Kymco MXU 150 User Manual
MXU 150/250/300 OFF-ROAD
Do not remove this Owner’s Manual from this ATV
according to the guidelines and agreement with the U.S.
Consumer Product Safety Commission.
Read this manual carefully.
It contains important safety information.
OWNER'S MANUAL
KYMCO is certificated to ISO9001, ISO13485, ISO14001, OHSAS18001, etc.; and
accredited to ISO17025. Details at http://www.kymco.com/
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.
RIDER TRAINING
Anyone who operates this vehicle should get proper instruction.
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only. This machine is
designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark
arrester laws and regulation in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this
machine.
A
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.
Indicates a strong possibility that serious injury or death may
WARNING
result if instructions are not followed.
CAUTION Indicates a possibility that equipment or property damage
could result if instructions are not followed.
Note: Gives helpful information
The Owner's Manual should be considered a permanent part of your ATV. It should
remain with the vehicle at all times and stay with the ATV if it is sold.
B
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.
This manual will provide you with a good basic understanding of the features and
operation of this machine. This manual includes important safety information. It
provides information about special techniques and skills necessary to ride your
machine. It also includes basic maintenance and inspection procedures. If you
have any questions regarding the operation or maintenance of your machine,
please consult a KYMCO dealer.
We wish you many years of safe and enjoyable riding.
While reading this manual, remember:
Indicates a strong possibility that serious injury or death may
WARNING
result if instructions are not followed.
All information in this publication is based on the latest product information
available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD
reserves the right to make changes at any time without notice and without
incurring any obligation.
C
CONTENTS
Page Page
LOCATION OF THE WARNING AND
SPECIFICATION LABELS...................1
SAFETY INFORMATION........ ............ ..7
DESCRIPTION AND MACHINE
IDENTIFICATION................................13
IDENTIF ICATION NUMBER
RECORDS....... ............................... ....13
KEY IDENTIFICATION NUMBER.........13
FRAME SERIAL NUMBER...................14
ENGINE SERIAL N UMBER..................14
PARTS LOCATION...................... .......15
CONTROL FUNCTIONS....... ............ .20
IGNITIO N SWITCH/HEADL IGHT &
POSITIO N LIGHT SWITCH.. ............ ....20
INSTRUMENTS AND INDICATOR........21
Multi-function display.......................23
HANDLEBAR SWITC HES......... ...........31
Headlight dimmer switch..................31
Start button................. ............ ........32
Engine stop switch.............. ............ .33
Passing signal switch....................... 34
RECOIL START ER (MXU 300/250 ).......35
KICK STARTER (MXU 150)..... .............36
THROTTL E LEVER ............ .................37
SPEED LIMI TER......... ........................38
FRONT BRAKE ........... .......................39
REAR BRAKE ........... .........................39
(Cont'd)
D
Page Page
PARKING BR AKE...............................40
DRIVE SELECT LEVER ............ ...........41
FUEL TANK CAP ................................42
FUEL VALVE......................................43
CHOKE KNOB....................................4 5
SEAT (MXU 300/2 50)..........................46
SEAT ( MXU 150 )........... ......................47
FLAG POLE BRACK ET.......................48
TRAILER HITCH. ............ ....................48
STORAGE COMPARTMENT............ ....49
ACCESSORY SO CKET
SEAT (MXU 300/25 0)...........................49
PRE-OPERATION CHECKS......... ....51
