KYMCO MX 125 Service Manual
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KYMCO MX 125 Service Manual

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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO MX'er
125/150.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part,
starting from periodic maintenance.
Sections 4 through 17 give instructions
for disassembly, assembly and
inspection of engine, chassis frame and
electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

SYSTEM
REAR WHEEL /SWING
ARM/HYDRAULIC BRAKE
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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Summary of Contents for KYMCO MX 125

  • Page 1: Table Of Contents

    PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing FRAME COVERS/EXHAUST MUFFLER procedures for the KYMCO MX’er INSPECTION/ADJUSTMENT 125/150. LUBRICATION SYSTEM Section 1 contains the precautions for FUEL SYSTEM all operations stated in this manual.
  • Page 2 . GENERAL INFORMATION MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ GENERAL INFORMATION ____________________________________________________________________ SERIAL NUMBER---------------------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 4 TORQUE VALUES --------------------------------------------------------- 1-12 SPECIAL TOOLS ----------------------------------------------------------- 1-14 LUBRICATION POINTS -------------------------------------------------- 1-15 CABLE & HARNESS ROUTING ---------------------------------------- 1-18 WIRING DIAGRAM-------------------------------------------------------- 1-22 TROUBLESHOOTING----------------------------------------------------- 1-23...

  • Page 3: General Information

    . GENERAL INFORMATION MX’er SYSTEM SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...

  • Page 4: General Information

    . GENERAL INFORMATION MX’er SYSTEM Cooling Type Forced air cooling SPECIFICATIONS Name & Model No. LA30AA, AB Motorcycle Name & Type MX’er Air cleaner type & No Sponge Overall length (mm) 1600 Fuel capacity 8.1 liters Overall width (mm) Type Overall height (mm) Float lever 14.8mm...
  • Page 5 . GENERAL INFORMATION MX’er SYSTEM SPECIFICATIONS Name & Model No. LA25AB Motorcycle Name & Type MX’er Air cleaner type & No Sponge Overall length (mm) 1685 Fuel capacity 8.1 liters Overall width (mm) Type Overall height (mm) Piston dia. (mm) 14.8mm φ...

  • Page 6: Service Precautions

    . GENERAL INFORMATION MX’er SYSTEM SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
  • Page 7 . GENERAL INFORMATION MX’er SYSTEM Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
  • Page 8 . GENERAL INFORMATION MX’er SYSTEM If the fuse is burned out, find the cause Confirm and repair it. Replace it with a new one Capacity according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 9 . GENERAL INFORMATION MX’er SYSTEM The connector shall be inserted completely. Snapping! If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
  • Page 10 . GENERAL INFORMATION MX’er SYSTEM After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
  • Page 11 . GENERAL INFORMATION MX’er SYSTEM Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
  • Page 12 . GENERAL INFORMATION MX’er SYSTEM After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
  • Page 13 . GENERAL INFORMATION MX’er SYSTEM Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Engine Oil : Apply grease for lubrication.

  • Page 14: Torque Values

    . GENERAL INFORMATION MX’er SYSTEM TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kgf-m) Item Torque (kgf-m) 5mm bolt, nut 0.45 0.6 4mm screw 0.15 0.4 6mm bolt, nut 0.8 1.2 0.3 0.5 5mm screw 8mm bolt, nut 1.8 2.5 0.7 1.1 6mm screw, SH bolt 10mm bolt, nut 3.0 4.0...
  • Page 15 . GENERAL INFORMATION MX’er SYSTEM Item Q‘ty Thread dia.(mm) Torque (kgf-m) Remarks R cover 0.8 1.2 Head cover 0.8 1.2 Cap R cover 0.8 1.2 Guide star change handle 0.8 1.2 Sprocket drive plate 1.0 1.6 Carburetor 0.8 1.2 Check bolt oil 1.0 1.5 FRAME Item...

  • Page 16: Special Tools

    . GENERAL INFORMATION MX’er SYSTEM SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Flywheel puller E003 Lock nut wrench E009 Valve adjuster E012 Valve spring compressor E040 Oil seal and bearing install E014 Universal holder E017 Flywheel holder E021 Clutch spring compressor E027 Bearing puller...

  • Page 17: Lubrication Points

    . GENERAL INFORMATION MX’er SYSTEM LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API SG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
  • Page 18 . GENERAL INFORMATION MX’er SYSTEM FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle. Rear Brake Cable Front Brake Cable Throttle Cable...
  • Page 19 . GENERAL INFORMATION MX’er SYSTEM Swing arm Thrust Cover Rear Brake Cam/ Axle Hub Collar/Oil Seal/Bearing Sprocket hub/Rear Axle Hub Collar/Oil Seal/Bearing Driven Sprocket 1-17...

  • Page 20: Cable & Harness Routing

    . GENERAL INFORMATION MX’er SYSTEM CABLE & HARNESS ROUTING Rear Brake Cable Throttle Cable Handlebar Switch Lead Front Brake Cable Right Front Brake Cable Left Front Brake Cable 1-18...
  • Page 21 . GENERAL INFORMATION MX’er SYSTEM Breather Hose (CYL Head Cover) Main Switch Inlet Hose Breather Hose 1-19...
  • Page 22 . GENERAL INFORMATION MX’er SYSTEM Breather Hose Wire Harness Rectifier/Regulato Fuse Outlet Hose Ignition Coil 1-20...
  • Page 23 . GENERAL INFORMATION MX’er SYSTEM A.C.G Wire Connector Breather Hose (CYL Head Cover) Battery Negative Cable Positive Cable Battery CDI Unit Starter Relay Change Gear Control Fuse 1-21...

