION/ADJUSTMENT
MXU 500
6. Install the oil filler cap and oil level
check bolt.
Torque:
Oil filler cap: 1.5 kgf-m (15 N-m, 12 lbf-ft)
Oil level check bolt:
2 kgf-m (20 N-m, 15 lbf-ft)
* Be sure no foreign material enters the
crankcase.
7. Install the skid plate.
FRONT DRIVE GEAR OIL
Change the oil in the front drive gear case
when specified by the Maintenance
Schedule. Change the oil with the front
drive gear case warm, and the ATV on level
ground to assure complete and rapid
draining.
Front drive gear oil replacement
1. To drain the oil, first place an oil drain
pan under the oil drain plug (1).
2. Remove the oil filler bolt (2).
3. Remove the drain plug.
4. After the oil has completely drained,
reinstall and tighten the drain plug to the
specified torque.
Torque: 3.2 kgf-m (32 N-m, 23 lbf-ft)
5. Fill the gear case with the recommended
oil.
Recommended oil: SAE 90
Oil quantity:
Periodic oil change:
0.3 L (10.6 lmp oz, 10.1 US oz)
3-18
3. INSPECTION/ADJUSTMENT
6. Remove the oil level check bolt (3).
Make sure the oil level reaches the oil
level check hole.
7. Install and tighten the oil filler bolt and
oil level check bolt to the specified
torque.
Torque:
Oil filler cap:
3.5 kgf-m (35 N-m, 25.5 lbf-ft)
Oil level check bolt:
1 kgf-m (10 N-m, 7.2 lbf-ft)
* Be sure no foreign material enters the
crankcase.
SPARK ARRESTER
Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
1. Remove the three bolts (1).
2. Remove the spark arrester (2) and the
gasket (3) from the muffler.
3-19
MXU 500
3. INSPECTION/ADJUSTMENT
MXU 500
3. Use a brush to remove carbon deposits
from the spark arrester screen. Be careful
to avoid damaging the spark arrester
screen. The spark arrester must be free of
breaks and holes. Replace, if necessary.
Check the gasket. Replace, if necessary.
4. Install the spark arrester and the gasket in
the muffler and tighten the three bolts
securely.
DRIVE SHAFT BOOTS
Check the protective boots for holes or
tears.
If any damage is found, have them replaced.
3-20
3. INSPECTION/ADJUSTMENT
MXU 500
DRIVE BELT
Remove the left crankcase cover (refer to
the “LEFT CRANKCASE COVER
REMOVAL/INSTALLATION” section in the
chapter 10).
Inspect the drive belt for cracks, scaling,
chipping or excessive wear.
Measure the V-belt width
Service limit (A): 30.8 mm (1.232 in)
Replace the drive belt if out of specification.
Refer to the “DRIVE PULLEY, DRIVE
V-BELT AND DRIVEN PULLEY
REMOVAL/INSPECTION/
INSTALLATION” section in the chapter
10 for removal/installation.
BRAKE PADS INSPECTION
A wear indicator is provided on each brake.
The indicators allows checking of brake
pads wear. Check the position of the
indicator. If the indicator reaches the wear
limit line, to replace the pads.
3-21
Drive Belt
(A)
3. INSPECTION/ADJUSTMENT
BRAKE FLUID INSPECTION
MXU 500
Inspection Window (R/L Brake Lever)
Check if the fluid level is below the lower
level mark through the inspection window.
Inspection Window (Rear Brake Pedal)
HEADLIGHT AIM
Adjust Screws
Turn the ignition switch ON and start the
engine.
Turn on the headlight switch.
Adjust the headlight aim by turning the
headlight aim adjusting screws.
3-22
3. INSPECTION/ADJUSTMENT
MXU 500
STEERING SYSTEM
INSPECTION
Place the machine on a level place.
Check the steering column bushings and
bearings:
Move the handlebar up and down, and/or
back and forth.
Replace the steering column bushings and
or bearings if excessive play
Check the tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then slightly move
the handlebar from left to right.
Replace the tie-rod ends if tie-rod end has
any vertical play.
Tie-rod Ends
Raise the front end of the machine so that
there is no weight on the front wheels.
Check ball joints and/or wheel bearings.