DRIVE SELECT LEVER ................... ...52
Drive select lever adjus tment....... .....54
FRONT AND RE AR BRAKES.............. ..56
FUEL... .. ....... .. ....... ......... ......... ....... .5 7
ENGINE, TRANSMISSION OIL AND
REAR FINAL GEAR CASE OIL..............59
CHAIN.................. .. .. ....................... .6 0
THROTTL E LEVER ............ .................60
FITTING S AND FASTENERS.. ............ .60
LIGHTS................... ................ ...........60
SWITCHES...... ...................................60
TI RES...... ......... ......... ......... ......... ......61
How to measure tire pr essure ...........63
Tire wea r limit .................................63
COOLANT (MXU 300/250) . ............ ......64
(Cont'd)
E
Page Page
OPERATION.... .................... ......... .......66
STARTING A COLD ENGINE. ............ ..66
Using the recoil
starter (MXU 300/250)......................68
Using the kic k s tarter (MXU 150).......69
STARTING A WARM ENGINE. ............ .70
WARMING UP........ .............................70
DRIVE SEL ECT LEVER OPERATION
AND REVERSE DRIVING... .................71
ENGINE BREAK-IN... ............ .............74
PARKING (MXU 300 /250)....................75
PARKING (MXU 150). .........................76
Parking on a slope...................... ......77
ACCESSORIES . .................................78
LOADING ............ ............ ...................79
RIDING YOUR ATV ...... ............ ..........81
GETTING TO K NOW YOUR ATV . ........82
RIDE WITH CARE AND
JU DGEMENT............ ......... ................ .83
AP PAREL................... ........................8 5
PRE-OPE RATION CHECKS............. ...88
Speed limiter
LOADING AND AC CESSORIES... .......90
Load Limits........................ ............ ..90
Loading and Operational Guidelines...90
Accessori es..... ....... .........................91
MO DIFICATI ONS...... ..........................92
No Modifications...................... ........92
EXHAUST SYSTEM..... ............ ...........93
BE CARFUL WHERE YOU RIDE..........94
FOR OFF-ROAD USE ONLY............... ..99
DURING OPERATION....... ................101
TURNING YOUR ATV.. ............ ...........103
SLIDING AND SK IDDING...... .............105
CLIMBIN G UP HILL........ ....................107
RIDING DOW NHILL....... ...................113
F
....... ............ .................89
GOOD
(Cont'd)
Page
CROSSIN G A SLOPE........................115
RIDING OVER ROUGH TERRAIN ......117
CROSSIN G TROUGH SHALLOW
WATE R...... .............................. ....... ..118
PARKING............... .. ................... .. ...119
WHAT TO DO IF ............ ...................120
WHAT TO DO ....... ...........................120
Page
PERIODIC MAINTENANCE AND
ADJUSTMENT.... ................ ....... ........122
TOOL KIT....... ...................................122
PERIODI C M AINTENANCE/
LU BRICATION.......... ........... .............124
ENGINE OIL (MXU 300/250)...............126
ENGINE OIL (MXU 150) ............ .........130
TRANSMISSION OIL.. ............ ..........135
REAR FINA L GEA R CASE
OIL (MXU 30 0)..................................138
SPARK PLUG INSPECT ION..............140
AIR FILTER C LEANING..... ................141
AIR CLEANER HOUSING DRAIN
TU BE......... .................... ........... .......147
IDLE SPEED ADJUSTMENT ........... ..149
THROTTL E LEVER ADJUSTMENT....150
VALVE CLEARANCE AD JUSTMENT..152
FRONT AND R EAR BRAKE PADS
INSPECTION (MXU 300/250) .............152
FRONT BRAKE SHOES
INSPECTION (MXU 150)...... .............155
(Cont'd)
G
Page Page
REAR BRAKE PADS
INSPECTION (MXU 150)...... .............155
BRAKE FLUID INSP ECTION...... .......156
FRONT BRAKE LEVER FREE PLAY
ADJUSTMENT (M XU 150)...... ............ 158
COOLING S YSTEM
INSPECTION (MXU 250)...... .............160
Engine overheating.......................161
DRIVE CHAIN SLACK CHECK
(MXU 250/150 )..................................162
Drive chain slack
adjustment (MXU 250)... ....................162
