5.

FUEL SYSTEM MXU 500

5
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5
FUEL SYSTEM
__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 5- 2
TROUBLESHOOTING----------------------------------------------------- 5- 3
FUEL TANK ----------------------------------------------------------------- 5- 4
FUEL VALVE --------------------------------------------------------------- 5- 4
CARBURETOR REMOVAL/CHOKE INSPECTION/INSTALLATION-- 5- 7
CARBURETOR DISASSEMBLY/INSPECTION/ASSEMBLY ----- 5- 9
AIR CLEANER HOUSING ------------------------------------------------ 5-19
PAIR SOLENOID VALVE ------------------------------------------------ 5-20

5-0
5. FUEL SYSTEM MXU 500

5-1
5. FUEL SYSTEM MXU 500

SERVICE INFORMATION
GENERAL INSTRUCTIONS

Gasoline is very dangerous. When working with gasoline, keep sparks and flames away
from the working area.
Gasoline is extremely flammable and is explosive under certain conditions. Be sure to
work in a well-ventilated area.

• Do not bend or twist control cables. Damaged control cables will not operate smoothly.
• When disassembling fuel system parts, note the locations of O-rings. Replace them with new
ones during reassembly.
• Before float chamber disassembly, loosen the drain screw to drain the residual gasoline into a
clean container.
• After the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent
foreign matters from entering.
• When cleaning the carburetor air and fuel jets, the O-rings and diaphragm must be removed first
to avoid damage. Then, clean with compressed air.
• When the machine is not used for over one month, drain the residual gasoline from the float
chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel.

SPECIFICATIONS
Item Standard
Type CVK
I.D. No. L88A ATKF
Bore size φ36.5 mm (φ1.46 in)
Float level 17 mm (0.67 in)
Main jet No. ON ROAD #128
OFF ROAD #130
Slow jet No. #40
Choke jet No. #90
Idle speed 1500±100 rpm
Throttle grip free play 3～5 mm (0.12～0.2 in)
Pilot screw opening 1 1/4±1/2

5-2
5. FUEL SYSTEM MXU 500

TROUBLESHOOTING
Engine cranks but won’t start Engine lacks power
• No fuel in tank • Clogged air cleaner
• No fuel to carburetor • Faulty carburetor
• Cylinder flooded with fuel • Faulty ignition system
• No spark at plug
• Clogged air cleaner Lean mixture
• Intake air leak • Clogged carburetor fuel jets
• Improper throttle operation • Float level too low
• Intake air leak
Engine idles roughly, stalls or runs poorly • Clogged fuel tank cap breather hole
• Excessively used choke • Kinked or restricted fuel line
• Ignition malfunction
• Faulty carburetor Rich mixture
• Poor quality fuel • Float level too high
• Lean or rich mixture • Clogged air jets
• Incorrect idle speed • Clogged air cleaner

Misfiring during acceleration

• Faulty ignition system
• Faulty carburetor

Backfiring at deceleration
• Float level too low
• Incorrectly adjusted carburetor
• Faulty exhaust muffler

5-3
5. FUEL SYSTEM MXU 500

Fuel Tube
FUEL TANK

REMOVAL
Warning
• Keep sparks and flames away from the
work area.
• Wipe off any spilled gasoline.

Remove the seat, right and left side frame

cover and fuel tank cover (refer to the
“FRAME COVERS” section in the chapter
2).

Switch the fuel valve “OFF”. Fuel Valve

Remove the 2 mounting bolts.
Disconnect the fuel tube from carburetor.

Disconnect the fuel unit connectors.

Remove the two bolts and two nuts from the
fuel tank, then remove the fuel tank.

INSTALLATION

Fuel tank installation is in the reverse order

of removal.

Fuel Unit Connectors

Fuel Tubes
FUEL VALVE
REMOVAL
＊ • Keep sparks and flames away from the
work area.
• Drain gasoline into a clean container.
Remove the screw and then remove control
switch.
Disconnect all fuel tubes and remove the two
screws, then remove fuel valve.

