Page 1: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the FRAME COVERS/EXHAUST MUFFLER technical features and servicing INSPECTION/ADJUSTMENT procedures for the KYMCO MX’er 50. LUBRICATION SYSTEM Section 1 contains the precautions for FUEL SYSTEM all operations stated in this manual. ENGINE REMOVAL/INSTALLATION Read them carefully before starting any operation.
Page 2 . GENERAL INFORMATION MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER ------------------------------------------------------ 1- 2 SPECIFICATIONS ------------------------------------------------------ 1- 3 SERVICE PRECAUTIONS--------------------------------------------- 1- 4 TORQUE VALUES ----------------------------------------------------- 1-12 SPECIAL TOOLS ------------------------------------------------------- 1-13 LUBRICATION POINTS----------------------------------------------- 1-13 CABLE & HARNESS ROUTING ------------------------------------- 1-16 WIRING DIAGRAM ---------------------------------------------------- 1-20 TROUBLESHOOTING ------------------------------------------------- 1-22 www.PlanDeGraissage.org...
Page 3: Serial Number
. GENERAL INFORMATION MX’er 50 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number www.PlanDeGraissage.org...
Page 4: General Information
. GENERAL INFORMATION MX’er 50 SPECIFICATIONS Name & Model No. LA10AD Motorcycle Name & Type MX’er Overall length (mm) 1685 Air cleaner type & No Sponge Overall width (mm) Fuel capacity 8.1 liters Overall height (mm) 1030 Type Wheel base (mm) 1120 Main jet No.
Page 5: Service Precautions
. GENERAL INFORMATION MX’er 50 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 6 . GENERAL INFORMATION MX’er 50 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 7 . GENERAL INFORMATION MX’er 50 n If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm 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 8 . GENERAL INFORMATION MX’er 50 n The connector shall be inserted completely. n If the double connector has a lock, lock Snapping! 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 9 . GENERAL INFORMATION MX’er 50 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 10 . GENERAL INFORMATION MX’er 50 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 11 . GENERAL INFORMATION MX’er 50 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. Do you understand n When a testing device is used, make sure to the instrument? Is...
Page 12 . GENERAL INFORMATION MX’er 50 n Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use Engine Oil designated engine oil for lubrication.) Engine Oil Grease : Apply grease for lubrication.
Page 13: Torque Values
. GENERAL INFORMATION MX’er 50 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 14: Special Tools
SPECIFICATIONS MX’er 50 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Flywheel puller E001 Oil seal and bearing install E014 Universal holder E017 Clutch spring compressor E034 Bearing puller E037 Crankshaft install E016 Crankshaft & crankcase install E024 Crankcase puller E026 Crankshaft Bearing puller E030...
Page 15 . GENERAL INFORMATION MX’er 50 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 16 SPECIFICATIONS MX’er 50 Swing arm Thrust Cover Rear Brake Cam/ Axle Hub Collar/Oil Seal/Bearing Sprocket hub/Rear Axle Hub Collar/Oil Seal/Bearing Driven Sprocket 1-15 www.PlanDeGraissage.org...
Page 17: Cable & Harness Routing
. GENERAL INFORMATION MX’er 50 CABLE & HARNESS ROUTING Rear Brake Cable Throttle Cable Front Brake Cable Handlebar Switch Lead A.C.G Wire Starter Motor Wire Auto Bystarter Wire Left Front Brake Cable Right Front Brake Cable 1-16 www.PlanDeGraissage.org...
Page 18 SPECIFICATIONS MX’er 50 Fuel Filter Fuel Tube Ignition Coil Wire Throttle Cable Oil Meter Wire Left Front Brake Cable Right Front Brake Cable Rear Brake Cable 1-17 www.PlanDeGraissage.org...
Page 19 . GENERAL INFORMATION MX’er 50 Ignition Coil Wire Harness Rectifier/Regulator Resistor Oil Tube Right Front Brake Cable 1-18 www.PlanDeGraissage.org...
Page 20 SPECIFICATIONS MX’er 50 Main Switch Rear Brake Cable Breather Hose Oil Meter Wire Battery Negative Cable Positive Cable Starter Relay Fuse CDI Unit 1-19 www.PlanDeGraissage.org...
Page 21: Wiring Diagram
. GENERAL INFORMATION MX’er 50 WIRING DIAGRAM (ON ROAD) 1-20 www.PlanDeGraissage.org...
Page 22 SPECIFICATIONS MX’er 50 WIRING DIAGRAM (OFF ROAD) 1-21 www.PlanDeGraissage.org...
Page 23: Troubleshooting
. GENERAL INFORMATION MX’er 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. Å Empty fuel tank Ç Clogged float valve Fuel reaches Fuel does not É...
Page 24 SPECIFICATIONS MX’er 50 ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw. Å Empty fuel tank Ç Clogged float valve Fuel reaches Fuel does not É Clogged charcoal carburetor reach carburetor canister Ñ...
Page 25 . GENERAL INFORMATION MX’er 50 Inspection/Adjustment Symptom Probable Cause Check carburetor gasket for air leaks. Å Carburetor not securely tightened No air leak Air leaks Ç Faulty intake manifold gasket É Deformed or broken carburetor O-ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged.
Page 26 SPECIFICATIONS MX’er 50 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate lightly for observation. Å Clogged air cleaner Engine speed does Ç Clogged fuel filter Engine speed not increase É Clogged exhaust increases sufficiently muffler Ñ Faulty auto bystarter Ö...
Page 27 . GENERAL INFORMATION MX’er 50 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Å Faulty CDI unit Incorrect timing Correct timing Ç Faulty A.C. generator Check carburetor air screw adjustment. Å Mixture too rich (turn Correctly adjusted Incorrectly adjusted screw out)
Page 28 SPECIFICATIONS MX’er 50 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Å Faulty CDI unit Correct timing Incorrect timing Ç Loose A.C.G. stator É Faulty A.C. generator Check auto fuel valve for fuel supply. Å Empty fuel tank Fuel flows freely Fuel flow Ç...
Page 29 . GENERAL INFORMATION MX’er 50 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Å Worn or slipping drive belt Ç Broken ramp plate É Broken driven face spring Engine starts but Ñ Separated clutch lining motor-cycle does not Ö Damaged driven pulley shaft move splines Ü...
Page 30 SPECIFICATIONS MX’er 50 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Å Steering stem nut too tight Steering is heavy Ç Broken steering steel balls Å Excessive wheel bearing play Front or rear wheel is Ç...
