KYMCO MX’er 125 Service Manual

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Service manual (42 pages)

Driver manual (142 pages)

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Table of Contents

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Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO MX’er 125

Page 1: Table Of Contents
PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing GENERAL INFORMATION procedures for the KYMCO MX’er FRAME COVERS/EXHAUST MUFFLER 125/150. INSPECTION/ADJUSTMENT Section 1 contains the precautions for LUBRICATION SYSTEM all operations stated in this manual. FUEL SYSTEM...
Page 2 . GENERAL INFORMATION MX’er SYSTEM __________________________________________________________________________________ GENERAL INFORMATION SERIAL NUMBER ------------------------------------------------------------- 1- 1 SPECIFICATIONS ------------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS -------------------------------------------------- 1- 4 TORQUE VALUES ------------------------------------------------------------ 1-12 SPECIAL TOOLS -------------------------------------------------------------- 1-14 LUBRICATION POINTS----------------------------------------------------- 1-15 CABLE & HARNESS ROUTING------------------------------------------- 1-18 WIRING DIAGRAM----------------------------------------------------------- 1-22 TROUBLESHOOTING ------------------------------------------------------- 1-23...
Page 3: General Information
. GENERAL INFORMATION MX’er SYSTEM SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...
Page 4: Specifications
. GENERAL INFORMATION MX’er SYSTEM SPECIFICATIONS Name & Model No. LA30AA, AB Motorcycle Name & Type MX’er Air cleaner type & No Sponge Overall length (mm) 1600 Fuel capacity 8.1 liters Overall width (mm) Type Overall height (mm) Float lever 14.8mm Wheel base (mm) 1120...
Page 5 . GENERAL INFORMATION MX’er SYSTEM SPECIFICATIONS Name & Model No. LA25AB Motorcycle Name & Type MX’er Air cleaner type & No Sponge Overall length (mm) 1685 Fuel capacity 8.1 liters Overall width (mm) Type Overall height (mm) Piston dia. (mm) 14.8mm φ...
Page 6: General Information
. GENERAL INFORMATION MX’er SYSTEM SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 7 . GENERAL INFORMATION MX’er SYSTEM n Apply or add designated greases and lubricants to the specified lubrication points. n After reassembly, check all parts for proper tightening and operation. n When two persons work together, pay attention to the mutual working safety. n Disconnect the battery negative (-) terminal before operation.
Page 8 . GENERAL INFORMATION MX’er SYSTEM n If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity n After operation, terminal caps shall be installed securely. n When taking out the connector, the lock on the connector shall be released before operation.
Page 9 . GENERAL INFORMATION MX’er SYSTEM n The connector shall be inserted completely. Snapping! n If the double connector has a lock, lock it at the correct position. n Check if there is any loose wire. n Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 10 . GENERAL INFORMATION MX’er SYSTEM n After clamping, check each wire to make sure it is secure. n Do not squeeze wires against the weld or its clamp. n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 11 . GENERAL INFORMATION MX’er SYSTEM n Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
Page 12 . GENERAL INFORMATION MX’er SYSTEM n After routing, check that the wire harnesses are not twisted or kinked. n Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. n When a testing device is used, make sure to Do you understand understand the operating methods thoroughly...
Page 13 . GENERAL INFORMATION MX’er SYSTEM n Symbols: 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.) Engine Oil : Apply grease for lubrication. Grease : Transmission Gear Oil (90#) Gear Oil...
Page 14: Torque Values
. GENERAL INFORMATION MX’er SYSTEM TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kgf-m) Item Torque (kgf-m) 5mm bolt, nut 0.45 0.6 4mm screw 0.15 0.4 6mm bolt, nut 0.8 1.2 0.3 0.5 5mm screw 8mm bolt, nut 1.8 2.5 0.7 1.1 6mm screw, SH bolt 10mm bolt, nut 3.0 4.0...
Page 15 . GENERAL INFORMATION MX’er SYSTEM Item Q‘ty Thread dia.(mm) Torque (kgf-m) Remarks R cover 0.8 1.2 Head cover 0.8 1.2 Cap R cover 0.8 1.2 Guide star change handle 0.8 1.2 Sprocket drive plate 1.0 1.6 Carburetor 0.8 1.2 Check bolt oil 1.0 1.5 FRAME Item...
Page 16: Special Tools
. GENERAL INFORMATION MX’er SYSTEM SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Flywheel puller E003 Lock nut wrench E009 Valve adjuster E012 Valve spring compressor E040 Oil seal and bearing install E014 Universal holder E017 Flywheel holder E021 Clutch spring compressor E027 Bearing puller...
Page 17: Lubrication Points
. GENERAL INFORMATION MX’er SYSTEM LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API SG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
Page 18 . GENERAL INFORMATION MX’er SYSTEM 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.
Page 19 . GENERAL INFORMATION MX’er SYSTEM Swing arm Thrust Cover Rear Brake Cam/ Axle Hub Collar/Oil Seal/Bearing Sprocket hub/Rear Axle Hub Collar/Oil Seal/Bearing Driven Sprocket 1-17...
Page 20: Cable & Harness Routing
. GENERAL INFORMATION MX’er SYSTEM CABLE & HARNESS ROUTING Rear Brake Cable Throttle Cable Handlebar Switch Lead Front Brake Cable Right Front Brake Cable Left Front Brake Cable 1-18...
Page 21 . GENERAL INFORMATION MX’er SYSTEM Breather Hose (CYL Head Cover) Main Switch Inlet Hose Breather Hose (Crankcase) 1-19...
Page 22 . GENERAL INFORMATION MX’er SYSTEM Breather Hose Wire Harness Rectifier/Regulator Fuse Outlet Hose Ignition Coil 1-20...
Page 23 . GENERAL INFORMATION MX’er SYSTEM A.C.G Wire Connector Breather Hose (CYL Head Cover) Battery Negative Cable Positive Cable Battery CDI Unit Starter Relay Change Gear Control Fuse 1-21...
Page 24: Wiring Diagram
. GENERAL INFORMATION MX’er SYSTEM WIRING DIAGRAM 1-22...
Page 25: Troubleshooting
. GENERAL INFORMATION MX’er SYSTEM TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel does not Fuel reaches Clogged fuel tank cap breather...
Page 26 . GENERAL INFORMATION MX’er SYSTEM ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Restricted fuel flow Engine speed does Engine speed Clogged fuel tank cap breather hole not increase increases Clogged exhaust muffler sufficiently Carburetor fuel level too low Check ignition timing...
Page 27 . GENERAL INFORMATION MX’er SYSTEM POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check carburetor air screw adjustment Mixture too rich (turn screw out) Correctly adjusted Incorrectly Mixture too lean (turn screw in)
Page 28 . GENERAL INFORMATION MX’er SYSTEM POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat Check fuel pump for fuel supply Empty fuel tank...
Page 29 . GENERAL INFORMATION MX’er SYSTEM Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C. generator coil Normal Resistance too high Broken yellow wire...
Page 30 . GENERAL INFORMATION MX’er SYSTEM Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose spark plug cap Loose Check CDI unit coupler for looseness Good Good...
Page 31: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER SERVICE INFORMATION -------------------------------------------------- 2- 2 TROUBLESHOOTING ------------------------------------------------------- 2- 2 FRAME COVERS-------------------------------------------------------------- 2- 3 HEADLIGHT REMOVAL ---------------------------------------------------- 2- 5 EXHAUST MUFFLER REMOVAL ---------------------------------------- 2- 5...
