KYMCO MXU 150 Owner's Manual
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KYMCO MXU 150 Owner's Manual

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OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 250/150/50
ON-ROAD
Issued: 23.DEC.2005

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  • Page 1 OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. MXU 250/150/50 ON-ROAD Issued: 23.DEC.2005...
  • Page 3 IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle. AGE RECOMMENDATION The minimum recommended age for this ATV model is 16. Children under age 16 should never operate this vehicle.
  • Page 4 SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol . Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.
  • Page 5 PREFACE Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service. For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.

  • Page 6: Table Of Contents

    KEYS IDENTIFICATION NUMBER..10 Start switch........40 FRAME SERIAL NUMBER....11 ENGINE SERIAL NUMBER RECOIL STARTER (MXU 250).....41 (MXU 250/150)........11 KICK STARTER (MXU 150/50)....42 ENGINE SERIAL NUMBER (MXU 50)..12 THROTTLE LEVER......43 PARTS LOCATION (MXU 250).....13 SPEED LIMITER.........44 PARTS LOCATION (MXU 150/50)..19 FRONT BRAKE LEVER.......45...
  • Page 7 DRIVE SELECT LEVER ......59 BRAKE PEDAL (MXU 250/150).....45 Drive select lever adjustment....61 PARKING BRAKE (MXU 250)....46 FRONT AND REAR BRAKES....63 PARKING BRAKE (MXU 150/50)...46 FUEL..........64 LOCKING STEERING (MXU 250/150)...48 ENGINE OIL (MXU 250/150)....66 DRIVE SELECT LEVER.......49 ENGINE OIL (MXU 50)......67 TRANSMISSION OIL ......68...
  • Page 8 GETTING TO KNOW YOUR ATV ..90 STARTING A COLD ENGINE....75 RIDE WITH CARE AND GOOD Using the recoil starter (MXU 250)..77 JUDGEMENT........91 Using the kick starter (MXU 150/50)..78 APPAREL...........95 STARTING A WARM ENGINE....79 PRE-OPERATION CHECKS....97 WARMING UP........79 LOADING AND ACCESSORIES..99 DRIVE SELECT LEVER OPERATION Loading and operational guidelines...99...
  • Page 9 ADJUSTMENT (MXU 150)....154 PERIODIC MAINTENANCE/ BRAKE PEDAL LUBRICATION........120 ADJUSTMENT (MXU 150)....155 ENGINE OIL (MXU 250) .....122 COOLING SYSTEM ENGINE OIL (MXU 150) .....126 INSPECTION (MXU 250)....159 TRANSMISSION OIL......130 Engine overheating......160 SPARK PLUG INSPECTION....133 DRIVE CHAIN SLACK CHECK.....161 AIR FILTER CLEANING.....134...
  • Page 10 SPECIFICATIONS (MXU 50)....189 Wheel installation......168 BATTERY..........169 NOISE REGULATION......193 Battery remove (MXU 250)....170 Battery installation (MXU 250)..172 MAINTENANCE RECORD.......194 Battery remove (MXU 150/50)..173 Battery installation (MXU 150/50)...173 INDEX...........195 FUSE REPLACEMENT (MXU 250)..174 FUSE REPLACEMENT (MXU 150/50).175 HEADLIGHT BEAM ADJUSTMENT..178 TROUBLESHOOTING .......179...

  • Page 11: Location Of The Warning And Specification Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS (1-1): MXU 250 (4-1): MXU 250 (1-2): MXU 150/50 (4-2): MXU 150/50 (6-1): MXU 250/150 (5-1): MXU 250 (7-1): MXU 250 (8): MXU 50 (6-2): MXU 50 (5-2): MXU 150/50 (7-2): MXU 150...
  • Page 12 ATV. INJURY or DEATH. The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements. ALWAYS USE NEVER USE WITH...
  • Page 13 (4-1): MXU 250 REAR 25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi Never set tire pressure below recommended. CAUTION ． Never carry passenger (5-2): MXU 150/50 This carrier. ． ： Maximum load 30 Kg (66 lbs) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL.
  • Page 14 MAXIMUM TOWING CAPACITY: 150kg (331 lbs) TONGUE WEIGHT: 14kg (30 lbs) Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. (7-2): MXU 150 NEVER operate this ATV if you are WARNING under age 16.

  • Page 15: Safety Information

    SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.
  • Page 16 Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. Never attempt wheel, jump, or other stunt.
  • Page 17 Always follow proper procedures for going down slopes and for braking on slopes as described in this manual. Check the terrain carefully before you start down any slope. Shift your weight backward. Never go down a slope at high speed. Avoid going down slope at an angle that would cause the vehicle to lean sharply to one side.
  • Page 18 WARNING WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Improper handling of gasoline. If you should swallow some gasoline or inhale WHAT CAN HAPPEN a lot of gasoline vapor, or get some gasoline in Gasoline can catch fire and you could be your eyes, see your doctor immediately.
  • Page 19 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation.

  • Page 20: Description And Machine Identification

    DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION NUMBER RECORDS KEYS IDENTIFICATION NUMBER Record the keys identification number, frame The keys identification number is stamped on serial number and engine serial number the hang tag as shown in the following information for assistance when order illustration.

  • Page 21: Frame Serial Number

    FRAME SERIAL NUMBER ENGINE SERIAL NUMBER (MXU 250/150) The frame serial number is stamped on the The engine serial number is stamped on the left front of the frame. crankcase. (1) Frame serial number (2) Engine serial number...

  • Page 22: Engine Serial Number (Mxu 50)

    ENGINE SERIAL NUMBER (MXU 50) The engine serial number is stamped on the right crankcase. (2) Engine serial number...

  • Page 23: Parts Location (Mxu 250)

    PARTS LOCATION (MXU 250) (03) (02) (02) (01) (01) Rear brake lever (02) Headlights/Position lights (03) Front brake lever (04) Right front turn signal light (05) Steering handlebar lock (06) Left front turn signal light (04) (05) (06)
  • Page 24 (10) (08) (09) (08) (07) (07) Right rear turn signal light (08) Taillights/Stop lights (09) Instrument and indicators (10) Left rear turn signal light (11) Exhaust system (12) Trailer hitch (13) License light (14) Battery (11) (12) (13) (14)
  • Page 25 (18) (17) (16) (15) (15) Drive select lever (16) Fuel valve (17) Seat (18) Tool kit (19) Reservoir water tank (20) Brake pedal fluid reservoir (19) (20)
  • Page 26 (22) (21) (21) Exhaust system ) Choke knob (23) Recoil starter (23)
  • Page 27 (30) (29) (28) (27) (26) (25) (24) (24) Front brake lever /Parking brake ) Front cargo rack (26) Front brake fluid reservoir (27) Ignition switch (28) Rear brake fluid reservoir (29) Accessory socket seat (30) Rear brake lever (31) Headlight dimmer switch Starter button Hazard switch Turn signal switch...
  • Page 28 (37) Rear cargo rack ) Flag pole bracket NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. (37) (38)

