KYMCO 150 MXU - User manual

OWNER'S MANUAL
MXU 150/250/300 OFF-ROAD
Do not remove this Owner’s Manual from this ATV
according to the guidelines and agreement with the U.S.
Consumer Product Safety Commission.
Read this manual carefully.
It contains important safety information.

KYMCO is certificated to ISO9001, ISO13485, ISO14001, OHSAS18001, etc.; and
accredited to ISO17025. Details at http://www.kymco.com/

IMPORTANT NOTICES
READ THIS MANUAL CAREFULLY
Your Owner's Manual contains important information on safety, operation, and
maintenance. Any one who operates this ATV should carefully read and
understand the contents of this manual before riding the vehicle.
AGE RECOMMENDATION
The minimum recommended age for this ATV model is 16. Children under age 16
should never operate this vehicle.
RIDER TRAINING
Anyone who operates this vehicle should get proper instruction.
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only. This machine is
designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark
arrester laws and regulation in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this
machine.
A

SPECIAL MESSAGES
KYMCO provides many important safety messages both in this manual and on the
vehicle. For your safety and the safety of others, pay special attention to all
warnings preceded by this alert symbol . Failure to follow the warnings
contained in this manual can result in SERIOUS INJURY or DEATH.
Indicates a strong possibility that serious injury or death may
result if instructions are not followed.
CAUTION Indicates a possibility that equipment or property damage
could result if instructions are not followed.
Note: Gives helpful information
The Owner's Manual should be considered a permanent part of your ATV. It should
remain with the vehicle at all times and stay with the ATV if it is sold.
B
WARNING

PREFACE
Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a
worldwide reputation for quality-in research, design, production and service.
For replacement parts and accessories, we recommend genuine KYMCO
products. They've been specially designed for your vehicle and manufactured to
meet KYMCO's demanding standards.
This manual will provide you with a good basic understanding of the features and
operation of this machine. This manual includes important safety information. It
provides information about special techniques and skills necessary to ride your
machine. It also includes basic maintenance and inspection procedures. If you
have any questions regarding the operation or maintenance of your machine,
please consult a KYMCO dealer.
We wish you many years of safe and enjoyable riding.
While reading this manual, remember:
Indicates a strong possibility that serious injury or death may
result if instructions are not followed.
All information in this publication is based on the latest product information
available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD
reserves the right to make changes at any time without notice and without
incurring any obligation.
C
WARNING

D
CONTROL FUNCTIONS....................20
IGNITION SWITCH/HEADLIGHT &
POSITION LIGHT SWITCH..................20
INSTRUMENTS AND INDICATOR........21
Multi-function display.......................23
HANDLEBAR SWITCHES....................31
Headlight dimmer switch..................31
KICK STARTER (MXU 150)..................36
THROTTLE LEVER.............................37
SPEED LIMITER.................................38
FRONT BRAKE ..................................39
Start button.....................................32
Engine stop switch...........................33
Passing signal switch.......................34
RECOIL STARTER (MXU 300/250).......35
REAR BRAKE ....................................39
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS...................1
SAFETY INFORMATION......................7
DESCRIPTION AND MACHINE
IDENTIFICATION................................13
IDENTIFICATION NUMBER
RECORDS..........................................13
KEY IDENTIFICATION NUMBER.........13
FRAME SERIAL NUMBER...................14
ENGINE SERIAL NUMBER..................14
PARTS LOCATION.............................15
Page Page
(Cont'd)

E
PARKING BRAKE...............................40
DRIVE SELECT LEVER.......................41
FUEL TANK CAP ................................42
FUEL VALVE......................................43
CHOKE KNOB....................................45
SEAT (MXU 300/250)..........................46
SEAT (MXU 150).................................47
FLAG POLE BRACKET.......................48
TRAILER HITCH.................................48
STORAGE COMPARTMENT................49
ACCESSORY SOCKET
SEAT (MXU 300/250)...........................49
PRE-OPERATION CHECKS.............51
DRIVE SELECT LEVER ......................52
Drive select lever adjustment............54
FRONT AND REAR BRAKES................56
FUEL...............................................57
ENGINE, TRANSMISSION OIL AND
REAR FINAL GEAR CASE OIL..............59
CHAIN..............................................60
THROTTLE LEVER.............................60
FITTINGS AND FASTENERS...............60
LIGHTS..............................................60
SWITCHES.........................................60
TIRES................................................61
How to measure tire pressure ...........63
Tire wear limit .................................63
COOLANT (MXU 300/250) ...................64
Page Page
(Cont'd)