Page 32 . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM...
Page 33: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt 3.2 3.8kgf-m...
Page 34: Frame Covers
. FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM Seat FRAME COVERS SEAT REMOVAL Pull the lever backward, then pull up the seat at the rear. Remove the seat. Bolt Screws LEFT REAR FENDER REMOVAL Remove seven screws and two bolts attaching the left rear fender. During removal, do not pull the joint claws forcedly to avoid damage.
Page 35 . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM Remove right rear fender under bolt. Remove the right rear fender. Bolt Floor Board Cover FLOOR BOARD COVER REMOVAL Remove the four bolts on the floorboard cover. Remove the floorboard cover. Bolts Front Cover FRONT COVERS REMOVAL Remove the two screws on the front cover.
Page 36: Headlight Removal
. FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM HEADLIGHT REMOVAL Remove the headlight connector wire. Remove the two bolts on the headlight. Bolts EXHAUST MUFFLER REMOVAL Remove the two bolts attaching the exhaust muffler. Bolts Joint Lock Nuts Remove the two exhaust muffler joint lock nuts. Remove the exhaust muffler joint packing collar.
Page 37 . INSPECTION/ADJUSTMENT MX’er SYSTEM __________________________________________________________________________________ INSPECTION/ADJUSTMENT SERVICE INFORMATION -------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE----------------------------------------------- 3- 2 FUEL LINE/THROTTLE OPERATION/AIR CLEANER-------------- 3- 3 AIR FILTER FOR DRIVE BELT ------------------------------------------- 3- 4 SPARK PLUG------------------------------------------------------------------- 3- 5 VALVE CLEARANCE/CARBURETOR IDLE SPEED ---------------- 3- 6 IGNITION TIMING/CYLINDER COMPRESSION--------------------- 3- 7 ENGINE OIL/FINAL REDUCTION GEAR OIL------------------------- 3- 8 DRIVE BELT/BRAKE SHOE/BRAKE SYSTEM------------------------ 3- 9...
Page 38: Inspection/Adjustment
. INSPECTION/ADJUSTMENT MX’er SYSTEM SERVICE INFORMATION GENERAL ! WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.
Page 39: Maintenance Schedule
Check toe-in/adjust if necessary. Knuckle shafts Lubricate every 6 months. Check all chassis fittings and fasteners. Fitting/Fasteners Correct if necessary. • In the interest of safety, we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer.
Page 40: Fuel Line/Throttle Operation/Air Cleaner
. INSPECTION/ADJUSTMENT MX’er SYSTEM Fuel tube FUEL LINE Remove the met-in box. Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage. Do not smoke or allow flames or sparks in your working area. Fuel Filter THROTTLE OPERATION Check the throttle to swing for smooth...
Page 41: Air Filter For Drive Belt
. INSPECTION/ADJUSTMENT MX’er SYSTEM CLEAN AIR FILTER ELEMENT Wash the element gently, but throughly in solvent. Use parts cleaning solvent only. Never use gasoline or low flash point solvents which may lead to a fire or explosion. Squeeze the excess solvent out of the element and let dry.
Page 42: Spark Plug
. INSPECTION/ADJUSTMENT MX’er SYSTEM Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air. Install the air filter element and air filter case. Install the front cover. SPARK PLUG Remove the spark plug. Check the spark plug for wear and fouling deposits.
Page 43: Ignition Timing/Cylinder Compression
. INSPECTION/ADJUSTMENT MX’er SYSTEM Remove the cylinder head cover. Bolts Turn the flywheel counterclockwise so that the “T” mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke.
Page 44: Engine Oil/Final Reduction Gear Oil
. INSPECTION/ADJUSTMENT MX’er SYSTEM Remove the timing hole cap. Timing Light Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase.
Page 45 . INSPECTION/ADJUSTMENT MX’er SYSTEM Remove the oil dipstick and check the oil level with the oil dipstick. If the level is near the lower level, fill to the Upper Level Oil Dipstick upper level with the specified engine oil. Oil Filter Screen Cap OIL CHANGE The engine oil will drain more easily while the engine is warm.
Page 46: Drive Belt/Brake Shoe/Brake System
. INSPECTION/ADJUSTMENT MX’er SYSTEM Fill with the recommended oil. Oil Capacity: At disassembly : 400cc At change : 200cc Oil Drain Bolt/ Sealing Washer Reinstall the oil filler bolt and check for oil leaks. Torque: 0.8 1.2kgf-m DRIVE BELT Remove the left crankcase cover. Inspect the drive belt for cracks, scaling, chipping or excessive wear.
Page 47: Headlight Aim
. INSPECTION/ADJUSTMENT MX’er SYSTEM Turning adjusters out that the free play is decreased. The difference between both clearances should be 2 mm or less when front brake is applied. Tighten the lock nuts. Make sure that the brake does not drag after adjusting.
Page 48: Steering System Inspection
. INSPECTION/ADJUSTMENT MX’er SYSTEM Adjusting Screw STEERING SYSTEM INSPECTION Place the machine on a level place. Check the steering column bushings and bearings: Move the handlebar up and down, and/or back and forth. Replace the steering column bushings and or bearings if excessive play Check the tie-rod ends Turn the handlebar to the left and/or right until it...
Page 49: Wheels/Tires
. INSPECTION/ADJUSTMENT MX’er SYSTEM is no weight on the front tires. Fix the handlebar straight ahead. Measure the width A between the marks. Rotate the front tires 180 degrees until the marks come exactly opposite. Measure the width B between the marks. Calculate the toe-in using the formula given below.
Page 50 . INSPECTION/ADJUSTMENT MX’er SYSTEM Front Axle Nut TIRE PRESSURE 1 Rider Front 0.20kgf/cm² Rear 0.25kgf/cm² TIRE SIZE Front : 20*7-8 Rear : 22*10-8 Check the front axle nut for looseness. Rear Axle Nut Check the rear axle nut for looseness. If the axle nuts are loose, tighten them to the specified torque.
Page 51: Drive Chain Slack Adjustment
. INSPECTION/ADJUSTMENT MX’er SYSTEM DRIVE CHAIN SLACK ADJUSTMENT Before checking and/or adjusting, rotate the rear wheels several revolutions and check slack at several points to find the tightest point. Check and/or adjust the chain slack with the rear wheels in this “tightest” position. Too little of chain slack will overload the engine and other vital parts;...
Page 52: Cable Inspection And Lubrication
. INSPECTION/ADJUSTMENT MX’er SYSTEM Turn out: Slack is decreased. Turn in: Slack is increased. Bolts Tighten four bolts attaching rear axle hub to the specification. While pushing up or down on the chain to zero slack. Torque: 6.0 8.0kgf-m Adjuster Tighten the adjuster.
Page 53: Front Suspension Lubrication
. INSPECTION/ADJUSTMENT MX’er SYSTEM Replace if damage. Check the cable operation. Lubricate or replace if unsmooth operation. Hold cable end high and apply several drops of lubricant to cable. LEVER LUBRICATION Lubricate the pivoting parts of each lever. FRONT SUSPENSION LUBRICATION Inject grease into the nipples using a grease gun until slight over flow is observed from the thrust...
Page 54 . LUBRICATION SYSTEM MX’er SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM SERVICE INFORMATION -------------------------------------------------- 4- 2 TROUBLESHOOTING ------------------------------------------------------- 4- 2 ENGINE OIL/OIL FILTER --------------------------------------------------- 4- 3 OIL PUMP ----------------------------------------------------------------------- 4- 3...
Page 55: Lubrication System
. LUBRICATION SYSTEM MX’er SYSTEM LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 56: Lubrication System
. LUBRICATION SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 57: Engine Oil/Oil Filter