Move the wheels lately back and froth.
Replace the front arms and/or wheel
bearings if excessive free play.
3-23
3. INSPECTION/ADJUSTMENT
TOE-IN ADJUSTMENT
Place the machine on a level place.
Measure the toe-in
Adjust if out of specification.
Toe-in measurement steps:
Mark both front tire tread centers.
Raise the front end of the machine so that
there is no weight on the front tires.
Fix the handlebar straight ahead.
Measure the width A between the marks.
Rotate the front tires 180 degrees until the
marks come exactly opposite.
Measure the width B between the marks.
Calculate the toe-in using the formula given
below.
Toe-in = B-A
Toe-in: 0~15 mm (0~0.6 in)
If the toe-in is incorrect, adjust the toe-in.
Adjust the toe-in step:
Mark both tie-rods ends.
This reference point will be needed during
adjustment.
Loosen the lock nuts (tie-rod end) of both
tie-rods
The same number of turns should be given
to both tie-rods right and left until the
specified toe-in is obtained, so that the
lengths of the rods will be kept the same.
Tighten the rod end lock nuts of both tierods
MXU 500
A
B
Tie-rod
Torque: 3.5 kgf-m (35 N-m, 25.2 lbf-ft)
* • Be sure that both tie-rod are turned the
same amount. If not, the machine will
drift tight or left even though the
handlebar is positioned straight which
may lead to mishandling and accident.
• After setting the toe-in to specification,
run the machine slowly for some
distance with hands placed lightly on
the handlebar and check that the
handlebar responds correctly. If not,
turn either the right or left tie-rod
within the toe-in specification.
Tie-rod End Nuts
3-24
3. INSPECTION/ADJUSTMENT
*
MXU 500
The threads on both rod-end must be of
the same length.
WHEELS/TIRES
Check the tires for cuts, imbedded nails or
other damages.
Check the tire pressure.
* Tire pressure should be checked when
tires are cold.
TIRE PRESSURE
1 Rider
Front
0.28 kgf/cm² (28 Kpa, 3.2 psi)
Rear
0.28 kgf/cm² (28 Kpa, 3.2 psi)
TIRE SIZE
Front
Rear
: 25X8-12
: 25X10-12
Check the front axle nut for looseness.
3-25
Front Axle Nut
3. INSPECTION/ADJUSTMENT
MXU 500
Check the rear axle nut for looseness.
If the axle nuts are loose, tighten them to the
specified torque.
Torque:
Front: 7 kgf-m (70 N-m, 50 lbf-ft)
Rear: 10 kgf-m (100 N-m, 72 lbf-ft)
Rear Axle Nut
Inspect the tire surfaces.
Replace if wear or damage.
Tire wear limit: 4 mm (0.16 in)
* It is dangerous to ride with a worn out
tire. When a tire wear is out of
specification, replace the tire
immediately.
WHEEL INSPECTION
Inspect the wheel.
Replace if damage or bends
Always balance the wheel when a tire or
wheel has been changed or replaced.
* • Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a
tire to allow it to seat itself properly on
the rim.
3-26
3. INSPECTION/ADJUSTMENT
FRONT SHOCK ABSORBER
* Always adjust both front shock absorber
spring preload to the same setting.
Uneven adjustment can cause poor
handling and loss of stability.
Adjustment
Turn the adjuster to increase or decrease the
spring preload.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5
REAR SHOCK ABSORBER
* Always adjust both rear shock absorber
spring preload to the same setting.
Uneven adjustment can cause poor
handling and loss of stability.
Adjustment
Turn the adjuster to increase or decrease the
spring preload.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5
DRIVE SELECT LEVER
ADJUSTMENT
1. Turn the ignition switch is ON and make
sure the engine stop.
2. Remove 3 fasteners (1), then remove the
left side cover (2).
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MXU 500
3. INSPECTION/ADJUSTMENT
MXU 500
3. Loosen the lock nuts (3) of rod (4).
4. Remove the bolt and nut from the rod
end (shift arm side).
Bolt/Nut
5. Shift the drive select lever to neutral
along the shift guide.
6. Shift the gear to neutral by moving the
shift arm (The neutral indicator lamp
comes on.)
