KYMCO MX'ER 50 User manual

PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO 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 17 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/FRIVEN PULLEY
9
FINAL REDUCTION/TRANSMISSION
SYSTEM
10
CRANKCASE/CRANKSHAFT
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 ATVON ROAD AVAILABLE
18
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS EQUIPMENT
ENGINE
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1. GENERAL INFORMATION
1-1
MX’er 50
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER ------------------------------------------------------ 1- 2
SPECIFICATIONS ------------------------------------------------------ 1- 3
SERVICE PRECAUTIONS--------------------------------------------- 1- 4
TORQUE VALUES ----------------------------------------------------- 1-12
SPECIAL TOOLS ------------------------------------------------------- 1-13
LUBRICATION POINTS----------------------------------------------- 1-13
CABLE & HARNESS ROUTING ------------------------------------- 1-16
WIRING DIAGRAM ---------------------------------------------------- 1-20
TROUBLESHOOTING ------------------------------------------------- 1-22
1
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1. GENERAL INFORMATION
1-2
MX’er 50
SERIAL NUMBER
Location of Frame Serial Number
Location of Engine Serial Number
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1. GENERAL INFORMATION
1-3
MX’er 50
SPECIFICATIONS
Name & Model No.
LA10AD
Motorcycle Name & Type
MX’er
Overall length (mm)
1685
Overall width (mm)
980
Overall height (mm)
1030
Wheel base (mm)
1120
Engine type
Air cooled 2-stroke
Displacement (cc)
49.4
Fuel Used
92# nonleaded gasoline
Front wheel
67
Net weight (kg)
Rear wheel
73
Total
140
Front wheel
73
Gross weight(kg)
Rear wheel
77
Total
150
Front wheel
20*7-8
Rear wheel
22*10-8
Ground clearance (mm)
130
Perform
-
Breaking distance
(m)(ANSI)
20.6 below
Ance
Min. turning radius (m)
2.5
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 (mm)
39 x 41.4
Compression ratio
7.2:1
Compression pressure
(kg/cm_)
12.0
Max. output (ps/rpm)
4.3/6000
Max. torque (kg m/rpm)
0.55/5500
Intake
Open
Automatic controlled
Port
(1mm)
Close
Automatic controlled
timin
g
Exhaust
Open
°–
(1mm)
Close
°–
Valve clearance
Intake
°–
(cold) (mm)
Exhaust
°–
Idle speed (rpm)
2000rpm
Lubrication type
Separate type
Oil pump type
Plunger type
Oil filter type
Full-flow filtration
Air cleaner type & No
Sponge
Fuel capacity
8.1 liters
Type
PB
Main jet No.
80
Venturi dia.(mm)
f14
Throttle type
VALVE PISTON
Type
CDI
Ignition timing
22°/2000rpm
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
°–
Tire pressure
Front
0.35
(kg/cm_)
Rear
0.35
Turning
Left
44°
angle
Right
44°
Brake system
Rear
Disk brake
type
Front
Drum brake
Suspension
Front
Swing
type
Rear
Swing arm
Shock
absorber
Front
Swing
type
Rear
Swing arm
Frame type
SP pipe
Tires
Engine
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Reduction Gear
Moving Device Damping
Device
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1. GENERAL INFORMATION
1-4
MX’er 50
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
nWhen tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
nUse genuine parts and lubricants.
nWhen servicing the motorcycle, be sure to
use special tools for removal and
installation.
nAfter disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
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1. GENERAL INFORMATION
1-5
MX’er 50
nApply or add designated greases and
lubricants to the specified lubrication
points.
nAfter reassembly, check all parts for
proper tightening and operation.
nWhen two persons work together, pay
attention to the mutual working safety.
nDisconnect the battery negative (-) terminal
before operation.
nWhen using a spanner or other tools, make
sure not to damage the motorcycle surface.
nAfter operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
nWhen connecting the battery, the positive
(+) terminal must be connected first.
nAfter connection, apply grease to the
battery terminals.
nTerminal caps shall be installed securely.
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1. GENERAL INFORMATION
1-6
MX’er 50
nIf the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
nAfter operation, terminal caps shall be
installed securely.
nWhen taking out the connector, the lock on
the connector shall be released before
operation.
nHold the connector body when connecting
or disconnecting it.
nDo not pull the connector wire.
nCheck if any connector terminal is bending,
protruding or loose.
Confirm
Capacity
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1. GENERAL INFORMATION
1-7
MX’er 50
nThe connector shall be inserted
completely.
nIf the double connector has a lock, lock
it at the correct position.
nCheck if there is any loose wire.
nBefore connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
nCheck the double connector cover for
proper coverage and installation.
nInsert the terminal completely.
nCheck the terminal cover for proper
coverage.
nDo not make the terminal cover opening
face up.
nSecure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Snapping!
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1. GENERAL INFORMATION
1-8
MX’er 50
nAfter clamping, check each wire to make
sure it is secure.
nDo not squeeze wires against the weld or
its clamp.
nAfter clamping, check each harness to make
sure that it is not interfering with any
moving or sliding parts.
nWhen fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
nRoute wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
nRoute wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !
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1. GENERAL INFORMATION
1-9
MX’er 50
nRoute harnesses so they are neither
pulled tight nor have excessive slack.
nProtect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
nWhen rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
nDo not break the sheath of wire.
nIf a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
nWhen installing other parts, do not press or
squeeze the wires.
Do not pull too
tight!
Do not press or
squeeze the wire.
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1. GENERAL INFORMATION
1-10
MX’er 50
nAfter routing, check that the wire harnesses
are not twisted or kinked.
nWire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
nWhen a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
nBe careful not to drop any parts.
nWhen rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !
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1. GENERAL INFORMATION
1-11
MX’er 50
nSymbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
:Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
:Apply grease for lubrication.
:Use special tool.
: Caution
:Warning
Engine Oil
Engine Oil
Grease
Special
°Ø
＊
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1. GENERAL INFORMATION
1-12
MX’er 50
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kgf-m)
Item
Torque (kgf-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
14mm bolt, nut
0.45_0.6
0.8_1.2
1.8_2.5
3.0_4.0
5.0_6.0
6.0_8.0
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
0.15_0.4
0.3_0.5
0.7_1.1
1.0_1.4
2.4_3.0
3.5_4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Cylinder head bolt
Clutch drive plate nut
Drive face nut
Clutch outer nut
A.C.G flywheel nut
Oil check bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
4
1
1
1
1
1
2
2
BF7X115
39
12
NH10
10
8
NC6mm
BF8X35
1.5_1.7
5.0_6.0
3.5_4.0
3.5_4.0
3.5_4.0
1.0_1.5
1.0_1.4
3.0_3.6
1.1_1.7
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Steering stem nut
Swing arm nut
Rear wheel nut
Front wheel nut
Rear shock absorber upper mount bolt
Front shock absorberupper mount bolt
Front shock absorberlower mount bolt
Rear fork axle
Rear hub nut
Rear wheel shaft nut
Rear engine bracket up bolt
Rear engine bracket bolt
Enginehangerbracket bolt
1
4
4
4
1
2
2
1
4
2
1
2
1
14
10
14
14
10
10
10
14
12
32
10
10
10
6.0_8.0
4.0_5.0
6.0_8.0
6.0_8.0
3.5_4.5
3.5_4.5
3.5_4.5
6.0_8.0
6.0_8.0
11.0_13.0
3.5_4.5
3.5_4.5
4.0_5.0
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1. SPECIFICATIONS
1-13
MX’er 50
SPECIAL TOOLS
Tool Name
Tool No.
Remarks Ref. Page
Flywheel puller
E001
Oil seal and bearing install
E014
Universal holder
E017
Clutch spring compressor
E034
Bearing puller
E037
Crankshaft install
E016
Crankshaft & crankcase install
E024
Crankcase puller
E026
Crankshaft Bearing puller
E030
Nut wrench
F010
Float level gauge
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Crankcase sliding & movable parts
Cylinder movable parts
Transmission gear (final gear)
Kick starter spindle bushing
Drive pulley movable parts
Starter pinion movable parts
JASO-FC or API-TC
JASO-FC or API-TC
Gear oil: SAE90#
Grease
Grease
Grease
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1. GENERAL INFORMATION
1-14
MX’er 50
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Steering knuckle/Thrust
Cover/Bush/Collar
Steering Column Upper
Rear Brake Cable
Front Brake
camshaft/Oil
Seal/O-ring
Throttle Cable
Front Brake Cable
Steering Column Lower
Front Wheel
Oil Seal
Front Arm Bush
Front Brake
camshaft/Oil
Seal/O-ring
Front Wheel
Oil Seal
Steering knuckle/Thrust
Cover/Bush/Collar
Front Arm Bush
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1. SPECIFICATIONS
1-15
MX’er 50
Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing
Rear Brake Cam/ Axle
Hub Collar/Oil
Seal/Bearing
Driven Sprocket
Swing arm Thrust
Cover
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1. GENERAL INFORMATION
1-16
MX’er 50
CABLE & HARNESS ROUTING
Throttle Cable
Rear Brake Cable
Right Front Brake Cable
Handlebar Switch Lead
Front Brake Cable
Left Front Brake Cable
A.C.G Wire
Starter Motor Wire
Auto Bystarter
Wire
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1. SPECIFICATIONS
1-17
MX’er 50
Front Brake Fluid Tube
Throttle Cable
Rear Brake Cable
Ignition Coil Wire
Fuel Tube
Fuel Filter
Oil Meter Wire
Right Front Brake Cable
Left Front Brake Cable
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1. GENERAL INFORMATION
1-18
MX’er 50
Wire Harness
Rectifier/Regulator
Oil Tube
Resistor
Ignition Coil
Right Front Brake Cable
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1. SPECIFICATIONS
1-19
MX’er 50
Battery
Starter Relay
CDI Unit
Fuse
Rear Brake Cable
Breather Hose
Oil Meter Wire
Positive Cable
Negative Cable
Main Switch
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