. LUBRICATION SYSTEM MX’er SYSTEM Lower Level ENGINE OIL/OIL FILTER OIL LEVEL • Place the motorcycle upright on level ground for engine oil level check. • Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes.
Page 58 . LUBRICATION SYSTEM MX’er SYSTEM Remove the starter idle gear and starter clutch. Special Lock nut socket wrench E009 Bolts Remove the two bolts and oil separator cover. Oil Separator Cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.
Page 59 . LUBRICATION SYSTEM MX’er SYSTEM Remove the screw and disassemble the oil pump. Pump Body Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.12mm Inner Rotor Measure the rotor end-to-pump body clearance.
Page 60 . LUBRICATION SYSTEM MX’er SYSTEM Install the outer rotor, inner rotor and pump shaft into the pump body. Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor. Install the dowel pin. Install the pump cover by aligning the hole in the cover with the dowel pin.
Page 61 . LUBRICATION SYSTEM MX’er SYSTEM the pump shaft. Install and tighten the pump driven gear nut. Torque: 0.8 1.2kgf-m Pump Driven Gear Bolts Install the oil separator cover and tighten the bolts. Oil Separator Cover Dowel Pin Install the starter idle gear and starter clutch. Install the starter clutch nut and tighten it to specified torque..
Page 62: Fuel System
MX’er SYSTEM . FUEL SYSTEM __________________________________________________________________________________ FUEL SYSTEM SERVICE INFORMATION -------------------------------------------------- 5- 2 TROUBLESHOOTING ------------------------------------------------------- 5- 3 THROTTLE VALVE DISASSEMBLY/CARBURETOR REMOVAL--- 5- 4 FLOAT/FLOAT VALVE/JETS ---------------------------------------------- 5- 5 CARBURETOR INSTALLATION ----------------------------------------- 5- 8 FUEL TANK--------------------------------------------------------------------- 5- 9 FUEL VALVE REMOVAL --------------------------------------------------- 5- 9 AIR CLEANER------------------------------------------------------------------ 5-10...
Page 63 . FUEL SYSTEM MX’er SYSTEM...
Page 64: Service Information
. FUEL SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.
Page 65: Troubleshooting
. FUEL SYSTEM MX’er SYSTEM SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine cranks but won’t start Engine lacks power • No fuel in tank • Clogged air cleaner • No fuel to carburetor • Faulty carburetor • Cylinder flooded with fuel •...
Page 66: Throttle Valve Disassembly/Carburetor Removal
. FUEL SYSTEM MX’er SYSTEM THROTTLE VALVE DISASSEMBLY Remove the front cover. Remove the front fender. Remove the carburetor cap. Pull out the throttle valve. Disconnect the choke knob cable. Spring Throttle Cable Disconnect the throttle cable and remove the spring from the throttle valve.
Page 67: Float/Float Valve/Jets
. FUEL SYSTEM MX’er SYSTEM Loosen the air cleaner connecting tube band screw. Remove the two carburetor lock nuts. Remove the carburetor Screw FLOAT/FLOAT VALVE/JETS FLOAT/FLOAT VALVE DISASSEMBLY Remove the float chamber attaching three screws and remove the float chamber. Screws Float Remove the float pin, float and float valve.
Page 68 MX’er SYSTEM . FUEL SYSTEM SCREW REMOVAL Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Remove the air screw and throttle stop screw. Air Screw Throttle Stop Screw CAUTIONS ! O-ring Air Screw Slow Jet •...
Page 69: Carburetor Installation
. FUEL SYSTEM MX’er SYSTEM Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and air screw • When installing the air screw, return it to the original position as noted during removal •...
Page 70 . FUEL SYSTEM MX’er SYSTEM Install the carburetor onto the intake manifold and tighten the two lock nuts. Torque: 0.8 1.2kgf-m Install the air cleaner connecting tube and tighten the band screw. Band Screw Needle Retainer Clip THROTTLE VALVE ASSEMBLY Install the jet needle into the throttle valve and secure with the needle retainer.
Page 71: Fuel Tank
. FUEL SYSTEM MX’er SYSTEM FUEL TANK Choke Cable FUEL TANK REMOVAL Side Warning • Keep sparks and flames away from the work area. • Wipe off any spilled gasoline. Remove the seat. Remove the center cover. Remove the right and left front fender. Fuel Tank Bolts Switch the fuel valve “OFF”.
Page 72: Air Cleaner
. FUEL SYSTEM MX’er SYSTEM Remove the two screws on the fuel valve body. INSPECTION Inspect the fuel valve strainer for dirt and clog. Clean if necessary. Replace the O-rings with new ones if they are damaged or deteriorated. Rubber Gasket Retaining Ring Control Shaft Air Cleaner Case Cover...
Page 73 . ENGINE REMOVAL/INSTALLATION MX’er SYSTEM __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION -------------------------------------------------- 6- 1 ENGINE REMOVAL----------------------------------------------------------- 6- 2 ENGINE INSTALLATION --------------------------------------------------- 6- 4...
Page 74 6. ENGINE REMOVAL/INSTALLATION MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the machine body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal. •...
Page 75: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION MX’er SYSTEM ENGINE REMOVAL Drain engine oil and transmission oil. Remove seat, front cover, center cover, front fender and rear fender. Remove the carburetor. Disconnect the battery negative cable. Remove the frame body cover. Disconnect the engine negative cable. Disconnect the A.C.G.
Page 76 6. ENGINE REMOVAL/INSTALLATION MX’er SYSTEM Disconnect the spark plug high-tension wire. Remove the spark plug cap and disconnect the ignition coil wire from the set plate. Ignition Coil Wire Remove the rear drive chain gear on the bolts. Drive Chain Gear Remove the drive chain gear.
Page 77: Engine Installation
. ENGINE REMOVAL/INSTALLATION MX’er SYSTEM Bolt Engine Hanger Bracket ENGINE HANGER BRACKET REMOVE Remove the two bolts on the left engine hanger bracket. Remove the left engine hanger bracket. Remove the engine. Bolts ENGINE INSTALLATION Install the engine and tighten the engine mounting bolts.
Page 78 . CYLINDER HEAD/VALVES MX’er SYSTEM __________________________________________________________________________________ CYLINDER HEAD/VALVES SERVICE INFORMATION -------------------------------------------------- 7- 2 TROUBLESHOOTING ------------------------------------------------------- 7- 3 CAMSHAFT REMOVAL----------------------------------------------------- 7- 4 CYLINDER HEAD REMOVAL --------------------------------------------- 7- 7 CYLINDER HEAD DISASSEMBLY --------------------------------------- 7- 8 CYLINDER HEAD ASSEMBLY -------------------------------------------- 7-10 CYLINDER HEAD INSTALLATION-------------------------------------- 7-10 CAMSHAFT INSTALLATION---------------------------------------------- 7-11...
Page 79 7. CYLINDER HEAD/VALVES MX’er SYSTEM...
Page 80: Cylinder Head/Valves
. CYLINDER HEAD/VALVES MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication. •...
Page 81: Troubleshooting
7. CYLINDER HEAD/VALVES MX’er SYSTEM TORQUE VALUES Cylinder head nut 1.8 2.2kgf-m Apply engine oil to threads Valve clearance adjusting nut 1.4 1.8kgf-m Apply engine oil to threads Stud bolt 0.7 1.1kgf-m SPECIAL TOOLS Valve spring compressor E040 Tappet adjuster E012 TROUBLESHOOTING •...
Page 82: Camshaft Removal
. CYLINDER HEAD/VALVES MX’er SYSTEM CAMSHAFT REMOVAL Remove seat, front cover, center cover. Front fender, fuel tank and exhaust pipe. Remove the four cylinder head cover bolts to remove the cylinder head cover. Bolts Remove the cam chain tensioner cap bolt and the O-ring.
