KYMCO MXU 150 Service Manual
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KYMCO MXU 150 Service Manual

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KYMCO
SERVICE MANUAL
MXU 150
MX'er 150/125
Issued: 08.06.2005

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Summary of Contents for KYMCO MXU 150

  • Page 1 KYMCO SERVICE MANUAL MXU 150 MX’er 150/125 Issued: 08.06.2005...
  • Page 2 By KWANG YANG Motor Co., Ltd. First Edition, Jun 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LCA4/LLB1-S00...
  • Page 3 The information and contents included in this manual may be different from the ATV in case specifications are changed. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation. KWANG YANG MOTOR CO., LTD.
  • Page 4 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 5 TORQUE VALUES --------------------------------------------------------- 1-13 SPECIAL TOOLS ----------------------------------------------------------- 1-15 LUBRICATION POINTS -------------------------------------------------- 1-16 CABLE & HARNESS ROUTING (MX’er 150/125) ------------------- 1-19 CABLE & HARNESS ROUTING (MXU 150) ------------------------- 1-23 WIRING DIAGRAM-------------------------------------------------------- 1-28 TROUBLESHOOTING----------------------------------------------------- 1-32...

  • Page 5: General Information

    . GENERAL INFORMATION ATV 150/125 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...
  • Page 6 . GENERAL INFORMATION ATV 150/125 SPECIFICATIONS (MX’er 150) Model No. LA30 Air cleaner type & No Sponge ATV Name MX’er 150 8.1 liters (1.7 lmp gal, Fuel capacity 2.11 Usgal) Overall length 1600 mm (64 in) Type Overall width 980 mm (39.2 in) Float lever 14.8 mm (0.592 in) Overall height...
  • Page 7 . GENERAL INFORMATION ATV 150/125 (MX’er 125) Air cleaner type & No Sponge Model No. LA25 8.1 liters (1.7 lmp gal, ATV Name MX’er 125 Fuel capacity 2.11 Usgal) Overall length 1685 mm (67.4 in) Type Overall width 980 mm (39.2 in) Float lever 14.8 mm (0.592 in) Overall height...
  • Page 8 . GENERAL INFORMATION ATV 150/125 (MXU 150) Air cleaner type & No Sponge Model No. LA30 8.1 liters (1.7 lmp gal, ATV Name MXU 150 Fuel capacity 2.11 Usgal) Overall length 1775 mm (71 in) Type Overall width 950 mm (38 in) Piston dia.
  • Page 9 . GENERAL INFORMATION ATV 150/125 SERVICE PRECAUTIONS „ Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. „ When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
  • Page 10 . GENERAL INFORMATION ATV 150/125 „ Apply or add designated greases and lubricants to the specified lubrication points. „ After reassembly, check all parts for proper tightening and operation. „ When two persons work together, pay attention to the mutual working safety. „...
  • Page 11 . GENERAL INFORMATION ATV 150/125 „ If the fuse is burned out, find the cause Confirm and repair it. Replace it with a new one Capacity according to the specified capacity. „ After operation, terminal caps shall be installed securely. „...
  • Page 12 . GENERAL INFORMATION ATV 150/125 „ The connector shall be inserted completely. Snapping! „ If the double connector has a lock, lock it at the correct position. „ Check if there is any loose wire. „ Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
  • Page 13 . GENERAL INFORMATION ATV 150/125 „ After clamping, check each wire to make sure it is secure. „ Do not squeeze wires against the weld or its clamp. „ After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
  • Page 14 . GENERAL INFORMATION ATV 150/125 „ Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! „ Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. „...
  • Page 15 . GENERAL INFORMATION ATV 150/125 „ After routing, check that the wire harnesses are not twisted or kinked. „ 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.
  • Page 16 . GENERAL INFORMATION ATV 150/125 „ 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.
  • Page 17 . GENERAL INFORMATION ATV 150/125 TORQUE VALUES STANDARD TORQUE VALUES Torque Torque Item Item kgf-m (N-m, lbf-ft) kgf-m (N-m, lbf-ft) 5mm bolt and nut 0.5 (5, 3.6) 4mm screw 0.3 (3, 2.2) 6mm bolt and nut 1 (10, 7.2) 0.4 (4, 2.9) 5mm screw 8mm bolt and nut 2.2 (22, 16)