Page 31 . GENERAL INFORMATION MX’er 50 POOR BRAKE PERFORMANCE Symptom Probable Cause (Adjust brake according to standards) Å Worn brake linings Index mark on brake Ç Worn brake cam contacting area panel aligns with wear indicator arrow brake shoes É Worn brake cam Ñ...
Page 32 SPECIFICATIONS MX’er 50 OIL METER 1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn Å Burned out fuse signals. Ç Weak or dead battery Signals dim, remain Signals operate É...
Page 33 . GENERAL INFORMATION MX’er 50 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Å Burned out fuse Ç Weak or dead battery Signals operate Signals dim, remain É...
Page 34 SPECIFICATIONS MX’er 50 STARTER MOTOR 1. Starter motor won‘t turn Symptom Probable Cause Inspection/Adjustment Check operation of Å Burned out fuse stop switch by Ç Weak or dead battery applying brake. É Faulty stop switch Stoplight does not Stoplight comes Ñ...
Page 35 . FRAME COVERS/EXHAUST MUFFLER MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 2- 2 TROUBLESHOOTING ------------------------------------------------- 2- 2 FRAME COVERS ------------------------------------------------------- 2- 3 HEADLIGHT REMOVAL---------------------------------------------- 2- 5 EXHAUST MUFFLER REMOVAL ----------------------------------- 2- 5 www.PlanDeGraissage.org...
Page 36 . FRAME COVERS/EXHAUST MUFFLER MX’er 50 www.PlanDeGraissage.org...
Page 37: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MX’er 50 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 3.0_ 3.6kgf-m...
Page 38: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER MX’er 50 Lever Seat FRAME COVERS SEAT REMOVAL Pull the lever backward, then pull up the seat at the rear. Remove the seat. Screws Bolt LEFT AND RIGHT FENDER REMOVAL Remove seven screws and two bolts attaching the left rear fender.
Page 39 . FRAME COVERS/EXHAUST MUFFLER MX’er 50 Front Cover FRONT COVERS REMOVAL Remove the two screws on the front cover. Screws Remove the left and right front fender under bolt. Remove the front cover. Bolts Right Front Cover FRONT FENDER REMOVAL Remove screws attaching the left and right front fender.
Page 40: Headlight Removal
. FRAME COVERS/EXHAUST MUFFLER MX’er 50 FLOOR BOARD COVER REMOVAL Remove the four bolts on the floorboard cover. Remove the floorboard cover. Bolts Floor Board HEADLIGHT REMOVAL Remove the headlight connector wire. Remove the two bolts on the headlight. Bolts Nuts Nuts EXHAUST MUFFLER...
Page 41 . FRAME COVERS/EXHAUST MUFFLER MX’er 50 Muffler Remove the exhaust muffler lock bolts. Remove the exhaust muffler and them remove exhaust pipe. When installing, first install the exhaust pipe onto the engine and then install the exhaust muffler. Torque: Exhaust muffler lock bolt: 3.0_ 3.6kgf-m Exhaust muffler joint lock nut: 1.0_ 1.4kgf- Bolt Bolt...
Page 42 . INSPECTION/ADJUSTMENT MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/THROTTLE OPERATION/AIR CLEANER ---------- 3- 3 SPARK PLUG/LUBRICATION SYSTEM---------------------------- 3- 5 CARBURETOR IDLE SPEED ----------------------------------------- 3- 7 CYLINDER COMPRESSION/FINAL REDUCTION GEAR OIL-- 3- 8 DRIVE BELT/BRAKE SHOE/BRAKE SYSTEM ------------------- 3- 9 HEADLIGHT AIM ------------------------------------------------------ 3-11 STEERING SYSTEM INSPECTION --------------------------------- 3-11...
Page 43: Service Information
. INSPECTION/ADJUSTMENT MX’er 50 SERVICE INFORMATION GENERAL °I 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. •Gasoline is extremely flammable and is explosive under some conditions.
Page 44: Inspection/Adjustment
Lubricate every 6 months. °≥ °≥ °≥ Check all chassis fittings and Fitting/Fasteners °≥ °≥ °≥ °≥ °≥ fasteners. Correct if necessary. In the interest of safety, we recommend these items should be serviced only by an • authorized KYMCO motorcycle dealer. www.PlanDeGraissage.org...
Page 45: Fuel Line/Throttle Operation/Air Cleaner
. INSPECTION/ADJUSTMENT MX’er 50 FUEL LINE Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage or leakage. °Ø Do not smoke or allow flames or sparks in your working area. Fuel tube Fuel Filter THROTTLE OPERATION Check the throttle to swing for smooth movement.
Page 46 . INSPECTION/ADJUSTMENT MX’er 50 CLEAN AIR FILTER ELEMENT Wash the element gently, but throughly in solvent. °Ø 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 47: Spark Plug/Lubrication System
. INSPECTION/ADJUSTMENT MX’er 50 SPARK PLUG Remove the spark plug Check the spark plug for wear and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush. Specified Spark Plug: NGK: BR8HAS Gap, Wear, and Fouling Deposits Measure the spark plug gap.
Page 48 . INSPECTION/ADJUSTMENT MX’er 50 Clean the oil filter screen with compressed Filter Screen air. Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level. Bleed air from the oil pump and oil lines. °Ø...
Page 49: Carburetor Idle Speed
. INSPECTION/ADJUSTMENT MX’er 50 Throttle Stop Screw CARBURETOR IDLE SPEED °Ø • The engine must be warm for accurate idle speed inspection and adjustment. Warm up the engine before this operation. Start the engine and connect a tachometer. Turn the throttle stop screw to obtain the specified idle speed.
Page 50: Cylinder Compression/Final Reduction Gear Oil
. INSPECTION/ADJUSTMENT MX’er 50 CYLINDER COMPRESSION Warm up the engine before compression test. Remove the spark plug. Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression. Compression: 12kg/cm_ If the compression is low, check for the following: - Leaky valves - Valve clearance too small...
Page 51: Drive Belt/Brake Shoe/Brake System
. INSPECTION/ADJUSTMENT MX’er 50 DRIVE BELT Remove the left crankcase cover. Inspect the drive belt for cracks, scaling, chipping or excessive wear. Measure the V-belt width Service limit: 16.5mm Replace the drive belt if out of specification. Drive Belt Wear Indicator BRAKE SHOE Replace the brake shoes if the arrow on the wear indicator plate aligns with the punch...
