OWNER'S 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.
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.
WARNING
CAUTION
Note:
Indicates a strong possibility that serious injury or death may result if instructions are not followed.
Indicates a possibility that equipment or property damage could result if instructions are not followed.
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:
WARNING
Indicates a strong possibility that serious injury or death may 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 |
LOCATION OF THE WARNING AND |
|
SPECIFICATION LABELS |
...................1 |
SAFETY INFORMATION...................... |
7 |
DESCRIPTION AND MACHINE |
|
IDENTIFICATION................................ |
13 |
IDENTIFICATION NUMBER |
|
RECORDS.......................................... |
13 |
KEY IDENTIFICATION NUMBER......... |
13 |
FRAME SERIAL NUMBER................... |
14 |
ENGINE SERIAL NUMBER.................. |
14 |
PARTS LOCATION............................. |
15 |
|
Page |
CONTROL FUNCTIONS.................... |
20 |
IGNITION SWITCH/HEADLIGHT & |
|
POSITION LIGHT SWITCH.................. |
20 |
INSTRUMENTS AND INDICATOR........ |
21 |
Multi-function display....................... |
23 |
HANDLEBAR SWITCHES.................... |
31 |
Headlight dimmer switch.................. |
31 |
Start button..................................... |
32 |
Engine stop switch........................... |
33 |
Passing signal switch....................... |
34 |
RECOIL STARTER (MXU 300/250)....... |
35 |
KICK STARTER (MXU 150).................. |
36 |
THROTTLE LEVER............................. |
37 |
SPEED LIMITER................................. |
38 |
FRONT BRAKE .................................. |
39 |
REAR BRAKE .................................... |
39 |
(Cont'd)
D
|
Page |
PARKING BRAKE............................... |
40 |
DRIVE SELECT LEVER....................... |
41 |
FUEL TANK CAP ................................ |
42 |
FUEL VALVE...................................... |
43 |
CHOKE KNOB.................................... |
45 |
SEAT (MXU 300/250).......................... |
46 |
SEAT (MXU 150)................................. |
47 |
FLAG POLE BRACKET....................... |
48 |
TRAILER HITCH................................. |
48 |
STORAGE COMPARTMENT................ |
49 |
ACCESSORY SOCKET |
|
SEAT (MXU 300/250)........................... |
49 |
|
Page |
PRE-OPERATION CHECKS.............51 |
|
DRIVE SELECT LEVER ...................... |
52 |
Drive select lever adjustment............ |
54 |
FRONT AND REAR BRAKES................ |
56 |
FUEL............................................... |
57 |
ENGINE, TRANSMISSION OIL AND |
|
REAR FINAL GEAR CASE OIL.............. |
59 |
CHAIN.............................................. |
60 |
THROTTLE LEVER............................. |
60 |
FITTINGS AND FASTENERS............... |
60 |
LIGHTS.............................................. |
60 |
SWITCHES......................................... |
60 |
TIRES................................................ |
61 |
How to measure tire pressure ........... |
63 |
Tire wear limit ................................. |
63 |
COOLANT (MXU 300/250) ................... |
64 |
(Cont'd)
E
|
Page |
OPERATION........................................ |
66 |
STARTING A COLD ENGINE............... |
66 |
Using the recoil |
|
starter (MXU 300/250)...................... |
68 |
Using the kick starter (MXU 150)....... |
69 |
STARTING A WARM ENGINE.............. |
70 |
WARMING UP..................................... |
70 |
DRIVE SELECT 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 |
Page |
|
RIDING YOUR ATV ............................ |
81 |
GETTING TO KNOW YOUR ATV ......... |
82 |
RIDE WITH CARE AND GOOD |
|
JUDGEMENT...................................... |
83 |
APPAREL........................................... |
85 |
PRE-OPERATION CHECKS................ |
88 |
Speed limiter.................................... |
89 |
LOADING AND ACCESSORIES.......... |
90 |
