Kymco xciting 500 Installation And Removal Manual

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Filed Under (Kymco) by admin on 04-05-2012

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Refer to diagram for bracket identification 1. Place scooter in a secure upright position. 2. Remove center stand and underseat storage compartment 3. Attach bracket E to center stand mounting brackets using new bolts provided 4. Use jack underneath scooter to support scooter weight and remove left rear shock bolts. 5. Attach bracket C (left) to top of left rear shock tower using new bolt provided. Insert bolt through bracket, top of rear shock, and thread into shock tower. Reattach left lower shock bolt and tighten at this time. 6. Remove right rear shock bolts and attach bracket D (right) to top of right rear shock tower using new bolt provided. Insert bolt through bracket, top of rear shock, and thread into shock tower. Reattach right lower shock bolt and tighten at this time. 7. Ensure shock bolts are replaced and remove jack from step 4. 8. Attach wheels and axles to MiniTrike frame and carefully position in proper relation behind scooter. 9. Attach bottom of brackets C/D to rear mounting plate on MiniTrike frame 10. Attach brackets A (left) / B (right) to forward mounting points on MiniTrike frame.

Kymco People 125/ 150 FRONT WHEEL/ FRONT BRAKE/ FRONT SUSPENSION

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Filed Under (Kymco) by admin on 12-12-2010

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SERVICE INFORMATION GENERAL INSTRUCTIONS Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. During servicing, keep oil or grease off the brake drum and brake linings. Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads. Do not use brake fluid for cleaning. Bleed air from the brake system if the brake system is removed or the brake is soft. Do not allow any foreign matters to enter the brake system when filling it with brake fluid. Brake fluid will damage painted surfaces and plastic parts. When servicing the brake system, use shop towels to cover and protect rubber, plastic parts and coated surfaces. Wipe off any spilled brake fluid with a clean shop towel. Inspect the brake system before riding. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Axle shaft runout ─ 0.2 Radial ─ 2.0 Axial ─ 2.0 Front brake lining thickness 5.5 2.75 Front shock absorber spring free length 260 252 Brake disk thickness 3.2_3.5 3.0 Brake disk runout ─ 0.25 Brake master cylinder I.D. 12.700_12.74312.75 Brake master cylinder piston O.D. 12.657_12.68412.64 Brake caliper piston O.D. 33.910_33.93433.901 Brake caliper cylinder I.D.

KYMCO MXU 500 SPECIFICATION AND OWNER'S MANUAL

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Filed Under (Kymco) by admin on 12-11-2010

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OFF ON (1) CONTROL FUNCTIONS 17 (1) Ignition switch (2) Key IGNITION SWITCH ON: Functions oft he respective switch positions areas follows: The key cannot be removed. Theenginecanbe started. OFF: “”: All electrical circuits are switched off except hazard light. The key can be removed in this position. All electrical circuits are switched on. The ignitions witch is ON while the position light and taillightwill light. All electrical circuits are switched on. Theenginecanbe started. The key cannot be removed. 18 INSTRUMENTS AND INDICATOR (1) Multi-function display (2) (3) (5) (6) Low-range indicator light”L” (7) High-range indicator light”H” (8) Neutral indicator light”N” (9) Reverse indicator light”N: (10) Park indicator light”P” (11) (12) Right turn signal indicator High beam indicator (4) Coolant temperature warning indicator Set button Mode button Left turn signal indicator (11) (2) (3) (4) (5) (8) (1) Multi-function display The display includes the following functions: Speedometer Odometer/Tripmeter Digital clock 2WD/4WDindicator Fuel gauge (2) Right turn signal indicator Flashes when the right turn signal operates. (3) High beam indicator The ignition switch is at the”"position, the high beam indicator will light when the headlight switch to select High beam () . Both left and right turn signal indicator will flash at the meantime when the hazard switch is operated and turn signal switch is turned off. NOTE: (12) (1) (7) (6) (9) (10) TRIP ODO mile kmPM 2WD 4WD SET MODE PRNHL
19 (4) Coolant temperature warning indicator When the coolant temperature reachesa specified level, this indicator comes onto warn that the coolant temperature is too hot. If the indicator comes on during operation, stopt he engine as soon as it is safe to do so and allow the engine to cooldown for about 10 minutes. (5) Set button This button is used to select ODO, TRIP A andT RIPB. This button is also used to adjust the time and reset the tripmeter. (6) Low-range indicator light”L” This indicator light comes on when the drive select lever is in the”L”position. (7) High-range indicator light”H” This indicator light comes on when the drive select lever is in the”H”position. (8) Neutral indicator light”N” This indicator light comes on when the drive select lever is in the”N”position