  • Page 29: Parts Location (Mxu 150/50)

    PARTS LOCATION (MXU 150/50) (03) (02) (02) (01) (01) Rear brake lever (02) Headlights/Position lights (03) Front brake lever/Parking brake (04) Right front turn signal light (05) MXU 150: Steering handlebar lock (06) Left front turn signal light (04) (05)
  • Page 30 (09) (08) (07) (07) Right rear turn signal light (08) Instrument and indicators (09) Left rear turn signal light (10) Exhaust system (11) MXU 150: Trailer hitch (12) License light/Taillights/Stop lights (10) (11) (12)
  • Page 31 (15) (14) (13) (13) Drive select lever (14) Seat (15) Battery (16) MXU 150: Brake pedal fluid reservoir (16)
  • Page 32 (20) (19) (18) (17) (17) Exhaust system ) Tool kit (19) MXU 50: Oil tank (20) Fuel valve (21) MXU 150: Choke knob (22) Kick starter (21) (22)
  • Page 33 (26) Headlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch (27) Left footpeg (28) Fuel fill cap (29) Throttle lever (30) Right footpeg (31) MXU 150: Rear brake pedal (26) (27) (28) (29) (30) (31)
  • Page 34 (32) Rear cargo rack ) Flag pole bracket NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. (32) (33)

  • Page 35: Control Functions Ignition Switch/Headlight & Position Light Switch

    CONTROL FUNCTIONS IGNITION SWITCH/HEADLIGHT & POSITION LIGHT SWITCH Functions of the respective switch positions are as follows: "OFF" position: All electrical circuits are switched off except hazard light. The key can be removed in this position. "ON" position : With the transmission in neutral and set the (1) Ignition switch (2) Key parking brake, the engine can be started.

  • Page 36: Instruments And Indicator

    INSTRUMENTS AND INDICATOR (1) Multi-function display The display includes the following functions: Speedometer Odometer/Tripmeter Digital clock Coolant temperature gauge (MXU 250) Fuel gauge (2) Left turn signal indicator Flashes when the left turn signal operates. NOTE: Both left and right turn signal indicator will flash at (1) Multi-function display the meantime when the hazard switch is operated (2) Left turn signal indicator...
  • Page 37 MXU 50: Low oil level indicator " " (6) Reverse indicator The low level indicator lights when the 2-stroke The reverse indicator will light when the engine oil level is low. transmission is in reverse and the ignition switch is ON CAUTION: If the low oil level indicator comes on while (7) Right turn signal indicator...

  • Page 38: Multi-Function Display

    Multi-function display Multi-function display (MXU 250) Multi-function display (MXU 150/50) (1) Digital clock (1) Digital clock (2) Coolant temperature gauge (2) Speedometer (3) Speedometer (3) Fuel gauge (4) Fuel gauge (4) Odometer/Tripmeter (5) Odometer/Tripmeter...
  • Page 39 (1) Digital clock 3. To set the hour, press the Mode/Adjust button Show the time (hours and minutes) while the (A) until the desired hour. ignition is ON. To adjust the time manually, proceed as follows: 1. Turn the ignition switch ON. 2.
  • Page 40 4. Press the Mode/Adjust button (B). The minute 5. To set minute, press the Mode/Adjust button display will start flashing. (A) until the desired minute.
  • Page 41 6. To end the adjustment, press the Mode/Adjust button (A) and Mode/Adjust button (B). The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 10 seconds.
  • Page 42 (2) Coolant temperature gauge (MXU 250) Overheating message When the coolant is over specified temperature, The coolant temperature gauge shows the coolant temperature gauge flashing. coolant temperature. If this occurs, stop the engine and check the reserve tank coolant level. Read pages 159 The normal operating temperature range is to not ride the scooter until the problem has...
  • Page 43 (3) Speedometer (4) Fuel gauge Shows riding speed in km/h or mph. The fuel gauge shows the approximate fuel supply available in a graduated display. The normal operating fuel range is with the Press and hold Mode/Adjust button (B)for section between the segment F and segment more than 2 seconds to select km/h or mph.
  • Page 44 (5) Odometer/Tripmeter The odometer shows the total distance travelled in Km or in miles. The tripmeter shows the trip distance travellled in Km or in miles. Press and hold Mode/Adjust button (B)for more than 2 seconds to select km or mile. Press and hold Mode/Adjust button (A)for more than 2 seconds to select ODO or TRIP...
  • Page 45 To reset the tripmeter: 1. Press and hold Mode/Adjust button (A)for more than 2 seconds to select TRIP and do not release the Mode/Adjust button (A). 2. Press and hold the Mode/Adjust button (B) until the tripmeter is reset.

  • Page 46: Handlebar Switches

    HANDLEBAR SWITCHES (1) Horn button (MXU 250) (1) Horn button (MXU 150/50) Horn button When the ignition switch is ON, push the horn button and it will sound.

  • Page 47: Turn Signal Switch

    (2) Turn signal switch (MXU 250) (2) Turn signal switch (MXU 150/50) Turn signal switch Use the turn signal switch while turning to another direction or shifting to another lane. The turn signal light will flash when the switch is operated and ignition switch is ON.

  • Page 48: Headlight Dimmer Switch

    (3) Headlight dimmer switch (MXU 250) (3) Headlight dimmer switch (MXU 150/50) Headlight dimmer switch NOTE: Turn the switch to the " " position to switch on The headlight can be turned on only when the low beam. the ignition switch in the "...

  • Page 49: Hazard Switch

    (4) Hazard switch (MXU 250) (4) Hazard switch (MXU 150/50) Hazard switch CAUTION: When the hazard switch is pressed, the right and ． Turn on this switch when parking or there is left turn signal lights flash together. a special condition.

  • Page 50: Start Switch

    (5) Start switch (MXU 250) (5) Start switch (MXU 150/50) CAUTION: Start switch " " The start switch is used for starting the engine. See starting instructions prior to starting Pushing the switch in starts the engine. engine (see page 75 for details).

  • Page 51: Recoil Starter (Mxu 250)

    RECOIL STARTER (MXU 250) The recoil starter is on the left side of the ATV. It 1. Turning starter grip counterclockwise to is used to start the engine when the battery is unlock and g rasp the starter grip firmly, then low.

