KYMCO MXU 300 - User manual

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 300/250
ON-ROAD
Issued: 21.02.2005

A
IMPORTANT NOTICES
READ THIS MANUAL CAREFULLY
AGE RECOMMENDATION
RIDER TRAINING
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.
The minimum recommended age for this ATV model is 16. Children under age 16
should never operate this vehicle.
Anyone who operates this vehicle should get proper instruction.
FOR ON-ROAD USE ONLY
This machine is designed and manufactured for ON-ROAD use only. It is illegal and unsafe to
operate this machine on any hills and rough or loose terrain.
This machine complies with all applicable ON-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.

B
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.
WARNING

C
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.
WARNING

D
CONTROL FUNCTIONS....................18
IGNITION SWITCH..............................18
INSTRUMENTS AND INDICATOR........19
Multi-function display.......................21
HANDLEBAR SWITCHES....................28
Horn button.....................................28
THROTTLE LEVER.............................33
SPEED LIMITER.................................34
FRONT BRAKE LEVER.......................35
Turn signal switch............................28
Headlight dimmer switch..................29
Hazard switch.................................30
Start switch.....................................31
RECOIL STARTER..............................32
REAR BRAKE LEVER..........................35
BRAKE PEDAL...................................35
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
SAFETY INFORMATION
DESCRIPTION AND MACHINE
IDENTIFICATION
...................1
......................5
................................10
IDENTIFICATION NUMBER
RECORDS..........................................10
KEY IDENTIFICATION NUMBER.........10
FRAME SERIAL NUMBER...................11
ENGINE SERIAL NUMBER..................11
PARTS LOCATION.............................12
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(Cont'd)

E
PARKING BRAKE...............................36
LOCKING STEERING.........................37
DRIVE SELECT LEVER.......................38
FUEL TANK CAP ................................39
FUEL VALVE......................................39
CHOKE KNOB....................................41
SEAT..................................................42
FLAG POLE BRACKET.......................43
TRAILER HITCH.................................43
STORAGE COMPARTMENT................44
ACCESSORY SOCKET SEAT...............44
PRE-OPERATION CHECKS.............46
DRIVE SELECT LEVER ......................47
Drive select lever adjustment.....49
FRONT AND REAR BRAKES................51
FUEL...............................................52
ENGINE, TRANSMISSION OIL AND
REAR FINAL GEAR CASE OIL .............54
CHAIN..............................................55
THROTTLE LEVER.............................55
FITTINGS AND FASTENERS...............55
LIGHTS..............................................55
SWITCHES.........................................55
TIRES................................................56
How to measure tire pressure ..............57
Tire wear limit ....................................58
COOLANT..........................................58
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(Cont'd)

F
RIDING YOUR ATV ............................73
GETTING TO KNOW YOUR ATV .........74
RIDE WITH CARE AND
APPAREL...........................................78
PRE-OPERATION CHECKS................80
LOADING AND ACCESSORIES..........82
Loading and operational guidelines...82
Accessories.....................................83
MODIFICATIONS................................84
DURING OPERATION.........................85
EXHAUST SYSTEM............................87
PRACTICING......................................88
TURNING YOUR ATV ..........................89
CLIMBING UP SLOPE..........................90
RIDING DOWN SLOPE.........................96
JUDGEMENT......................................75
GOOD
No modifications..............................84
PARKING...........................................97
WHAT TO DO IF ..................................98
WHAT TO DO ......................................98
OPERATION........................................60
STARTING A COLD ENGINE...............60
Using the recoil starter......................62
STARTING A WARM ENGINE..............63
WARMING UP.....................................63
DRIVE SELECT LEVER OPERATION
AND REVERSE DRIVING....................64
ENGINE BREAK-IN.............................67
ACCESSORIES ..................................70
PARKING..........................................68
Parking on a slope............................69
LOADING ...........................................71
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(Cont'd)

G
PERIODIC MAINTENANCE AND
ADJUSTMENT.....................................99
TOOL KIT...........................................99
PERIODIC MAINTENANCE/
LUBRICATION..................................101
ENGINE OIL .....................................103
TRANSMISSION OIL........................107
REAR FINAL GEAR CASE
OIL (MXU 300)...................................109
SPARK PLUG INSPECTION..............110
AIR FILTER CLEANING.....................112
AIR CLEANER HOUSING DRAIN
TUBE...............................................115
IDLE SPEED ADJUSTMENT .............116
THROTTLE LEVER ADJUSTMENT....117
VALVE CLEARANCE ADJUSTMENT..118
FRONT BRAKE PADS INSPECTION...115
REAR BRAKE PADS (MXU 250)
INSPECTION..................................119
REAR BRAKE PADS (MXU 300)
INSPECTION....................................120
BRAKE FLUID INSPECTION.............121
COOLING SYSTEM INSPECTION.....123
Engine overheating.......................124
DRIVE CHAIN SLACK
CHECK (MXU 250).............................125
Drive chain slack
Adjustment (MXU 250)........................125
DRIVE CHAIN CLEANING AND
LUBRICATION (MXU 250)..................127
REAR SWING ARM
LUBRICATION (MXU 250)............. ....127
DRAINING THE V-BELT
COMPARTMENT...............................128
CABLE INSPECTION AND
LUBRICATION..................................128
WHEEL REMOVAL............................129
Wheel installation.........................129
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(cont'd)

H
CLEANING AND STORAGE...........138
A. CLEANING ...................................138
B. STORAGE ....................................140
SPECIFICATIONS..................................142
INDEX...................................................148
NOISE REGULATION.............................146
MAINTENANCE RECORD.......................147
Page
BATTERY..........................................130
FUSE REPLACEMENT......................134
HEADLIGHT BEAM ADJUSTMENT....135
TROUBLESHOOTING .......................136
Troubleshooting chart...................137
Battery remove.............................131
Battery installation........................133
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