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KYMCO MXU 300/ 250 SPECIFICATION AND OWNER'S MANUAL

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Filed Under (Kymco) by admin on 12-11-2010

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FRAMES ERIAL NUMBER The frames erial number is stamped on the front oft he frame. (1) Frame serial number (2) Engine serial number 11 (1) (2) (01) Rear brake lever (03) Front brake lever (04) Right front turn signal light (02) Headlights/Position lights (05) Steering handlebar lock (06) Left front turn signal light 12 PARTS LOCATION (01) (02) (02) (03) (04) (05) (06) (07) Right rear turn signal light (08) Ta illights/Stoplights (11) Exhaust system (12) Trailer hitch (13) License light (14) Battery (09) Instrument and indicators (10) Left rear turn signal light (09) (08) (08) (10) (07) 13 (14) (13) (11) (12) 14 (15) Drive select lever Tool kit (19) Reservoir water tank (20) Brake pedal fluid reservoir (16) Fuel valve (17) Seat (18) (16) (15) (18) (17) (19) (20) 15 (21) ) Choke knob (23) Recoil starter Exhaust system (22 (23) (22) (21) (24) Front brake lever ) Front cargo rack (26) Front brake fluid reservoir (27) Ignition switch (28) Rear (29) Accessory socket seat (30) Rear brake lever (31) (32) Leftfootpeg /Parking brake (25 brake fluid reservoir Headlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch (33) Fuel fill cap (34) Throttle lever (35) Rightfootpeg (36) Rear brake pedal 16 (33) (34) (32) (31) (35) (36) (24) (25) (26) (27) (28) (29) (30) NOTE: Themachineyou have purchased may differ slightly from those shown in the figures of this manual. (37) Rear cargo rack ) Flagpole bracket (38

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KYMCO Super 8 150 Exhaust System with M-2 Canister Installation Instructions

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Filed Under (Kymco) by admin on 26-10-2010

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1.*Make*sure*the*bike*is*completely*cool*before*starting* the*installation.*Make*sure*the*bike*is*secure*on*a* centerstand*or*ideally*a*service*lift. 2.*Remove*OEM*exhaust*assembly. 3.*Attach*supplied*muffler*hanger*bracket*using*the* supplied*flange*bolts*and*tighten*to*15lbs-ft. 4.*Attach*TBR*header*to*muffler*using*the*X-ring*and*4* 6x14mm*bolts*with*lock*washers*provided,*leave*loose* for*now. 5.*Install*TBR*exhaust*to*scooter*keeping*the*OEM*exhaust* gasket*between*header*and*cylinder*head. 6.*Slide*rubber*lined*muffler*clamp*over*muffler*assembly* and*secure*to*bracket*using*supplied*8x20mm*bolt*and* nut. 7 .*Check*muffler*alignment*and*tighten*header*nuts*then* X-ring*bolts*and*finally*muffler*clamp*bolt. 8.*Before*you*run*the*bike,*clean*off*all*fingerprints*and* dirt,*as*any*oily*residue*will*etch*the*metal*and*become* somewhat*permanent*when*the*system*gets*hot.*Run* the*bike*and*enjoy.*It*is*normal*for*some*white*smoke*to* appear*the*first*time*you*start*the*bike.*This*is*packing/ manufacturing*oil*from*inside*the*pipe*burning*off.* Check*for*gaps*or*leaks.*If*you*find*a*leak,*a*little*high* temperature*silicon*sealant*should*fix*it.*After*50*to*100* miles,*recheck*all*fasteners*for*tightness. Qty.*Description* Part*Number 1* Muffler*Canister*M-2** Varies 1* Header* 005-27401H 1* Muffler*Clamp* Varies 1* HARDWARE*KIT* 005-274-3 2* *X-Ring* (half)* 005-7-2-3 1* *Long*Muffler*Mounting*Bracket* 005-274-B 1* *8mm*Flange*Nut* 005-FN8

KYMCO MXU 375 ATV WINCH MOUNT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kymco) by admin on 26-10-2010

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WINCH MOUNT INSTALLATION INSTRUCTIONS 1. Remove molded plastic bumper guard from the ATV. 2. Mount the winch mount weldment (Item 1) to the ATV as shown below. 3. Mount the roller hawse to the winch mount weldment as shown above. 4
4. Mount the winch to the winch mount weldment and route the winch cable through the rollers. (Installer may need to remove rollers to allow cable end to pass through). 5. Wire the winch according to the manufacturer instructions. 6. Re-install the molded plastic bumper guard. 5 *CAUTION BE AWARE OF WHEN THE CABLE STOP CONTACTS THE ROLLER HAWSE AS CABLE IS WOUND IN. FAILURE TO RELEASE MAY CAUSE DAMAGE TO WINCH PARTS OR TO THE ATV. When using the winch to raise and lower a blade a cable stop must be installed. Carefully raise the blade until the top of the push tube’s are no closer than 1″ anywhere on the ATV. Place the Cable Stop onto the Winch Cable up against the Winch Hawse. Secure the Cable Stop to the Winch Cable using the Cable Clamp Assembly as shown in the pictures below.