Shift Arm
3-28
3. INSPECTION/ADJUSTMENT
MXU 500
7. Turn the rod clockwise or
counterclockwise to align the joint ball in
the rod with the hole on the shift arm,
then install and tighten the bolt and nut.
* When align the joint ball in the rod with
the hole on the shift arm. Always keep
the joint ball original position, do not
turn the joint ball.
8. Tighten the lock nuts of the rod.
CABLE INSPECTION AND
LUBRICATION
* Damaged cable sheath may cause
corrosion and interfere with the cable
movement. An unsafe condition may
result so replace such cable as soon as
possible.
Inspect the cable sheath.
Replace if damage.
Check the cable operation.
Lubricate or replace if unsmooth operation.
* Hold cable end high and apply several
drops of lubricant to cable.
LEVER LUBRICATION
Lubricate the pivoting parts of each lever.
Lock Nut
ADJUSTING THE REAR BRAKE
LIIGHT SWITCH (BRAKE
PEDAL)
1. Loosen the lock nut.
2. Turn the adjusting nut clockwise or
counterclockwise until the rear brake
light comes on at the proper time.
3. Tighten the lock nut securely.
3-29
Adjuster
3. INSPECTION/ADJUSTMENT
MXU 500
COOLING SYSTEM
COOLANT LEVEL INSPECTION
Place the machine on the level ground.
Remove the front center cover (refer to the
“FRAME COVERS” section in the chapter
2).
Check the coolant level in the coolant
reservoir when the engine is cold as the
coolant level will vary with engine
temperature. The level should be between
the “FULL” (2) and “LOW” (3) level
surface.
If the level is low, remove the reserve tank
cap (1) and fill the tank to the “FULL”
level line with 1:1 mixture of distilled water
and antifreeze (coolant mixture preparation:
refer to the chapter 6 “COOLING
SYSTEM”)
* Using coolant with silicate inhibitors
may cause premature wear of water
pump seals or blockage of radiator
passages. Using tap water may cause
engine damage.
Check to see if there are any coolant leaks
when the coolant level decrease very
rapidly.
If reserve tank becomes completely empty,
there is a possibility of air getting into the
cooling system.
Be sure to remove all air from the cooling
system (refer to the “COOLANT
REPLACEMENT” section in the chapter
6).
Reinstall the filler cap.
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3. INSPECTION/ADJUSTMENT
Check for any coolant leakage from the
water pump, radiator hoses and hose joints.
Check the radiator hoses for cracks or
deterioration and replace if necessary.
Check that all hose clamps are tight.
Check the radiator air passages for clogs or
damage.
Straighten any bent fins, and remove insects,
mud or other obstructions with compressed
air or low water pressure.
Replace the radiator if the air flow is
restricted over more than 20% of the
radiating surface.
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MXU 500
3. INSPECTION/ADJUSTMENT
MXU 500
REAR PARKING BRAKE
ADJUSTMENT (ON ROAD)
Parking brake adjustment may be required if
the parking brake does not work properly.
Every time the brake pads are replaced,
adjust the parking brake.
To adjust:
1. Release the parking brake lever.
Parking Brake Lever
2. Loosen the lock nut and adjusting bolt on
the rear caliper.
Lock Nut
Adjusting bolt
3-32
3. INSPECTION/ADJUSTMENT
MXU 500
3. Loosen the lock nut and adjuster on the
cable.
4. Turn the adjuster in or out until the
specified brake cable end length “L” is
obtained.
Tighten the lock nut.
Lock Nut
Adjuster
Parking brake cable end length:
L: 53 ± 2 mm (2.12 ± 0.08 in)
5. Slowly turn the adjusting bolt on the
caliper clockwise until resistance is felt,
then turn adjusting bolt 1/8
counterclockwise.
6. Tighten the lock nut to the specified
torque while hold the adjusting bolt.
Torque:
1.6 kgf-m (16 N-m, 11.52 lbf-ft)
Lock Nut
3-33
Adjusting bolt
3. INSPECTION/ADJUSTMENT
MXU 500
7. Check the parking brake lever free play
“C”.
Free play: 0 mm (0 in)
8. If the free play is incorrect, adjust the
free play by adjuster on the cable.
Lock Nut
Adjuster
3-34
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