Page 52 . INSPECTION/ADJUSTMENT MX’er 50 Lock Nuts Adjusters Adjust brake lever free play: Loosen the lock nuts. Turn the adjusters in or out until the specified free play is obtained. Turning adjusters in that the free play is increased. Turning adjusters out that the free play is decreased.
Page 53: Headlight Aim
. INSPECTION/ADJUSTMENT MX’er 50 HEADLIGHT AIM Turn the ignition switch ON and start the engine. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting screw. 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...
Page 54: Toe-In Adjustment
. INSPECTION/ADJUSTMENT MX’er 50 TOE-IN ADJUSTMENT Place the machine on a level place. Measure the toe-in Adjust if out of specification. Toe-in measurement steps: Mark both front tire tread centers. Raise the front end of the machine so that there is no weight on the front tires. Fix the handlebar straight ahead.
Page 55: Wheels/Tires
. INSPECTION/ADJUSTMENT MX’er 50 WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. °Ø Tire pressure should be checked when tires are cold. Front Axle Nut TIRE PRESSURE 1 Rider Front 0.35kgf/cm_ Rear 0.35kgf/cm_ TIRE SIZE Front : 20*7-8 Rear : 22*10-8...
Page 56: Drive Chain Slack Adjustment
. INSPECTION/ADJUSTMENT MX’er 50 Inspect the wheel. Replace if damage or bends Always balance the wheel when a tire or wheel has been changed or replaced. °Ø Never attempt even small repairs • to the wheel. Ride conservatively after • installing a tire to allow it to seat itself properly on the rim.
Page 57 . INSPECTION/ADJUSTMENT MX’er 50 Adjuster Turn the adjuster in or out until the specified slack is obtained. Turn in: Slack is increased. Turn out: Slack is decreased. Tighten four bolts attaching rear axle hub to Bolts the specification. While pushing up or down on the chain to zero slack.
Page 58: Cable Inspection And Lubrication
. INSPECTION/ADJUSTMENT MX’er 50 CABLE INSPECTION AND LUBRICATION °Ø Damaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result so replace such cable as soon as possible. Inspect the cable sheath. Replace if damage. Check the cable operation.
Page 59 . LUBRICATION SYSTEM MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION............4-2 TROUBLESHOOTING.............. 4-2 OIL PUMP REMOVAL ............. 4-3 OIL PUMP INSPECTION............4-3 OIL PUMP INSTALLATION.............4-4 OIL PUMP BLEEDING............. 4-5 OIL TANK ................4-6 www.PlanDeGraissage.org...
Page 60 . LUBRICATION SYSTEM MX’er 50 LUBRICATION SYSTEM www.PlanDeGraissage.org...
Page 61: Lubrication System
. LUBRICATION SYSTEM MX’er 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. • Do not attempt to disassemble the oil pump. •...
Page 62: Oil Pump Removal
. LUBRICATION SYSTEM MX’er 50 Oil Pump Oil Outlet Line OIL PUMP REMOVAL °Ø Do not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Disconnect the oil pump control cable from the pump body.
Page 63: Lubrication System
. LUBRICATION SYSTEM MX’er 50 OIL PUMP INSTALLATION °Ø • Lubricate the O-ring with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion. Bolts Grease or Engine Oil Install the oil pump onto the crankcase.
Page 64: Oil Pump Bleeding
. LUBRICATION SYSTEM MX’er 50 Oil Outlet Line OIL PUMP BLEEDING °Ø • Air in the oil lines will block oil flow and result in severe engine damage. • Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines.
Page 65: Oil Tank
. LUBRICATION SYSTEM MX’er 50 Wire Connector OIL TANK OIL TANK REMOVAL Remove the seat. ( 2-3) Remove the oil meter connector. Remove the two bolts attaching the oil tank. Disconnect the oil inlet line. Drain the oil inside the oil tank into a clean container.
Page 66: Fuel System
MX’er 50 . FUEL SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 5- 2 TROUBLESHOOTING ------------------------------------------------- 5- 2 THROTTLE VALVE DISASSEMBLY/CARBURETOR REMOVAL- 5- 3 AUTO BYSTARTER---------------------------------------------------- 5- 6 FLOAT/FLOAT VALVE/JETS ---------------------------------------- 5- 8 CARURETOR INSTALLATION -------------------------------------- 5-11 AIR SCREW ADJUSTMENT ------------------------------------------ 5-12 REED VALVE----------------------------------------------------------- 5-13 FUEL TANK------------------------------------------------------------- 5-14...
Page 67 . FUEL SYSTEM MX’er 50 www.PlanDeGraissage.org...
Page 68: Service Information
MX’er 50 . FUEL SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames.. • Note the locations of O-rings when disassembling and replace them with new ones during assembly. • All cables, fuel lines and wires must be routed and secured at correct locations. •...
Page 69: Throttle Valve Disassembly/Carburetor Removal
. FUEL SYSTEM MX’er 50 Carburetor Cap THROTTLE VALVE DIS- ASSEMBLY/CARBURETOR REMOVAL Loosen the carburetor cap and remove the throttle valve. Disconnect the throttle cable from the throttle valve. Throttle Valve Rubber Seal Carburetor Cap Remove the throttle valve spring, carburetor cap and rubber seal.
Page 70 MX’er 50 . FUEL SYSTEM Remove the jet needle by removing the needle clip. Needle Clip Check the jet needle and throttle valve for wear or damage. Needle Retainer 2nd Notch (STD) Jet Needle Throttle Valve Carburetor Cap Rubber Seal THROTTLE VALVE INSTALLA-TION Install the jet needle on the throttle valve and secure with the needle clip.
Page 71 . FUEL SYSTEM MX’er 50 Install the throttle valve by aligning the Groove groove in the throttle valve with the throttle stop screw. Tighten the carburetor cap. Carburetor Cap After installation, perform the following adjustments and inspections. • Throttle cable free play ( 3-3) •...
Page 72: Auto Bystarter
MX’er 50 . FUEL SYSTEM Remove the two carburetor lock nuts. Remove the carburetor. Nuts AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5W (10 minutes minimum after stopping the engine) If the resistance exceeds 5W, replace the auto bystarter with a new one.