  • Page 24: Wiring Diagram

    . GENERAL INFORMATION MX’er SYSTEM WIRING DIAGRAM 1-22...

  • Page 25: Troubleshooting

    . GENERAL INFORMATION MX’er SYSTEM TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel does not Fuel reaches Clogged fuel tank cap breather...
  • Page 26 . GENERAL INFORMATION MX’er SYSTEM ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Restricted fuel flow Engine speed does not Engine speed Clogged fuel tank cap breather hole increase sufficiently increases Clogged exhaust muffler Carburetor fuel level too low Check ignition timing...
  • Page 27 . GENERAL INFORMATION MX’er SYSTEM POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check carburetor air screw adjustment Mixture too rich (turn screw Correctly adjusted Incorrectly adjusted out)
  • Page 28 . GENERAL INFORMATION MX’er SYSTEM POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat Check fuel pump for fuel supply Empty fuel tank...
  • Page 29 . GENERAL INFORMATION MX’er SYSTEM POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
  • Page 30 . GENERAL INFORMATION MX’er SYSTEM NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose spark plug cap Loose...

  • Page 31: Frame Covers/Exhaust Muffler

    . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 2 TROUBLESHOOTING----------------------------------------------------- 2- 2 FRAME COVERS ----------------------------------------------------------- 2- 3 HEADLIGHT REMOVAL ------------------------------------------------- 2- 5 EXHAUST MUFFLER REMOVAL-------------------------------------- 2- 5...
  • Page 32 . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM...

  • Page 33: Frame Covers/Exhaust Muffler

    . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt 3.2 3.8kgf-m...

  • Page 34: Frame Covers

    . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM Seat FRAME COVERS SEAT REMOVAL Pull the lever backward, then pull up the seat at the rear. Remove the seat. Bolt Screws LEFT REAR FENDER REMOVAL Remove seven screws and two bolts attaching the left rear fender. During rem oval, do not pull the joint claws forcedly to avoid dam ge.
  • Page 35 . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM Remove right rear fender under bolt. Remove the right rear fender. Bolt Floor Board Cover FLOOR BOARD COVER REMOVAL Remove the four bolts on the floorboard cover. Remove the floorboard cover. Bolts Front Cover FRONT COVERS REMOVAL Remove the two screws on the front cover.

  • Page 36: Headlight Removal

    . FRAME COVERS/EXHAUST MUFFLER MX’er SYSTEM HEADLIGHT REMOVAL Remove the headlight connector wire. Remove the two bolts on the headlight. Bolts EXHAUST MUFFLER REMOVAL Remove the two bolts attaching the exhaust muffler. Bolts Joint Lock Nuts Remove the two exhaust muffler joint lock nuts.

  • Page 37: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ INSPECTION/ADJUSTMENT ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 2 FUEL LINE/THROTTLE OPERATION/AIR CLEANER ------------ 3- 3 AIR FILTER FOR DRIVE BELT ----------------------------------------- 3- 4 SPARK PLUG---------------------------------------------------------------- 3- 5 VALVE CLEARANCE/CARBURETOR IDLE SPEED--------------- 3- 6 IGNITION TIMING/CYLINDER COMPRESSION ------------------- 3- 7 ENGINE OIL/FINAL REDUCTION GEAR OIL----------------------- 3- 8 DRIVE BELT/BRAKE SHOE/BRAKE SYSTEM --------------------- 3- 9...

  • Page 38: Service Information

    . INSPECTION/ADJUSTMENT MX’er SYSTEM SERVICE INFORMATION GENERAL WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions.

  • Page 39: Inspection/Adjustment

    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. FUEL LINE Remove the met-in box.

  • Page 40: Throttle Operation

    . INSPECTION/ADJUSTMENT MX’er SYSTEM Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage. Do not smoke or allow flames or sparks in your working area. Fuel Filter THROTTLE OPERATION Check the throttle to swing for smooth movement.

  • Page 41: Air Filter For Drive Belt

    . INSPECTION/ADJUSTMENT MX’er SYSTEM 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. Do not twist or wring out the foam element.

  • Page 42: Spark Plug

    . INSPECTION/ADJUSTMENT MX’er SYSTEM the dust and dirt. Blow out the remaining dirt with compressed air. Install the air filter element and air filter case. Install the front cover. SPARK PLUG Remove the spark plug. Check the spark plug for wear and fouling deposits.

  • Page 43: Ignition Timing/Cylinder Compression

    . INSPECTION/ADJUSTMENT MX’er SYSTEM Remove the cylinder head cover. Bolts Turn the flywheel counterclockwise so that the “T” mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke.

  • Page 44: Engine Oil/Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT MX’er SYSTEM Remove the timing hole cap. Timing Light Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase.
  • Page 45 . INSPECTION/ADJUSTMENT MX’er SYSTEM • Place the motorcycle upright on level ground for engine oil level check. • Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes. Remove the oil dipstick and check the oil level with the oil dipstick.

  • Page 46: Drive Belt/Brake Shoe/Brake System

    . INSPECTION/ADJUSTMENT MX’er SYSTEM thoroughly. Install the oil drain bolt. Torque: 0.8 1.2kgf-m Make sure that the sealing washer is in good condition. Fill with the recommended oil. Oil Capacity: At disassembly : 400cc At change : 200cc Oil Drain Bolt/ Sealing Washer Reinstall the oil filler bolt and check for oil leaks.