  • Page 52: Kick Starter (Mxu 150/50)

    KICK STARTER (MXU 150/50) The kick starter cranks the engine when the kick 3. After the engine starts, allow the starter grip starter is operated. to return slowly and turning it clockwise to lock. CAUTION: NOTE: See starting instructions prior to starting Do not allow water enter the V-belt engine (see page 78 for details).

  • Page 53: Throttle Lever

    Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a KYMCO dealer if you can't find or solve the problem yourself. (1) Throttle lever...

  • Page 54: Speed Limiter

    HOW TO AVOID THE HAZARD MXU 250: Do not turn the speed adjuster out more than 13 mm (0.52 in). MXU 150: Do not turn the speed adjuster out more than 8 mm (0.32 in). Always make sure the throttle lever free play is adjusted to 1.0~4.0 mm (0.04~0.16...

  • Page 55: Front Brake Lever

    FRONT BRAKE LEVER BRAKE PEDAL (MXU 250/150) The front brake lever is next to the right This ATV is equipped with a combined brake handgrip. system. Operating the brake pedal applies the rear brake and a portion of the front brake. The front brakes are operated by squeezing the front brake lever.

  • Page 56: Parking Brake (Mxu 250)

    Using the parking brake in freezing weather may cause the brakes to freeze in the locked cause the brakes to freeze in the locked position. (See page 83.) position. (See page 84.) (1) Lock lever (MXU 250) (1) Lock pin (MXU 150/50)
  • Page 57 WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 58: Locking Steering (Mxu 250/150)

    HOW TO AVOID THE HAZARD Always be sure you have released the locking steering handlebar and steering Unlocking lock key is taken out before you begin to ride. Never lock the steering handlebar, when the engine is starting. (2) Steering lock key (MXU 150)

  • Page 59: Drive Select Lever

    DRIVE SELECT LEVER FUEL TANK CAP The drive select lever is used for driving the After refueling, be sure to tighten the fuel tank machine either forward or in reverse. Refer to cap until it clicks. page 59 ~ 63 and 80 ~81 for drive select lever Insert the breather tube into the handlebar cover adjustment and operation.

  • Page 60: Fuel Valve

    FUEL VALVE The fuel valve supplies fuel from the fuel tank to the carburetor. The fuel valve has three positions. (1) Fuel valve (MXU 250) (2) Fuel valve (MXU 150/50)
  • Page 61 OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever " " mark in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

  • Page 62: Choke Knob (Mxu 250/150)

    CHOKE KNOB (MXU 250/150) CAUTION: Starting a cold engine requires a richer air-fuel Extended use of the choke may impair piston mixture. A separate starter circuit supplies this and cylinder wall lubrication and shorten the mixture. life of the engine. Pushing the choke knob too hard to the OFF Move in direction (A) to turn on the choke knob.

  • Page 63: Seat (Mxu 250)

    SEAT (MXU 250) To install the seat, align the tabs on the seat with To remove the seat, pull right the seat lock lever the grommets on the frame and press the seat and pull up the seat at the rear. down until it locks.

  • Page 64: Seat (Mxu 150/50)

    To install the seat, align the tabs on the seat with SEAT (MXU 150/50) the grommets on the frame and press the seat To remove the seat, pull upward the seat lock down until it locks. lever and pull up the seat the rear.

  • Page 65: Flag Pole Bracket

    Flag poles are optional equipment available The trailer hitch is located on the rear axle from your KYMCO dealer. To mount a flag pole housing. To use the hitch, you will need proper in the bracket to make you more visible.

  • Page 66: Storage Compartment

    The storage compartment is located under the The accessory socket is optional equipment seat. To remove the seat, see page 53~54 available from your KYMCO dealer. The owner's manual should be stored in the The accessory socket's rated capacity is DC storage compartment.
  • Page 67 (0.8A) in the accessory socket. Using non-KYMCO accessory socket may drain the battery or blow a fuse in this ATV's electrical system. Be carful not to flood this accessory socket when washing your ATV.

  • Page 68: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE ～ Check the lever for proper operation. DRIVE SELECT LEVER 59 63 Check operation, condition,free play (drum brake and brake fluid level (disk brake). ～ ～ 63 64, 147 158 BRAKE Adjust (drum brake) if necessary.

  • Page 69: Drive Select Lever

    DRIVE SELECT LEVER WARNING CAUTION: POTENTIAL HAZARD Before shifting, you must stop the machine Failure to inspect the ATV before operating. and return the throttle lever to its closed position until the engine speed to the Failure to properly maintain the ATV. specified idling speed.
  • Page 70 WARNING POTENTIAL HAZARD Operating with improperly adjusted drive select lever. WHAT CAN HAPPEN You may lose control of the gear shifting, which lead to accident. HOW TO AVOID THE HAZARD Make sure moving the shift lever into the "N" position and neutral indicator lamp comes on before start the engine.

  • Page 71: Drive Select Lever Adjustment

    Drive select lever adjustment Turn the ignition switch is ON and make sure the engine stop. MXU 250/150: Remove 6 screws/nuts, 4 bolts and the right footboard. (1) Right footboard...
  • Page 72 Loosen the locknuts (1) of rod (2). Shift the gear to neutral by moving the shift lever and/or turn the rod. (The neutral indicator lamp comes on.) MXU 250: Provide standard/phillips screwdriver (3) (tool kit) and pass the standard/phillips screwdriver through the shift arm (4) into the index hole (5) at the transmission case cover.

  • Page 73: Front And Rear Brakes

    If not, have the machine inspected by a KYMCO After adjustment, start the engine and test dealer. ride the ATV to be sure the drive select lever is operating properly.

  • Page 74: Fuel

    If a problem (1) Fuel neck cannot be corrected by the adjustment procedures provided in this manual, have Recommended fuel: the ATV inspected by a KYMCO dealer. UNLEADED FUEL Fuel tank capacity: MXU 250: Total: 12.5L(2.64 lmp gal, 3.19 US gal) Reserve: 1.8L(0.38 lmp gal, 0.46 US gal)
  • Page 75 Your KYMCO engine has been designed to use WARNING regular unleaded gasoline with a pump octane POTENTIAL HAZARD number of 86 or higher, or research octane Improper care when refueling. number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or WHAT CAN HAPPEN premium unleaded fuel.

  • Page 76: Engine Oil (Mxu 250/150)

    ENGINE OIL (MXU 250/150) CAUTION: Make sure the engine oil at the specified level. Be sure to use motor oils that do not Add oil as necessary. (See page 122~130.) contain anti-friction modifiers. Passenger Check for leaks. car motor oils (often labeled "Energy Conserving") contain anti-friction additives which will cause starter clutch slippage, resulting in reduced component...

  • Page 77: Engine Oil (Mxu 50)

    KYMCO ATV and is a proper oil. ． if the engine has been run after the low oil level indicator has come on, the scooter...