Page 73 . FUEL SYSTEM MX’er 50 Connect the auto bystarter yellow wire to the battery positive (+) terminal and green/ black wire to the battery negative (-) terminal and wait 5 minutes. Connect a hose to the fuel enriching circuit and blow the hose with mouth. If air can be blown into the hose, the auto bystarter is faulty and replace it with a new one.
Page 74: Float/Float Valve/Jets
MX’er 50 . FUEL SYSTEM Screws Auto Bystarter AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms.. Install the set plate and then tighten the two screws. Set Plate FLOAT/FLOAT VALVE/JETS FLOAT CHAMBER Remove the two float chamber screws and the float chamber.
Page 75 . FUEL SYSTEM MX’er 50 Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float. Check the float valve seat for wear or damage. Float Seat Main Jet JETS/SCREWS REMOVAL Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly.
Page 76 MX’er 50 . FUEL SYSTEM Needle Jet holder Main Jet FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder. Install the air screw and throttle stop screw according to the rotations recorded. °Ø If the air screw must be replaced, be sure to perform the air screw adjustment again.
Page 77: Caruretor Installation
. FUEL SYSTEM MX’er 50 O-rings CARBURETOR INSTALLATION °Ø When installation, do not allow foreign particles to enter the carburetor. Check the carburetor insulator and O-ring for wear or damage. Insulator Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts.
Page 78: Air Screw Adjustment
MX’er 50 . FUEL SYSTEM AIR SCREW ADJUSTMENT Air Screw Turn the air screw clockwise until it seats lightly and back it to the specification given. °Ø Do not force the air screw against its seat to prevent damage. Start the engine and turn the air screw in or out slowly to obtain the highest engine speed.
Page 79: Reed Valve
. FUEL SYSTEM MX’er 50 Bolts REED VALVE REMOVAL Remove the four intake manifold bolts and gasket. Remove the reed valve and gasket. Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds. Check the reed valve seat for cracks, damage or clearance between the seat and reed.
Page 80: Fuel Tank
MX’er 50 . FUEL SYSTEM Lever Seat FUEL TANK FUEL TANK REMOVAL 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. Screws Bolts Remove two bolts on the end of the fuel...
Page 81: Fuel Valve Removal
. FUEL SYSTEM MX’er 50 Fuel Tubes FUEL VALVE REMOVAL Disconnect the fuel tubes and remove the bolts. Fuel Valve Fuel Valve Remove the fuel valve and fuel cup. Fuel Valve Body Control Switch Washer Remove the screw on the fuel valve control switch.
Page 82 . ENGINE REMOVAL/INSTALLATION MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 6- 1 ENGINE REMOVAL --------------------------------------------------- 6- 2 ENGINE INSTALLATION -------------------------------------------- 6- 4 www.PlanDeGraissage.org...
Page 83 6. ENGINE REMOVAL/INSTALLATION MX’er 50 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 84: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION MX’er 50 ENGINE REMOVAL Band Remove the two bolts attaching the air cleaner case. Loosen the band between the air cleaner and carburetor to remove the air cleaner case. Remove the carburetor cap. Carburetor Cap Bolts Disconnect the auto bystarter, A.C. A.C.Generator Wire Connector generator and starter motor wire connectors.
Page 85 6. ENGINE REMOVAL/INSTALLATION MX’er 50 Carburetor Lock Nuts Disconnect the oil pump control cable from the pump body. Disconnect the oil inlet line from the oil pump. °Ø After the oil inlet line is disconnected, plug the oil line opening to prevent oil from flowing out.
Page 86 . ENGINE REMOVAL/INSTALLATION MX’er 50 ENGINE REMOVAL Remove the engine any connector thing. Remove the engine back bracket bolt, nut and collar. Remove the engine front right bracket bolt and nut. Bolt Remove the engine front left bracket bolt and nut. Bolt ENGINE INSTALLATION Install the engine and tighten the engine...
Page 87: Cylinder Head/Cylinder/Piston
CYLINDER HEAD/CYLINDER/PISTON MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/CYLINDER/PISTON __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER HEAD------------------------------------------------------ 7-3 CYLINDER/PISTON---------------------------------------------------- 7-6 www.PlanDeGraissage.org...
Page 88 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 www.PlanDeGraissage.org...
Page 89: Cylinder Head/Cylinder/Piston
CYLINDER HEAD/CYLINDER/PISTON MX’er 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head, cylinder and piston can be serviced with the engine installed in the frame. • Before disassembly, clean the engine to prevent dust from entering the engine. • Remove all gasket material from the mating surfaces. •...
Page 90: Cylinder Head
CYLINDER HEAD/CYLINDER/PISTON MX’er 50 Spark Plug Cap CYLINDER HEAD REMOVAL Remove the spark plug cap. Remove the exhaust muffler. ( 2-5) Bolts Remove the three bolts attaching the fan cover to remove the fan cover. Remove the bolt attaching the engine hood to remove the engine hood.
Page 91 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber °Ø Avoid damaging the combustion cham- ber wall and cylinder mating surface. Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge.
Page 92 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 Cylinder head Bolts Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times. Torque: 1.5_ 1.7kg-m Install the spark plug. Torque: 1.1_ 1.7kg-m Spark Plug Cylinder Head Engine Hood Engine Hood Installation Install the engine hood.
Page 93: Cylinder/Piston
CYLINDER HEAD/CYLINDER/PISTON MX’er 50 Cylinder CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head. Remove the cylinder. Remove the cylinder gasket. °Ø Do not pry between the cylinder and crankcase or strike the fins. Piston Piston Pin PISTON REMOVAL Remove the piston pin clip to remove the piston pin and piston.
Page 94 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Clean carbon deposits from the exhaust port area. °Ø Be careful not to damage the cylinder inside wall. Measure the cylinder bore at three levels of A, B and C in both X and Y directions.
Page 95 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 A Mark °Ø The cylinder has an “A” mark or no mark on it. When replacing the cylinder with a new one, use a cylinder having the same mark as the old one. Measure the piston O.D. at a point 5mm from the bottom of the piston skirt.
Page 96 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 PISTON RING INSPECTION Measure each piston ring end gap. Service Limits: Top/Second 0.40mm replace if over °Ø Set each piston ring squarely into the cylinder using the piston and measure the end gap. CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for...
Page 97 CYLINDER HEAD/CYLINDER/PISTON MX’er 50 “IN” Mark Install a new cylinder gasket on the mating Cylinder Gasket surface between the cylinder and crankcase. Position the piston “IN” mark on the intake valve side. Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves.