Control Switch Fuel Tube

5-4
5. FUEL SYSTEM MXU 500

Screws Control Shaft Washer

DISASSEMBLY

Remove the two screws on the retaining ring

and then remove retaining ring.
Remove the washer and control shaft.

Retaining Ring

Rubber Gasket Fuel Valve Body

Remove the rubber gasket from the fuel
valve body.

INSPECTION

Inspect the fuel valve body for dirt and clog.

Clean if necessary.
Replace the rubber gasket with new ones if
they are damaged or deteriorated.

Control Shaft O-ring

Replace the O-ring with a new one if they
are damaged or deteriorated.

5-5
5. FUEL SYSTEM MXU 500

Tab Tab
ASSEMBLY

Reverse the “DISASSEMBLY” procedures.

Install rubber gasket, control shaft, washer
and retaining ring.

＊ • Aligning the tab on the control shaft

with the outlet duct in the fuel valve
body.
• Aligning the tab on the retaining ring
with the outlet duct in the fuel valve Outlet Duct Outlet Duct
body.

Main Fuel Tube Outlet Fuel Tube

INSTALLATION

Reverse the “REMOVEAL” procedures.

Connect all fuel tube.

Reserve Fuel Tube

Arrow Mark

Install the fuel filter with the arrow mark

facing forward.

Fuel Filter

5-6
5. FUEL SYSTEM MXU 500

Over Flow Hose

CARBURETOR REMOVAL/CHOKE
INSPECTION/INSTALLATION

REMOVAL

Remove the fuel tank (refer to the “FUEL

TANK” section in this chapter).
Remove the air cleaner housing (refer to the
“AIR CLEANER HOUSING” section in
this chapter).

Disconnect the over flow hose.

Loosen the carburetor clamp screw, then
remove carburetor from intake pipe.
Carburetor Clamp Screw

Throttle Cable

Remove a screw, then remove the throttle

valve cover.
Disconnect the throttle cable from
carburetor.

Throttle Valve Cover

Choke Cable Choke Plunger

Remove the choke cable/choke plunger from
carburetor, then remove the carburetor.

5-7
5. FUEL SYSTEM MXU 500

CHOKE INSPECTION O-ring

Inspection the choke plunger, spring and O-

ring for bends, wear or damage.

Spring Choke Plunger

Lug

INSTALLATION

Installation is in the reverse order of

removal.
＊ Make sure the lug on the carburetor into
the cutout on the intake pipe.

Cutout

Cutout

＊ Make sure the lug on the carburetor into

the cutout on the air cleaner hose.

Lug

5-8
5. FUEL SYSTEM MXU 500

CARBURETOR
DISASSEMBLY/INSPECTION/
ASSEMBLY
DISASSEMBLY
Remove the carburetor (refer to the
“CARBURETOR REMOVAL/CHOKE
INSPECTION/INSTALLATION” section in
this chapter).

Loosen the drain screw to drain the gasoline

from the float chamber.
＊ • Keep sparks and flames away from the
Fuel Drain Plug
work area.
• Drain gasoline into a clean container.
• Do not loosen or tighten the painted
bolts and screws of the carburetor.
Loosening or tightening them can
cause throttle and piston valve
synchronization failure. Top Cap

Remove the four screws and top cap

Spring

Remove the spring and piston valve.

Piston Valve

5-9
5. FUEL SYSTEM MXU 500

Remove the spring retainer, jet needle. Jet Needle Spring Retainer

Piston Valve

Casting Enrichment Valve Cover/Spring O-ring

Remove the two screws and casting enrichment
valve cover and then take out the spring.

Remove the casting enrichment valve and O-

ring.

Casting Enrichment Valve

Accelerating Pump Cover/Spring O-ring

Remove the three screws and accelerating
pump cover and then take out the spring.

Remove the accelerating pump and O-ring.

Accelerating Pump Diaphragm

5-10
5. FUEL SYSTEM MXU 500

Remove the four screws and float chamber.