  • Page 78: Transmission Oil

    TRANSMISSION OIL Make sure the transmission oil at the specified To fill, lift seat (see page 54) , remove the cap from the oil tank, and fill with the recommended level. Add oil as necessary. (See page oil up to the upper level mark (do not overfill the 130~132.) oil tank neck).

  • Page 79: Chain

    Repair as necessary for proper operation. necessary for proper operation. FITTINGS AND FASTENERS Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a KYMCO dealer or refer to the Service Manual for correct tightening torque.

  • Page 80: Tires

    Other tire combinations Check and adjust tire pressures when the are not recommended. tires are cold. Tire pressures must be equal on both Size Type sides. MXU 250 22X7-10 Front Tubeless MXU 150/50 21X7-10 MXU 250 22X10-10 Rear Tubeless MXU 150/50...
  • Page 81 25 kpa 32 kpa (0.28 kgf/cm , (0.25 kgf/cm , Rear (0.32 kgf/cm , MXU 150/50: 3.92 psi) 3.5 psi) 4.5 psi) Front 25 kpa (0.25 kgf/cm , 3.5 psi) Rear 25 kpa (0.25 kgf/cm , 3.5 psi) MXU 150...

  • Page 82: How To Measure Tire Pressure

    How to measure tire pressure Tire wear limit Use the low-pressure tire gauge. (Tool kit) When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading.

  • Page 83: Coolant (Mxu 250)

    COOLANT (MXU 250) Check the coolant level in the reservoir tank when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the "FULL" and "LOW" marks on the tank. If the coolant level is at or below the "LOW"...
  • Page 84 Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. Should be serviced by your authorized KYMCO dealer when changing the coolant.

  • Page 85: Operation

    Read the Owner's Manual carefully. If there When riding in cold weather, always make is a control or function you do not sure all control cables work smoothly understand, ask your KYMCO dealer. before you begin riding. 1. Set the parking brake MXU 250/150:...
  • Page 86 When the select lever is in neutral, the neutral indicator light should come on. If the light does not come on, ask a KYMCO dealer to inspect it. MXU 250/150: Use the choke knob in reference to the figure: 1.

  • Page 87: Using The Recoil Starter (Mxu 250)

    Using the recoil starter (MXU 250) 7. Completely close the throttle lever and start The recoil starter is used to start the engine the engine by pushing the start switch. when the battery is low. NOTE: If the engine fails to start, release the start switch, then push the start switch again.

  • Page 88: Using The Kick Starter (Mxu 150/50)

    Using the kick starter (MXU 150/50) To start the engine without the electric starter The kick starter is used to start the engine when (MXU 250): the battery is low. 1. Follow steps 1 through 6. 2. With the throttle closed turning starter grip...

  • Page 89: Starting A Warm Engine

    CAUTION: See the "engine break-in" section prior to To start the engine without the electric starter operating engine for the first time. (MUX 150/50) 1. Follow steps 1 through 6. 2. With the throttle closed, operate the kick starter with a rapid, continuous motion. STARTING A WARM ENGINE To start a warm engine, refer to the "Starting a CAUTION:...

  • Page 90: Drive Select Lever Operation And Reverse Driving

    DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING CAUTION: Before shifting, you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed. Otherwise, the transmission may be damaged. (1) Drive select lever (N) Neutral (F) Forward (R) Reverse...
  • Page 91 When in reverse, the reverse indicator light Improperly operation in reverse. should be on. If the light does not come on, ask a KYMCO dealer to inspect the machine. WHAT CAN HAPPEN You could hit an obstacle or person behind D.

  • Page 92: Engine Break-In

    If any abnormality is noticed during this period, consult a KYMCO dealer.

  • Page 93: Parking (Mxu 250)

    PARKING (MXU 250) When parking, stop the engine and shift into neutral. Turn the fuel lock to "OFF" and apply the parking brake. The front brake lever has three locked position that allow it to be used as a parking brake. To set the parking brake, see page 46.

  • Page 94: Parking (Mxu 150/50)

    Parking (MXU 150/50) When parking, stop the engine. Turn the fuel lock to "OFF" and apply the parking brake. Make sure the lock pin into the locked position. To set the parking brake, see page 46. (1)Locked position...

  • Page 95: Parking On A Slope

    Parking on a slope 1. Bring the machine to a stop by applying the brakes. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the brake applied, apply the parking brake. Parking on a slope or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident.

  • Page 96: Accessories

    Choose only accessories designed for your to move around on the seat, or one that limits ATV. Your KYMCO dealer has a variety of your view. genuine KYMCO accessories. Other Use extra caution when riding an ATV with accessories may also be available on the accessories.

  • Page 97: Loading

    Maximum towing capacity: Front cargo rack: 20 kg (44 lbs) 150 kg (331 lbs) Tongue weight: 14kg (30 lbs) Maximum load (MXU 150/50) Trailer (MXU 150) Rear cargo rack: 20 kg (44 lbs) Maximum towing capacity: Front cargo rack: 15 kg (33 lbs)
  • Page 98 Load cargo on the cargo racks as close to the WARNING center of the vehicle as possible. Put cargo at POTENTIAL HAZARD the rear of the front cargo rack and at the front Overloading this ATV or carrying or towing of the rear cargo rack .

  • Page 99: Riding Your Atv

    RIDING YOUR ATV...

  • Page 100: Getting To Know Your Atv

    WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This Manual completely and understand the section, riding your ATV, provides general ATV operation of the controls. Pay particular riding instructions for recreational riding.

  • Page 101: Ride With Care And Good Judgement

    RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners and inexperienced riders should get proper instruction on how to operate this ATV. WARNING POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without proper Become familiar with this ATV at slow instruction.
  • Page 102 AGE RECOMMENDATION (MXU 250/150) Not recommended for children under 16 year of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.
  • Page 103 AGE RECOMMENDATION (MXU 50) The minimum recommended age for this ATV model is 6. For safety, never let children under 6 years old operate this vehicle. HOW TO AVOID THE HAZARD Children under 16 should be supervised by A child under 6 should never operate this ATV.
  • Page 104 Never carry passenger on the cargo racks WARNING POTENTIAL HAZARD Carrying a passenger on the cargo racks WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.

  • Page 105: Apparel

    APPAREL Operating without protective clothing WARNING increases your chances of severe injury in POTENTIAL HAZARD the event of an accident. Operating this ATV without wearing an approved motorcycle helmet, eye HOW TO AVOID THE HAZARD protection and protective clothing. Always wear an approved motorcycle helmet that fits properly.
  • Page 106 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator's performance capability is reduced by Operating this ATV after consuming the influence of alcohol or drugs. alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.