Page 98 . A.C. GENERATOR MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR __________________________________________________________________________________ SERVICE INFORMATION............8-2 A.C. GENERATOR REMOVAL..........8-3 A.C. GENERATOR INSTALLATION ........8-4 www.PlanDeGraissage.org...
Page 99 . A.C. GENERATOR MX’er 50 Torque: 0.8_ 1.2kg-m Torque: 3.5_ 4.0kg-m Torque: 0.6_ 1.0kg-m Torque: 0.8_ 1.2kg-m www.PlanDeGraissage.org...
Page 100 . A.C. GENERATOR MX’er 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • All A.C. generator maintenance and inspection can be made with the engine installed. • Refer to Section 14, 15 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 3.5_ 4.0kg-m SPECIAL TOOLS Flywheel puller Universal holder...
Page 101 . A.C. GENERATOR MX’er 50 Fan Cover A.C. GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover. Bolts Bolt Remove the cooling fan by removing the four bolts. Cooling Fan Hold the flywheel with an universal holder and then remove the flywheel nut.
Page 102 . A.C. GENERATOR MX’er 50 Remove the A.C. generator flywheel using the flywheel puller. Flywheel Puller Lock Nut Wrench A.C. Generator Wire Connector Remove the A.C. generator wire connector. Stator Remove the two pulser coil bolts and pulser coil from the right crankcase. Remove the two bolts attaching the A.C.
Page 103 . A.C. GENERATOR MX’er 50 A.C. Generator Wire Connector Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft key way. Universal Holder Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key.
Page 104 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SERVICE INFORMATION ............9-2 TROUBLESHOOTING ..............9-2 KICK STARTER ................9-3 DRIVE BELT................9-7 DRIVE PULLEY ................9-9 STARTER PINION...............9-11 CLUTCH/DRIVEN PULLEY............9-12 www.PlanDeGraissage.org...
Page 105: Kick Starter/Drive Pulley
9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY www.PlanDeGraissage.org...
Page 106: Clutch/Driven Pulley
9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS MX’er 50 Item Standard (mm) Service Limit (mm) Drive pulley collar O.D. 20.01 20.025 19.97 Movable drive face I.D.
Page 107: Kick Starter/Drive Pulley/Clutch/Friven Pulley
9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Left Crankcase Cover KICK STARTER LEFT CRANKCASE COVER REMOVAL Remove the left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration. Bolts Kick Starter Spindle KICK STARTER SPINDLE REMOVAL...
Page 108 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Return Spring Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Kick Starter Spindle Return Spring Spindle KICK S TARTER S PINDLE INS PECTION Inspect the kick starter spindle and gear for wear or damage.
Page 109 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Kick Starter Spindle Forcing Part Inspect the kick starter spindle and driven gear forcing parts for wear or damage. Kick Starter Driven Gear Forcing Part Friction Spring KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover.
Page 110 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Seal Gasket LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal gasket.
Page 111 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm replace if below °Ø Use specified genuine parts for replace- ment.
Page 112 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt.
Page 113 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the drive face nut. Remove the drive pulley face. Drive Pulley Face Drive Face Nut Movable Drive Face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft.
Page 114 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Weight Roller Remove the weight rollers. Remove the weight rollers. Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: 12.4mm replace if below Movable Drive Face DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft.
Page 115 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Install the drive belt on the crankshaft. Install the drive face, then tighten the drive face nut. Torque: 3.5_ 4.0kg-m °Ø Keep grease or oil off the drive belt and drive pulley faces. Drive Pulley Face Drive Face Nut Starter Pinion...
Page 116 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY 14mm Clutch Outer Nut Clutch Outer CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 9-9) Hold the clutch outer with the universal holder and remove the clutch outer nut Remove the clutch outer. Universal Holder Clutch/Driven Pulley Remove the clutch/driven pulley.
Page 117 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Remove the seal collar. Seal Collar Driven Pulley Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley. O-rings Guide Roller Pin CLUTCH/DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage.
Page 118 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: 92.8mm replace if below Check the driven face assembly for wear or damage.
Page 119 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face.
Page 120 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up Driven Pulley CLUTCH/DRIVEN PULLEY ASS EMBLY First install the movable driven face onto the driven face.
Page 121 9. KICK STARTER/DRIVE PULLEY/ MX’er 50 CLUTCH/DRIVEN PULLEY Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 39mm drive plate nut. Tighten the 39mm nut to the specified torque. Torque: 5.0_ 6.0kg-m Clutch Spring Compressor Clutch/Driven Pulley...
Page 122 . FINAL REDUCTION MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION............10-2 TROUBLESHOOTING.............. 10-2 FINAL REDUCTION DISASSEMBLY........10-3 FINAL REDUCTION INSPECTION........... 10-3 FINAL REDUCTION ASSEMBLY..........10-6 10-0 www.PlanDeGraissage.org...
Page 123 . FINAL REDUCTION MX’er 50 10-1 www.PlanDeGraissage.org...
Page 124: Final Reduction/Transmission System
. FINAL REDUCTION MX’er 50 SERVICE INFORMATION Specified Oil: SAE90# At disassembly: 0.12 liter At change: 0.09 liter SPECIAL TOOLS Bearing remover set, 12mm Bearing remover set, 15mm Bearing outer driver, 37x40mm Bearing outer driver, 32x35mm Bearing driver pilot, 17mm Bearing driver pilot, 15mm Bearing driver pilot, 12mm Bearing outer driver handle...
Page 125: Final Reduction Disassembly
. FINAL REDUCTION MX’er 50 Bolts FINAL REDUCTION DISAS- SEMBLY Remove the left crankcase cover. ( 9-3) Remove the clutch/driven pulley. ( 9-9) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts. Remove the transmission case cover. Remove the gasket and dowel pins.
Page 126: Final Reduction Inspection
. FINAL REDUCTION MX’er 50 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Oil Seal Inspect the drive shaft and gear for wear or damage.
Page 127: Final Reduction Assembly
. FINAL REDUCTION MX’er 50 Drive Shaft Bearing BEARING REPLACEMENT (Transmission Case Cover) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Set Bearing Outer Driver Handle Drive new bearings into the transmission case cover.
Page 128 . FINAL REDUCTION MX’er 50 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Bearing Outer Driver Drive Shaft FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Install the final gear and final shaft into the left crankcase.