  • Page 47: Headlight Aim

    . INSPECTION/ADJUSTMENT MX’er SYSTEM 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. The difference between both clearances should be 2 mm or less when front brake is applied.

  • Page 48: Steering System Inspection

    . INSPECTION/ADJUSTMENT MX’er SYSTEM 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 back and forth.

  • Page 49: Wheels/Tires

    . INSPECTION/ADJUSTMENT MX’er SYSTEM 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. Measure the width A between the marks.
  • Page 50 . INSPECTION/ADJUSTMENT MX’er SYSTEM Tire pressure should be checked when tires are cold. Front Axle Nut TIRE PRESSURE 1 Rider Front 0.20kgf/cm² Rear 0.25kgf/cm² TIRE SIZE Front : 20*7-8 Rear : 22*10-8 Check the front axle nut for looseness. Rear Axle Nut Check the rear axle nut for looseness.

  • Page 51: Drive Chain Slack Adjustment

    . INSPECTION/ADJUSTMENT MX’er SYSTEM DRIVE CHAIN SLACK ADJUSTMENT Before checking and/or adjusting, rotate the rear wheels several revolutions and check slack at several points to find the tightest point. Check and/or adjust the chain slack with the rear wheels in this “tightest” position.

  • Page 52: Cable Inspection And Lubrication

    . INSPECTION/ADJUSTMENT MX’er SYSTEM Turn out: Slack is decreased. Turn in: Slack is increased. Bolts Tighten four bolts attaching rear axle hub to the specification. While pushing up or down on the chain to zero slack. Torque: 6.0 8.0kgf-m Adjuster Tighten the adjuster.

  • Page 53: Front Suspension Lubrication

    . INSPECTION/ADJUSTMENT MX’er SYSTEM Inspect the cable sheath. Replace if damage. Check the cable operation. Lubricate or replace if unsmooth operation. Hold cable end high and apply several drops of lubricant to cable. LEVER LUBRICATION Lubricate the pivoting parts of each lever. FRONT SUSPENSION LUBRICATION Inject grease into the nipples using a grease...

  • Page 54: Lubrication System

    . LUBRICATION SYSTEM MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ LUBRICATION SYSTEM ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 4- 2 TROUBLESHOOTING----------------------------------------------------- 4- 2 ENGINE OIL/OIL FILTER ------------------------------------------------ 4- 3 OIL PUMP -------------------------------------------------------------------- 4- 3...
  • Page 55 . LUBRICATION SYSTEM MX’er SYSTEM LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...

  • Page 56: Lubrication System

    . LUBRICATION SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 57: Engine Oil/Oil Filter

    . LUBRICATION SYSTEM MX’er SYSTEM Lower Level ENGINE OIL/OIL FILTER OIL LEVEL • Place the motorcycle upright on level ground for engine oil level check. • Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes.
  • Page 58 . LUBRICATION SYSTEM MX’er SYSTEM Starter Clutch Starter Idle Gear Remove the starter idle gear and starter clutch. Special Lock nut socket wrench E009 Bolts Remove the two bolts and oil separator cover. Oil Separator Cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.
  • Page 59 . LUBRICATION SYSTEM MX’er SYSTEM Screw DISASSEMBLY Remove the screw and disassemble the oil pump. Pump Body Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.12mm Inner Rotor Measure the rotor end-to-pump body clearance.
  • Page 60 . LUBRICATION SYSTEM MX’er SYSTEM Outer Rotor Inner Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body. Insert the pump shaft by aligning the flat on the shaf t with the fl at in the inner rotor.
  • Page 61 . LUBRICATION SYSTEM MX’er SYSTEM Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft. Install and tighten the pump driven gear nut. Torque: 0.8 1.2kgf-m Pump Driven Gear Install the oil separator cover and tighten Bolts the bolts.

  • Page 62: Fuel System

    . FUEL SYSTEM MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ FUEL SYSTEM ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5- 2 TROUBLESHOOTING----------------------------------------------------- 5- 3 THROTTLE VALVE DISASSEMBLY/CARBURETOR REMOVAL-- 5- 4 FLOAT/FLOAT VALVE/JETS-------------------------------------------- 5- 5 CARBURETOR INSTALLATION --------------------------------------- 5- 8 FUEL TANK ----------------------------------------------------------------- 5- 9 FUEL VALVE REMOVAL ------------------------------------------------ 5- 9 AIR CLEANER -------------------------------------------------------------- 5-10...
  • Page 63 . FUEL SYSTEM MX’er SYSTEM...

  • Page 64: Fuel System

    . FUEL SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. •...

  • Page 65: Troubleshooting

    . FUEL SYSTEM MX’er SYSTEM SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine cranks but won’t start Engine lacks power • No fuel in tank • Clogged air cleaner • No fuel to carburetor • Faulty carburetor • Cylinder flooded with fuel •...

  • Page 66: Throttle Valve Disassembly/Carburetor Removal

    . FUEL SYSTEM MX’er SYSTEM Carburetor Cap THROTTLE VALVE DISASSEMBLY Remove the front cover. Remove the front fender. Remove the carburetor cap. Pull out the throttle valve. Disconnect the choke knob cable. Spring Throttle Cable Disconnect the throttle cable and remove the spring from the throttle valve.

