KYMCO MXU 500 2010 – 2012 ATV Service Manual Printed by Cyclepedia

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The CYCLEPEDIA PRESS LLC 2010 – 2012 KYMCO MXU 500 4×4 and MXU 500i ATV service manual features detailed, photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran dealer trained ATV technician.

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KYMCO MXU 500 ATVs covered by this online service manual:

2010 KYMCO MXU 500 4×4 IRS
2011 KYMCO MXU 500 4×4 IRS
2012 KYMCO MXU 500 4×4 IRS

2010 KYMCO MXU 500 LE 4×4 IRS
2011 KYMCO MXU 500 LE 4×4 IRS

2012 KYMCO MXU 500i IRS LE
2012 KYMCO MXU 500i

The KYMCO MXU 500 ATV online manual covers the following topics:

Note: Printed manuals are in black and white.

General Information

KYMCO MXU 500 4x4 atv specifications service information torque specs wiring diagram hose routing

Serial Number Locations
Service Precautions
Torque Values
Special Tools
Lubrication Points
Cable and Harness Routing
Wiring Diagram

Frame Covers-Exhaust Muffler

KYMCO MXU 500 irs 4x4 atv seat removal bodywork cargo rack fenders

Service Information
Fasterner Removal and Reinstallation
Frame Covers
Exhaust Muffler Removal

KYMCO MXU 500 4wd atv oil change level inspection filter replacement

Service Information
Maintenance Schedule
Fuel Line/Throttle Operation
Air Cleaner
Spark Plug
Front Drive Gear Oil
Spark Arrester
Drive Shaft Boots
Valve Clearance
Carburetor Idle Speed
Cylinder Compression
Engine Oil
Rear Drive Gear Oil
Rear Parking Brake Adjustment
Brake Fluid/Headlight Aim
Drive Belt/Brake Pads Inspection
Steering System Inspection
Toe-In Adjustment
Drive Select Lever Adjustment
Cable Inspection and Lubrication
Cooling System

Lubrication System

KYMCO MXU 500 4x4 atv oil pump replacement lubrication system diagram oil flow chart

Lubrication System Diagram
Service Information
Engine Oil & Oil Filter
Oil Pump

Fuel System

 KYMCO MXU 500 4x4 carburetor jets float bowl height inspection vacuum diaphragm cap

Service Information
Fuel Tank
Fuel Valve
Carburetor Removal/Choke Inspection/Installation
Carburetor Disassembly/Inspection/Assembly
Air Cleaner Housing
Pair Solenoid Valve

Fuel Injection System

Cooling System

KYMCO MXU 500 4x4 atv coolant replacement filling draning bleeding thrermostat

System Flow Pattern
Service Information
Cooling System Testing
Coolant Replacement
Fan Motor
Fan Motor Switch
Radiator Reserve Tank
Water Pump
Water Temperature Sensor

Engine Removal

KYMCO MXU 500 4x4 engine removal and installation instructions

Service Information
Engine Removal

Cylinder Head / Valves

KYMCO MXU 500 4x4 cylinder head removal camshaft timing

Service Information
Cylinder Compression Test
Cylinder Head Removal/Installation
Cylinder Head Cover Disassembly/Assembly
Cylinder Head Cover Removal/Installation
Camshaft Removal/Inspection/Installation
Rocker Arms Removal/Inspection/Installation
Cylinder Head Disassembly/Inspection/Assembly
Cam Chain Removal/Inspection/Installation


KYMCO MXU 500 4x4 cylinder and piston removal and inspection

Schematic Drawing
Service Information
Cylinder and Piston Removal/Inspection/Installation

Drive And Driven Pulleys

KYMCO MXU 500 4x4 CVT clutch removal and inspection

Schematic Drawing
Service Information
Clutch Disassembly/Inspection/Assembly
Drive Pulley Disassembly/Inspection/Assembly
Driven Pulley Disassembly/Inspection/Assembly
Left Crankcase Cover Removal/Installation
Drive Pulley, Drive V-Belt and Driven Pulley Removal/Inspection/Installation
Clutch Removal/Installation

Final Reduction
KYMCO MXU 500 4x4 transmission shifting shaft inspection shift fork shaft

Service Information
Right Crankcase Removal/Installation
Bearing Replacement in the Right Crankcase
Countershaft Disassembly/Assembly/Inspection
Secondary Drive/Driven Bevel Gear Removal/Inspection/Installation
Secondary Gear Shims Adjustment
Transmission Removal/Inspection/Installation
Upper Shift Fork Disassembly/Assembly
Drive Shaft Disassembly/Assembly/Inspection