Page 129 . FINAL REDUCTION MX’er 50 Install the countershaft and gear into the left Dowel Pins crankcase. Install the resin washer onto the counter- shaft. Install the dowel pins and a new gasket. Resin Washer Countershaft Install the transmission case cover. Transmission Case Cover Bolts Install and tighten the transmission case cover...
Page 130 . FINAL REDUCTION MX’er 50 Oil Check Bolt Hole/Filler After installation, fill the transmission case with the specified oil. °Ø • Place the motorcycle on its main stand on level ground. • Check the sealing washer for wear or damage. Specified Gear Oil: SAE90# Oil Capacity: at disassembly: 0.12 liter...
Page 131 . CRANKCASE/CRANKSHAFT MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION............11-2 TROUBLESHOOTING.............. 11-2 CRANKCASE SEPARATION ............ 11-3 CRANKSHAFT REMOVAL............11-3 CRANKSHAFT INSPECTION ........... 11-4 CRANKSHAFT INSTALLATION..........11-5 CRANKCASE ASSEMBLY ............11-7 11-0 www.PlanDeGraissage.org...
Page 132 . CRANKCASE/CRANKSHAFT MX’er 50 11-1 www.PlanDeGraissage.org...
Page 133: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT MX’er 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. Engine ( Section 6) Driven pulley ( Section 9) Carburetor ( Section 5) A.C.
Page 134: Crankcase Separation
. CRANKCASE/CRANKSHAFT MX’er 50 CRANKCASE SEPARATION Remove the crankcase attaching bolts. Bolt Crankcase Puller Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Crankcase Puller CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase.
Page 135: Crankshaft Inspection
. CRANKCASE/CRANKSHAFT MX’er 50 Remove the remaining bearing on the crankshaft side using the universal bearing puller. °Ø When separating the crankcase, the oil seals must be removed. Replace the oil seals with new ones. Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance.
Page 136: Crankshaft Installation
. CRANKCASE/CRANKSHAFT MX’er 50 Measure the crankshaft runout. Service Limit 0.150mm 0.100mm replace if over replace if over Check the crankshaft bearings for excessive play. The bearings must be replaced if they Play Play are noisy or have excessive play. Radial Axial CRANKSHAFT INSTALLATION...
Page 137 Bearing Outer Driver, 42x47mm Pilot, 20mm Install the crankshaft into the left crankcase. °Ø • Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crank- shaft bearings and connecting rod big end. • Apply grease to the lip of the oil seal and then install it.
Page 138: Crankcase Assembly
. CRANKCASE/CRANKSHAFT MX’er 50 Dowel Pins CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface. Assemble the crankcase halves. Crankcase Assembly Tool The distance between the right crankcase oil seal and crankcase surface is about 12.5±0.5 °Ø...
Page 139 . CRANKCASE/CRANKSHAFT MX’er 50 The distance between the left crankcase oil seal and crankcase surface is about 1.0mm. Oil Seal 1.0mm Install and tighten the crankcase attaching bolts. °Ø After assembly, check the crankshaft for smooth operation. Bolt 11-8 www.PlanDeGraissage.org...
Page 140 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 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 www.PlanDeGraissage.org...
Page 141 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 12-1 www.PlanDeGraissage.org...
Page 142: Front Wheel/Front Brake/Front Suspension/Steering System
. FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 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 143: Troubleshooting
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 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 Steers to one side or does not track straight •...
Page 144: Front Wheel/Front Brake/ Front Suspension/Steering
. FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM FRONT WHEEL REMOVAL 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. °Ø...
Page 145 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 Measure the wheel run out. Replace wheel or check bearing play if out 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.
Page 146 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM Remove the dust seal. Dust Seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub. BEARING REPLACEMENT Remove the front wheel bearings and distance collar.
Page 147: Front Brake
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 Brake Lining FRONT BRAKE FRONT BRAKE LINING INSPECTION Measure the front brake lining thickness. Service limit: 2.0mm replace if below °Ø Keep oil or grease off the brake linings. Camshaft lever REMOVAL Brake Plate Inspect the shoe springs, O-rings, camshaft lever and wear indicator.
Page 148 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM Install the brake shoe plate. Boss °Ø Make sure that the boss on the knuckle correctly engages with the locating slot on the brake shoe plate. Apply the grease onto the bearings and oil seal lips of the wheel hub.
Page 149: Front Suspension
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 Upper Bolt FRONT SUSPENSION REMOVAL Elevate the front wheels by placing a suitable stand under the frame. °Ø Support the machine securely so there is no danger of it falling over. Remove the front wheel, wheel hub, brake shoe plate.
Page 150 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM INSPECTION Check the front arm brackets of the frame. If bent, cracked or damaged, repair or replace the frame. Check the tightening torque of the front arms securing nuts. Torque: 4.0_ 5.0kgf-m Check the front arm side play by moving it from side to side.
Page 151 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 Inspect the steering knuckle. Replace if cracks, pitting or damage. Inspect the front arm. Replace if cracks, bends or damage. °Ø Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Bushes Inspect bushes.
Page 152 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM Apply the grease onto the bush, collars and covers, then install the steering knuckle onto the front arm and tighten the nut. Torque: 4.0_ 5.0kgf-m Install the cotter pin and band ends of cotter pin.
Page 153: Steering System
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 Handlebar Cover STEERING SYSTEM REMOVAL Remove the following parts: Seat, Front cover, Center cover and Front fender Refer to the “FENDERS” section in the CHAPTER 2 Disconnect the main switch lead. Remove the handlebar cover with main Main Switch Lead switch.
Page 154 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM Screws Handlebar Switch Remove the two screws and remove the handlebar switch. 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...
Page 155 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 Collar Steering Column Cable Holder Remove the two bolts to remove the cable holder, steering bracket, collars and steering column. Bolts Steering Bracket INSPECTION Inspect the handlebar. Replace if cracks, bends or damage. Inspect the steering column.
Page 156 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM Inspect the tie-rod. Replace if bend or damage. 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.
Page 157 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 °Ø The threads on both rod-end must be of the same length. Dust Seal Inspect the collar, duty seal, snap ring and bearing. Replace if wear or damage. Collar Dust Seal Bearing Snap Ring INSTALLATION Reverse the “REMOVAL”...
Page 158 . FRONT WHEEL/FRONT BRAKE/FRONT MX’er 50 SUSPENSION/STEERING SYSTEM Cotter Pin Install the steering column and collar, then tighten the nut. Torque: 6.0_ 8.0kgf-m Install the cotter pin and band ends of cotter pin. °Ø Always use a new cotter pin. Cotter Pin Install the tie rods and tighten the nut.