  • Page 107: Pre-Operation Checks

    PRE-OPERATION CHECKS Always perform the pre-operation checks listed page 58 before riding for safety and proper WARNING care of the machine. POTENTIAL HAZARD Operating this ATV with improper tires, or WARNING with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before operating.
  • Page 108 Do not operate at speeds too fast your skills Speed limiter or the conditions. For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits WARNING the power and top speed of the machine. POTENTIAL HAZARD Turning the screw in decreases top speed, and Operating this ATV at speeds too fast for...

  • Page 109: Loading And Accessories

    MAXIMUM TOWING CAPACITY: MXU 250: 150kg (331 lbs) 1. Do not tow another vehicle. MXU 150: 100kg (220 lbs) 2. Make sure all cargo is secured before riding. 3. Allow extra room for starting, stopping and TONGUE WEIGHT :...

  • Page 110: Accessories

    WARNING Genuine KYMCO accessories have been POTENTIAL HAZARD specifically designed for and tested on this vehicle. Because KYMCO cannot test all other Overloading this ATV or carrying or towing cargo improperly. accessories, you are personally responsible for properly selecting, installing, and using non- KYMCO accessories.

  • Page 111: Modifications

    Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction. If you have question, consult...

  • Page 112: During Operation

    DURING OPERATION WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the Removing hands from handlebars or feet rear wheels. from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg, your foot or leg may come...
  • Page 113 Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.

  • Page 114: Exhaust System

    EXHAUST SYSTEM The exhaust on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system...

  • Page 115: Practicing

    PRACTICING With the engine idling, return the starter knob to Select a flat area to become familiar with your the closed position and shift the drive select ATV. Make sure that this area is free of lever into the forward position. Then release the obstacles and other riders.

  • Page 116: Speed Limiter For New Riders

    SPEED LIMITER FOR NEW RIDERS Your ATV has an adjustable throttle limiter. The screw and locknut in the lower throttle housing can be adjusted to limit throttle lever movement. To adjust the throttle limiter: 1. Loosen the lock nut (2). 2.

  • Page 117: Braking

    BRAKING Pulling one or both brake levers or/and Practice starting and stopping at slow depressing brake pedal too hard may cause speeds. Gradually work up to faster starts the front and/or rear wheels to skid or slide and stops. out of control. If this happens, release all pressure on the lever(s) immediately.

  • Page 118: Turning Your Atv

    TURNING YOUR ATV To achieve maximum traction while riding on-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. When approaching a corner or turn, close the throttle fully, and slow the ATV down by applying WARNING...

  • Page 119: Climbing Up Slope

    CLIMBING UP SLOPE WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on slopes. Be sure that you can Operating on excessively steep slopes. maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
  • Page 120 WARNING POTENTIAL HAZARD An obstacle or a sharp drop could be on the Climbing slopes improperly other side of the slope. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing slopes as described in this Owner's Manual.
  • Page 121 If you are climbing a slope and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have When crossing the side of a slope: the room to do so) and go down the slope.
  • Page 122 If your ATV has stalled or stopped and you WARNING believe you can continue up the slope, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improperly wheels which could cause you to lose control. If dismounting while climbing a slope.
  • Page 123 Apply the front brake. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on up slope side or to a side if pointed straight up slope. Turn the ATV around and remount, following the procedure described in the Owner's Manual.
  • Page 124 If the slope is not too steep and you have good footing, you may be able to walk the ATV back down slope . Make sure your intended path is clear in case you lose control of the ATV. If you decide you can walk the ATV safely: 1.

  • Page 125: Riding Down Slope

    RIDING DOWN SLOPE WARNING When riding your ATV down slope, shift your POTENTIAL HAZARD weight as far to the rear and up slope side of the Going down a slope improperly. ATV as possible. Move back on the seat and sit with your arms straight.

  • Page 126: Parking

    PARKING Always choose a level place to park. After bringing your ATV to a stop, hold the brakes while you shift into neutral. Then set the parking brake and turn the ignition switch OFF. If you're through riding for the day, also turn the fuel valve OFF.

  • Page 127: What To Do If

    WHAT TO DO IF If your ATV can't make it up a slope you are This section is designed to be a reference guide trying to climb: only. Be sure to read each section on riding techniques completely. Turn the ATV around if you still have forward speed.

  • Page 128: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT Have KYMCO dealer perform service if you Periodic inspection, adjustment and lubrication are not familiar with machine service. will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most...
  • Page 129 The tools in the kit are sufficient to perform WARNING routine maintenance and simple repairs. Any POTENTIAL HAZARD extensive work requiring additional tools should be performed by your authorized KYMCO Operating this ATV with improper dealer. modifications. The tool kit includes the following items:...

  • Page 130: Periodic Maintenance/Lubrication

    PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH ! Replace (Warm engine before draining). Engine oil (MXU 250/150) Clean. *Oil strainer (MXU 250/150) Replace if necessary. Check oil level/oil leakage Transmission oil Replace every 12 months. Check operation.
  • Page 131 *Knuckle shafts/ ! Lubricate every 6 months. Steering shaft Check all chassis fittings and fasteners. *Fittings and Fasteners Correct if necessary. : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

  • Page 132: Engine Oil (Mxu 250)

    ENGINE OIL (MXU 250) 1.Engine oil level measurement (MXU 250) A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Check the oil level through the inspection window (1). D. The oil level should be between the maximum (H) and minimum (L) marks.
  • Page 133 2-1. Engine oil replacement and oil filter cleaning (MXU 250) A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil fill cap (1) and oil filter cap (2) to drain the oil.
  • Page 134 H. Fill the engine with oil and install the oil fill E. Clean the oil strainer with solvent. cap. F. Inspect the O-ring and replace if damaged. G. Reinstall the O-ring, oil strainer, compression Recommended oil: see page 186 spring and oil filter cap. Tighten the oil filter Oil quantity: cap to specification.
  • Page 135 2-2. Engine oil replacement (MXU 250) A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil fill cap (1) and drain plug (2) to drain the oil.

  • Page 136: Engine Oil (Mxu 150)

    ENGINE OIL (MXU 150) 1.Engine oil level measurement (MXU 150) A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Remove the dipstick (1) and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in.
  • Page 137 2-1. Engine oil replacement and oil filter CAUTION: cleaning (MXU 150) ．Be sure no foreign material enters the A. Place the machine on a level place. crankcase. B. Warm up the engine for several minutes and stop it. ．When removing the drain plug, the C.
  • Page 138 H. Fill the engine with oil and install the oil filler E. Clean the oil strainer with solvent. F. Inspect the O-ring and replace if damaged. cap. G. Reinstall the O-ring, oil strainer, compression Recommended oil: see page 186. spring and drain plug. Tighten the drain plug Oil quantity: to specification.
  • Page 139 2-2. Engine oil replacement A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil filler cap (1) and drain plug (2) to drain the oil.

