•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. The working area
must be well-ventilated and do not smoke or allow flames or sparks near the working area or
fuel storage area.
SPECIFICATIONS
ENGINE
Throttle grip free play : 1~4 mm (0.04~0.16 in)
Spark plug gap: 0.6~0.7 mm (0.002~0.003 in)
Spark plug: Standard: DPR7EA-9
Valve clearance: IN: 0.1 mm (0.004 in)
EX: 0.1 mm (0.004 in)
Idle speed: 1500±100 rpm
Engine oil capacity:
At disassembly : 1.6 liter (1.4 lmp qt, 1.7 Us qt)
At change: 1.4 liter (1.23 lmp qt, 1.48 Us qt)
Gear oil capacity:
At disassembly : 400 cc (0.35 lmp qt, 0.42 Us qt)
At change: 300 cc (0.26 lmp qt, 0.32 Us qt)
Cylinder compression : 15±2 kg/cm²
Ignition timing: BTDC 5°±1°/2000 rpm
This chapter includes all information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, if followed, will ensure more reliable
vehicle operation and a longer service life. The need for costly overhaul work will be greatly
reduced. This information applies to vehicles already in service ad well as new vehicles that are
being prepared for sale. All service technicians should be familiar with this entire chapter.
MXU 250
•In the interest of safety, we recommend these items should be serviced only by an authorized
KYMCO motorcycle dealer.
3-2
3. INSPECTION/ADJUSTMENT
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FUEL LINE
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.
MXU 250
Fuel Filte
Fuel tubes
THROTTLE OPERATION
Check the throttle to swing for smooth
movement.
Measure the throttle to swing free play.
Free Play (A): 1~4 mm (0.04~0.16 in)
To adjust throttle free play:
Slide the rubber sleeve back to expose the
throttle cable adjuster.
Loosen the lock nut, then turn the adjuster
to obtain the correct free play. (1~4 mm or
0.04~0.16 in)
Tighten the lock nut and reinstall the sleeve.
AIR CLEANER
AIR CLEANER REPLACEMENT
Remove the seat. (See page 2-3)
Unlatch the four retainer clips (1) and
remove the air cleaner housing cover (2).
Lock nu
Rubber sleeve
Cable adjuste
3-3
3. INSPECTION/ADJUSTMENT
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Unscrew (3) the clamp (5) and remove the
air cleaner assembly (4) from the air cleaner
housing.
MXU 250
Remove the screw and remove the air
cleaner assembly from the air cleaner
holder.
Remove the air cleaner and air cleaner
screen from the air cleaner body.
Remove the air cleaner net from the air
cleaner.
ScrewAir Cleaner Holde
Air Cleane
Reassemble by reversing the disassembly
sequence.
Air Cleaner screen
Air Cleaner body
3-4
3. INSPECTION/ADJUSTMENT
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CLEAN AIR FILTER ELEMENT
Wash the element gently, but throughly in
solvent.
*
Use parts cleaning solvent only. Neve
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 foa
element. This could damage the foam
material.
Apply the engine oil.
Squeeze out the excess oil.
*
The element should be wet but not
dripping.
More frequent replacement is required when
riding in unusually dusty or rainy areas.
MXU 250
AIR CLEANER HOUSING DRAIN
Remove the drain tube (under air cleaner
case) by removing the clip.
Drain the deposits.
Reinstall the drain tube, securing it with the
clip.
AIR FILTER FOR DRIVE BELT
To clean the air filter:
Remove front center cover. (See page 2-7)
Remove air filter.
Tap the element lightly to remove most of
the dust and dirt.
Blow out the remaining dirt with
compressed air.
Drain Tube
Air Cleaner Housing
Clip
Installation is in the reverse order of
removal.
If necessary replace the air filter.
3-5
Air Filte
3. INSPECTION/ADJUSTMENT
MXU 250
SECONDARY AIR SUPPLY
SYSTEM
This model is equipped with a built-in
secondary air supply system. The pulse
secondary air supply system is located on
the cylinder head cover.
The secondary air supply system introduces
filtered air into exhaust gases in the exhaust
port. The secondary air is drawn into the
exhaust port whenever there is negative
pressure pulse in the exhaust system. This
charged secondary air promotes burning of
the unburned exhaust gases and changes a
considerable amount of hydrocarbons and
carbon monoxide into relatively harmless
carbon dioxide and water.
Check the PAIR (pulse secondary air
injection) hoses between the PAIR control
solenoid valve and cylinder head cover for
deterioration, damage or loose connections.
Make sure the hoses are not cracked.
If the hoses show any signs of heat damage,
inspect the PAIR check valve in the PAIR
reed valve cover damage.
Vacuum Hose
PAIR Control solenoid Valve
Air Supply HosePAIR Check Valve
SPARK PLUG
Remove ignition coil cap and spark plug.
Check the spark plug for wear and fouling
deposits.
Clean any fouling deposits with a spark
plug cleaner or a wire brush.
Specified Spark Plug:DPR7EA-9
Ignition Coil Cap
Spark Plug
3-6
3. INSPECTION/ADJUSTMENT
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MXU 250
Measure the spark plug gap.
Spark Plug Gap: 0.6~0.7 mm (0.002~
0.003 in)
*
When installing, first screw in the spar
plug by hand and then tighten it with a
spark plug wrench.
VALVE CLEARANCE
*
Inspect and adjust valve clearance while
the engine is cold (below 35℃).
Gap, Wear, and Fouling Deposits
Washer Deformation
Cylinder Head Cove
Cracks, Damage
Remove the cylinder head cover. (See
chapter 7)
Turn the flywheel clockwise so that the “T”
mark on the flywheel aligns with the index
mark on the right crankcase cover to bring
the round hole on the camshaft gear facing
up to the top dead center on the
compression stroke.
Inspect and adjust the valve clearance.
Valve Clearance: IN: 0.1 mm (0.004 in)
EX: 0.1 mm (0.004 in)
“T” MarkIndex Mark
3-7
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