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Kymco MXU 250 WINCH MOUNTING KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kymco) by admin on 26-10-2010

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Begin by placing winch in freespool. Support the winch so that it will stand upright on the workbench, Fig. 1. This will ensure that the winch drivetrain will not be dislocated during disassembly. 2. Remove the two lower cap screws and nuts. Next remove the two upper cap screws, Fig. 2. Figure 2: Remove Cap Screws Figure 1: Position the Winch Upright Lower Cap Screws Upper Cap Screws Freespool Lever Position 3 Lift the gear housing straight up off the gears. Take care not to disturb the gear set. 4. Rotate the gear housing clockwise 90 degrees and place back down over the gear set. It may take slight twisting motion to have the housing align and drop over the gear set. 5. Align holes and replace hardware securing the endhousing back on the winch. Torque bolts to 45 in-lbs. The winch is now ready to be installed. Figure 3: Lift Gear Housing Figure 5: Reinstall Hardware Figuere 4: Rotate and Replace Gear Housing Rotate and Lower IV. Kymco MXU 250 Installation 1. Begin by removing the plastic bumper located on the front of the ATV. Remove the four front bolts and two bolts securing the bumper on the back side, Fig. 6. 2. Set the bumper aside. Save the fasteners to reinstall the bumper.

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KYMCO CLUTCH KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kymco) by admin on 26-10-2010

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Remove the key from the ignition switch. Remove the passenger seat, the plastic cover around the sides of the passenger seat support brackets and the support brackets to gain access to remove the fuel tank. The fuel tank is held in place by 2 straps and 1 center bolt. After removing the straps/bolt the tank will need to be lifted and twisted to slide it forward and out. You need to nearly stand it up on end to get it out from between the braces surrounding it. Next remove the clutch cover bolts (8mm Socket). Note the length of the bolts and their location. Remove the clutch cover being careful not to damage the gasket. Set cover and gasket on a flat clean surface. 2. Once the clutch cover is removed you should be able to see both clutches. Remove the nut (26mm) that holds the primary clutch (front clutch) on. Pull the clutch off the machine and place it face down on a flat clean surface. Carefully slide the inside plate up and out of the clutch. This should reveal eight clutch rollers. 3. Remove all eight of the stock rollers and set them to the side. Press the new weights supplied in the kit into the new roller housings supplied in the kit and then place the complete rollers in the clutch where you removed the stock ones. The weights can only be pushed into the housings one direction, make sure you are inserting them the right way or damage can occur. Make sure you have all eight of the rollers in the proper place and position. Reinstall the inside plate making sure all the rollers are in the proper location. Place clutch out of the way and start working on the secondary clutch. NOTE: IF YOUR KIT INCLUDES 2 DIFFERENT SETS OF 4 ROLLERS, YOU NEED TO BE SURE TO INSTALL EACH MATCHING EPI ROLLER DIRECTLY ACROSS FROM EACH OTHER (OR IN AN EVERY OTHER SEQUENCE) IN THE CLUTCH TO MAINTAIN A BALANCED SET-UP

KYMCO MAXXER 300/ 250 MONGOOSE 300/ 250 SERVICE MANUAL

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Filed Under (Kymco) by admin on 26-10-2010

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apply or add designated greases and lubricants to the specified lubrication points. ÑAfter reassembly, check all parts for proper tightening and operation. ÑWhen two persons work together, pay attention to the mutual working safety. ÑDisconnect the battery negative (-) terminal before operation. ÑWhen using a spanner or other tools, make sure not to damage the motorcycle surface. ÑAfter operation, check all connecting points, fasteners, and lines for proper connection and installation. ÑWhen connecting the battery, the positive (+) terminal must be connected first. ÑAfter connection, apply grease to the battery terminals. ÑTerminal caps shall be installed securely. 1 . GENERAL INFORMATION 1-6 ATV 300/250 ÑIf the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. ÑAfter operation, terminal caps shall be installed securely. ÑWhen taking out the connector, the lock on the connector shall be released before operation. ÑHold the connector body when connecting or disconnecting it. ÑDo not pull the connector wire. ÑCheck if any connector terminal is bending, protruding or loose. Confirm Capacity 1 . GENERAL INFORMATION 1-7 ATV 300/250 ÑThe connector shall be inserted completely. ÑIf the double connector has a lock, lock it at the correct position. ÑCheck if there is any loose wire

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