  • Page 140: Transmission Oil

    TRANSMISSION OIL Transmission oil replacement Tightening torque: MXU 250: Drain plug (engine): Remove 6 screws/nuts, 4 bolts and right 30 Nm (3.0 m-kg, 21.6 ft-lb) footboard. (Page 61) 2. Place the machine on a level place. 3. Place a container under the engine. CAUTION: 4.
  • Page 141 (1) Oil filler bolt (MXU 250) (1) Oil filler bolt (MXU 150) (2) Drain plug (MXU 250) (2) Drain plug (MXU 150)
  • Page 142 Recommended oil : See page 178`. Oil quantity : Periodic oil change MXU 250: 0.3 L (0.27 lmp qt, 0.31 US qt) MXU 150: 0.2 L(0.18 lmp qt, 0.21 US qt) MXU 50: 0.25 L (0.22 lmp qt, 0.26 US qt) CAUTION: Be sure no foreign material enters the crankcase.

  • Page 143: Spark Plug Inspection

    Do not attempt to diagnose such problems yourself. Instead, take the machine to a KYMCO dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 144: Air Filter Cleaning

    AIR FILTER CLEANING The air cleaner accumulates dust and must be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule. If the ATV is submerged in water, the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine.
  • Page 145 5. Remove the screw (6) and remove the air cleaner assembly from the air cleaner holder. 6. Remove the air cleaner (7) and air cleaner screen ( 8) from the air cleaner guide (9). 7. Remove the air cleaner screen from the air cleaner.
  • Page 146 8. Gently wash the air cleaner in clean, non- 9. Soak the air cleaner an equivalent (gear oil: flammable (high flash point) solvent such as SAE 80 - 90) until saturated, then squeeze out ─ kerosene not gasoline. Allow the air cleaner the excess oil.
  • Page 147 To clean the air cleaner (MXU 150): 1. Remove the seat. (See page 54.) 2. Remove the four screw (1) and remove the air cleaner housing cover (2). 3. Remove the air filter element (3) from the air cleaner housing.
  • Page 148 4. Remove the screw (4) and separate air filter WARNING element from the element guide (5). POTENTIAL HAZARD Using gasoline or low flash point solvents for cleaning ATV parts. WHAT CAN HAPPEN A fire or explosion could result. HOW TO AVOID THE HAZARD Use only a nonflammable or high flash point solvent to clean ATV parts.
  • Page 149 To clean the air cleaner (MXU 50): 6. Soak the air cleaner an equivalent (gear oil: SAE 80 - 90) until saturated, then squeeze out 1. Remove the air filter case cover. the excess oil. NOTE: The element should be wet but not dripping. CAUTION: Twisting the air cleaner when squeezing out excess oil could damage the air cleaner.
  • Page 150 2. Remove the air filter element, and WARNING separate it from the box. POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element.
  • Page 151 5. Inspect the element. If damaged, replace 6. Apply quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used. NOTE: The element should be wet but not dripping. 7. Reinstall the element to the air filter case 8.

  • Page 152: Air Cleaner Housing Drain Tube (Mxu 250/150)

    AIR CLEANER HOUSING DRAIN TUBE (MXU 250/150) The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle.
  • Page 153 To clean the drain tube (MXU 150): 1. Remove the drain plug (1) by removing the clip (2). 2. Drain the deposits. 3. Reinstall the drain plug, securing it with the clip. (1) Drain plug (2) Clip...

  • Page 154: Idle Speed Adjustment

    Turn the screw in to increase engine speed, and out to decrease engine speed. Specified idle speed: MXU 250: 1,400~1,600 r/min MXU 150: 1,600~1,800 r/min MXU 50: 1,700~1,900 r/min (1) Throttle stop screw (MXU 50)

  • Page 155: Throttle Lever Adjustment

    THROTTLE LEVER ADJUSTMENT NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. To adjust throttle free play (MXU 250): 1. Slide the rubber sleeve (1) back to expose the throttle cable adjuster. (2) (3) 2. Loosen the lock nut (3), then turn the adjuster (2) to obtain the correct free play.
  • Page 156 To adjust throttle free play (MXU 150/50): 1. Slide the rubber sleeves (1) back to expose the throttle cable adjuster. 2. Loosen the lock nut (3), then turn the adjuster (2) to obtain the correct free play. (1~4 mm or 0.04~0.16 in) 3.

  • Page 157: Valve Clearance Adjustment

    This adjustment however, wear.Check the position of the indicator. If the should be left to a professional KYMCO service indicator reaches the wear limit line, ask a technician. KYMCO dealer to replace the pads.
  • Page 158 (1) Rear brake pads cover (Rear brake lever) (1) Rear brake pads cover (Rear brake pedal) Rear brake pads (Rear brake lever) Rear brake pads (Rear brake pedal) Wear indicator Wear indicator...

  • Page 159: Front Brake Shoes Inspection (Mxu 150/50)

    If the indicator reaches the wear limit KYMCO dealer to replace the pads. line(2), ask a KYMCO dealer to replace the shoes as a set. (1) Wear indicator (2) Rear brake...

  • Page 160: Brake Fluid Inspection

    BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection window. WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation. (1) Lower level mark (Hand Brake lever) HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes.
  • Page 161 (page 147~149), There is probably air in the brake system and it must be bled. See your authorized KYMCO dealer for this service. CAUTION: To prevent damage to the brake system, use UPPER only fluid from a sealed container.

  • Page 162: Front Brake Lever Free Play Adjustment (Mxu 150/50)

    FRONT BRAKE LEVER FREE PLAY ADJUSTMENT (MXU 150/50) The front brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. If the free play is incorrect, adjust as follows: (1) Upper locknut...
  • Page 163 Make sure the brakes do not drag. (1) Cable joint ( A) Cable length Replacement of brake components requires professional knowledge. These procedures 6. Tighten the upper locknut. should be performed by KYMCO dealer.

  • Page 164: Rear Brake Lever Free Play Adjustment (Mxu 150)

    REAR BRAKE LEVER FREE PLAY ADJUSTMENT (MXU 150) The rear brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. If the free play is incorrect, adjust as follows: (1) Lock nut...