  • Page 67: Float/Float Valve/Jets

    . FUEL SYSTEM MX’er SYSTEM Lock Nuts Loosen the air cleaner connecting tube band screw. Remove the two carburetor lock nuts. Remove the carburetor Screw FLOAT/FLOAT VALVE/JETS FLOAT/FLOAT VALVE DISASSEMBLY Remove the float chamber attaching three screws and remove the float chamber. Screws Float Remove the float pin, float and float valve.
  • Page 68 . FUEL SYSTEM MX’er SYSTEM Slow Jet Main Jet JETS/AIR SCREW/THROTTLE STOP SCREW REMOVAL Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Remove the air screw and throttle stop screw. Air Screw Throttle Stop Screw CAUTIONS ! O-ring Air Screw...
  • Page 69 . FUEL SYSTEM MX’er SYSTEM Main Jet Slow Jet SLOW/MAIN JET INSTALLATION Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and air screw • When installing the air screw, return it to the original position as noted during removal •...

  • Page 70: Carburetor Installation

    . FUEL SYSTEM MX’er SYSTEM Lock Nut CARBURETOR INSTALLATION Install the carburetor onto the intake manifold and tighten the two lock nuts. Torque: 0.8 1.2kgf-m Install the air cleaner connecting tube and tighten the band screw. Band Screw Needle Retainer Clip THROTTLE VALVE ASSEMBLY Install the jet needle into the throttle valve...

  • Page 71: Fuel Tank

    . FUEL SYSTEM MX’er SYSTEM Screw Tighten the choke cable. FUEL TANK Choke Cable FUEL TANK REMOVAL Side • 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.

  • Page 72: Air Cleaner

    . FUEL SYSTEM MX’er SYSTEM Fuel Valve Body Control Switch Washer Remove the screw on the fuel valve control switch. Remove the two screws on the fuel valve body. INSPECTION Inspect the fuel valve strainer for dirt and clog. Clean if necessary. Replace the O-rings with new ones if they are damaged or deteriorated.
  • Page 73 . ENGINE REMOVAL/INSTALLATION MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ENGINE REMOVAL/INSTALLATION ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 6- 1 ENGINE REMOVAL ------------------------------------------------------- 6- 2 ENGINE INSTALLATION ------------------------------------------------ 6- 4...
  • Page 74 6. ENGINE REMOVAL/INSTALLATION MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. careful not to damage the machine body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal. •...

  • Page 75: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION MX’er SYSTEM ENGINE REMOVAL Drain engine oil and transmission oil. Remove seat, front cover, center cover, front fender and rear fender. Remove the carburetor. Disconnect the battery negative cable. Remove the frame body cover. Disconnect the engine negative cable. Disconnect the A.C.G.
  • Page 76 6. ENGINE REMOVAL/INSTALLATION MX’er SYSTEM Disconnect the spark plug high-tension wire. Remove the spark plug cap and disconnect the ignition coil wire from the set plate. Ignition Coil Wire Remove the rear drive chain gear on the Drive Chain Gear bolts.
  • Page 77 . ENGINE REMOVAL/INSTALLATION MX’er SYSTEM Remove the engine front bracket bolt. Bolt Engine Hanger Bracket ENGINE HANGER BRACKET REMOVE Remove the two bolts on the left engine hanger bracket. Remove the left engine hanger bracket. Remove the engine. Bolts ENGINE INSTALLATION Install the engine and tighten the engine mounting bolts.
  • Page 78 . CYLINDER HEAD/VALVES MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ CYLINDER HEAD/VALVES ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 7- 2 TROUBLESHOOTING----------------------------------------------------- 7- 3 CAMSHAFT REMOVAL -------------------------------------------------- 7- 4 CYLINDER HEAD REMOVAL ------------------------------------------ 7- 7 CYLINDER HEAD DISASSEMBLY ------------------------------------ 7- 8 CYLINDER HEAD ASSEMBLY ----------------------------------------- 7-10 CYLINDER HEAD INSTALLATION ----------------------------------- 7-10 CAMSHAFT INSTALLATION ------------------------------------------- 7-11...
  • Page 79 7. CYLINDER HEAD/VALVES MX’er SYSTEM...

  • Page 80: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication. •...

  • Page 81: Troubleshooting

    7. CYLINDER HEAD/VALVES MX’er SYSTEM TORQUE VALUES Cylinder head nut 1.8 2.2kgf-m Apply engine oil to threads Valve clearance adjusting nut 1.4 1.8kgf-m Apply engine oil to threads Stud bolt 0.7 1.1kgf-m SPECIAL TOOLS Valve spring compressor E040 Tappet adjuster E012 TROUBLESHOOTING •...

  • Page 82: Camshaft Removal

    . CYLINDER HEAD/VALVES MX’er SYSTEM CAMSHAFT REMOVAL Remove seat, front cover, center cover. Front fender, fuel tank and exhaust pipe. Remove the four cylinder head cover bolts to remove the cylinder head cover. Bolts Remove the cam chain tensioner cap bolt and the O-ring.
  • Page 83 7. CYLINDER HEAD/VALVES MX’er SYSTEM Remove the four cylinder head nuts and washers. Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Remove the camshaft holder and dowel Camshaft Holder pins. Camshaft Dowel Pins Remove the camshaft gear from the cam chain and remove the camshaft.
  • Page 84 . CYLINDER HEAD/VALVES MX’er SYSTEM Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. CAMSHAFT HOLDER DISASSEMBLY Rocker Arm Bolt Remove the bolt attaching the stop plate. Take out the valve rocker arm shafts using a 5mm bolt.