F
RIDING YOUR ATV ............................81
GETTING TO KNOW YOUR ATV .........82
RIDE WITH CARE AND
JUDGEMENT......................................83
APPAREL...........................................85
PRE-OPERATION CHECKS................88
Speed limiter
LOADING AND ACCESSORIES..........90
Loading and Operational Guidelines...90
Accessories.....................................91
MODIFICATIONS................................92
EXHAUST SYSTEM............................93
BE CARFUL WHERE YOU RIDE..........94
FOR OFF-ROAD USE ONLY.................99
DURING OPERATION.......................101
TURNING YOUR ATV.........................103
GOOD
....................................89
Load Limits......................................90
No Modifications..............................92
SLIDING AND SKIDDING...................105
CLIMBING UPHILL............................107
RIDING DOWNHILL..........................113
OPERATION........................................66
STARTING A COLD ENGINE...............66
Using the recoil
starter (MXU 300/250)......................68
Using the kick starter (MXU 150).......69
STARTING A WARM ENGINE..............70
WARMING UP.....................................70
DRIVE SELECT LEVER OPERATION
AND REVERSE DRIVING....................71
ENGINE BREAK-IN............................74
ACCESSORIES ..................................78
PARKING (MXU 300/250)....................75
PARKING (MXU 150)..........................76
Parking on a slope............................77
LOADING ...........................................79
Page Page
(Cont'd)

G
PERIODIC MAINTENANCE AND
ADJUSTMENT...................................122
TOOL KIT..........................................122
PERIODIC MAINTENANCE/
LUBRICATION..................................124
ENGINE OIL (MXU 300/250)...............126
TRANSMISSION OIL........................135
REAR FINAL GEAR CASE
OIL (MXU 300)..................................138
SPARK PLUG INSPECTION..............140
AIR FILTER CLEANING.....................141
AIR CLEANER HOUSING DRAIN
TUBE...............................................147
IDLE SPEED ADJUSTMENT .............149
THROTTLE LEVER ADJUSTMENT....150
VALVE CLEARANCE ADJUSTMENT..152
FRONT AND REAR BRAKE PADS
INSPECTION (MXU 300/250).............152
FRONT BRAKE SHOES
INSPECTION (MXU 150)...................155
ENGINE OIL (MXU 150).....................130
Page
CROSSING A SLOPE........................115
RIDING OVER ROUGH TERRAIN......117
CROSSING TROUGH SHALLOW
WATER.............................................118
PARKING.........................................119
WHAT TO DO IF ...............................120
WHAT TO DO ..................................120
Page
(Cont'd)

H
REAR BRAKE PADS
INSPECTION (MXU 150)...................155
BRAKE FLUID INSPECTION.............156
FRONT BRAKE LEVER FREE PLAY
ADJUSTMENT (MXU 150)..................158
COOLING SYSTEM
INSPECTION (MXU 250)...................160
Engine overheating.......................161
DRIVE CHAIN SLACK CHECK
(MXU 250/150)..................................162
Drive chain slack
adjustment (MXU 250).......................162
Drive chain slack
adjustment (MXU 150).......................164
DRIVE CHAIN CLEANING AND
LUBRICATION (MXU 250/150)...........165
REAR SWING ARM
LUBRICATION (MXU 250).................165
KNUCKLE SHAFT & REAR SWING ARM
LUBRICATION (MXU 150).................166
BRAKE LEVER LUBRICATION..........167
CABLE INSPECTION AND
LUBRICATION..................................167
DRAINING THE V-BELT
COMPARTMENT...............................168
Battery remove (MXU 300/250).......171
Battery installation (MXU 300/250)..173
Battery remove (MXU 150).............174
Battery installation (MXU 150).......174
FUSE REPLACEMENT (MXU 150).....176
SPARK ARRESTER CLEANING........180
WHEEL REMOVAL............................169
Wheel installation.........................169
BATTERY..........................................170
FUSE REPLACEMENT
(MXU 300/250).................................175
HEADLIGHT BEAM ADJUSTMENT....179
TROUBLESHOOTING .......................182
Troubleshooting chart...................183
Page Page
(Cont'd)