Float Chamber

Float Float Valve

Pull float pin outs, then remove the float and
float valve.

Float Valve

Slow Jet Needle Jet Holder

Remove the slow jet.
Remove choke jet.
Remove main jet.

Remove the needle jet holder.

Choke Jet Main Jet

5-11
5. FUEL SYSTEM MXU 500

Needle Jet
Remove the needle jet.

Remove the pilot screw, spring, washer and

O-ring.
＊ Before pilot screw removal, slowly turn
the pilot screw clockwise and count the
number of turns until the screw is
lightly seated. Make a note of how
many turns were made so the screw can
be reset correctly.

Pilot Screw

5-12
5. FUEL SYSTEM MXU 500

INSPECTION

CARBURETOR BODY/JETS CLEANING

Check carburetor body and each jet for wear

or damage.

Clean all jets with a spray-type carburetor

cleaner and dry them using compressed air.
Clean all circuits of the carburetor
thoroughly-not just the perceived problem
area.

Clean the circuits in the carburetor body with

a spray-type cleaner and allow each circuit to
soak, if necessary, to loosen dirt and varnish.
Blow the body dry using compressed air.
＊ ● Some carburetor cleaning chemicals ,
especially dip type soaking solutions,
are very corrosive and must be handled
carefully. Always follow the chemical
manufacturer’s instructions on proper
use, handling and storage.
● Do not use a wire to clean the jets or
passageways. A wire can damage the
jets and passageways. If the
components cannot be cleaned with a
spray cleaner it may be necessary to
use a dip-type cleaning solution and
allow them to soak. Always follow the
chemical manufacturer’s instructions
for proper use and cleaning of the
carburetor components.

After cleaning, reassemble the carburetor

with new seals.

5-13
5. FUEL SYSTEM MXU 500

Float Float Tang

Check the float and float tang for
deformation or damage.

Check the float valve and valve seat for

foreign substance, clogging or damage.
Check the tip of the float valve, where it
contacts the valve seat, for stepped wear or
contamination.
Check the operation of the float valve.

Piston Valve

Check the piston valve for scratches, wear

and damage.

Check the rubber diaphragm for tears.

Rubber Diaphragm

5-14
5. FUEL SYSTEM MXU 500

Check top cap and spring for cracks and

damage.

Top Cap Spring

Spring Covers
Check the diaphragms (coasting enrichment
valve and accelerating pump) for tears.

Check the spring (coasting enrichment valve

and accelerating pump) and cover (coasting
enricher and accelerating pump) for damage.

Diaphragms Spring

Jet Needle
Check jet needle, needle jet, slow jet, needle
jet holder, main jet, choke jet and pilot screw
for bends, wear and damage.
Needle Jet

Slow Jet

Needle Jet Holder

Pilot Screw

Main Jet

Choke Jet

5-15
5. FUEL SYSTEM MXU 500

Insert the piston valve into the carburetor

body, and check for free movement. If stick
is found, replace the part with a new one.

Check throttle valve for free movement.

If stick is found, replace the part with a new
carburetor.

Check the float level after checking the float

valve, valve seat and float.
(A)
Set the carburetor so that the float valve end
just contacts the float arm lip. Make sure the
float valve tip is securely in contact with the
valve seat.
Measure the float level with the float level
gauge.

Float level (A): 17 mm (0.67 in)

Bend the tongue as necessary to bring the

float height (A) to the specified level.

5-16
5. FUEL SYSTEM MXU 500

ASSEMBLY

Carburetor reassembly can be performed in

the reverse order of disassembly. When
reassembling, carefully observe the
following instructions.

＊
● Assemble the parts taking
consideration of their function.
● Before assembling, wash all of the
parts in a clean petroleum based
solvent.
● Replace O-rings and seals with new
ones.
● After cleaning, reinstall the pilot screw
to the original setting by turn the screw
in until it lightly seats, and then
backing it out the same number of
turns counted during disassembly.