Drive chain slack
adjustment (MXU 150)... ....................164
DRIVE CHAIN CLEANING AND
LUBRICATION (MXU 250/150).......... .165
REAR SWIN G ARM
LUBRICATION (MXU 250).................165
KNUCKLE SHAFT & REAR SWING ARM
LUBRICATION (MXU 150).................166
BRAKE LEVER LUBRICATION..........167
CABLE INS PECTION AND
LU BRICATION.......... ........... .............167
DRAINING THE V-BELT
CO MPARTMEN T... ........... ........... ......168
WHEEL REMOVAL......... ............ .......169
Wheel installatio n.........................169
BATTERY..........................................170
Battery r emove (MXU 30 0/250).......171
Battery installation (MXU 300/250)..173
Battery remove (MXU 150)....... ......174
Battery installation (MXU 150). ......174
FUSE REPL ACEMENT
(MXU 300 /250)....... ............ ..............175
FUSE REPLACEMENT (MXU 150 ).....176
HEADLIGHT BEAM ADJUSTMEN T....179
SPARK ARRESTER CLEANING........180
TROUBLESHOOTING ......... ..............182
Troublesho oting chart...................183
(Cont'd)
H
Page
CLEANING AND STORAGE........... 184
A. CLEANING .. .................................184
B. STORAGE .... ................................186
SPECIFI CATIONS (MXU 300 /250)...........188
SPECIFI CATIONS (MXU 150). ................192
NOISE REGULATION... ............ ..............196
MAINTEN ANCE RECORD.... ............ .......197
IN DEX............. ......................... .............198
I
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
HANG TAG_GENERAL USE
1. DECAL OF EPA 2. CERTIFICATE LABEL OF SVIA
MXU 300
MXU 250
MXU 150
For US
For France
1
2
1
(7-1): MXU 300/250
(7-2): MXU 150
(6)
(5)
(4-1): MXU 300/250
(4-2): MXU 150
(2)(1) (8-1): MXU 300/250
(3-1): MXU 300/250
(3-2): MXU 150
2
(8-2); MXU 150
Warning information
Anyone who rides the vehicle should rea d and under stand this information before riding. They contain
important information for safe and proper operati on of your ATV.
The labels should b e considered as permanent parts of the vehicle. If a label comes off o r becomes hard
to read, contact your KYMCO dealer for replacements.
(1)
(2)
MXU 150
(3-1)MXU 250/300
MXU 250/300
3
(3-2) MXU 150
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS
OF CONTROL.
LOSS OF CONTROL CAN RESULT IN S EVE RE IN JURY OR DEATH.
OPERATING TIRE PRESSURE : Set with tires cold
‧Recommended : FRONT : 25~30kpa, (0.25~0.3kgf/cm ) , 3.5 ~4. 2ps i
REAR :
‧Never set tire pressure below recommended.
LOADING
‧Maximum Vehicle Load: 100Kg. (220 lbs).
Including weight of operator, cargo and accessories.
25~30kpa, (0.25~0.3kgf/cm ), 3.5~4.2psi
2
2
(4-1): MXU 300/250
CAUTION
．Never carry passenger
This carrier.
．Maximum load：30 Kg (66 lbs)
(4-2): MXU 150
on
CAUTION
．Never carry passenger
This carrier.
．Maximum load：20 Kg (44 lbs)
on
(5)
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.
4
(6)
5
(7-1): MXU 300/250
(8-1): MXU 250
CAUTION
．Never carry passenger
This carrier.
．Maximum load：20 Kg (44 lbs)
(7-2): MXU 150
on
CAUTION
．Never carry passenger
This carrier.
．Maximum load：15 Kg (33 lbs)
(8-1): MXU 300
on
WARNING
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner's manual for details.
MAXIMUM TOWING CAPAC ITY: 150kg (331 lbs)
TONGUE WEIGHT: 14kg (30 lbs)
(8-2): MXU 150
WARNING
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner's manual for details.
MAXIMUM TOWING CAPAC ITY: 100kg (220 lbs)
6
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV han dles diff erently fro m
other v ehicles including motorcycles and cars. An accident can occur quickly, even during routine
maneuvers such as turni ng and riding on hills or over obstacles, if you fail to take p roper pre-cautions .
SEVERE IN JURY OR DEATH can result if you do not follow these instructions:
‧Read this manual and all labels carefully and follow the operating procedures described.
‧Never operate an ATV without proper training or instruction.
Beginners should receive training from a certified instructor.
