KYMCO MXU 50 REVERSE User manual

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 250/150/50
ON-ROAD
Issued: 23.DEC.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....................25
IGNITION SWITCH/HEADLIGHT &
POSITION LIGHT SWITCH..................25
INSTRUMENTS AND INDICATOR........26
Multi-function display.......................28
HANDLEBAR SWITCHES....................36
Horn button.....................................36
THROTTLE LEVER.............................43
SPEED LIMITER.................................44
FRONT BRAKE LEVER.......................45
Turn signal switch............................37
Headlight dimmer switch..................38
Hazard switch.................................39
Start switch.....................................40
RECOIL STARTER (MXU 250).............41
KICK STARTER (MXU 150/50)..............42
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
SAFETY INFORMATION
DESCRIPTION AND MACHINE
IDENTIFICATION
...................1
......................5
................................10
IDENTIFICATION NUMBER
RECORDS..........................................10
KEYS IDENTIFICATION NUMBER........10
FRAME SERIAL NUMBER...................11
ENGINE SERIAL NUMBER
(MXU 250/150)....................................11
ENGINE SERIAL NUMBER (MXU 50)....12
PARTS LOCATION (MXU 250).............13
PARTS LOCATION (MXU 150/50).........19
Page Page
(Cont'd)

E
REAR BRAKE LEVER..........................45
BRAKE PEDAL (MXU 250/150).............45
PARKING BRAKE (MXU 250)...............46
PARKING BRAKE (MXU 150/50)...........46
LOCKING STEERING (MXU 250/150)...48
DRIVE SELECT LEVER.......................49
FUEL TANK CAP ................................49
FUEL VALVE......................................50
CHOKE KNOB (MXU 250/150)..............52
SEAT (MXU 250).................................53
SEAT (MXU 150/50).............................54
FLAG POLE BRACKET.......................55
TRAILER HITCH (MXUN 250/150).......55
STORAGE COMPARTMENT.................56
ACCESSORY SOCKET
SEAT (MXU 250).................................56
PRE-OPERATION CHECKS.............58
DRIVE SELECT LEVER ......................59
Drive select lever adjustment............61
FRONT AND REAR BRAKES................63
FUEL...............................................64
ENGINE OIL (MXU 250/150).................66
TRANSMISSION OIL ..........................68
CHAIN..............................................69
THROTTLE LEVER.............................69
FITTINGS AND FASTENERS...............69
LIGHTS..............................................69
SWITCHES.........................................69
TIRES................................................70
How to measure tire pressure ...........72
Tire wear limit ................................72
COOLANT (MXU 250).........................73
ENGINE OIL (MXU 50).........................67
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(Cont'd)

F
RIDING YOUR ATV ............................89
GETTING TO KNOW YOUR ATV .........90
RIDE WITH CARE AND
APPAREL...........................................95
PRE-OPERATION CHECKS................97
LOADING AND ACCESSORIES..........99
Loading and operational guidelines...99
Accessories...................................100
MODIFICATIONS..............................101
DURING OPERATION........................102
EXHAUST SYSTEM...........................104
PRACTICING....................................105
SPEED LIMITER FOR NEW RIDERS...106
BRAKING.........................................107
TURNING YOUR ATV .......................108
CLIMBING UP SLOPE........................109
RIDING DOWN SLOPE......................115
JUDGEMENT......................................91
GOOD
No modifications.............................101
PARKING..........................................116
WHAT TO DO IF ................................117
WHAT TO DO ....................................117
OPERATION........................................75
STARTING A COLD ENGINE...............75
Using the recoil starter (MXU 250).....77
Using the kick starter (MXU 150/50)....78
STARTING A WARM ENGINE..............79
WARMING UP.....................................79
DRIVE SELECT LEVER OPERATION
AND REVERSE DRIVING....................80
ENGINE BREAK-IN............................82
PARKING (MXU 150/50)......................84
ACCESSORIES ..................................86
PARKING (MXU 250)...........................83
Parking on a slope............................85
LOADING ...........................................87
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(Cont'd)

G
PERIODIC MAINTENANCE AND
ADJUSTMENT...................................118
TOOL KIT..........................................118
PERIODIC MAINTENANCE/
LUBRICATION..................................120
ENGINE OIL (MXU 250) .....................122
TRANSMISSION OIL.........................130
SPARK PLUG INSPECTION..............133
AIR FILTER CLEANING.....................134
AIR CLEANER HOUSING DRAIN
TUBE (MXU 250/150)........................142
IDLE SPEED ADJUSTMENT .............144
THROTTLE LEVER ADJUSTMENT....145
VALVE CLEARANCE ADJUSTMENT..147
FRONT AND REAR BRAKE PADS
INSPECTION (MXU 250)...................147
FRONT BRAKE SHOES
INSPECTION (MXU 150/50)
ENGINE OIL (MXU 150) .....................126
...............149
REAR BRAKE PADS
INSPECTION (MXU 150/50)...............149
BRAKE FLUID INSPECTION.............150
FRONT BRAKE LEVER FREE PLAY
ADJUSTMENT (MXU 150/50).............152
REAR BRAKE LEVER FREE PLAY
ADJUSTMENT (MXU 150)..................154
BRAKE PEDAL
ADJUSTMENT (MXU 150)..................155
COOLING SYSTEM
INSPECTION (MXU 250)....................159
Engine overheating........................160
DRIVE CHAIN SLACK CHECK.............161
Drive chain slack
adjustment (MXU 250)..................161
Drive chain slack
adjustment (MXU 150/50)..............163
DRIVE CHAIN CLEANING AND
LUBRICATION..................................164
REAR SWING ARM
LUBRICATION (MXU 250)..................164
KNUCKLE SHAFT & REAR SWING
ARM LUBRICATION (MXU 150/50).....165
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(cont'd)

H
CLEANING AND STORAGE...........181
A. CLEANING ...................................181
B. STORAGE ....................................183
SPECIFICATIONS (MXU 250/150)...........185
SPECIFICATIONS (MXU 50)...................189
INDEX...................................................195
NOISE REGULATION.............................193
MAINTENANCE RECORD.......................194
Page
BRAKE LEVER LUBRICATION...........166
CABLE INSPECTION AND
LUBRICATION..................................166
DRAINING THE V-BELT
COMPARTMENT (MXU 250/150)........167
Battery remove (MXU 250)............170
Battery installation (MXU 250).......172
Battery remove (MXU 150/50)........173
Battery installation (MXU 150/50)...173
FUSE REPLACEMENT (MXU 150/50).175
WHEEL REMOVAL............................168
Wheel installation.........................168
BATTERY..........................................169
FUSE REPLACEMENT (MXU 250)......174
HEADLIGHT BEAM ADJUSTMENT....178
TROUBLESHOOTING .......................179
Troubleshooting chart...................180
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