(1) Spring
(2) Retainer (1)
(3) Jet needle
(3)
(4) Piston valve
(5) Cover (2)
(6) Choke plug
(7) Spring
(5)
(8) Guide holder (4)
(9) Cap
(10) Cover
(11) Spering
(12) Casting enrichment valve (6)
(13) O-ring (7)
(8)
(14) Choke jet
(9)
(15) Main jet
(16) Needle jet holder
(17) Needle jet (11)
(18) Slow jet (16)
(19) Float valve
(17)
(20) Float (22) (12) (10)
(21) Float pin (14)
(22) Pilot screw (13)
(18)
(19) (15)
(20) (21)

5-17
5. FUEL SYSTEM MXU 500

Fit a new O-ring in to the float chamber

groove securely.

O-ring

Small Convex O-ring Accelerating Pump Cover

Assemble the accelerating pump diaphragm
and new O-ring.
＊ Install the accelerating pump
diaphragm with the small convex facing
up

Accelerating Pump Diaphragm

5-18
5. FUEL SYSTEM MXU 500

AIR CLEANER HOUSING Band Screw

REMOVAL/INSTALLATION

Remove the seat and side covers (refer to the

“FRAME COVERS” section in the chapter
2).

Loosen the carburetor-to-air cleaner

connecting tube band screw.

Remove the clip and disconnect the

crankcase breather hose from the crankcase.
Remove the mounting bolts and then remove
the air cleaner housing from the carburetor
and the intake duct.

Installation is in the reverse order of

removal.

Breather Hose

5-19
5. FUEL SYSTEM MXU 500

Vacuum Hose
PAIR SOLENOID VALVE

REMOVAL/INSTALLATION

Disconnect air supply hose and vacuum hose

from the air solenoid valve, then remove the
air solenoid valve from frame.

PAIR Solenoid Valve Air Supply Hose

Installation is in the reverse order of

removal.

5-20
6. COOLING SYSTEM MXU 500

6
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__________________________________________________________________________________

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COOLING SYSTEM
__________________________________________________________________________________
6
SYSTEM FLOW PATTERN----------------------------------------------- 6- 1
SERVICE INFORMATION------------------------------------------------ 6- 2
TROUBLESHOOTING----------------------------------------------------- 6- 4
COOLING SYSTEM TESTING------------------------------------------- 6- 5
COOLANT REPLACEMENT --------------------------------------------- 6- 5
THERMOSTAT-------------------------------------------------------------- 6- 8
WATER PUMP -------------------------------------------------------------- 6-11
RADIATOR ------------------------------------------------------------------ 6-14
FAN MOTOR SWITCH ---------------------------------------------------- 6-15
FAN MOTOR ---------------------------------------------------------------- 6-16
WATER TEMPERATURE SENSOR ------------------------------------ 6-17
RAIDATOR RESERVE TANK ------------------------------------------- 6-18

6-0
6. COOLING SYSTEM MXU 500

SYSTEM FLOW PATTERN

6-1
6. COOLING SYSTEM MXU 500

SERVICE INFORMATION

GENERAL INSTRUCTIONS

WARING:
Removing the radiator cap while the engine is hot can allow the coolant to spray out,
seriously scalding you. Always let the engine and radiator cool down before removing the
radiator cap.

CAUTION:
Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes.

• If any coolant gets in your eyes, rinse them with water and consult a physician immediately.
• If any coolant in swallowed, induce vomiting, gargle and consult a physician immediately.
• If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.

NOTE:
Use coolant with silicate inhibitors may cause premature wear of water pump seals or blockage
of radiator passages. Using tap water may cause engine damage.

• This section covers service of the cooling system.

• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the
system.
• All cooling system services can be done with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.

SPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 2 liter (2.1 US qt, 1.76 lmp qt)
Reserve tank 0.45 liter (0.47 US qt, 0.39 lmp qt)
Radiator cap relief pressure 90 kPa (0.9 kgf/cm2, 12.8 psi)
Begin to open 80 - 84°C (176 - 183°F)
Thermostat Fully open 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum
Standard coolant concentration 1:1 mixture with soft water

6-2
6. COOLING SYSTEM MXU 500

COOLANT GRAVITY CHART

Temp. ℃
Coolant 0 5 10 15 20 25 30 35 40 45 50
concentration
5% 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.009 0.997
10% 1.018 1.107 1.017 1.016 1.015 1.014 0.013 1.011 1.009 1.007 1.005
15% 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20% 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25% 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30% 1.053 1.051 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032
35% 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40% 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45% 1.080 1.078 1.076 1.074 1.072 1.069 1.056 1.063 1.062 1.057 1.054
50% 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55% 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60% 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071

COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS)

Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water
-9℃ 20%
-15℃ 30% 425cc 975cc
-25℃ 40%
-37℃ 50%
-44.5℃ 55%

Cautions for Using Coolant:

• Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant
concentrate + 975cc distilled water is 30%.)
• Do not mix coolant concentrate of different brands.
• Do not drink the coolant which is poisonous.
• The freezing point of coolant mixture shall be 5℃lower than the freezing point of the riding
area.

6-3
6. COOLING SYSTEM MXU 500

TORQUE VALUES

Water pump cover bolt 1.3 kgf-m (13 N-m, 9 lbf-ft)

Fan motor bolt 0.53 kgf-m (5 N-m, 3.8 lbf-ft)
Fan motor switch 1.8 kgf-m (17 N-m, 13 lbf-ft)

TROUBLESHOOTING

Engine temperature too high

• Faulty radiator cap
• Faulty temperature gauge or thermosensor
• Air in system
• Thermostat stuck closed
• Insufficient coolant
• Passages blocked in radiator, hoses or water jacket
• Faulty cooling fan motor
• Faulty fan motor switch
• Faulty water pump

Engine temperature too low

• Faulty temperature gauge or thermosensor
• Thermostat stuck open
• Faulty fan motor switch

Coolant leak
• Faulty water pump mechanical seal
• Deteriorated O-rings
• Faulty radiator cap
• Damaged or deteriorated cylinder head gasket
• Loose hose connection or clamp
• Damaged or deteriorated hoses

6-4
6. COOLING SYSTEM MXU 500

COOLING SYSTEM TESTING

Cap Tester
RADIATOR CAP INSPECTION

Remove the radiator cap (refer to the

“COOLANT REPLACEMENT” section
in this chapter).

Pressure test the radiator cap.

Replace the radiator cap if it does not hold Radiator Cap
pressure, or if relief pressure is too high or
too low.
It must hold the specified pressure for at
least six seconds.
＊ Before installing the cap in the tester,
wet the sealing surface.

Cap Tester
Radiator Cap Relief Pressure:
90 kPa (0.9 kg/cm², 12.8 psi)

Pressurize the radiator, engine and hoses,

and check for leaks.
＊ Excessive pressure can damage the
cooling system components.
Do not exceed 105 kPa (1.05 kg/cm²,
14.9 psi).
Repair or replace components if the system
will not hold the specified pressure for at
least six seconds.

COOLANT REPLACEMENT

PREPARATION

● The effectiveness of coolant decreases

with the accumulation of rest or if there is
a change in the mixing proportion during
usage. Therefore, for best performance
change the coolant regularly as specified
in he maintenance schedule.
● Mix only distilled, low mineral water
with the antifreeze.

Recommended mixture:
1:1 (Distilled water and antifreeze)

6-5
6. COOLING SYSTEM MXU 500

Radiator Cap
REPLACEMENT/AIR BLEEDING

Remove the front center cover and right

footboard (refer to the “FRAME
COVERS” section in the chapter 2).
＊ When filling the system or reserve tank
with coolant (checking the coolant
level), place the machine in a vertical
position on a flat, level surface.

Remove the radiator cap.

Bypass Hose
Loosen the hose band
Disconnect the bypass hose from water
pump or remove the drain plug and drain
the coolant from the system.

Drain Plug Band

Reserve Tank Cap

Remove the reserve tank cap and drain the
coolant from the reserve tank.