  • Page 85: Cylinder Head Removal

    7. CYLINDER HEAD/VALVES MX’er SYSTEM CYLINDER HEAD REMOVE Intake Manifold Remove the camshaft. Remove the carburetor. Remove the exhaust muffler. Remove the carburetor intake manifold. Bolts Remove the two cylinder head bolts. Remove the cylinder head. Cylinder Head Bolts Remove the dowel pins and cylinder head gasket.

  • Page 86: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES MX’er SYSTEM CYLINDER HEAD Valve Spring Compressor DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. • Be sure to compress the valve springs with a valve spring compressor. •...
  • Page 87 7. CYLINDER HEAD/VALVES MX’er SYSTEM Measure each valve guide I.D. Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. Service limits: IN : 0.06mm replace if over EX: 0.08mm replace if over If the ste m-to-guide clearance exceeds the service limits, replace the cylinder head as necessary.

  • Page 88: Cylinder Head Assembly

    . CYLINDER HEAD/VALVES MX’er SYSTEM CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve stem seals. Be sure to install new valve stem seals. Lubricate each valve stem with engine oil and insert the valves into the valve guides. Install the valve springs and retainers.

  • Page 89: Camshaft Installation

    7. CYLINDER HEAD/VALVES MX’er SYSTEM Install two cylinder head bolts do not tighten completely. Bolts Install the cylinder head. Torque: Stud Bolts :0.8 1.2kgf-m Cylinder Head CAMSHAFT HOLDER ASSEMBLY Camshaft Holder Install the exhaust valve rocker arm to the “EX” mark side of the camshaft holder. Install the intake valve rocker arm and the rocker arm shafts.
  • Page 90 . CYLINDER HEAD/VALVES MX’er SYSTEM Camshaft Holder Install the camshaft holder, washers and nuts on the cylinder head. Tighten the four cylinder head nuts, then tighten two cylinder head bolts compeletly. Torque: Cylinder head nut: 1.8 2.2kgf-m • Apply engine oil to the threads of the cylinder head nuts.
  • Page 91 . CYLINDER/PISTON MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ CYLINDER /PISTON ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 2 CYLINDER REMOVAL --------------------------------------------------- 8- 4 PISTON REMOVAL-------------------------------------------------------- 8- 4 PISTON INSTALLATION------------------------------------------------- 8- 8 CYLINDER INSTALLATION -------------------------------------------- 8- 8...

  • Page 92: Cylinder/Piston

    . CYLINDER/PISTON MX’er SYSTEM...

  • Page 93: Cylinder/Piston

    . CYLINDER/PISTON MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. TROUBLESHOOTING • When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke.
  • Page 94 . CYLINDER/PISTON MX’er SYSTEM SPECIFICATIONS Mx’er 150 Standard (mm) Service Limit (mm) ⎯ I.D. 62.03 62.045 ⎯ Warpage 0.05 Cylinder ⎯ Cylindricity 0.05 ⎯ True roundness 0.05 Ring-to-groove Top 0.015 0.055 0.09 clearance Second 0.015 0.055 0.09 0.10 0.25 Ring end gap Second 0.10 0.25 Piston,...

  • Page 95: Cylinder Removal

    . CYLINDER/PISTON MX’er SYSTEM Bolt CYLINDER REMOVAL Turn the cam chain tension screw clockwise to tighten it. Remove the two bolts on the cam chain tension. Cylinder Remove the cylinder head. Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder Remove the cylinder gasket and dowel pins.
  • Page 96 . CYLINDER/PISTON MX’er SYSTEM Inspect the piston, piston pin and piston rings. Remove the piston rings. Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
  • Page 97 . CYLINDER/PISTON MX’er SYSTEM over Measure the piston pin O.D. Service Limit: 14.96mm replace if below Measure the piston O.D. Take measurement at 5mm from the bottom and 90° to the piston pin hole. Piston O.D.: 61.96 62mm (MX’er 150) Piston O.D.: 56.46 56.5mm (MX’er 125) Measure the piston-to-piston pin clearance.
  • Page 98 . CYLINDER/PISTON MX’er SYSTEM Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring.

  • Page 99: Piston Installation

    . CYLINDER/PISTON MX’er SYSTEM PISTON INSTALLATION Remove any gasket material from the crankcase surface. Be careful not to drop foreign matters into the crankcase. Piston Install the piston, piston pin and a new piston pin clip. • Position the piston “IN” mark on the intake valve side.
  • Page 100 . CYLINDER/PISTON MX’er SYSTEM...