CLEANING AND STORAGE...........184
A. CLEANING ...................................184
B. STORAGE ....................................186
SPECIFICATIONS (MXU 300/250)...........188
SPECIFICATIONS (MXU 150).................192
INDEX...................................................198
NOISE REGULATION.............................196
MAINTENANCE RECORD.......................197
Page
I

LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1
HANG TAG_GENERAL USE
MXU 300
MXU 250
MXU 150
1. DECAL OF EPA 2. CERTIFICATE LABEL OF SVIA
For US
For France
1
2

2
(6)
(7-1): MXU 300/250
(7-2): MXU 150
(3-1): MXU 300/250
(3-2): MXU 150
(5)
(4-1): MXU 300/250
(4-2): MXU 150
(2)(1) (8-1): MXU 300/250
(8-2); MXU 150

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Warning information
Anyone who rides the vehicle should read and understand this information before riding. They contain
important information for safe and proper operation of your ATV.
The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard
to read, contact your KYMCO dealer for replacements.
(1)
(2)
(3-1)MXU 250/300
MXU 250/300
MXU 150

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(4-1): MXU 300/250
．Never carry passenger
This carrier.
．Maximum load：30 Kg (66 lbs)
on
CAUTION
(4-2): MXU 150
．Never carry passenger
This carrier.
．Maximum load：20 Kg (44 lbs)
on
CAUTION
(5)
Before shifting, you must stop the machine and
return the throttle lever to its closed position until
the engine speed to the specified idling speed.
Otherwise, the transmission may be damaged.
CAUTION
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS
OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH.
OPERATING TIRE PRESSURE : Set with tires cold
2
‧Recommended : FRONT : 25~30kpa, (0.25~0.3kgf/cm ), 3.5~4.2psi
REAR :
‧Never set tire pressure below recommended.
2
25~30kpa, (0.25~0.3kgf/cm ), 3.5~4.2psi
LOADING
‧Maximum Vehicle Load: 100Kg. (220 lbs).
Including weight of operator, cargo and accessories.
WARNING
(3-2) MXU 150

5
(6)

6
(7-1): MXU 300/250
．Never carry passenger
This carrier.
．Maximum load：20 Kg (44 lbs)
on
CAUTION
(8-1): MXU 250
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner's manual for details.
MAXIMUM TOWING CAPACITY: 150kg (331 lbs)
TONGUE WEIGHT: 14kg (30 lbs)
WARNING
(8-2): MXU 150
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner's manual for details.
MAXIMUM TOWING CAPACITY: 100kg (220 lbs)
WARNING
(7-2): MXU 150
．Never carry passenger
This carrier.
．Maximum load：15 Kg (33 lbs)
on
CAUTION
(8-1): MXU 300

SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from
other vehicles including motorcycles and cars. An accident can occur quickly, even during routine
maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
‧Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
‧Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
‧Read this manual and all labels carefully and follow the operating procedures described.
‧Never operate an ATV without proper training or instruction.
Beginners should receive training from a certified instructor.
‧Always follow the age recommendation:
An operator over 14 years old or older under adult supervision could be permitted for operating an
ATV with engine size greater than 150cc.
‧Never carry a passenger on an ATV.
7

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Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
Never attempt wheel, jump, or other stunt.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.

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Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced
the skills necessary to control the ATV on such terrain. Always be especially cautious on these
kinds of terrain.
8

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Always follow proper procedures for climbing hills as described in this manual. Check the terrain
carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high
speed.
Never operate the ATV on hills too steep. Practice on smaller hills before attempting larger hills.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,
maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed
straight uphill. Turn the ATV around and remount, following the procedure described in this
manual.


Always follow proper procedures for going down hills and for braking on hills as described in this
manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
9