Page 159 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 50 °Ø Be sure the upper handlebar • holder mark face to front. Fist tighten the bolts on the front • side of the handlebar holder, and then tighten the bolts on the rear side. Apply the grease onto the end of the throttle cable and end of the brake cable.
Page 160 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 www.PlanDeGraissage.org...
Page 161 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 13-1 www.PlanDeGraissage.org...
Page 162 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 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 163: Rear Wheel /Swing Arm/Hydraulic Brake
. REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 SPECIAL TOOLS 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 •...
Page 164 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Inner Nut REAR WHEEL REMOVAL Place the machine on a level place. 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.
Page 165 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Inspection Measure the wheel runout. Service Limit: Vertical: 2.0 mm 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).
Page 166 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Bolts Loosen four bolts attaching rear axle hub. 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.
Page 167 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Inspection Inspect the inner surface of the brake drum is scratches, polish brake drum lightly and evenly with emery cloth. Measure the inside diameter of the brake drum. Service limit: 131mm Replace if it is out of specification. Brake Cable Disconnect the rear brake cable from the camshaft lever.
Page 168 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 bolts Remove four bolts and the rear axle hub. 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.
Page 169 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 DRIVE CHAIN INSPECTION Remove rear wheels, rear hub (with rear axle) and swing arm. Refer to the “REAR WHEEL°– REMOVAL” and “SWING ARM REMOVAL” section. Remove right foot board. Remove the drive sprocket. Remove the drive chain.
Page 170 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Bearings Inspect rear axle hub. Replace if bearings allow play in the axle hub or the bearing turns roughly. Replace if oil seals is wear or damage. Replace if rear axle hub is cracks, bend or damage.
Page 171 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Bolts Install the brake drum. Install the rubber spacer and brake drum cover. Torque: 0.8_ 1.2kgf-m 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.
Page 172 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Tighten the two nuts with the nut wrench. Special Nut wrench F010 Torque: 11.0_ 13.0kgf-m Install wheel hub, plate washer and nut (wheel hub). Torque: 6.0_ 8.0kgf-m Install cotter pins. °Ø Do not loosen the axle nut after torque tightening.
Page 173 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 SWING ARM Place the machine on a level place. Elevate the rear wheels by placing a suitable stand under the rear of frame. °Ø Support the machine securely so there is no danger of it falling over. Cotter Pin Remove the rear wheels, rear hub with rear axle.
Page 174 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Check the swing°@ arm side play by moving it from side to side. If side play noticeable, check the inner collar, bearing, bushing and thrust cover, or adjust the shim. Check the swing arm vertical movement by moving it up and down.
Page 175 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 INSPECTION Inspect the shock absorber rod. Replace the shock absorber assembly if bends or damage. Inspect the shock absorber. Replace the shock absorber assembly if oil leaks Inspect the spring. Replace the shock absorber assembly if fatigue.
Page 176 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Pivot Shaft INSTALLATION Reverse the “REMOVAL” procedure. Apply grease onto the collar, bush, pivot shaft and thrust cover. Install the swing arm and tightening the nut. Torque: 6.0_ 8.0kgf-m Install the shock absorber and tightening the bolt.
Page 177 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 HYDRAULIC BRAKE Screws BRAKE FLUID CHANGE/AIR BLEED Place the motorcycle on its main stand on level ground and set the handlebar upright. Remove the two screws attaching the brake fluid reservoir cap. ＊...
Page 178 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Bleed Valve HYDRAULIC BRAKE BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake lever after continuously pull it several times. Then, loosen the bleed valve nut to bleed air from the brake system.
Page 179 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0mm Measure the brake disk run out. Service Limit: 0.3mm Fluid Tube Bolt BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic brake system.
Page 180 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder. Snap Ring Pliers Master Cylinder Remove the washer, main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid.
Page 181 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 ASSEMBLY Before assembly, apply brake fluid to all removed parts. Install the spring together with the 1st rubber cup. ＊ • During assembly, the master cylinder, main piston and spring must be installed as a unit without exchange.
Page 182 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 BRAKE CALIPER REMOVAL Remove the brake caliper, brake pads and pad spring. Place a clean container under the brake caliper and disconnect the brake fluid tube from the brake caliper. ＊ Be careful not to splash brake fluid on any coated surfaces.
Page 183 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 INSPECTION Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service limit: 33.85mm replace if below 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.
Page 184 . REAR WHEEL/SWING ARM/ HYDRAULIC BRAKE MX’er 50 Aligning The Fluid Tube With Groove INSTALLATION Connect the brake fluid tube to the brake caliper, aligning the fluid tube with groove in the caliper and tighten the fluid tube bolt. Torque: 2.8_ 3.5kg-m Add the recommended brake fluid into the brake reservoir and bleed air from the brake system.
Page 185: A.c. Generator
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTER/CHARGING SYSTEM/ A.C. GENERATOR __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 14- 2 TROUBLESHOOTING ------------------------------------------------- 14- 3 BATTERY REMOVAL ------------------------------------------------- 14- 4 PERFORMANCE TEST ------------------------------------------------ 14- 5 A.C. GENERATOR CHARGING COI -------------------------------- 14- 5 RESIETOR/REGULATOR/RECTIFIER ------------------------------ 14- 6 14-0...
Page 186: Batter/Charging System
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 Main Switch Fuse/Battery Regulator/Rectifier Resistdor A.C. Generator CHARGING CIRCUIT 14-1 www.PlanDeGraissage.org...
Page 187: Service Information
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 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 188: Troubleshooting
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 TORQUE VALUES 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 189: Battery Removal
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 Battery Cover BATTERY BATTERY REMOVAL Open the seat and battery cover. Disconnect the battery cables . °Ø First disconnect the battery negative (-) cable and then the positive (+) cable. Remove the battery. The installation sequence is the reverse of Screws removal.
Page 190: Performance Test
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 PERFORMANCE TEST Warm up the engine. Open the seat and battery cover. °Ø Use a fully charged battery to check the charging system output. Stop the engine and open the fuse box. Disconnect the wire lead from the fuse terminal.
Page 191 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR MX’er 50 Resister B RESISTOR INSPECTION Measure the resistance between the resistor B pink wire and ground. Measure the resistance between the resistor A green/black wire and ground. Resistances: Resistor A: 9.2_ 9.8W Resistor B: 5.6_ 6.2W °Ø...
