Kymco MXU 50 ATV OEM Service & Repair Manual

By KWANG YANG Motor Co., Ltd. First Edition, Jan 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100LB10DE

PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO MXU 50 REVERSE/MXU 50/MX’ER 50. 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 19 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/CYLINDER/PISTON 7 A.C. GENERATOR 8 KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY 9 FINAL REDUCTION (MXU 50/MX’ER 50) 10 FINAL REDUCTION/TRANSMISSION SYSTEM (MXU 50 REVERSE) 11 CRANKCASE/CRANKSHAFT 12 FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION/STEERING SYSTEM 13 REAR WHEEL /SWING ARM/HYDRAULIC BRAKE 14 BATTERY/CHARGING SYSTEM/A.C. GENERATOR 15 IGNITION SYSTEM 16 STARTING SYSTEM 17 LIGHTS/SWITCHES 18 ONLY ATV ON ROAD AVAILABLE 19 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. ENGINE CHASSIS ELECTRICAL EQUIPMENT

1. GENERAL INFORMATION 1-0 ATV 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER---------------------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 5 TORQUE VALUES --------------------------------------------------------- 1-13 SPECIAL TOOLS ----------------------------------------------------------- 1-14 LUBRICATION POINTS -------------------------------------------------- 1-14 CABLE & HARNESS ROUTING (MX’ER 50) ------------------------ 1-17 CABLE & HARNESS ROUTING (MXU 50 REVERSE/MXU 50) - 1-21 WIRING DIAGRAM (MX’ER 50 ON ROAD) ------------------------- 1-26 WIRING DIAGRAM (MX’ER 50 OFF ROAD) ------------------------ 1-27 WIRING DIAGRAM (MXU 50 ON ROAD) ---------------------------- 1-28 WIRING DIAGRAM (MXU 50 REVERSE ON ROAD) -------------- 1-29 TROUBLESHOOTING----------------------------------------------------- 1-30 1

1. GENERAL INFORMATION 1-1 ATV 50 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number

1. GENERAL INFORMATION 1-2 ATV 50 SPECIFICATIONS Model No. LA10 Name MX’ER 50 Overall length 1685 mm (67.4 in) Overall width 980 mm (39.2 in) Overall height 1030 mm (41.2 in) Wheel base 1120 mm (44.8 in) Engine type Air cooled 2-stroke Displacement 49.4 cm 3 (2.964 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 67 kg (147.4 lbs) Dry weight Rear wheel 73 kg (160.6 lbs) Total 140 kg (308 lbs) Front wheel 73 kg (160.6 lbs) Curb weight Rear wheel 77 kg (169.4 lbs) Total 150 kg (330 lbs) Front wheel 20*7-8 Tires Rear wheel 22*10-8 Ground clearance 130 mm (5.2 in) Min. turning radius 2500 mm (100 in) Starting system Starting motor & kick starter Type Air cooled 2-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement Reed valve & piston Bore x stroke 39 x 41.4 mm (1.56 x 1.656 in) Compression ratio 7.2:1 Compression pressure 12 kgf/cm 2 (1200 kPa, 170.4 psi) Open Port Intake Close Automatic controlled timing Open Exhaust Close Automatic controlled Intake － Valve clearance Exhaust － Idle speed (rpm) 1800 Lubrication type Separate type Oil pump type Plunger type Oil filter type Full-flow filtration Air cleaner type Sponge Fuel capacity 8.1 liters Type PB Main jet No. 80 Venturi dia φ14 mm (φ0.56 in) Throttle type Valve piston Type CDI Ignition timing 22°/2000 rpm Spark plug NGK-BR8HAS Spark plug gap 0.6～0.7mm Battery Capacity 12V4AH Clutch Type CVT Operation Automatic centrifugal Type Type Chain drive Reduction 1st － ratio 2nd － Final gear ratio 23.678 Front Caster angle － Axle Trail length － Front 0.35 kgf/cm 2 (35 kPa, 4.97 psi) Tire pressure Rear 0.35 kgf/cm 2 (35 kPa, 4.97 psi) Turning Left 44° angle Right 44° Brake system Rear Disk brake type Front Drum brake Suspension Front Swing type Rear Swing arm Shock b b Front Swing type Rear Swing arm Frame type SP pipe Engine Fuel System Carburetor Electrical Equipment Ignition System Power Drive System Reduction Gear Moving Device Damping Device