Page 83 7. CYLINDER HEAD/VALVES MX’er SYSTEM washers. Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Camshaft Holder Remove the camshaft holder and dowel pins. Remove the camshaft gear from the cam chain Camshaft Dowel Pins and remove the camshaft. Cam Chain Camshaft Gear CAMSHAFT INSPECTION...
Page 84: Cylinder Head Removal
. CYLINDER HEAD/VALVES MX’er SYSTEM damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. Rocker Arm Bolt CAMSHAFT HOLDER DISASSEMBLY Remove the bolt attaching the stop plate. Take out the valve rocker arm shafts using a 5mm bolt.
Page 85: Cylinder Head Disassembly
7. CYLINDER HEAD/VALVES MX’er SYSTEM Remove the carburetor. Remove the exhaust muffler. Remove the carburetor intake manifold. Remove the two cylinder head bolts. Bolts Remove the cylinder head. Cylinder Head Remove the dowel pins and cylinder head Bolts gasket. Remove the cam chain guide. Cam Chain Guide Dowel Pins Cylinder Head Gasket...
Page 86 . CYLINDER HEAD/VALVES MX’er SYSTEM Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. • Be sure to compress the valve springs with a valve spring compressor. • Mark all disassembled parts to ensure correct reassembly.
Page 87: Cylinder Head Assembly
7. CYLINDER HEAD/VALVES MX’er SYSTEM Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. Service limits: IN : 0.06mm replace if over EX: 0.08mm replace if over If the stem-to-guide clearance exceeds the service limits, replace the cylinder head as necessary.
Page 88: Cylinder Head Installation
. CYLINDER HEAD/VALVES MX’er SYSTEM Be sure to install new valve stem seals. Lubricate each valve stem with engine oil and insert the valves into the valve guides. Install the valve springs and retainers. Valve Spring Compressor Compress the valve springs using the valve spring compressor, then install the valve cotters.
Page 89: Camshaft Installation
7. CYLINDER HEAD/VALVES MX’er SYSTEM Cylinder Head Camshaft Holder CAMSHAFT HOLDER ASSEMBLY Install the exhaust valve rocker arm to the “EX” mark side of the camshaft holder. Install the intake valve rocker arm and the rocker arm shafts. Tighten the bolt attaching stop plate. •...
Page 90 . CYLINDER HEAD/VALVES MX’er SYSTEM • Apply engine oil to the threads of the cylinder head nuts. • Diagonally tighten the cylinder head nuts in 2 3 times. Washer Adjust the valve clearance. Turn the cam chain tensioner screw counter-clockwise to release it. Tensioner Screw Apply engine oil to a new O-ring and install it.
Page 91 . CYLINDER/PISTON MX’er SYSTEM __________________________________________________________________________________ CYLINDER /PISTON SERVICE INFORMATION -------------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------------- 8- 2 CYLINDER REMOVAL ------------------------------------------------------ 8- 4 PISTON REMOVAL----------------------------------------------------------- 8- 4 PISTON INSTALLATION --------------------------------------------------- 8- 8 CYLINDER INSTALLATION----------------------------------------------- 8- 8...
Page 92: Cylinder/Piston
. CYLINDER/PISTON MX’er SYSTEM...
Page 93: Cylinder/Piston
. CYLINDER/PISTON MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. TROUBLESHOOTING • When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke.
Page 94: Cylinder Removal
. CYLINDER/PISTON MX’er SYSTEM SPECIFICATIONS Mx’er 150 Standard (mm) Service Limit (mm)  I.D. 62.03 62.045  Warpage 0.05 Cylinder  Cylindricity 0.05  True roundness 0.05 0.015 0.055 0.09 Ring-to-groove clearance Second 0.015 0.055 0.09 0.10 0.25 Ring end gap Second 0.10 0.25 Piston,...
Page 95: Piston Removal
. CYLINDER/PISTON MX’er SYSTEM tighten it. Remove the two bolts on the cam chain tension. Cylinder Remove the cylinder head. Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.
Page 96 . CYLINDER/PISTON MX’er SYSTEM Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance. Service Limits: Top: 0.09mm replace if over 2nd: 0.09mm replace if over...
Page 97 . CYLINDER/PISTON MX’er SYSTEM Measure the piston O.D. Take measurement at 5mm from the bottom and 90° to the piston pin hole. Piston O.D.: 61.96 62mm (MX’er 150) Piston O.D.: 56.46 56.5mm (MX’er 125) Measure the piston-to-piston pin clearance. Service Limit: 0.02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage.
Page 98: Piston Installation
. CYLINDER/PISTON MX’er SYSTEM over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring. • Be careful not to damage or break the piston and piston rings.
Page 99: Cylinder Installation
. CYLINDER/PISTON MX’er SYSTEM Be careful not to drop foreign matters into the crankcase. Piston Install the piston, piston pin and a new piston pin clip. • Position the piston “IN” mark on the intake valve side. • Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.
Page 100: Drive And Driven Pulleys
9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION ...............9-2 TROUBLESHOOTING..............9-2 LEFT CRANKCASE COVER............9-3 DRIVE PULLEY................9-3 CLUTCH/DRIVEN PULLEY .............9-3...
Page 101 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS 5.5kg-m 5.5kg-m 5.5kg-m...
Page 102 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed in the frame. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 103: Left Crankcase Cover
MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS LEFT CRANKCASE COVER Air Tube Band REMOVAL Loosen the drive belt air tube band screw. Screw Remove the left crankcase cover bolts and left crankcase cover. Left Crankcase Cover Remove the gasket and dowel pins. Bolts DRIVE PULLEY Drive Pulley Face...
Page 104 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 17.0mm replace if below Use specified genuine parts for replace-ment. Drive Pulley Collar Remove the movable drive face assembly.
Page 105 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 20.42mm replace if below. Measure the movable drive face bushing I.D. Service Limit: 27.06mm replace if over Check the drive pulley bushing for wear or damage.
Page 106 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM ASSEMBLY Install the weight rollers into the movable drive face. Weight Roller Install the ramp plate. Ramp Plate...
Page 107 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D.
Page 108 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Driven Pulley Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor. Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor E027 Set the clutch spring compressor in a vise and remove the clutch drive plate nut.
Page 109 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Movable Driven Face Oil Sea Remove the oil seal from the movable driven face. INSPECTION Measure the driven face spring free length. Service Limit: 83.2mm replace if below Check the driven face for wear or damage. Measure the driven face O.D.
Page 110 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. Discard the removed bearing and replace with a new one. Outer Bearing Remove the snap ring and drive the outer bearing out of the driven face.
Page 111 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Circlip Clutch Lining CLUTCH / DRIVEN PULLEY ASSEMBLY 9-11...
Page 112 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Retainer Plate Drive Plate Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips. Springs Clutch Weights/Shoes Circlip...
Page 113 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS T orque: 5.5 6.5kgf-m Driven Face Clutch Spring Compressor Compress the clutch spring compressor and install the drive plate nut. Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque.
Page 114 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Left Crankcase Cover Install the left crankcase cover and tighten the cover bolts diagonally. Connect the drive belt air tube and tighten the band screw. Screw 9-14...