  • Page 101: Drive And Driven Pulleys

    9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION..............9-2 TROUBLESHOOTING................9-2 LEFT CRANKCASE COVER ..............9-3 DRIVE PULLEY ..................9-3 CLUTCH/DRIVEN PULLEY ..............9-3...
  • Page 102 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS 5.5kg-m 5.5kg-m 5.5kg-m...
  • Page 103 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed in the frame. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
  • Page 104 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Screw Left Crankcase Cover Remove the left crankcase cover bolts and left crankcase cover. Remove the gasket and dowel pins. Bolts Drive Pulley Face DRIVE PULLEY...
  • Page 105 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 17.0mm replace if below Use specified genuine parts for replace-ment. Drive Pulley Collar Remove the movable drive face assembly.
  • Page 106 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 20.42mm replace if below. Measure the movable drive face bushing I.D. Service Limit: 27.06mm replace if over Check the drive pulley bushing for wear or damage.
  • Page 107 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM ASSEMBLY Install the weight rollers into the movable drive face. Weight Roller Ramp Plate Install the ramp plate.
  • Page 108 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D.
  • Page 109 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor. Be sure to use a clutch spring comp ressor to avoid spring damage. Special Clutch Spring Compressor E027 Set the clutch spring compressor in a vise and remove the clutch drive plate nut.
  • Page 110 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Oil Sea Remove the oil seal from the movable driven face. INSPECTION Measure the driven face spring free length. Service Limit: 83.2mm replace if below Check the driven face for wear or damage. Measure the driven face O.D.
  • Page 111 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. Discard the removed bearing and replace with a new one. Outer Bearing Remove the snap ring and drive the outer bearing out of the driven face.
  • Page 112 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS CLUTCH / DRIVEN PULLEY ASSEMBLY 9-11...
  • Page 113 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Retainer Plate Drive Plate Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips. Clutch Weights/Shoes Springs Circlip...
  • Page 114 MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Clutch Spring Compressor Compress the clutch spring compressor and install the drive plate nut. Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque. Torque: 5.0 6.0kgf-m Be sure to use a clutch spring compressor to avoid spring damage.
  • Page 115 9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Left Crankcase Cover Install the left crankcase cover and tighten the cover bolts diagonally. Connect the drive belt air tube and tighten the band screw. Screw 9-14...
  • Page 116 . FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ FINAL REDUCTION/TRANSMISSION SYSTEM ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 10- 2 TROUBLESHOOTING----------------------------------------------------- 10- 2 FINAL REDUCTION DISASSEMBLY --------------------------------- 10- 3 FINAL REDUCTION INSPECTION------------------------------------- 10- 4 TRANSMISSION GEARS/CRANKSHAFT REMOVAL ------------- 10- 6 FINAL REDUCTION INSTALLATION -------------------------------- 10- 7 10-0...

  • Page 117: Final Reduction/Transmission System

    . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM 10-1...

  • Page 118: Final Reduction/Transmission System

    . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At change : 0.2 liter At disassembly : 0.4 liter TORQUE VALUES...

  • Page 119: Final Reduction Disassembly

    . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM FINAL REDUCTION DISASSEMBLY Drain engine oil and transmission gear oil into a clean container. Remove the engine. Remove the right crankcase cover. Bolts Starter Motor Flywheel Balance Gear Remove the shift gear spindle. Remove the flywheel and starter clutch.
  • Page 120 . FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM Remove gasket and two dowel pins. Dowel Pins FINAL REDUCTION/ TRANSMISSION INSPECTION Inspect the change gear shaft for wear, damage or seizure. Change Gear Shaft Check the transmission operation. Repair if unsmooth operation. Plug Remove the plug.
  • Page 121 . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM Shift Cam Stopper Remove spring, washer and shift cam stopper. Plug Transmission fork Remove the transmission fork shaft and transmission fork. Transmission fork shaft Measure the transmission fork shaft O.D. Service Limit: 11.936 Measure the transmission fork shaft hole I.D.
  • Page 122 . FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM Check the shift cam groove and shift cam gear. Replace if wear or damage. TRANSMISSION GEARS/ Countershaft Driver Shaft CRANKSHAFT REMOVAL Remove the final gear and main shaft. Main Shaft GEAR/SHAFT COLLAR INSPECTION Check each gear and gear teeth for wear, damage, or poor lubrication.

  • Page 123: Final Reduction Inspection

    . FINAL REDUCTION/ MX’er SYSTEM TRANSMISSION SYSTEM FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Countershaft Bearing Drive Shaft Inspect the drive shaft and gear for wear or damage. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
  • Page 124 . FINAL REDUCTION/ TRANSMISSION SYSTEM MX’er SYSTEM Transmission Fork Install the shift cam into the left crankcase. Install the transmission fork to the main shaft gear and install the transmission fork guide pin into the shift cam groove. Shift cam Install the transmission fork shaft into the left crankcase.
  • Page 125 Install and tighten the right case cover bolt. Install the shift gear spindle. Install the cylinder. Specified Gear Oil: KYMCO SIGMA GEAR OIL 90# Oil Capacity: At disassembly : 0.4 liter At change : 0.2 liter...
  • Page 126 CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ CRANKCASE/CRANKSHAFT/BALANCE SHAFT ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 11- 2 TROUBLESHOOTING----------------------------------------------------- 11- 2 CRANKCASE SEPARATION -------------------------------------------- 11- 3 CRANKSHAFT INSPECTION-------------------------------------------- 11- 4 CRANKCASE/BALANCE SHAFT ASSEMBLY ---------------------- 11- 5 11-0...

  • Page 127: Crankcase/Crankshaft

    CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM 11-1...

  • Page 128: Crankcase/Crankshaft/Balance Shaft

    CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. −Cylinder head ( Section 7) −Cylinder/piston ( Section 8) −Drive and driven pulleys ( Section 9) −A.C.

  • Page 129: Balance Shaft

    CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM CRANKCASE SEPARATION Remove the left and right crankcase attaching bolts. (Section 10) Separate the left and right crankcase halves. Do not damage the crankcase gasket surface. Crankcase Bolts Remove the gasket and dowel pins. Gasket Balance Shaft Dowel Pins Remover balance shaft from the left...