‧Always follow the age recommendation:
An operator over 14 years old or older under adult supervision could be permitted for operating an
ATV with engine size greater than 150cc.
‧Never carry a passenger on an ATV.
‧Always avoid operating an ATV on any paved surfaces, including sidewalks , driveways, par king
lots and streets.
‧Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
7
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
Never consume alcohol or drugs before or while operating thisATV.
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.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced
the skills necessary to control theATV on such terrain. Always be especially cautious on these
kinds of terrain.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating theATV.
8
Always follow proper procedures for climbing hills as described in this manual. Check the terrain
carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high
speed.
Always follow proper procedures for going down hills and for braking on hills as described in this
manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
Never operate the ATV on hills too steep. Practice on smaller hills before attempting larger hills.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,
maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed
straight uphill. Turn the ATV around and remount, following the procedure described in this
manual.
9
Always check for obstacles before operating in a new area. Never attempt to operate over large
obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating
over obstacles as described in this manual.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of
control.
Always be sure there are no obstacles or people behind you when you operate in reverse. When it
is safe to proceed in reverse, go slowly.
Always use the size and type tires specified in this manual. Always maintain proper tire pressure
as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow
greater distance for braking.
10
WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be
burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or exhaust
pipe/muffler when refueling.
Never refuel while smoking, or while in the
vicinity of sparks, open flames, or other
sources of ignition such as the pilot lights of
water heaters and clothes dryers.
When transporting the machine in another
vehicle, be sure it is kept upright and that the
fuel valve is in the "OFF" position.
Otherwise, fuel may leak out of the carburetor
or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immediately.
If gasoline spills on your skin, wash with soap
and water. If gasoline spills on your clothing,
change your clothes.
11
WARNING
POTENTIAL HAZARD
ON
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.
12
DESCRIPTION AND MACHINE IDENTIFICATION
IDENTIFICATION NUMBER RECORDS
Record the key identification number, frame
serial number, engine serial number and
model code information for assistance when
order replacement parts.
KEY NO.
FRAME NO.
ENGINE NO.
MODEL CODE
KEY IDENTIFICATION NUMBER
The key identification number is stamped on
the hang tag as shown in the following
illustration.
(1)
(1) Key identification number
13
FRAME SERIAL NUMBER
The frame serial number is stamped on the
front of the frame.
(1)
(1) Frame serial number (2) Engine serial number
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left
crankcase.
(2)
14
PARTS LOCATION
(01)(03) (02)(04)(05)(03)
(01) Rear cargo
2) Rear brake lever
(0
(03)
Headlight/Position light
(04)
Front cargo
(05) Front brake lever
15
(12)(11) (13)
(06)(07)(10) (08)(09)
(06)
Drive select lever
) Fuel valve (MXU 300/250)
(07
(08)
Seat
(09) Battery (MXU 150)
(10) Taillight/Stop light
(11) Battery (MXU 300/250)
(12) Reservoir water tank (MXU 300/250)
(13) Rear brake pedal fluid r
16
eservoir (MXU 300/250)
(17) (14)(15)
(16)
(20)
(14)
Exhaust system
(15) Tool kit
(16) Fuel valve (MXU 150)
) Choke knob
(17
(18)
Front wheel
(19) Recoil starter (MXU 300/250)
(20) Kick starter (MXU 150)
(21) Rear wheel
(21)(18) (19)
17
(23)
(24)(25)(26)
(22)
(22) Parking brake
) Front brake fluid reservoir (MXU 300/250)
(23
(24) Instrument and indicators
(25) Accessory socket seat (MXU 300/250)
(26) Rear brake fluid reservoir
(27) Headlight dimmer switch
Starter button
Engine stop switch
Passing signal switch
(28)
Left operator footpeg
(29)
Ignition switch/Headlight switch
/Position light switch
(30)
Fuel fill cap
(31) Throttle lever
(32)
Right operator footpeg
(33) Rear brake pedal (MXU 300/250)
(28) (32)
(30)
(33)(27) (31)(29)
18
(31)
(31) Flag pole bracket
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
19
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