  • Page 165: Brake Pedal Adjustment (Mxu 150)

    BRAKE PEDAL ADJUSTMENT (MXU 150) Adjust: The brake pedal free play should be adjusted 1. Keep front brake lever free play at 10~20 to 5~10 mm (0.2~0.4 in) at the brake pedal mm (0.4~0.8 in). pivot. If the free play is incorrect, adjust as 2.
  • Page 166 3. Turn the adjusting bolts (2) until the front Lower brake cables (3) is tensed. 4. Apply the front brake lever and check front brake cam levers to make sure that the brake does not drag after adjusting. (2) Adjusting bolts (3) R/L front lower cables...

  • Page 167: Brake Pedal

    5. While remove the two screws (4) and cable joint case cover (5) and applying the brake pedal, make sure the left and right front lower cable lengths (A and B) are equal. The cable joint (6) will become parallel. 6.

  • Page 168: Brake Pedal

    Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by KYMCO dealer. (7) Locknut (8) Adjusting bolt...

  • Page 169: Cooling System Inspection (Mxu 250)

    You may use distilled water if rou NOTE: can not get soft water. 1. If water is added, have a KYMCO dealer check the antifreeze content of the coolant as soon as possible. 2. The radiator fan operation is completely automatic.

  • Page 170: Engine Overheating

    Should be serviced by your authorized KYMCO dealer when changing the coolant. Restart the engine. If the engine overheats again, ask a KYMCO dealer to inspect and/or repair the cooling system NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it...

  • Page 171: Drive Chain Slack Check

    10 20 mm (0.39 0.79in). If the deflection exceeds 20 mm (0.79 in), adjust the chain slack. (1) Hub stopper bolt (2) Axle hub holder bolt － － (A) MXU 250: 30 40 mm (1.18 1.57in) － － MXU 150/50: 10 20 mm (0.39 0.79in)
  • Page 172 2. Provide standard/phillips screwdriver (5) (tool kit) and pass the standard/phillips screwdriver through the axle hub (4) and driven sprocket holder (3) holes. 3. To loosen the chain, push the ATV forward. tighten the chain, pull the ATV backward. 4. Retighten the two axle hub holder bolt and hub stopper bolt to the specification.

  • Page 173: Drive Chain Slack Adjustment (Mxu 150/50)

    Drive chain slack adjustment (MXU 150/50) 1.Loosen the upper and lower axle holding bolts (1). 2.Turn the adjusting nut (2), to decrease or increase chain slack. 3.Retighten the upper and lower axle holding bolts. Tightening torque: Axle holding bolts (upper): (1) Axle holding bolt x 4 70 Nm (7.0 m-kg, 48 ft-lb)

  • Page 174: Drive Chain Cleaning And Lubrication

    DRIVE CHAIN CLEANING AND LUBRICATION REAR SWING ARM LUBRICATION (MXU 250) The drive chain is equipped with rubber O-rings Lubricate the pivot points using a grease gun. between the chain plates. Steam cleaning, high- pressure washes, and certain solvents can damage these O-rings.

  • Page 175: Knuckle Shaft & Rear Swing Arm Lubrication (Mxu 150/50)

    KNUCKLE SHAFT & REAR SWING ARM LUBRICATION (MXU 150/50) Lubricate the pivot points using a grease gun.

  • Page 176: Brake Lever Lubrication

    Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a KYMCO dealer to replace them. Recommended lubricant: KYMCO chain and cable lube or SAE 10W40 motor oil...

  • Page 177: Draining The V-Belt Compartment (Mxu 250/150)

    Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a (1) Drain bolt (MXU 150) (1) Drain bolt (MXU 250)

  • Page 178: Wheel Removal

    WHEEL REMOVAL Be sure the tapered side of the wheel nuts (1) 1. Elevate the wheel by placing a suitable stand face the wheel rim (2). under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. (1) Wheel nut (2) Wheel rim WARNING...

  • Page 179: Battery

    If battery. the battery seems weak, see your authorized KYMCO dealer for information on recharging or WHAT CAN HAPPEN Gases may explode and possibly cause replacement. If you replace the battery, choose one injury.

  • Page 180: Battery Remove (Mxu 250)

    Battery remove (MXU 250) 1. Make sure the ignition switch is OFF. 2. Remove the seat (page 53). 3. Hang license light holder (1), by removing the left mount bolt (2) and loosen the right mount bolt (3). (1) License light holder (2) Left bolt (3) Right bolt 4.
  • Page 181 5. Release the rings and remove the rubber band (6). (6) Rubber band 6. Shift the battery (7) and the terminal leads face yourself. 7. Disconnect the negative (-) terminal lead (8) from the battery first, then disconnect the positive (+) terminal lead (9).

  • Page 182: Battery Installation (Mxu 250)

    Battery installation (MXU 250) 1. Install in the reverse order of removal. 2. Make sure the battery is installed upright as shown. 3. Check all bolts and other fasteners are secure. 4. After installing the battery, check to see if the battery cables are routed correctly.

  • Page 183: Battery Remove (Mxu 150/50)

    Battery remove (MXU 150/50) Battery installation (MXU 150/50) 1. Make sure the ignition switch is OFF. 1. Install in the reverse order of removal. 2. Remove the seat (page 54). 2. Check all bolts and other fasteners are secure. 3. Remove the battery cover (2), by removing the 3.

  • Page 184: Fuse Replacement (Mxu 250)

    FUSE REPLACEMENT (MXU 250) 2. Remove the seat (page 53). The fuse box stored in the battery compartment 3. Open the fuse box cap (3). under the seat. The fuse box contains a spare 4. Pull the old fuse out of the fuse holder. fuse.

  • Page 185: Fuse Replacement (Mxu 150/50).175

    FUSE REPLACEMENT (MXU 150/50) When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your authorized KYMCO CAUTION: dealer for repair. To prevent accidental short-circuiting, turn off the ignition switch before checking or There is a spare fuse under the battery cover.
  • Page 186 Fuse box: The fuse box is located in the storage box under To replace a fuse: the seat. 1. Make sure the ignition switch is OFF. The specified fuses are: 20A 2. Remove the seat (page 54). 3. Remove the fuse box cap (1). (1) Fuse box (1) Fuse box cap...
  • Page 187 4. Pull the old fuse out of the fuse box. 5. Push the new fuse in to the fuse box. 6. Reinstall the fuse box cap and install seat. (1) Fuse: 20 A...

  • Page 188: Headlight Beam Adjustment

    HEADLIGHT BEAM ADJUSTMENT CAUTION: It is advisable to have a KYMCO dealer make this adjustment. To adjust: Turn the ignition switch at " " position and start the engine. Turn on the dimmer switch. Adjust the headlight aim by turning the headlight aim adjusting screws.

  • Page 189: Troubleshooting

    The troubleshooting chart describes a WHAT CAN HAPPEN quick, easy procedure for making checks. If your Fuel can ignite or explode, causing severe machine requires any repair, take it to a KYMCO dealer. injury or property damage. HOW TO AVOID THE HAZARD...