Page 115 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS 9-15...
Page 116 . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM __________________________________________________________________________________ FINAL REDUCTION/TRANSMISSION SYSTEM SERVICE INFORMATION --------------------------------------------------10- 2 TROUBLESHOOTING -------------------------------------------------------10- 2 FINAL REDUCTION DISASSEMBLY------------------------------------10- 3 FINAL REDUCTION INSPECTION---------------------------------------10- 4 TRANSMISSION GEARS/CRANKSHAFT REMOVAL--------------10- 6 FINAL REDUCTION INSTALLATION-----------------------------------10- 7 10-0...
Page 117: Final Reduction/Transmission System
. FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM 10-1...
Page 118: Final Reduction/Transmission System
. FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At change : 0.2 liter At disassembly : 0.4 liter TORQUE VALUES...
Page 119: Final Reduction Disassembly
. FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM Crankcase Cover FINAL REDUCTION DISASSEMBLY Drain engine oil and transmission gear oil into a clean container. Remove the engine. Remove the right crankcase cover. Bolts Starter Motor Balance Gear Flywheel Remove the shift gear spindle. Remove the flywheel and starter clutch.
Page 120 . FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM Gasket Remove gasket and two dowel pins. Dowel Pins FINAL REDUCTION/ TRANSMISSION INSPECTION Inspect the change gear shaft for wear, damage or seizure. Change Gear Shaft Check the transmission operation. Repair if unsmooth operation. Plug Remove the plug.
Page 121 . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM Shift Cam Stopper Remove spring, washer and shift cam stopper. Plug Transmission fork Remove the transmission fork shaft and transmission fork. Transmission fork shaft Measure the transmission fork shaft O.D. Service Limit: 11.936 Measure the transmission fork shaft hole I.D.
Page 122: Transmission Gears/Crankshaft Removal
. FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM Check the shift cam groove and shift cam gear. Replace if wear or damage. TRANSMISSION GEARS/ Countershaft Driver Shaft CRANKSHAFT REMOVAL Remove the final gear and main shaft. Main Shaft GEAR/SHAFT COLLAR INSPECTION Check each gear and gear teeth for wear, damage, or poor lubrication.
Page 123: Final Reduction Installation
. FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Countershaft Bearing Drive Shaft Inspect the drive shaft and gear for wear or damage. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
Page 124 . FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM and install the transmission fork guide pin into the shift cam groove. Shift cam Install the transmission fork shaft into the left crankcase. Transmission Fork Shaft Install the change gear shaft by aligning the punch mark between with the punch mark of the shift cam gear.
Page 125 Install and tighten the right case cover bolt. Install the shift gear spindle. Install the cylinder. Specified Gear Oil: KYMCO SIGMA GEAR OIL 90# Oil Capacity: At disassembly : 0.4 liter At change : 0.2 liter Install and tighten the oil check bolt.
Page 126 CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM __________________________________________________________________________________ CRANKCASE/CRANKSHAFT/BALANCE SHAFT SERVICE INFORMATION --------------------------------------------------11- 2 TROUBLESHOOTING -------------------------------------------------------11- 2 CRANKCASE SEPARATION-----------------------------------------------11- 3 CRANKSHAFT INSPECTION----------------------------------------------11- 4 CRANKCASE/BALANCE SHAFT ASSEMBLY------------------------11- 5 11-0...
Page 127: Crankcase/Crankshaft
CRANKCASE/CRANKSHAFT/ MX’er SYSTEM BALANCE SHAFT 11-1...
Page 128 CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. −Cylinder head ( ð Section 7) −Cylinder/piston ( ð...
Page 129: Balance Shaft
CRANKCASE/CRANKSHAFT/ MX’er SYSTEM BALANCE SHAFT CRANKCASE SEPARATION Remove the left and right crankcase attaching bolts. (Section 10) Separate the left and right crankcase halves. Do not damage the crankcase gasket surface. Crankcase Bolts Gasket Balance Shaft Remove the gasket and dowel pins. Dowel Pins Remover balance shaft from the left crankcase.
Page 130: Crankshaft Inspection
CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM Remove the crankshaft and cam chain from the left crankcase. Clean off all gasket material from the crankcase Gasket mating surfaces. Avoid damaging the crankcase mating surfaces. CRANKSHAFT INSPECTION Measure the connecting rod small end I.D. Service Limit: 15.06 mm replace if over Measure the connecting rod big end side clearance.
Page 131 CRANKCASE/CRANKSHAFT/ MX’er SYSTEM BALANCE SHAFT Play Turn the crankshaft bearings and check for Play excessive play. Measure the crankshaft bearing play. Service Limit: Axial : 0.20mm replace if over Radial : 0.05mm replace if over Radial Axial Measure the crankshaft run out. Service Limit: 0.10mm replace if over Crankshaft CRANKCASE/BALANCE SHAFT...
Page 132 CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM Right Crankcase Mark Align the mark on the balance gear with the mark on the crankshaft gear. Right Case Cover Install the right and left case cover. Install the cylinder. 11-6...
Page 133 CRANKCASE/CRANKSHAFT/ MX’er SYSTEM BALANCE SHAFT 11-7...
Page 134 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM __________________________________________________________________________________ FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION\STEERING SYSTEM SERVICE INFORMATION --------------------------------------------------12- 2 TROUBLESHOOTING -------------------------------------------------------12- 3 FRONT WHEEL----------------------------------------------------------------12- 4 FRONT BRAKE ----------------------------------------------------------------12- 7 FRONT SUSPENSION--------------------------------------------------------12- 9 STEERING SYSTEM----------------------------------------------------------12-13 12-0...
Page 135: Front Wheel/Front Brake/Front Suspension/Steering System
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM 12-1...
Page 136: Service Information
. FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the machine frame covers before removing the front wheel. Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. •...
Page 137: Front Wheel/Front Brake/ Front Suspension/Steering
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM SPECIAL TOOLS Oil seal and bearing install E014 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •Insufficient tire pressure • Bent rim • Excessive wheel bearing play • Bent spoke plate • Faulty tire •...
Page 138 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Place the machine on a level place. Remove four nuts attaching the wheel panel and front wheel. Elevate the front wheels by placing a suitable stand under the frame. Support the machine securely so there is no danger of it falling over.
Page 139 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM of specification Rim run out limits: Vertical: 2.0mm Lateral: 2.0mm Inspect the front wheel hub. Replace if cracks or damage. Inspect the front brake drum. Measure the front brake drum I.D. Service limits: 111mm Keep oil or grease off the brake drum.
Page 140: Front Brake
. FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM hub. BEARING REPLACEMENT Remove the front wheel bearings and distance collar. Side Collar Collar Dust Seal Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub.
Page 141 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Camshaft lever Brake Plate REMOVAL Inspect the shoe springs, O-rings, camshaft Brake shoe pivot pin lever and wear indicator. Replace if damage. Inspect the brake shoe plate. Replace if cracks or damage. Inspect the brake shoe pivot pin.
Page 142: Front Suspension
. FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Apply the grease onto the bearings and oil Locating Slot seal lips of the wheel hub. Install wheel hub, plate washer and tight the nut (wheel hub). Torque: 6.0 8.0kgf-m Install cotter pins. Always use a new cotter pin.
Page 143 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Remove the front wheel, wheel hub, brake shoe plate. Remove the upper and lower bolt, then remove Lower Bolt the shock absorber. Tie-rod Remove the cotter pin and nut, then remove tie-rod from steering knuckle. Steering Knuckle Cotter pin Front arm...
Page 144 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Check the front arm side play by moving it from side to side. If side play noticeable, replace the inner collar, bushings and thrust covers as a set. Check the front arm vertical movement by moving it up and down.
Page 145 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Inspect the front arm. Replace if cracks, bends or damage. Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Inspect bushes. Replace if wear or damage. Bushes INSTALLATION Reverse the “REMOVAL”...
Page 146: Steering System
. FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Install the tie-rod onto the steering knuckle and tighten the nut. Torque: 4.0 5.0kgf-m Install the cotter pin and band ends of cotter pin. Always use a new cotter pin. Bleed Valve Install the shock absorber and tighten the upper and lower bolts.
Page 147 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Remove the handlebar cover with main switch. Main Switch Lead Brake Switch Disconnect the front brake cables from the brake lever, rear brake cable from the brake lever and brake switch from the bracket of the brake lever.
Page 148 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Headlight Unit Bolts Remove the two bolts and remove headlight unit. Remove the four handlebar holder bolts and remove the handlebar. Bolts Handlebar Cotter Pin Remove the cotter pins and nuts attaching the tie-rods, then remove tie-rods.
Page 149 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Bolts Steering Bracket INSPECTION Inspect the handlebar. Replace if cracks, bends or damage. Inspect the steering column. Replace if bends or damage. Do not attempt to straighten a bent shaft, this may dangerously weaken the shaft. Oil Seal Inspect the steering brackets and oil seal.
Page 150 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Check the tie-rod end movement. Replace if the tie-rod end exists free play or turns roughly. Check the tapered surface of the tie-rod end. Replace if pitting, wear or damage. Adjust the tie-rod length. Adjustment steps: (The following procedures are done on both tie-rods, right and left.)
Page 151 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Dust Seal Inspect the collar, duty seal, snap ring and bearing. Replace if wear or damage. Snap Ring Collar Dust Seal Bearing INSTALLATION Reverse the “REMOVAL” procedures. Apply the grease onto the collar, duty seal, and bearing.
Page 152 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er SYSTEM SUSPENSION/STEERING SYSTEM Cotter Pin Install the tie rods and tighten the nut. Torque: 4.0 5.0kgf-m Install the cotter pin and band ends of cotter pin. Always use a new cotter pin. Cotter Pin Tie-rod Indentation Surface Be sure that the rod-end on the indentation surface side is connected to...
Page 153 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Apply the grease onto the end of the throttle cable and end of the brake cable. Refer to the “TOE-IN ADJUSTMENT” section in the CHAPTER 3 to adjust toe-in. Refer to the “FRONT BRAKE ADJUSTMENT”...
Page 154 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM __________________________________________________________________________________ REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE SERVICE INFORMATION --------------------------------------------------13- 2 TROUBLESHOOTING -------------------------------------------------------13- 3 REAR WHEEL ------------------------------------------------------------------13- 4 SWING ARM--------------------------------------------------------------------13- 13 HYDRAULIC BRAKE---------------------------------------------------------13- 17 13-0...
Page 155 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM 13-1...
Page 156: Rear Wheel /Swing Arm/Hydraulic Brake
. REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake drum and brake linings. • Drain the brake fluid from the hydraulic brake system before disassembly. • Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads.
Page 157 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Nut wrench F010 TROUBLESHOOTING Rear wheel wobbling Poor brake performance • Bent rim • Brake not adjusted properly • Faulty tire • Worn brake linings • Axle not tightened properly • Worn brake shoes at cam contacting area •...
Page 158 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Use the nut wrench to loosen two nuts (inner and outer) of the rear axle. Special Nut wrench F010 Outer Nut Cotter Pin Remove the cotter pin. Nut Attaching The Wheel Hub Remove four nuts attaching the wheel panel of the both rear wheels.
Page 159 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Lateral: 2.0mm Replace wheel or check bearing play if out of specification. Outer Nut Remove two nuts of the rear axle (outer and inner). Inner Nut Remove five bolts attaching left and right lower Bolts Bolts guard.
Page 160 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Remove the drive chain from driven sprocket. Drive Chain Bolts Remove six bolts attaching brake drum cover. Brake Drum Cover Rubber Spacer Remove brake drum cover and rubber spacer. Bolts Inspection Inspect the inner surface of the brake drum is scratches, polish brake drum lightly and evenly with emery cloth.
Page 161 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Replace if it is out of specification. Disconnect the rear brake cable from the camshaft lever. Remove the brake shoes. INSPECTION Measure lining thickness of the brake shoes. Service limit: 2.0 mm Replace if it is out of specification.
Page 162 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Splines Wheel Hub INSPECTION Replace if the wheel hub is cracks or damage. Replace if splines of the wheel hub is wear or damage. Replace if the rear axle is scratched (excessively) or damage. Replace if splines and threads of the rear axle is wear or damage.
Page 163 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Remove the drive chain. Inspect the drive chain stiffness. Clean and lubricate or replace if stiff. Inspect the drive sprocket and the driven sprocket. Replace sprocket if more than 1/4 teeth wear or bent teeth.
Page 164 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Remove the oil seal by a flat-head screw driver. Place a wood block against the outer edge to protect this edge. Remove the bearing by a general bearing puller. Install the new bearings and oils seal by reversing the previous steps.