  • Page 130: Crankshaft Inspection

    CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM Remove the crankshaft and cam chain from the left crankcase. Gasket Clean off all gasket material from the crankcase mating surfaces. Avoid damaging the crankcase mating surfaces. CRANKSHAFT INSPECTION Measure the connecting rod small end I.D. Service Limit: 15.06 mm replace if over Measure the connecting rod big end side clearance.

  • Page 131: Crankcase/Balance Shaft Assembly

    CRANKCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM Turn the crankshaft bearings and check for Play excessive play. Play Measure the crankshaft bearing play. Service Limit: Axial : 0.20mm replace if over Radial : 0.05mm replace if over Radial Axial Measure the crankshaft run out. Service Limit: 0.10mm replace if over Crankshaft CRANKCASE/BALANCE SHAFT...
  • Page 132 CRANKSCASE/CRANKSHAFT/ BALANCE SHAFT MX’er SYSTEM Align the mark on the balance gear with the mark on the crankshaft gear. Right Case Cover Install the right and left case cover. Install the cylinder. Mark 11-6...
  • Page 133 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION\STEERING SYSTEM ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 12- 2 TROUBLESHOOTING----------------------------------------------------- 12- 3 FRONT WHEEL------------------------------------------------------------- 12- 4 FRONT BRAKE ------------------------------------------------------------- 12- 7 FRONT SUSPENSION ----------------------------------------------------- 12- 9 STEERING SYSTEM------------------------------------------------------- 12-13 12-0...

  • Page 134: Front Wheel/Front Brake/Front Suspension/Steering System

    . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM 12-1...

  • Page 135: Service Information

    . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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 136: Troubleshooting

    . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM SPECIAL TOOLS Oil seal and bearing install E014 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •Insufficient tire pressure • Bent rim • Excessive wheel bearing play • Bent spoke plate • Faulty tire •...

  • Page 137: Front Wheel/Front Brake/ Front Suspension/Steering

    . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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. Support the machine securely so there is no danger of it falling over.
  • Page 138 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM 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 139 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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 140 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Brake Lining FRONT BRAKE FRONT BRAKE LINING INSPECTION Measure the front brake lining thickness. Service limit: 2.0mm replace if below 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 141 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Install the brake shoe plate. Boss 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 142: Front Suspension

    . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Upper Bolt FRONT SUSPENSION REMOVAL Elevate the front wheels by placing a suitable stand under the frame. Support the machine securely so there is no danger of it falling over. Remove the front wheel, wheel hub, brake shoe plate.
  • Page 143 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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 144 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Inspect the steering knuckle. Replace if cracks, pitting or damage. Inspect the front arm. Replace if cracks, bends or damage. Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Bushes Inspect bushes.
  • Page 145 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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 146: Steering System

    . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM 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 147 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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 148 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM Steering Column Collar Cable Holder Remove the two bolts to remove the cable holder, steering bracket, collars and steering column. Steering Bracket Bolts INSPECTION Inspect the handlebar. Replace if cracks, bends or damage. Inspect the steering column.
  • Page 149 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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 150 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM 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. Snap Ring Collar Dust Seal Bearing INSTALLATION Reverse the “REMOVAL”...
  • Page 151 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er 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. Always use a new cotter pin. Cotter Pin Install the tie rods and tighten the nut.
  • Page 152 . FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM MX’er SYSTEM • 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 153 . IGNITION SYSTEM MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ IGNITION SYSTEM ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 15- 2 TROUBLESHOOTING----------------------------------------------------- 15- 3 CDI UNIT INSPECTION--------------------------------------------------- 15- 4 IGNITION COIL------------------------------------------------------------- 15- 6 PULSER COIL --------------------------------------------------------------- 15- 7 15-0...

  • Page 154: Ignition System

    . IGNITION SYSTEM MX’er SYSTEM CDI Unit/Change Gear Control. Ignition Switch Spark Plug Ignition Coil A.C. Generator/ Pulser Coil IGNITION CIRCUIT PULSER COIL 15-1...

  • Page 155: Ignition System

    . IGNITION SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. • The ignition system adopts CDI unit , change gear control and the ignition timing cannot be adjusted. •...

  • Page 156: Troubleshooting

    . IGNITION SYSTEM MX’er SYSTEM 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 157 . IGNITION SYSTEM MX’er SYSTEM CDI unit. Measure the resistance between the terminals using the electric tester. • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper CDI Unit tester in an improper range may give false readings.

  • Page 158: Ignition Coil

    CDI Tester Ignition Coil . IGNITION SYSTEM Spark MX’er SYSTEM Window Connect the special connector to the CDI coupler and CDI tester. Switch Range Good CDI Faulty CDI ⎯⎯ 1. OFF No spark ⎯⎯ 2. P No spark CDI Unit Spark Plug 3.

  • Page 159: Pulser Coil

    . IGNITION SYSTEM MX’er SYSTEM Remove the front cover. Remove the spark plug cap. Disconnect the ignition coil wires. This test is to inspect the continuity of ignition coil. Measure the resistance between the ignition coil primary coil terminals. Resistance: 0.2 0.3Ω/20 Remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and the primary coil terminal.
  • Page 160 . IGNITION SYSTEM MX’er SYSTEM Remove the front cover. Disconnect the pulser coil wire coupler and measure the resistance between the blue/ yellow and green/white wire terminals. Resistance: 50 60Ω EXCITER COIL INSPECTION Disconnect the exciter coil wire coupler and measure the resistance between the black/red wire terminal and ground.

