Kymco MXU 150 Service Workshop Repair Manual

KYMCO SERVICE MANUAL MXU 150 MX’er 150/125 Issued: 08.06.2005 Downloaded from www.Manualslib.com manuals search engine

By KWANG YANG Motor Co., Ltd. First Edition, Jun 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LCA4/LLB1-S00 Downloaded from www.Manualslib.com manuals search engine

PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO ATV 150/125. Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation. 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 18 give instructions for disassembly, assembly and inspection of engine, chassis frame and 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. OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 FRAME COVERS/EXHAUST MUFFLER 2 INSPECTION/ADJUSTMENT 3 LUBRICATION SYSTEM 4 FUEL SYSTEM 5 ENGINE REMOVAL/INSTALLATION 6 CYLINDER HEAD/VALVES 7 CYLINDER/PISTON 8 DRIVE AND DRIVEN PULLEYS 9 FINAL REDUCTION/TRANSMISSION SYSTEM 10 CRANKCASE/CRANKSHAFT/ BALANCE SHAFT 11 FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION/STEERING SYSTEM 12 REAR WHEEL /SWING ARM/HYDRAULIC BRAKE 13 BATTERY/CHARGING SYSTEM/A.C. GENERATOR 14 IGNITION SYSTEM 15 STARTING SYSTEM 16 LIGHTS/SWITCHES 17 ONLY ATV ON ROAD AVAILABLE 18 CHASSIS ELECTRICAL EQUIPMENT ENGINE The information and contents included in this manual may be different from the ATV in case specifications are changed. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation. Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-0 ATV 150/125 1 __________________________________________________________________________________ GENERAL INFORMATION SERIAL NUMBER---------------------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 5 TORQUE VALUES --------------------------------------------------------- 1-13 SPECIAL TOOLS ----------------------------------------------------------- 1-15 LUBRICATION POINTS -------------------------------------------------- 1-16 CABLE & HARNESS ROUTING (MX’er 150/125) ------------------- 1-19 CABLE & HARNESS ROUTING (MXU 150) ------------------------- 1-23 WIRING DIAGRAM-------------------------------------------------------- 1-28 TROUBLESHOOTING----------------------------------------------------- 1-32 1 Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-1 ATV 150/125 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-2 ATV 150/125 SPECIFICATIONS (MX’er 150) Model No. LA30 ATV Name MX’er 150 Overall length 1600 mm (64 in) Overall width 980 mm (39.2 in) Overall height 990 mm (39.6 in) Wheel base 1120 mm (44.8 in) Engine type O.H.C. Displacement 149.4 cc (9.1 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 74 kg (162.8 lbs) Dry weight Rear wheel 78 kg (171.6 lbs) Total 152 kg (334.4 lbs) Front wheel 80 kg (176 lbs) Gross weight Rear wheel 82 kg (180.4 lbs) Total 162 kg (356.4 lbs) Front wheel 20*7-8 Rear wheel 22*10-8 Ground clearance 130 mm (5.2 in) Perform- Breaking distance (m)(ANSI) 20.6 below ance Min. turning radius (m) 3 Starting system Starting motor Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive Bore x stroke 62 x 49.5 mm (2.48 x1.98 in) Compression ratio 9.7:1 Compression pressure (kg/cm²) 1600 kPa (16 kg/cm 2 , 227.2 psi) Open 5.5 BTDC Intake Close 27.5 ABDC Open 36 BBDC Exhaust Close 4 ATDC Intake 0.06 mm (0.0024 in) Valve clearance Exhaust 0.06 mm (0.0024 in) Idle speed 1700 rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 1 liter (0.88 lmp qt, 1.06 US qt) Oil exchanging capacity 0.9 liter (0.79 lmp qt, 0.95 US qt) Cooling Type Air cooling Air cleaner type & No Sponge Fuel capacity 8.1 liters (1.7 lmp gal, 2.11 Usgal) Type PD Float lever 14.8 mm (0.592 in) Venturi dia. 25 mm (1 in) Throttle type PISTON Type CDI Ignition timing 15BTDC/1700rpm Contact breaker Non-contact point type Spark plug (NGK) DE-8EA Spark plug gap 0.6 0.7 mm (0.024 0.028 in) Battery Capacity 12V8AH Clutch type CVT Primary reduction system Helical gear/spur gear Secondary reduction system Chain drive Primary reduction ratio 2.8-0.95 Secondary reduction ratio 7.226 Reverse ratio 26.902 FR/RR tire rolling circumference 1596/1756 mm (63.84/70.24 in) Front 20 kPa (0.2 kg/cm 2 , 2.84 psi) Tire pressure Rear 25 kPa (0.25 kg/cm 2 , 3.55 psi Turning Left 44 angle Right 44 Rear Disk brake Drum brake Brake system type Front Drum brake Suspension Front Swing type Rear Swing arm Shock Front Swing type Rear Swing arm Frame type Steel tube type Tires Lubrication System Fuel System Carburetor Electrical Equipment Ignition System Damping Device Moving Device Power Drive System Engine Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-3 ATV 150/125 (MX’er 125) Model No. LA25 ATV Name MX’er 125 Overall length 1685 mm (67.4 in) Overall width 980 mm (39.2 in) Overall height 990 mm (39.6 in) Wheel base 1120 mm (44.8 in) Engine type O.H.C. Displacement 124 cc (7.55 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 74 kg (162.8 lbs) Dry weight Rear wheel 78 kg (171.6 lbs) Total 152 kg (334.4 lbs) Front wheel 80 kg (176 lbs) Gross weight Rear wheel 82 kg (180.4 lbs) Total 162 kg (356.4 lbs) Front wheel 20*7-8 Rear wheel 22*10-8 Ground clearance 130 mm (5.2 in) Perform- Breaking distance (m)(ANSI) 20.6 below ance Min. turning radius (m) 2.5 Starting system Starting motor Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive Bore x stroke 56.5 x 49.5 mm (2.26 x1.98 in) Compression ratio 9.2:1 Compression pressure (kg/cm²) 1400 kPa (14 kg/cm 2 , 198.8 psi) Open 5.5 BTDC Intake Close 27.5 ABDC Open 36 BBDC Exhaust Close 4 ATDC Intake 0.06 mm (0.0024 in) Valve clearance Exhaust 0.06 mm (0.0024 in) Idle speed 1700 rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 1 liter (0.88 lmp qt, 1.06 US qt) Oil exchanging capacity 0.9 liter (0.79 lmp qt, 0.95 US qt) Cooling Type Air cooling Air cleaner type & No Sponge Fuel capacity 8.1 liters (1.7 lmp gal, 2.11 Usgal) Type PD Float lever 14.8 mm (0.592 in) Venturi dia. 25 mm (1 in) Throttle type PISTON Type CDI Ignition timing 15BTDC/1700rpm Contact breaker Non-contact point type Spark plug (NGK) DR-8EA Spark plug gap 0.6 0.7 mm (0.024 0.028 in) Battery Capacity 12V8AH Clutch type CVT Primary reduction system Helical gear/spur gear Secondary reduction system Chain drive Primary reduction ratio 2.8-0.95 Secondary reduction ratio 7.226 Reverse ratio 26.902 FR/RR tire rolling circumference 1596/1756 mm (63.84/70.24 in) Front 20 kPa (0.2 kg/cm 2 , 2.84 psi) Tire pressure Rear 25 kPa (0.25 kg/cm 2 , 3.55 psi Turning Left 44 angle Right 44 Rear Disk brake Drum brake Brake system type Front Drum brake Suspension Front Swing type Rear Swing arm Shock Front Swing type Rear Swing arm Frame type Steel tube type Tires Lubrication System Engine Fuel System Carburetor Electrical Equipment Ignition System Damping Device Moving Device Power Drive System Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-4 ATV 150/125 (MXU 150) Model No. LA30 ATV Name MXU 150 Overall length 1775 mm (71 in) Overall width 950 mm (38 in) Overall height 1040 mm (41.6 in) Wheel base 1115 mm (44.6 in) Engine type OHC Displacement 149 cc (9.1 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 87 kg (191.4 lbs) Dry weight Rear wheel 88 kg (193.6 lbs) Total 175 kg (385 lbs) Front wheel 92 kg (202.4 lbs) Gross weight Rear wheel 93 kg (204.6 lbs) Total 185 kg (407 lbs) Front wheel 21*7-10 Rear wheel 22*10-10 Ground clearance 155 mm (6.2 in) Perform- Breaking distance (m)(ANSI) 20.6 below ance Min. turning radius (m) 3 Starting system Starting motor Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive Bore x stroke 62 x 49.5 (2.48 x1.98 in) Compression ratio 9.7:1 Compression pressure 1600 kPa (16 kg/cm 2 , 227.2 psi) Open 5.5 BTDC Intake Close 27.5 ABDC Open 36 BBDC Exhaust Close 4 ATDC Intake 0.06 mm (0.0024 in) Valve clearance Exhaust 0.06 mm (0.0024 in) Idle speed 1700 rpm Lubrication type Forced pressure & Wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 1 liter (0.88 lmp qt, 1.06 US qt) Oil exchanging capacity 0.9 liter (0.79 lmp qt, 0.95 US qt) Cooling Type Air cooling Air cleaner type & No Sponge Fuel capacity 8.1 liters (1.7 lmp gal, 2.11 Usgal) Type PD Piston dia. 14.8 mm (0.592 in) Venturi dia.(mm) 25 mm (1 in) Throttle type PISTON Type CDI Ignition timing 15BTDC/1700rpm Contact breaker Non-contact point type Spark plug (NGK) DR-8EA Spark plug gap 0.6 0.7 mm (0.024 0.028 in) Battery Capacity 12V8AH Clutch type CVT Primary reduction system Helical gear/spur gear Secondary reduction system Chain drive Primary reduction ratio 2.8-0.95 Secondary reduction ratio 7.226 Reverse ratio 26.902 FR/RR tire rolling circumference 1675/1756 mm (67/70.24 in) Front 28 Kpa (0.28 kg/cm 2 , 3.976 psi) Tire pressure Rear 28 Kpa (0.28 kg/cm 2 , 3.976 psi) Turning Left 40 angle Right 40 Brake system Rear Disk brake Drum brake type Front Drum brake Suspension Front Swing type Rear Swing arm Shock Front Swing type Rear Swing arm Frame type Steel tube pipe Lubrication System Tires Fuel System Carburetor Electrical Equipment Ignition System Damping Device Power Drive System Moving Device Engine Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-5 ATV 150/125 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. Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-6 ATV 150/125  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. Downloaded from www.Manualslib.com manuals search engine

Kymco MXU 150 Service Workshop Repair Manual

You're Reading a Preview

Recently Viewed