Load Limits...................................... |
90 |
Loading and Operational Guidelines... |
90 |
Accessories..................................... |
91 |
MODIFICATIONS................................ |
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 SKIDDING................... |
105 |
CLIMBING UPHILL............................ |
107 |
RIDING DOWNHILL.......................... |
113 |
(Cont'd)
F
|
Page |
CROSSING A SLOPE........................ |
115 |
RIDING OVER ROUGH TERRAIN...... |
117 |
CROSSING TROUGH SHALLOW |
|
WATER............................................. |
118 |
PARKING......................................... |
119 |
WHAT TO DO IF ............................... |
120 |
WHAT TO DO .................................. |
120 |
|
Page |
PERIODIC MAINTENANCE AND |
|
ADJUSTMENT................................... |
122 |
TOOL KIT.......................................... |
122 |
PERIODIC MAINTENANCE/ |
|
LUBRICATION.................................. |
124 |
ENGINE OIL (MXU 300/250)............... |
126 |
ENGINE OIL (MXU 150)..................... |
130 |
TRANSMISSION OIL........................ |
135 |
REAR FINAL GEAR CASE |
|
OIL (MXU 300).................................. |
138 |
SPARK PLUG INSPECTION.............. |
140 |
AIR FILTER CLEANING..................... |
141 |
AIR CLEANER HOUSING DRAIN |
|
TUBE............................................... |
147 |
IDLE SPEED ADJUSTMENT ............. |
149 |
THROTTLE LEVER ADJUSTMENT.... |
150 |
VALVE CLEARANCE ADJUSTMENT..152 |
|
FRONT AND REAR BRAKE PADS |
|
INSPECTION (MXU 300/250)............. |
152 |
FRONT BRAKE SHOES |
|
INSPECTION (MXU 150)................... |
155 |
(Cont'd)
G
|
Page |
REAR BRAKE PADS |
|
INSPECTION (MXU 150)................... |
155 |
BRAKE FLUID INSPECTION............. |
156 |
FRONT BRAKE LEVER FREE PLAY |
|
ADJUSTMENT (MXU 150).................. |
158 |
COOLING SYSTEM |
|
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 SWING ARM |
|
LUBRICATION (MXU 250)................. |
165 |
KNUCKLE SHAFT & REAR SWING ARM |
|
LUBRICATION (MXU 150)................. |
166 |
BRAKE LEVER LUBRICATION.......... |
167 |
CABLE INSPECTION AND |
|
LUBRICATION.................................. |
167 |
H
Page |
|
DRAINING THE V-BELT |
|
COMPARTMENT............................... |
168 |
WHEEL REMOVAL............................ |
169 |
Wheel installation......................... |
169 |
BATTERY.......................................... |
170 |
Battery remove (MXU 300/250)....... |
171 |
Battery installation (MXU 300/250).. |
173 |
Battery remove (MXU 150)............. |
174 |
Battery installation (MXU 150)....... |
174 |
FUSE REPLACEMENT |
|
(MXU 300/250)................................. |
175 |
FUSE REPLACEMENT (MXU 150)..... |
176 |
HEADLIGHT BEAM ADJUSTMENT.... |
179 |
SPARK ARRESTER CLEANING........ |
180 |
TROUBLESHOOTING ....................... |
182 |
Troubleshooting chart................... |
183 |
(Cont'd)
|
Page |
CLEANING AND STORAGE |
...........184 |
A. CLEANING ................................... |
184 |
B. STORAGE .................................... |
186 |
SPECIFICATIONS (MXU 300/250)........... |
188 |
SPECIFICATIONS (MXU 150)................. |
192 |
NOISE REGULATION............................. |
196 |
MAINTENANCE RECORD....................... |
197 |
INDEX................................................... |
198 |
I
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
HANG TAG_GENERAL USE |
1. DECAL OF EPA |
2. CERTIFICATE LABEL OF SVIA |
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MXU 300 |
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For US
MXU 250
MXU 150
For France
1
2
1
(7-1): |
MXU 300/250 |
|
(4-1): |
MXU 300/250 |
(7-2): |
MXU 150 (6) |
(5) |
(4-2): |
MXU 150 |
(1) (2) |
(3-1): |
MXU 300/250 |
(8-1): |
MXU 300/250 |
|
(3-2): |
MXU 150 |
(8-2); |
MXU 150 |
2
Warning information
Anyone who rides the vehicle should read and understand this information before riding. They contain important information for safe and proper operation of your ATV.