  • Page 161: Starting System

    . STARTING SYSTEM MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ STARTING SYSTEM ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 16- 2 TROUBLESHOOTING----------------------------------------------------- 16- 2 STARTER MOTOR --------------------------------------------------------- 16- 3 STARTER RELAY---------------------------------------------------------- 16- 5 16-0...
  • Page 162 . STARTING SYSTEM MX’er SYSTEM Stop Switches Starter Button Ignition S it h Fuse/Battery/Starter Relay Starter Motor STARTING CIRCUIT 16-1...

  • Page 163: Starting System

    . STARTING SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to Section 4. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5 TROUBLESHOOTING Starter motor won‘t turn...

  • Page 164: Starter Motor

    . STARTING SYSTEM MX’er SYSTEM STARTER MOTOR REMOVAL Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 165 . STARTING SYSTEM MX’er SYSTEM STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary.

  • Page 166: Starter Relay

    . STARTING SYSTEM MX’er SYSTEM Commutator ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover. •...
  • Page 167 . STARTING SYSTEM MX’er SYSTEM STARTER MOTOR INSTALLATION Connect the starter motor cable connector and properly install the waterproof rubber jacket. Check the O-ring for wear or damage and replace if necessary. Apply grease to the O-ring and install the starter motor.
  • Page 168 . LIGHTS/ SWITCHES MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ LIGHTS/SWITCHES ____________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 17- 2 TROUBLESHOOTING----------------------------------------------------- 17- 2 HEADLIGHT ---------------------------------------------------------------- 17- 3 INSTRUMENTS/STOP LIGHT/TAILLIGHT -------------------------- 17- 4 IGNITION SWITCH -------------------------------------------------------- 17- 5 STOP SWITCH -------------------------------------------------------------- 17- 5 STARTER BUTTON-------------------------------------------------------- 17- 6 HEADLIGHT SWITCH ---------------------------------------------------- 17- 6 ENGINE STOP SWITCH -------------------------------------------------- 17- 6 17-0...

  • Page 169: Lights/Switches

    . LIGHTS/ SWITCHES MX’er SYSTEM ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Switch/ Starter Button Ignition Switch Taillight/Stop Light Headlight 17-1...

  • Page 170: Lights/Switches

    . LIGHTS/ SWITCHES MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • An electric tester is needed to measure or test the electric equipment. • Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment. •...

  • Page 171: Headlight

    . LIGHTS/ SWITCHES MX’er SYSTEM HEADLIGHT Cover 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 172 . LIGHTS/ SWITCHES MX’er SYSTEM Headlight Bulb Remove the headlight bulb INSTALLATION Install the headlight in the reverse order of removal. After installation, adjust the headlight beam. Bulb Socket Light Shell INSTRUMENTS REMOVAL Remove the two headlight attaching bolts. Remove the headlight and disconnect the headlight wire coupler.

  • Page 173: Ignition Switch

    . LIGHTS/ SWITCHES MX’er SYSTEM Bulb Remove the bulb and check the bulb for 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 174: Starter Button

    . LIGHTS/ SWITCHES MX’er SYSTEM Yellow/Brown Yellow/ Red STARTER BUTTON Remove the center cover. Disconnect the starter button yellow/brown and yellow/red wires. Check for continuity between the black and yellow/red wires. Color Yellow/Brown Yellow/Red Position FREE ○ ○ PUSH Starter Button White Black Brown...
  • Page 175 . LIGHTS/ SWITCHES MX’er SYSTEM 17-7...

  • Page 176: Only Atv On Road Available

    . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM __________________________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ONLY ATV ON ROAD AVAILABLE ____________________________________________________________________ WARING DIAGRAM ------------------------------------------------------ 18- 1 BRAKE PEDAL ADJUSTMENT ----------------------------------------- 18- 2 INSTRUMENT -------------------------------------------------------------- 18- 3 INDICATOR LIGHT-------------------------------------------------------- 18- 3 HAZARD SWITCH --------------------------------------------------------- 18- 4 HORN ------------------------------------------------------------------------- 18- 4 18-0...
  • Page 177 . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM WIRING DIAGRAM 18-1...

  • Page 178: Brake Pedal Adjustment

    . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM BRAKE PEDAL ADJUSTMENT Brake Pedal The brake pedal free play should be adjusted to 10~20 mm (0.4~0.8 in) at the brake pedal pivot. If the free play is incorrect, adjust as Follows: 10~20mm Keep front brake lever free play at 10~20 mm (0.4~0.8 in).

  • Page 179: Instrument

    . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM INSTRUMENT REMOVAL Remove the two instrument attaching screws. Disconnect the instrument. Screws Battery Cover Remove battery cover on instrument back to replace battery. After replace battery, the instrument will be reset. (Refer to owner’s manual) Speed Wheel SENSOR WHEEL If the sensor is lost or wore, the speed will...

  • Page 180: Hazard Switch

    . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM Bulb Socket Remove the bulb socket and bulb. Check the bulb for damage and replace with a new one if necessary. INSTALLATION The installation sequence is the reverse of removal. Bulb HAZARD SWITCH Check for continuity between the wires indicated below.
  • Page 181 . ONLY ATV ON ROAD AVAILABLE MX’er SYSTEM 18-5...

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Mx150

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