  • Page 190: Troubleshooting Chart

    Check fluid, recharge, check connections. over slowly. Use electric starter. Engine turns Battery good. over quickly. Ask a KYMCO dealer to inspect. 3. Ignition Wipe clean with dry Adjust plug gap or cloth. Remove plug and No spark. replace plug.

  • Page 191: Cleaning And Storage

    CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend the bills have resulted from improper high useful life of many components.
  • Page 192 7. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after washing. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid WHAT CAN HAPPEN combination cleaner-waxes.

  • Page 193: Storage

    B. STORAGE WARNING Before storing your ATV for an extended time, be POTENTIAL HAZARD sure you thoroughly check the vehicle for Refueling this ATV or handling fuel needed repairs and have them corrected. improperly. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage.
  • Page 194 4. Remove the battery (page 170 or 173) WARNING store it in an area protected from freezing POTENTIAL HAZARD temperatures and direct sunlight and out of Prolonged contact of fuel with the skin. the reach of children, slow charge the battery Breathing fuel vapor.

  • Page 195: Specifications (Mxu 250/150)

    SPECIFICATIONS (MXU 250/150) MXU 250 MXU 150 Model Dimension: Overall length 1810 mm (70.6 in) 1775 mm (70 in) Overall width 1050 mm (41.0 in) 950 mm (37.1 in) Overall height 1110 mm (43.3 in) 1040 mm (40.6 in) Seat height 810 mm (31.6 in)
  • Page 196 MXU 250 MXU 150 Model 110 F Engine oil/transmission oil: Type SAE 5W － SAE 10W 30 Engine oil classification: － SAE 10W 40 － SAE 20W 40 － SAE 20W 50 -1 0 40 C API Service SE, SF, SG type or higher...
  • Page 197 MXU 250 MXU 150 Model Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED FUEL UNLEADED FUEL Tank capacity 12.5 L (2.7 lmp gal, 3.2 US gal) 8.1 L (1.7 lmp gal, 2.11 US gal) Reserve amount 1.8 L (0.4 lmp gal, 0.47 US gal)
  • Page 198 MXU 250 MXU 150 Model Suspension: Front Dual swing A-arm Swing axle Rear Swing arm Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. C.D.I. Generator system C.D.I. Magneto C.D.I. Magneto Battery type...

  • Page 199: Specifications (Mxu 50)

    SPECIFICATIONS (MXU 50) MXU 50 Model Dimension: 1786 mm (71 in) Overall length Overall width 958 mm (38 in) Overall height 1010 mm (40 in) 750 mm (30 in) Seat height Wheel base 1105 mm (44 in) Minimum ground clearance 162 mm (6.6 in) Basic weight: With oil and full fuel tank...
  • Page 200 Model MXU 50 Engine oil/transmission oil: Type 2-stroke engine oil Engine oil classification: Transmission Oil classification: SAE 90# Quantity Engine oil: 2-stroke engine oil 1 L (0.9 lmp qt, 1.1 US qt) over Transmission oil: Periodic oil change 0.25 L (0.22 lmp qt, 0.26 US qt) Total amount 0.3 L (0.26 lmp qt, 0.32 US qt)
  • Page 201 Model MXU 50 Air filter: for engine Wet type element Fuel: Type UNLEADED FUEL Tank capacity 8.1 L(1.74 lmp gal, 2.08 US gal) Reserve amount 1 L(0.22 lmp gal, 0.26 US gal) Carburetor: Type Spark plug: Type NGK BR8 HAS 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clutch: Type Dry, centrifugal automatic...
  • Page 202 Model MXU 50 Suspension: Front Swing axle Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Battery type 12V4AH Tire: Type Tubeless Size: Front/Rear 21X7-10/22X10-10 Bulb voltage, wattage*quantity: Headlight 12V35/35WX2 Taillight/Brake light...

  • Page 203: Noise Regulation

    NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Some local laws and regulations prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 204: Maintenance Record

    MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

  • Page 205: Index

    INDEX Page Page ACCESSORIES......86, 99, 100 CABLE INSPECTION AND ACCESSORY SOCKET SEAT (MXU 250)..56 LUBRICATION........166 AGE RECOMMENDATION......A CHAIN............ 69 AIR CLEANER HOUSING CHOKE KNOB (MXU 250/150)....52 DRAIN TUBE (MXU 250/150)....142 CLEANING..........181 CLIMBING UP SLOPE ......109 AIR FILTER CLEANING ......134 CONTENTS..........
  • Page 206 IGNITION SWITCH........25 EXHAUST SYSTEM........104 IMPORTANT NOTICES......A INDICATOR..........26 INSTRUMENTS........26 FITTINGS AND FASTENERS....69 FLAG POLE BRACKET......55 FRONT BRAKE......63, 147, 149 KICK STARTER (MXU 150/50)....42, 78 FRONT BRAKE LEVER....45, 152 FUEL............64 KNUCKLE SHAFT........165 Fuel gauge..........33 FUEL TANK CAP........49 FUEL VALVE..........50 LABELS............1 FUSE REPLACEMENT....174, 175...
  • Page 207 Page Page MODIFICATIONS........101 PARKING ....... 83,84, 85, 116 Multi-function display........28 PARKING BRAKE........46 PARTS LOCATION......13, 19 PERIODIC MAINTENANCE/ LUBRICATION........120 Neutral indicator........27 PERIODIC MAINTENANCE AND ADJUSTMENT........118 POSITION LIGHT SWITCH.......25 Odometer ..........34 PRACTICING.........105 OPERATION ........... 75 PREFACE ..........C PRE-OPERATION CHECKS....58, 97 (Cont'd)
  • Page 208 Page Page THROTTLE LEVER.....43, 69, 145 REAR BRAKE......63, 147, 149 TIRES.............70 REAR BRAKE LEVER.......45, 154 Tire wear limit.......... 72 REAR SWING ARM TOOL KIT..........118 LUBRICATION........164, 165 TRAILER HITCH (MXU 250/150)....55 RECOIL STARTER (MXU 250)....41, 77 TRANSMISSION OIL......68, 130 Reverse indicator........27 Tripmeter..........34 RIDING DOWN SLOPE......115 TROUBLESHOOTING ......
  • Page 209 KWANG YANG MOTOR CO.,LTD. NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. First Edition, Dec 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.
  • Page 212 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN NEVER USE APPROVED HELMET WITH DRUGS AND PROTECTIVE OR ALCOHOL GEAR NEVER operate : Without proper training or instruction. At speeds too fast for your skills or the conditions. Do not operate the vehicle after consuming ALCOHOL OR DRUGS.

This manual is also suitable for:

Mxu 250

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