Reconnect the bypass hose securely.

Reserve Tank

6-6
6. COOLING SYSTEM MXU 500

Reserve Tank Cap

Place the machine on a flat, level surface.
Fill the reserve tank to the upper level
(FULL) line.

Filler Neck
Fill the system with the recommended
coolant through the filler opening up to the
filler neck.

Bleed air from the system as follow:

1. Start the engine and let it idle for 2−3
minutes.
2. Snap the throttle three to four times to
bleed air from the system.
3. Stop the engine and add coolant to the
proper level if necessary. Reinstall the
radiator cap.
4. Check the level of coolant in the reserve
tank and fill to the upper level if it is
low.

6-7
6. COOLING SYSTEM MXU 500

THERMOSTAT
REMOVAL

Remove the nut and thermostat housing

stay from the frame.

Remove the bolts, housing stay and

thermostat housing cover.

Housing stay Thermostat Housing Cover

Thermostat
Remove the O-ring from the housing cover.
Remove the thermostat.

O-ring

Thermostat

6-8
6. COOLING SYSTEM MXU 500

INSPECTION

Visually inspect the thermostat for damage. Thermostat

Heat the water with an electric heating Thermometer

element to operating temperature for five
minutes.
Suspend the thermostat in heated water to
check its operation.
＊ ● Keep flammable materials away from
the electric heating element.
● Do not let the thermostat or
thermometer touch the pan, or you will
get false readings.

Replace the thermostat if the valve stays

open at room temperature, or if it respond at
temperatures other than those specified.

Thermostat begin to open:

80−84°C (176−183°F)

Valve lift:
8 mm (0.3 in) minimum at 95°C (203°F)

Air Bleed Hole

INSTALLATION

Install the thermostat into the housing with

its air bleed hole facing up and aligning
bleed hole with the tab in the housing.

Tab Align

6-9
6. COOLING SYSTEM MXU 500

O-ring
Install a new O-ring into the housing cover
groove.

Install the housing cover and housing stay

to the housing.
Tighten the bolts securely.

Install the housing stay to the frame.

Tighten the nut securely.

Fill the system with recommended coolant

and bleed the air (refer to the “COOLANT
REPLACEMENT” section in this
chapter).

6-10
6. COOLING SYSTEM MXU 500

WATER PUMP

MECHANICAL SEAL INSPECTION

Inspect the coolant leakage.

If there is leakage, the mechanical seal is
defective, and water pump body should be
replaced.

REMOVAL

Drain the coolant (refer to the “COOLANT

REPLACEMENT” section in this
chapter).

Loosen the hose bands and disconnect the

lower radiator hoses and bypass hose from
the water pump.

Bypass Hose

Remove the four bolts and water pump

cover and O-ring.

Water Pump Cover/O-ring

6-11
6. COOLING SYSTEM MXU 500

Water Pump Body

Remove the water pump body from the
crankcase.

Align
INSTALLATION

Apply engine oil to a new O-ring and install

it onto the stepped portion of the water
pump.

Install the water pump into the crankcase

while aligning the water pump shaft groove
with oil pump shaft end.

O-ring

Align the mounting bolt holes in the water

pump and crankcase and make sure the
water pump is securely installed.

Install a new O-ring into the groove in the

water pump cover.

O-ring

6-12
6. COOLING SYSTEM MXU 500

Install the water pump cover and tighten the

bolts to the specified toque.

Torque: 1.3 kgf-m (13 N-m, 9 lbf-ft)

Water Pump Cover/O-ring

Water Hose

Connect the water hoses and bypass hose,

then tighten the hose bands.

Fill the system with recommended coolant

and bleed the air (refer to the “COOLANT
REPLACEMENT” section in this
chapter).

Water Hose Bypass Hose

6-13
6. COOLING SYSTEM MXU 500

Fan Guide
RADIATOR
REMOVAL

Drain the coolant (refer to the “COOLANT

REPLACEMENT” section in this
chapter).
Remove the front fender (refer to the
“FRAME COVERS” section in the
chapter 2).