  • Page 18 . GENERAL INFORMATION ATV 150/125 ENGINE (Cont’d) Torque Thread dia. Item Q‘ty Remarks kgf-m (N-m, lbf-ft) (mm) R cover 1 (10, 7) Head cover 1 (10, 7) Cap R cover 1 (10, 7) Guide star change handle 1 (10, 7) Sprocket drive plate 1 (10, 7) Carburetor...
  • Page 19 . GENERAL INFORMATION ATV 150/125 SPECIAL TOOLS Tool Name Tool No. Remarks Flywheel puller E003 Flywheel removal Lock nut wrench E009 Start clutch nut removal/installation Lock nut wrench E010 Balancer gear nut removal/installation Valve adjuster E012 Valve clearance adjustment Valve spring compressor E040 Cylinder head disassembly/assembly Oil seal and bearing install...
  • Page 20 ATV 150/125 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part xGenuine KYMCO Engine Oil (SAE15W-40) Cam lobes xAPI SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
  • Page 21 . GENERAL INFORMATION ATV 150/125 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. Rear Brake Cable Front Brake Cable Throttle Cable...
  • Page 22 . GENERAL INFORMATION ATV 150/125 Swing arm Thrust Cover Rear Brake Cam/ Axle Hub Collar/Oil Seal/Bearing Sprocket hub/Rear Axle Hub Collar/Oil Seal/Bearing Driven Sprocket 1-18...
  • Page 23 . GENERAL INFORMATION ATV 150/125 CABLE & HARNESS ROUTING (MX’er 150/125) Rear Brake Cable Throttle Cable Handlebar Switch Lead Front Brake Cable Right Front Brake Cable Left Front Brake Cable 1-19...
  • Page 24 . GENERAL INFORMATION ATV 150/125 Breather Hose (CYL Head Cover) Main Switch Inlet Hose Breather Hose 1-20...
  • Page 25 . GENERAL INFORMATION ATV 150/125 Breather Hose Wire Harness Rectifier/Regulator Fuse Outlet Hose Ignition Coil 1-21...
  • Page 26 . GENERAL INFORMATION ATV 150/125 A.C.G Wire Connector Breather Hose (CYL Head Cover) Battery Negative Cable Positive Cable Battery CDI Unit Starter Relay Change Gear Control Fuse 1-22...
  • Page 27 . GENERAL INFORMATION ATV 150/125 CABLE & HARNESS ROUTING (MXU 150) Hazard Unit Connector Rear Brake Hose Hazard Unit Harness Wire Fuel Valve RPM Sensor Wire Inlet Hose Headlight Rear Right Turn Signal Fuel Unit Wire Control Unit Light Connectors...
  • Page 28 . GENERAL INFORMATION ATV 150/125 Front Brake Light Switch Wire Fuel Tank Breather Hose Front Brake Cables Throttle Cable A.C. Generator Connector Throttle Cable Rear Brake Cables Handlebar Switch Wire Fuel Hose Rear Brake Light Switch Wire 1-24...
  • Page 29 . GENERAL INFORMATION ATV 150/125 Throttle Cable Front Brake Light Switch Meter Connector Headlight/Turn Signal Light Connectors (ON Handlebar Switch Wire ROAD) Harness Wire Handlebar Switch Connector Rear Brake Hose Headlight/Right Turn Signal Light Wire (ON ROAD) Front Right Brake Cable Horn (ON ROAD) Ignition Switch Wire Front Left Brake Cable...
  • Page 30 . GENERAL INFORMATION ATV 150/125 RPM Sensor Rear Brake Hose 1-26...
  • Page 31 . GENERAL INFORMATION ATV 150/125 Starter Relay Negative Battery Cable Starter Motor Cable Change Gear Control Unit CDI Unit Positive Battery Cable Fuse Box Battery 1-27...
  • Page 32 . GENERAL INFORMATION ATV 150/125 WIRING DIAGRAM (MX’er 150/125 ON ROAD) 1-28...
  • Page 33 . GENERAL INFORMATION ATV 150/125 (MX’er 150/125 OFF ROAD) 1-29...
  • Page 34 . GENERAL INFORMATION ATV 150/125 (MXU 150 ON ROAD) 1-30...
  • Page 35 . GENERAL INFORMATION ATV 150/125 (MXU 150 OFF ROAD) 1-31...

  • Page 36: Troubleshooting

    . GENERAL INFORMATION ATV 150/125 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom 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 37 . GENERAL INFORMATION ATV 150/125 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Restricted fuel flow Engine speed does not Engine speed Clogged fuel tank cap breather hole increase sufficiently increases Clogged exhaust muffler Carburetor fuel level too low Check ignition timing...
  • Page 38 . GENERAL INFORMATION ATV 150/125 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 Correctly adjusted Incorrectly adjusted out)
  • Page 39 . GENERAL INFORMATION ATV 150/125 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 40 . GENERAL INFORMATION ATV 150/125 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) 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.
  • Page 41 . GENERAL INFORMATION ATV 150/125 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause 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...

This manual is also suitable for:

Mx'er 150Mx'er 125

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