KYMCO MXU 50 REVERSE User manual

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
Issued: 08.JUL.2005
MXU 50
ON-ROAD

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 6. Children under age 6
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.
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
Turn signal switch ................................27
Headlight dimmer switch ......................28
Hazard switch.. . ..................................29
Stater switch.. . ....................................30
KICK STARTER...................................30
PRE-OPERATION CHECKS......................38
THROTTLE LEVER...............................31
SPEED LIMITER.... ................................32
FRONT AND REAR BRAKES...................33
FUEL TANK CAP.....................................34
FUEL VALVE . ........................................35
SEAT.....................................................36
FLAG POLE BRACKET........................... 37
STORAGE COMPARTMENT....................37
PARKING BRAKE...................................33
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS...........................1
SAFETY INFORMATION.............................6
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................11
IDENTIFICATION NUMBER RECORDS....11
KEY IDENTIFICATION NUMBER..............11
FRAME AND ENGINE SERIAL
NUMBER...............................................12
PARTS LOCATION..................................13
CONTROL FUNCTIONS........... ................18
IGNITION SWITCH/HEADLIGHT &
POSITION LIGHT SWITCH......................18
INSTRUMENTS AND INDICATOR............19
Multi-function display.................... ........21
HANDLEBAR SWITCHES........................27
Horn button.................................. ........27
Page Page
(Cont'd)

E
FRONT AND REAR BRAKES...................40
FUEL...................................................41
CHAIN...................................................45
THROTTLE LEVER.................................45
FITTINGS AND FASTENERS...................45
LIGHTS.................................................45
SWITCHES........................ ....................45
TIRES............................ .......................46
How to measure tire pressure.................47
Tire wear limit........................................48
OPERATION............................................49
ENGINE BREAK-IN.................................51
ENGINE OIL.........................
STARTING ENGINE................................49
..................42
TRANSMISSION OIL...............................44
PARKING..............................................52
Parking on a slope.................................53
ACCESSORIES......................................54
LOADING...............................................55
RIDING YOUR ATV...................................57
GETTING TO KNOW YOUR ATV..............58
RIDE WITH CARE AND
Loading and operational guidelines.........66
JUDGEMENT.........................................59
GOOD
AGE RECOMMENDATION.......................60
NEVER CARRY PASSENGER ON THE
CARGO RACK........................................61
APPAREL..............................................62
DO NOT OPERATE AFTER CONSUMING
ALCOHOL OR DRUGS............................63
PRE-OPERATION CHECKS....................64
LOADING AND ACCESSORIES...............66
Accessories.........................................67
NO MODIFICATIONS..............................68
DURING OPERATION.............................69
EXHAUST SYSTEM................................71
PRACTICING.........................................72
SPEED LIMITER FOR NEW RIDERS........73
Page Page
(Cont'd)

F
BRAKING..............................................74
TURNING YOUR ATV .............................75
CLIMBING UP SLOPE.............................76
RIDING DOWN SLOPE ...........................82
PARKING...............................................83
WHAT TO DO IF.....................................84
WHAT TO DO.........................................84
TRANSMISSION OIL..............................89
SPARK PLUG INSPECTION...................91
AIR FILTER CLEANING.........................92
IDLE SPEED ADJUSTMENT....................95
THROTTLE LEVER ADJUSTMENT.........96
PERIODIC MAINTENANCE AND
ADJUSTMENT.........................................85
Tool kit...................................................85
PERIODIC MAINTENANCE/
LUBRICATION.......................................87
FRONT BRAKE SHOES
INSPECTION........................................97
REAR BRAKE PADS INSPECTION.........97
FRONT BRAKE LEVER FREE PLAY
ADJUSTMENT.......................................98
BRAKE FLUID INSPECTION................100
DRIVE CHAIN SLACK CHECK..............102
Drive chain slack adjustment..............102
DRIVE CHAIN CLEANING AND
LUBRICATION....................................104
CABLE INSPECTION AND
LUBRICATION....................................104
KNUCKLE SHAFT AND REAR SWING
ARM LUBRICATION.............................105
HEADLIGHT BEAM ADJUSTMENT.......111
WHEEL REMOVAL...............................106
Wheel installation...............................106
BATTERY...........................................107
FUSE REPLACEMENT.........................109
TROUBLESHOOTING.........................112
Troubleshooting chart.........................113
Page Page
(Cont'd)

G
CLEANING AND STORAGE....................114
A. CLEANING .....................................114
B. STORAGE ......................................116
SPECIFICATIONS..................................118
INDEX...................................................124
NOISE REGULATION.............................122
MAINTENANCE RECORD.......................123
Page

LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1
(1) (2) (4)(3)

(5) (6)
2

(7)
3

WARNING INFORMATION
Your ATV comes with a hang tag and several labels
containing important safety information. Anyone who
rides the vehicle should read and understand this
information before riding.
Parents of young riders should make sure their
youngsters read and understand the hang tag and label
information before allowing them to ride.
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
4
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
Recommended :
FRONT : 25~30 kpa, (0.25~0.3 kgf/cm ), 3.5~4.2 psi
REAR :
Never set tire pressure over the recommended.
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2
25~30 kpa, (0.25~0.3 kgf/cm ), 3.5~4.2 psi
2
WARNING
Operating thisATV if you are under the
age of 6 increases your chance of severe
injury or death.
operate thisATV if you are under
age 6.
NEVER
UNDER
6
(2)
(1) (3)
WARNING
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

5
．
．：
Never carry passenger
This carrier.
Maximum load 15 Kg (33 lbs)
on
CAUTION
(5)
Improper ATV use can result in SEVERE
INJURY or DEATH.
NEVER operate :
Without proper training or instruction.
At speeds too fast for your skills
the conditions.
Do not operate the vehicle after
consuming ALCOHOL OR DRUGS.
ALWAYS :
Use proper riding techniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
For your safety, wear gear to include
helmet gloves and foot protection.
READ OWNER'S MANUAL, FOLLOW
ALL INSTRUCTIONS AND WARNINGS.
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or
Gasoline is flammable shut off engine,
avoid sparks and open flame when refueling.

NEVER USE WITH
ALCOHOL OR DRUGS
ALWAYS USE AN
APPROVED HELMET AND
PROTECTIVE GEAR
WARNING
(4)
．
．：
Never carry passenger
This carrier.
Maximum load 20 Kg (44 lbs)
on
CAUTION
(6)
(7)

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. A collision can occur quickly, even during
routine maneuvers, if you fail to take proper pre-cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
- A child under 6 years old should never operate an ATV with engine size greater than 70cc.
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.
- A child under 12 years old should never operate an ATV with engine size greater than 90cc.
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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:
Never allow a child under age 16 to operate an ATV without adult supervision, and never
allow continued use of an ATV by a child if he or she does not have the abilities to operate it
safely.
6

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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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Never operate on excessively rough, slippery or loose terrain.
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 the ATV on hills.
Always follow proper procedures for climbing slopes as described in this manual. Check the
terrain carefully before you start up any slope. Shift your weight forward. Never open the
throttle suddenly. Never go over the top of a slope at high speed.
7

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Always follow proper procedures for going down slopes and for braking on slopes as
described in this manual. Check the terrain carefully before you start down any slope. Shift
your weight backward. Never go down a slope at high speed. Avoid going down slope at an
angle that would cause the vehicle to lean sharply to one side. Go straight down the slope
where possible.
Never attempt to turn the ATV around on any slope until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side of a steep slope
if possible.
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Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles, such as large rocks or fallen trees. Always follow proper procedures when
operating over obstacles as described in this manual.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding
out of control.
Never operate an ATV in fast flowing water or in water deeper than that recommended in
this manual. Remember that wet brakes may have reduced stopping ability. Test your
brakes after leaving water. If necessary, apply them several times to let friction dry out the
linings.
Always use the size and type tires specified in this manual. Always maintain proper tire
pressure as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo.
Allow greater distance for braking.
8

POTENTIAL HAZARD
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
Improper handling of gasoline.
Gasoline can catch fire and you could be
burned.
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in the
vicinity of sparks, open flames, or other
sources of ignition such as the pilot lights of
water heaters and clothes dryers.
When transporting the machine in another
vehicle, be sure it is kept upright and that
the fuel cock is in the "OFF" position.
Otherwise, fuel may leak out of the
carburetor or fuel tank.
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
Gasoline is poisonous and can cause
injuries.
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get some
gasoline in your eyes, see your doctor
immediately.
If gasoline spills on your skin, wash with
soap and water. If gasoline spills on your
clothing, change your clothes.
9
WARNING

POTENTIAL HAZARD
Starting or running the engine in a closed
area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your machine in an area
with adequate ventilation.
10
ON
WARNING

KEYS IDENTIFICATION NUMBER
The keys identification number is stamped on
the hang tag as shown in the following
illustration.
DESCRIPTION AND MACHINE IDENTIFICATION
(1) Ignition switch key identification number
IDENTIFICATION NUMBER RECORDS
Record the keys identification number, frame
serial number, engine serial number and
model code information for assistance when
order replacement parts.
IGNITION SWITCH KEY NO.
FRAME NO.
ENGINE NO.
(1)
11