Remove the four mounting bolt from fan

guide and then remove fan guide.

Water Filler Hose Upper Water Hose

Loosen the hose bands and disconnect the
radiator lower water hose, water filler hose,
bleed hose and upper water hose from the
radiator.
Disconnect the fan switch connectors.

Lower Water Hose Bleed Hose Fan Motor SW

Remove the two mounting bolts under radiator

and two mounting bolts on the radiator, then
remove radiator.

＊ Be careful not to damage the radiator

core.

INSTALLATION

Installation is in the reverse order of

removal.
Fill the system with recommended coolant
and bleed the air (refer to the “COOLANT
REPLACEMENT” section in this
chapter).

6-14
6. COOLING SYSTEM MXU 500

FAN MOTOR SWITCH

REMOVAL

Disconnect the fan motor switch connectors

(refer to the “RADIATOR” section in this
chapter).

Remove the fan motor switch.

Fan Motor Switch

INSPECTION

Place the fan motor switch in oil contained

in a pan as shown and raise the oil
temperature gradually to check for the
temperature at which the switch starts to
operate.
If the switch operating temperature is not
within the specified range, replace the
switch with a new one.
OFF→ON Over 88−92°C
ON→OFF Lower 88−92°C
＊ ● Handle the cooling fan motor switch
carefully as it is vulnerable to impact.
● Do not allow the cooling fan motor
switch Îand the thermometer Ïto
come in contact with the bottom of the
pan. O-ring

INSTALLATION

Fit the O-ring.

Tighten the cooling fan motor switch to
specified torque.

Torque: 1.8 kgf-m (17 N-m, 13 lbf-ft)

＊ ● Replace the O-ring a new one.
● Do not coat grease to the O-ring.

6-15
6. COOLING SYSTEM MXU 500

FAN MOTOR Fan Motor Connector

REMOVAL

Remove the front fender (refer to the

“FRAME COVERS” section in the
chapter 2)

Disconnect the fan motor connector.

Remove the four mounting bolts and then
remove the fan motor

INSPECTION

Check the fan motor to operate using an

available battery.

INSTALLATION

Installation is in the reveres order of

removal.

6-16
6. COOLING SYSTEM MXU 500

Water Temperature Sensor

WATER TEMPERATURE
SENSOR

Remove the right side body cover and right

footboard (refer to the “FRAME
COVERS” section in the chapter 2).

Disconnect the water temperature sensor

connector.
Remove the water temperature sensor from
the water joint.

Water joint
INSPECTION

Connect the water temperature sensor to the

ohmmeter and dip it in oil contained in a Water Temperature Sensor
pan which is placed on an electric heater.
Gradually raise oil temperature while
reading the thermometer in the pan and the
ohmmeter connected. If the resistance
measured is out of specification, replace the
temperature gauge with a new one.
Temperature Standard resistance
50ºC 123.9–478.9 Ω Thermometer
100ºC 26–29.3 Ω

＊ ● Handle the water temperature sensor

carefully as it is vulnerable to impact.
● Do not allow the water temperature
sensor and the thermometer to come in
contact with the bottom of the pan.

After the water temperature sensor has been

installed, fill coolant and perform air
bleeding (refer to the “COOLANT
REPLACEMENT” section in this
chapter).

INSTALLATION

With thread lock applied to the threaded

part, tighten the water temperature sensor.

Torque: 0.8 kgf-m (8 N-m, 5.8 lbf-ft)

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6. COOLING SYSTEM MXU 500

RADIATOR RESERVE TANK

REMOVAL

Remove the front fender (refer to the

“FRAME COVERS” section in the
chapter 2).

Remove the two mounting bolts and then

remove the radiator reserve tank from
frame.

Open the reserve tank cap and drain the

coolant from the reserve tank.

Disconnect the siphon hose.

INSTALLATION

Installation is in the reverse order of

removal.

Pour the recommended coolant to the upper

level line with the center stand applied
Siphon Hose

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