Page 192 . IGNITION SYSTEM MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 15- 2 TROUBLESHOOTING ------------------------------------------------- 15- 3 IGNITION COIL -------------------------------------------------------- 15- 4 A.C.GENGRATOR ------------------------------------------------------ 15- 5 CDI UNIT INSPECTION----------------------------------------------- 15- 6 15-0 www.PlanDeGraissage.org...
Page 193: Ignition System
. IGNITION SYSTEM MX’er 50 Ignition Coil CDI Unit Ignition Switch ntrol Spark Plug A.C. Generator/ Pulser Coil IGNITION CIRCUIT 15-1 www.PlanDeGraissage.org...
Page 194: Ignition System
. IGNITION SYSTEM MX’er 50 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 195: Troubleshooting
. IGNITION SYSTEM MX’er 50 TROUBLESHOOTING 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 196: Ignition Coil
. IGNITION SYSTEM MX’er 50 IGNITION COIL INSPECTION Continuity Test °Ø This test is to inspect the continuity of ignition coil. Measure the resistance between the ignition coil primary coil terminals. Resistance (20¢J): 0.2_ 0.3W Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown.
Page 197 . IGNITION SYSTEM MX’er 50 Ignition Coil Performance Test Remove the ignition coil. Inspect the ignition coil with an ignition coil CDI Tester Ignition Coil tester. °Ø Follow the ignition coil tester manufac- turer‘s instructions. 1. Turn the changeover switch to 12V and connect the ignition coil to the tester.
Page 198: Cdi Unit Inspection
. IGNITION SYSTEM MX’er 50 CDI Unit CDI UNIT INSPECTION Remove the seat and battery cover. Disconnect the CDI coupler and remove the CDI unit. Coupler CDI CIRCUIT INSPECTION Measure the resistance between the terminals. Replace the CDI unit if the readings are not within the specifications in the table below.
Page 199 . STARTING SYSTEM MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 16- 2 TROUBLESHOOTING ------------------------------------------------- 16- 2 STARTER RELAY------------------------------------------------------ 16- 3 STARTER MOTOR ----------------------------------------------------- 16- 3 16-0 www.PlanDeGraissage.org...
Page 200 . STARTING SYSTEM MX’er 50 Stop Switches Starter Button Ignition Switch Fuse/Battery/Starter Relay Starter Motor STARTING CIRCUIT 16-1 www.PlanDeGraissage.org...
Page 201: Starting System
. STARTING SYSTEM MX’er 50 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. TROUBLESHOOTING Starter motor won‘t turn Lack of power •...
Page 202 . STARTING SYSTEM MX’er 50 STARTER RELAY INSPECTION Starter Relay Remove the seat and battery cover. Disconnect the starter relay coupler and then remove the starter relay. Yellow/Red Connect the starter relay green/yellow terminal to the 12V battery positive (+) terminal and the relay yellow/red terminal to the battery negative (-) terminal.
Page 203: Lights/Switches
. LIGHTS/ SWITCHES MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 17- 2 TROUBLESHOOTING ------------------------------------------------- 17- 2 HEADLIGHT ------------------------------------------------------------ 17- 3 INSTRUMENTS/STOP LIGHT/TAILLIGHT------------------------ 17- 4 IGNITION SWITCH ---------------------------------------------------- 17- 5 STOP SWITCH/OIL METER ------------------------------------------ 17- 5 STARTER BUTTON---------------------------------------------------- 17- 6 HEADLIGHT SWITCH------------------------------------------------- 17- 6 ENGINE STOP SWITCH----------------------------------------------- 17- 7...
Page 204 . LIGHTS/ SWITCHES MX’er 50 ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Switch/ Starter Button/Engine Ignition Switch Stop Switch Taillight/Stop Light Headlight Ignition Switch Ignition Switch Ignition Switch 17-1 www.PlanDeGraissage.org...
Page 205: Service Information
. LIGHTS/ SWITCHES MX’er 50 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 206: Headlight
. LIGHTS/ SWITCHES MX’er 50 Cover 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...
Page 207 . LIGHTS/ SWITCHES MX’er 50 Headlight Bulb Remove the headlight bulb INSTALLATION Install the headlight in the reverse order of removal. °Ø After installation, adjust the headlight beam. Bulb Socket INSTRUMENTS Light Shell REMOVAL Remove the two headlight attaching bolts. Remove the headlight and disconnect the headlight wire coupler.
Page 208: Ignition Switch
. LIGHTS/ SWITCHES MX’er 50 Remove the bulb and check the bulb for Bulb damage. Replace with a new one if necessary. IGNITION SWITCH Check for continuity between the wires indicated below. Black/ Color Black Green White Position °≥ °≥ °≥...
Page 209: Starter Button
. LIGHTS/ SWITCHES MX’er 50 Wire Terminals Resistance Oil Meter Black/Red(+)_ Green(-) 26KW Green(-)_ Black(+) ° ¤ °Ø Before removing the oil meter, be sure to drain the motor oil and do not allow sparks or flames near the working area. Ç...
Page 210: Engine Stop Switch
. LIGHTS/ SWITCHES MX’er 50 Engine Stop Switch Green ENGINE STOP SWITCH Remove the center cover. Disconnect the headlight switch wire coupler. Check for continuity between the headlight switch wires. Color Blue/Yellow Green Position °≥ °≥ Blue/Yellow 17-7 www.PlanDeGraissage.org...
Page 211: Only Atv On Road Available
. ONLY ATV ON ROAD AVAILABLE MX’er 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ONLY ATV ON ROAD AVAILABLE __________________________________________________________________________________ INSTRUMENT ---------------------------------------------------------- 18- 1 INDICATOR LIGHT---------------------------------------------------- 18- 1 WINKER SWITCH/HORN --------------------------------------------- 18- 2 18-0 www.PlanDeGraissage.org...
Page 212 . ONLY ATV ON ROAD AVAILABLE MX’er 50 INSTRUMENT REMOVAL Remove the two instrument attaching screws. Disconnect the instrument. Screws Battery Cover Remove battery cover on instrument back to replace battery. °Ø 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...
Page 213 . ONLY ATV ON ROAD AVAILABLE MX’er 50 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 WINKER SWITCH Check for continuity between the wires indicated below.

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Troubleshooting

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