Left Crankcase/Crankshaft/Balance Shaft

KYMCO MXU 500 4x4 crankcase crankshaft balancer shaft

Service Information
Crankshaft and Balance Shaft Removal/Inspection/Installation
Bearing/Oil Seal Replacement in the Left Crankcase

Brake System

KYMCO MXU 500 4x4 brake master cylinder rebuild caliper fluid bleeding

Service Information
Brake Pad Replacement
Combination Brake Fluid Change/Air Bleed (On Road)
Rear Brake/Parking Brake Caliper Disassembly/Inspection/Assembly (on Road)
Rear Brake/Parking Brake Caliper Removal/Installation (On Road)
Relay Valve Removal/Disassembly/Inspection/Assembly/Installation (On Road)
Front Brake Discs Removal/Inspection/Installation
Front Brake Fluid Change / Air Bleed (Off Road)
Brake Master Cylinders Removal/Inspection/Installation
Front Brake Calipers Removal/Installation
Brake Master Cylinder Disassembly/Inspection/Assembly
Rear Brake Disc Removal/Inspection/Installation
Rear Brake Fluid Change/Air Bleed
Brake Caliper Disassembly/Inspection/Assembly
Rear Brake Calipers Removal/Installation

Suspension/Steering System

KYMCO MXU 500 4x4 front suspension steering shaft tie-rods knuckles

Front Arms Disassembly/Inspection/Assembly
Service Information
Front Arms Inspection/Removal/Installation
Front Wheel Hub Removal/Inspection/Installation
Steering Knuckle Disassembly/Assembly
Steering Knuckle Removal/Inspection/Installation
Tie Rod Removal/Inspection/Installation
Front Wheel Removal/Inspection/Installation
Front Shock Absorber Removal/Inspection/Installation
Handlebar Removal/Inspection/Installation
Steering Column Removal/Inspection/Installation

Drive Train

KYMCO MXU 500 4x4 front differential final drive gear inspecation lubrication oil change

Service Information
Front Drive Shaft Removal/Inspection/Installation
Front Drive Shaft Disassembly/Inspection/Assembly
Front Drive Removal/Inspection/Installation
Front Drive Disassembly/Inspection/Assembly
Front Drive Shim Adjustment
Rear Drive Removal/Inspection/Installation
Rear Drive Disassembly/Inspection/Assembly
Rear Drive Shim Adjustment
Front Propeller Shaft Disassembly/Inspection/Assembly
Rear Propeller Shaft Disassembly/Inspection/Assembly

Rear Wheel /Axle/Shock Absorber/Swing Arm


Service Information
Rear Axle Housing Disassembly/Assembly
Rear Axle Housing Removal/Inspection/Installation
Rear Axle Removal/Inspection/Installation
Rear Shock Absorber Removal/Inspection/Installation
Rear Swing Arm Disassembly/Inspection/Assembly
Rear Swing Arm Removal/Installation
Rear Wheel Removal/Inspection/Installation
Rear Wheel Hub Removal/Inspection/Installation

Battery-Charging System AC Generator

KYMCO MXU 500 4x4 generator regulator/rectifier testing charging system battery

Charging System Layout/Charging Circuit
Service Information
Charging System Inspection
Alternator Charging Coil
Alternator Stator Removal/Inspection/Installation

Ignition System

KYMCO MXU 500 4wd ICM ignition coil testing spark plug replacement

Ignition System Layout
Ignition Circuit
Service Information
Ignition Coil Inspection
Ignition Control Module

Starting System

KYMCO MXU 500 4x4 starter motor relay inspection starter clutch

Service Information
Starting System Layout
Starting Circuit
Starter Motor
Starter Relay Switch/Starter Mag
Recoil Starter Removal/Inspection/Assembly
Recoil Starter Handle Replace
Recoil Starter Disassembly/Inspection/Assembly
Starter Pulley Removal/Inspection/Installation
Starter Clutch Removal/Inspection/Installation

Lights / Switches

KYMCO MXU 500 4x4 light bulb replacement switch continuity inspection

Service Information
Bulb Removal
Horn (On Road Only)
Ignition Switch
Handlebar Switch
Gear Indicator Switch
Speed Sensor
2WD/4WD Selecting System
Fuel Unit

KYMCO MXU 500 ATV Troubleshooting

Additional information

Weight 3 lbs
Dimensions 13 × 12 × 2 in