Page 165 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Adjust drive chain slack. Approximately: 30 mm Bolts Tighten the bolts. Torque: 6.0 8.0kgf-m Torque: 6.0 8.0kgf-m Adjuster Lock Nut Tighten the lock nut. Torque: 1.8 2.5kgf-m Bolts Tighten the two nuts with the nut wrench. Special Nut wrench F010 Torque: 11.0 13.0kgf-m...
Page 166: Swing Arm
. REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Install wheel hub, plate washer and nut (wheel hub). Torque: 6.0 8.0kgf-m Install cotter pins. Do not loosen the axle nut after torque tightening. If the axle nut groove id not aligned with the cotter pin hole, align groove with the hole by tightening ut on the axle nut.
Page 167 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Remove the rear wheels, rear hub with rear axle. Refer to the “REAR WHEEL REMOVAL” section Remove the cotter pin, washer and shaft. When removing the lower shaft, hold the swing arm so that it does not drop downwards when the shaft id removed.
Page 168 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Check the swing arm vertical movement by moving it up and down. If vertical movement is tight, binding or rough, check the inner collar, bearing, bushing and thrust cover, or adjust the shim. Remove the nut and pivot shaft, then remove swing arm.
Page 169 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Move the spring up and down. Bush Chain Guard Thrust Cover Inspect the swing arm. Replace if crack, bend or damage. Roll the axle on a flat surface to inspect the pivot shaft. Replace if bends.
Page 170 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Install the shock absorber and tightening the bolt. Torque: 3.5 4.5kgf-m Install the shaft, washer and cotter pin. Always use a new cotter pin. Install the rear hub and rear wheels. Refer to the “REAR WHEEL INSTALLATION”...
Page 171 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Bleed Valve BRAKE FLUID REFILLING Connect a transparent hose and syringe to the brake caliper bleed valve and then loosen the bleed valve nut.
Page 172 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM BRAKE PAD/DISK BRAKE PAD REPLACEMENT Remove the two bolts attaching the brake caliper holder. The brake pads can be replaced without removing the brake fluid tube. Bolts Remove the brake caliper. Brake Caliper Holder Brake Bad Push the brake caliper holder and then remove brake pad.
Page 173: Brake Master Cylinder
. REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic brake system. Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts.
Page 174 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Spring Snap Ring Main Piston INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks.
Page 175 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Install the rubber cover. Install the brake lever. Install the brake fluid tube with the bolt and two sealing washers. Then, install the rearview mirror. Fill the brake reservoir with recommended brake fluid to the upper level. Bleed air from the hydraulic brake system.
Page 176 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Remove the brake caliper holder from the brake caliper. Remove the pistons from the brake caliper. Use compressed air to press out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons.
Page 177 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Check the caliper cylinder for scratches or wear and measure the caliper cylinder I.D. Service limit: 34.05mm replace if over ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid.
Page 178 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er SYSTEM Install the brake caliper onto rear axle hub and tighten the bolts. Torque: 2.4 3.0kg-m Aligning The Fluid Tube With Groove Fluid Tube Bolt Washer 13-24...
Page 179 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM __________________________________________________________________________________ BATTER/CHARGING SYSTEM/ A.C. GENERATOR SERVICE INFORMATION --------------------------------------------------14- 2 TROUBLESHOOTING -------------------------------------------------------14- 3 BATTERY REMOVAL--------------------------------------------------------14- 4 CHARGING SYSTEM --------------------------------------------------------14- 5 REGULATOR/RECTIFIER --------------------------------------------------14- 6 A.C. GENERATOR CHARGING COI -----------------------------------14- 7 14-0...
Page 180: Batter/Charging System
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM Ignition Switch Fuse/Battery Regulator/Rectifier A.C. Generator CHARGING CIRCUIT 14-1...
Page 181: Service Information
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM SERVICE INFORMATIONN GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention •...
Page 182: Troubleshooting
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM Regulator/Rectifier lock nut 0.7~1.1kgf-m TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection •...
Page 183: Battery/Charging System/A
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM and then the positive (+) cable. Lock Lever The installation sequence is the reverse of removal. First connect the positive (+) cable and then negative (-) cable to avoid short circuit. BATTERY VOLTAGE (OPEN CIRCUIT VOLTAGE) INSPECTION Remove the seat.
Page 184: Regulator/Rectifier
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM Turn the ignition switch OFF and check for short circuit. Connect the electric tester positive (+) (-) Terminal terminal to ground wire and the tester negative (-) terminal to the battery negative (-) terminal. If any abnormality is found, check the ignition switch and wire harness for short circuit .
Page 185: Generator Charging Coil
. BATTERY/CHARGING SYSTEM/ MX’er SYSTEM A.C. GENERATOR Lock Nut Pink Black Green REGULATOR/RECTIFIER INSPECTION If the main harness terminals are normal, check the regulator/rectifier coupler for loose connection and measure the resistance between the regulator/rectifier terminals. • Do not touch the tester probes with your finger because human body has resistance.
Page 186 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er SYSTEM Disconnect the A.C. generator pink and yellow wires and measure the resistance between the pink and yellow wires. Resistance: 0.2Ω(at 20 ) Replace the A.C. generator charging coil if the reading is not within the specifications. 14-7...
Page 187 . IGNITION SYSTEM MX’er SYSTEM __________________________________________________________________________________ IGNITION SYSTEM SERVICE INFORMATION --------------------------------------------------15- 2 TROUBLESHOOTING -------------------------------------------------------15- 3 CDI UNIT INSPECTION -----------------------------------------------------15- 4 IGNITION COIL----------------------------------------------------------------15- 6 PULSER COIL ------------------------------------------------------------------15- 7 15-0...
Page 188: Ignition System
. IGNITION SYSTEM MX’er SYSTEM CDI Unit/Change Gear Control. Ignition Switch ntrol Spark Plug Ignition Coil A.C. Generator/ Pulser Coil IGNITION CIRCUIT PULSER COIL 15-1...
Page 189 . IGNITION SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. • The ignition system adopts CDI unit , change gear control and the ignition timing cannot be adjusted. •...
Page 190 . IGNITION SYSTEM MX’er SYSTEM High voltage too low No high voltage • Weak battery or low engine speed • Faulty ignition switch • Loose ignition system connection • Faulty CDI unit • Faulty CDI unit • Poorly connected or broken CDI ground wire •...
Page 191 . IGNITION SYSTEM MX’er SYSTEM • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper tester in an improper range may give false CDI Unit readings. • Use a Sanwa Electric Tester or Kowa Black/White Black/Red Green/Red...