The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements.
(1) |
(3-1)MXU 250/300 |
(2) MXU 150 |
MXU 250/300 |
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3
(3-2) MXU 150
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS
OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH.
OPERATING TIRE PRESSURE : Set with tires cold
Recommended : FRONT : 25~30kpa, (0.25~0.3kgf/cm2), 3.5~4.2psi REAR : 25~30kpa, (0.25~0.3kgf/cm2), 3.5~4.2psi
Never set tire pressure below recommended.
LOADING
Maximum Vehicle Load: 100Kg. (220 lbs).
Including weight of operator, cargo and accessories.
(4-1): MXU 300/250
CAUTION
Never carry passenger on This carrier.
Maximum load 30 Kg (66 lbs)
(4-2): MXU 150
CAUTION
Never carry passenger on This carrier.
Maximum load 20 Kg (44 lbs)
(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
CAUTION
Never carry passenger on This carrier.
Maximum load 20 Kg (44 lbs)
(7-2): MXU 150
CAUTION
Never carry passenger on
This carrier.
Maximum load 15 Kg (33 lbs)
(8-1): MXU 300
(8-1): MXU 250
WARNING
Exceeding vehicle towing limit could lead to an accident. Reduce speed when towing a trailer. Read owner's manual for details.
MAXIMUM TOWING CAPACITY: 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 CAPACITY: 100kg (220 lbs)
6
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. An accident can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
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, parking 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 this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.
Never attempt wheel, jump, or other stunt.
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 the ATV 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 the ATV.
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
ON
WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
HOW TO AVOID THE HAZARD
Always operate your machine in an area with adequate ventilation.
12
DESCRIPTION AND MACHINE IDENTIFICATION
IDENTIFICATION NUMBER RECORDS |
KEY IDENTIFICATION NUMBER |
Record the key identification number, frame |
The key identification number is stamped on |
serial number, engine serial number and |
the hang tag as shown in the following |
model code information for assistance when |
illustration. |
order replacement parts. |
|
|
KEY NO.
FRAME NO.
ENGINE NO.
(1)
MODEL CODE
(1) Key identification number
13
FRAME SERIAL NUMBER |
ENGINE SERIAL NUMBER |
The frame serial number is stamped on the |
The engine serial number is stamped on the left |
front of the frame. |
crankcase. |
(1)
(2)
(1) Frame serial number |
(2) Engine serial number |
14
PARTS LOCATION
(03) |
(05) |
(04) |
(03) |
(02) |
(01) |
(01) Rear cargo
(02) Rear brake lever
(03) Headlight/Position light
(04) Front cargo
(05) Front brake lever
15
(10) |
(09) |
(08) |
(07) |
(06) |
(06) Drive select lever
(07) Fuel valve (MXU 300/250)
(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 reservoir (MXU 300/250)
(11) (12) (13)
16
(17) (16) (15) (14)
(14) Exhaust system
(15) Tool kit
(16) Fuel valve (MXU 150)
(17) Choke knob
(18) Front wheel
(19) Recoil starter (MXU 300/250)
(20) Kick starter (MXU 150)
(21) Rear wheel
(18) |
(19) |
(21) |
|
(20) |
|
17
(26) |
(25) |
(24) |
(23) |
(22) |
(22) Parking brake
(23) Front brake fluid reservoir (MXU 300/250)
(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)
(27) |
(28) |
(29) |
(30) (31) |
(32) |
(33) |
18
(31) Flag pole bracket
NOTE:
The machine you have purchased may differ slightly from those shown in the figures of this manual.
(31)
19
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