1. GENERAL INFORMATION 1-3 ATV 50 Model No. LB10 Name MXU 50 Overall length 1775 mm (71 in) Overall width 950 mm (38 in) Overall height 1040 mm (41.6 in) Wheel base 1120 mm (44.8 in) Engine type Air cooled 2-stroke Displacement 49.4 cm 3 (2.964 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 87 kg (191.4 lbs) Dry weight Rear wheel 89 kg (195.8 lbs) Total 176 kg (387.2 lbs) Front wheel 92 kg (202.4 lbs) Curb weight Rear wheel 94 kg (206.8 lbs) Total 186 kg (409.2 lbs) Front wheel 21*7-10 Tires Rear wheel 22*10-10 Ground clearance 165 mm (6.6 in) Min. turning radius 2900 mm (116 in) Starting system Starting motor & kick starter Type Air cooled 2-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement Reed valve & piston Bore x stroke 39 x 41.4 mm (1.56 x 1.656 in) Compression ratio 7.2:1 Compression pressure 12 kgf/cm 2 (1200 kPa, 170.4 psi) Open Port Intake Close Automatic controlled timing Open Exhaust Close Automatic controlled Intake － Valve clearance Exhaust － Idle speed (rpm) 1800 Lubrication type Separate type Oil pump type Plunger type Oil filter type Full-flow filtration Air cleaner type Sponge Fuel capacity 8.1 liters Type PB Main jet No. 80 Venturi dia φ14 mm (φ0.56 in) Throttle type Valve piston Type CDI Ignition timing 22°/2000 rpm Spark plug NGK-BR8HAS Spark plug gap 0.6～0.7mm Battery Capacity 12V8AH Clutch Type CVT Operation Automatic centrifugal Type Type Chain drive Reduction 1st － ratio 2nd － Final gear ratio 23.678 Front Caster angle － Axle Trail length － Front 0.28 kgf/cm 2 (28 kPa, 4 psi) Tire pressure Rear 0.28 kgf/cm 2 (28 kPa, 4 psi) Turning Left 40° angle Right 40° Brake system Rear Disk brake type Front Drum brake Suspension Front Swing type Rear Swing arm Shock b b Front Swing type Rear Swing arm Frame type SP pipe Engine Fuel System Carburetor Electrical Equipment Ignition System Power Drive System Reduction Gear Moving Device Damping Device

1. GENERAL INFORMATION 1-4 ATV 50 Model No. LB10 Name MXU 50 REVERSE Overall length 1786 mm (71 in) Overall width 958 mm (38 in) Overall height 1010 mm (40 in) Wheel base 1105 mm (44 in) Engine type Air cooled 2-stroke Displacement 49.4 cm 3 (2.964 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 78 kg (171.6 lbs) Dry weight Rear wheel 80 kg (176 lbs) Total 158 kg (347.6 lbs) Front wheel 83 kg (182.6 lbs) Curb weight Rear wheel 84 kg (184.8 lbs) Total 167 kg (36734 lbs) Front wheel 21*7-10 Tires Rear wheel 22*10-10 Ground clearance 162 mm (6.6 in) Min. turning radius 2900 mm (116 in) Starting system Starting motor & kick starter Type Air cooled 2-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement Reed valve & piston Bore x stroke 39 x 41.4 mm (1.56 x 1.656 in) Compression ratio 7.2:1 Compression pressure 12 kgf/cm 2 (1200 kPa, 170.4 psi) Open Port Intake Close Automatic controlled timing Open Exhaust Close Automatic controlled Intake － Valve clearance Exhaust － Idle speed (rpm) 1800 Lubrication type Separate type Oil pump type Plunger type Oil filter type Full-flow filtration Air cleaner type Sponge Fuel capacity 8.1 liters Type PB Main jet No. 80 Venturi dia φ14 mm (φ0.56 in) Throttle type Valve piston Type CDI Ignition timing 13.5°/1500 rpm Spark plug NGK-BR8HAS Spark plug gap 0.6～0.7mm Battery Capacity 12V8AH Clutch Type CVT Operation Automatic centrifugal Type Primary reduction system Helical gear/spur gear Secondary reduction system Chain drive Primary reduction ratio 1.2 – 3.5 Secondary reduction ratio 20.12 Reverse ratio 46.11 Front Caster angle － Axle Trail length － Front 0.28 kgf/cm 2 (28 kPa, 4 psi) Tire pressure Rear 0.28 kgf/cm 2 (28 kPa, 4 psi) Turning Left 40° angle Right 40° Brake system Rear Disk brake type Front Drum brake Suspension Front Swing type Rear Swing arm Shock b b Front Swing type Rear Swing arm Frame type SP pipe Engine Fuel System Carburetor Electrical Equipment Ignition System Power Drive System Moving Device Damping Device

1. GENERAL INFORMATION 1-5 ATV 50 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.

1. GENERAL INFORMATION 1-6 ATV 50 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.

1. GENERAL INFORMATION 1-7 ATV 50 If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire. Check if any connector terminal is bending, protruding or loose. Confirm Capacity

Kymco MXU 50 ATV OEM Service & Repair Manual

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