Page 192: Ignition Coil Inspection
Ignition Coil Spark Window . IGNITION SYSTEM MX’er SYSTEM Switch Range Good CDI Faulty CDI  1. OFF No spark  2. P No spark CDI Unit Spark Plug 3. EXT No spark Good spark 4. ON1 Good spark No spark 5.
Page 193 . IGNITION SYSTEM MX’er SYSTEM Measure the resistance between the ignition coil primary coil terminals. Resistance: 0.2 0.3Ω/20 Remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and the primary coil terminal. Resistance: 3.2 4.8KΩ/20 This test is for reference only.
Page 194 . IGNITION SYSTEM MX’er SYSTEM EXCITER COIL INSPECTION Disconnect the exciter coil wire coupler and measure the resistance between the black/red wire terminal and ground. Resistance: 100 120Ω 15-7...
Page 195: Starting System
. STARTING SYSTEM MX’er SYSTEM __________________________________________________________________________________ STARTING SYSTEM SERVICE INFORMATION --------------------------------------------------16- 2 TROUBLESHOOTING -------------------------------------------------------16- 2 STARTER MOTOR -----------------------------------------------------------16- 3 STARTER RELAY-------------------------------------------------------------16- 5 16-0...
Page 196 . STARTING SYSTEM MX’er SYSTEM Stop Switches Starter Button Ignition Switch Fuse/Battery/Starter Relay Starter Motor STARTING CIRCUIT 16-1...
Page 197: Starting System
. STARTING SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to Section 4. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5 TROUBLESHOOTING Starter motor won‘t turn...
Page 198: Starter Motor
. STARTING SYSTEM MX’er SYSTEM STARTER MOTOR REMOVAL Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly. Starter Motor Cable Remove the two starter motor mounting bolts and the motor.
Page 199 . STARTING SYSTEM MX’er SYSTEM CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary. Wire Terminal Measure the length of the brushes.
Page 200: Starter Relay
. STARTING SYSTEM MX’er SYSTEM ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover. •...
Page 201 . STARTING SYSTEM MX’er SYSTEM Check the O-ring for wear or damage and replace if necessary. Apply grease to the O-ring and install the starter motor. Tighten the two mounting bolts. The starter motor cable connector must be O-ring installed properly. 16-6...
Page 202 . LIGHTS/ SWITCHES MX’er SYSTEM __________________________________________________________________________________ LIGHTS/SWITCHES SERVICE INFORMATION --------------------------------------------------17- 2 TROUBLESHOOTING -------------------------------------------------------17- 2 HEADLIGHT --------------------------------------------------------------------17- 3 INSTRUMENTS/STOP LIGHT/TAILLIGHT ----------------------------17- 4 IGNITION SWITCH-----------------------------------------------------------17- 5 STOP SWITCH-----------------------------------------------------------------17- 5 STARTER BUTTON ----------------------------------------------------------17- 6 HEADLIGHT SWITCH -------------------------------------------------------17- 6 ENGINE STOP SWITCH-----------------------------------------------------17- 6 17-0...
Page 203: Lights/Switches
. LIGHTS/ SWITCHES MX’er SYSTEM ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Switch/ Starter Button Ignition Switch Taillight/Stop Light Headlight 17-1...
Page 204: Lights/Switches
. LIGHTS/ SWITCHES MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • An electric tester is needed to measure or test the electric equipment. • Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment. •...
Page 205: Headlight
. LIGHTS/ SWITCHES MX’er SYSTEM HEADLIGHT BULB REPLACEMENT Disconnect the cover of the ignition switch and remove the two headlight attaching bolts. Remove the headlight and disconnect the headlight wire coupler. Bolts Remove the two headlight case attaching screws and disconnect the headlight. Screws Headlight Wire Coupler Check the bulb for damage and replace with a...
Page 206 . LIGHTS/ SWITCHES MX’er SYSTEM INSTALLATION Install the headlight in the reverse order of removal. After installation, adjust the headlight beam. INSTRUMENTS Bulb Socket Light Shell REMOVAL Remove the two headlight attaching bolts. Remove the headlight and disconnect the headlight wire coupler. Remove the two headlight case attaching screws and disconnect the headlight.
Page 207: Ignition Switch
. LIGHTS/ SWITCHES MX’er SYSTEM damage. Replace with a new one if necessary. IGNITION SWITCH Check for continuity between the wires indicated below. Black/ Color Black Green White Position STOP SWITCH Disconnect the front stop switch wire coupler. Check for continuity between the front stop switch wires.
Page 208: Headlight Switch
. LIGHTS/ SWITCHES MX’er SYSTEM Disconnect the starter button yellow/brown and yellow/red wires. Check for continuity between the black and yellow/red wires. Color Yellow/Brown Yellow/Red Position FREE PUSH White Black Brown HEADLIGHT SWITCH Remove the center cover. Disconnect the headlight switch wire coupler. Check for continuity between the headlight switch wires.
Page 209: Only Atv On Road Available
. ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM __________________________________________________________________________________ ONLY ATV ON ROAD AVAILABLE WARING DIAGRAM----------------------------------------------------------18- 1 BRAKE PEDAL ADJUSTMENT --------------------------------------------18- 2 INSTRUMENT ------------------------------------------------------------------18- 3 INDICATOR LIGHT-----------------------------------------------------------18- 3 HAZARD SWITCH ------------------------------------------------------------18- 4 HORN -----------------------------------------------------------------------------18- 4 18-0...
Page 210 . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM WIRING DIAGRAM 18-1...
Page 211: Brake Pedal Adjustment
. ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM Brake Pedal BRAKE PEDAL ADJUSTMENT The brake pedal free play should be adjusted to 10~20 mm (0.4~0.8 in) at the brake pedal pivot. If the free play is incorrect, adjust as Follows: 10~20mm Keep front brake lever free play at 10~20 mm (0.4~0.8 in).
Page 212: Instrument
. ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM INSTRUMENT REMOVAL Remove the two instrument attaching screws. Disconnect the instrument. Screws Battery Cover Remove battery cover on instrument back to replace battery. After replace battery, the instrument will be reset. (Refer to owner’s manual) Speed Wheel SENSOR WHEEL If the sensor is lost or wore, the speed will be...
Page 213: Hazard Switch
. ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM Bulb Socket Remove the bulb socket and bulb. Check the bulb for damage and replace with a new one if necessary. INSTALLATION The installation sequence is the reverse of removal. Bulb HAZARD SWITCH Check for continuity between the wires indicated below.

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La30aa La30ab Mx'er 150

KYMCO MX’er 125 Service Manual

Preface

Frame Covers/Exhaust Muffler

Inspection/Adjustment

Lubrication System

5 Fuel System

Cylinder Head/Valves 7

Cylinder /Piston

Final Reduction/Transmission System

Front Wheel/Front Brake/ Front Suspension\Steering System

Batter/Charging System/

Batter/Charging System

Generator

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TABLE OF CONTENTS

Chapters

Troubleshooting

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Summary of Contents for KYMCO MX’er 125

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Table of Contents