OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 250/150/50
ON-ROAD
Issued: 23.DEC.2005
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 ON-ROAD USE ONLY
This machine is designed and manufactured for ON-ROAD use only. It is illegal and unsafe to operate this machine on any hills and rough or loose terrain.
This machine complies with all applicable ON-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
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CONTENTS |
Page |
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LOCATION OF THE WARNING AND |
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SPECIFICATION LABELS................... |
1 |
SAFETY INFORMATION...................... |
5 |
DESCRIPTION AND MACHINE |
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IDENTIFICATION................................ |
10 |
IDENTIFICATION NUMBER |
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RECORDS.......................................... |
10 |
KEYS IDENTIFICATION NUMBER........ |
10 |
FRAME SERIAL NUMBER................... |
11 |
ENGINE SERIAL NUMBER |
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(MXU 250/150).................................... |
11 |
ENGINE SERIAL NUMBER (MXU 50).... |
12 |
PARTS LOCATION (MXU 250)............. |
13 |
PARTS LOCATION (MXU 150/50)......... |
19 |
D
Page |
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REAR BRAKE LEVER.......................... |
45 |
BRAKE PEDAL (MXU 250/150)............. |
45 |
PARKING BRAKE (MXU 250)............... |
46 |
PARKING BRAKE (MXU 150/50)........... |
46 |
LOCKING STEERING (MXU 250/150)... |
48 |
DRIVE SELECT LEVER....................... |
49 |
FUEL TANK CAP ................................ |
49 |
FUEL VALVE...................................... |
50 |
CHOKE KNOB (MXU 250/150).............. |
52 |
SEAT (MXU 250)................................. |
53 |
SEAT (MXU 150/50)............................. |
54 |
FLAG POLE BRACKET....................... |
55 |
TRAILER HITCH (MXUN 250/150)....... |
55 |
STORAGE COMPARTMENT................. |
56 |
ACCESSORY SOCKET |
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SEAT (MXU 250)................................. |
56 |
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Page |
PRE-OPERATION CHECKS.............58 |
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DRIVE SELECT LEVER ...................... |
59 |
Drive select lever adjustment............ |
61 |
FRONT AND REAR BRAKES................ |
63 |
FUEL............................................... |
64 |
ENGINE OIL (MXU 250/150)................. |
66 |
ENGINE OIL (MXU 50)......................... |
67 |
TRANSMISSION OIL .......................... |
68 |
CHAIN.............................................. |
69 |
THROTTLE LEVER............................. |
69 |
FITTINGS AND FASTENERS............... |
69 |
LIGHTS.............................................. |
69 |
SWITCHES......................................... |
69 |
TIRES................................................ |
70 |
How to measure tire pressure ........... |
72 |
Tire wear limit ................................ |
72 |
COOLANT (MXU 250)......................... |
73 |
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(Cont'd) |
E
Page |
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OPERATION........................................ |
75 |
STARTING A COLD ENGINE............... |
75 |
Using the recoil starter (MXU 250)..... |
77 |
Using the kick starter (MXU 150/50).... |
78 |
STARTING A WARM ENGINE.............. |
79 |
WARMING UP..................................... |
79 |
DRIVE SELECT LEVER OPERATION |
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AND REVERSE DRIVING.................... |
80 |
ENGINE BREAK-IN............................ |
82 |
PARKING (MXU 250)........................... |
83 |
PARKING (MXU 150/50)...................... |
84 |
Parking on a slope............................ |
85 |
ACCESSORIES .................................. |
86 |
LOADING ........................................... |
87 |
Page |
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RIDING YOUR ATV ............................ |
89 |
GETTING TO KNOW YOUR ATV ......... |
90 |
RIDE WITH CARE AND GOOD |
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JUDGEMENT...................................... |
91 |
APPAREL........................................... |
95 |
PRE-OPERATION CHECKS................ |
97 |
LOADING AND ACCESSORIES.......... |
99 |
Loading and operational guidelines... |
99 |
Accessories................................... |
100 |
MODIFICATIONS.............................. |
101 |
No modifications............................. |
101 |
DURING OPERATION........................ |
102 |
EXHAUST SYSTEM........................... |
104 |
PRACTICING.................................... |
105 |
SPEED LIMITER FOR NEW RIDERS... |
106 |
BRAKING......................................... |
107 |
TURNING YOUR ATV ....................... |
108 |
CLIMBING UP SLOPE........................ |
109 |
RIDING DOWN SLOPE...................... |
115 |
PARKING.......................................... |
116 |
WHAT TO DO IF ................................ |
117 |
WHAT TO DO .................................... |
117 |
(Cont'd)
F
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Page |
PERIODIC MAINTENANCE AND |
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ADJUSTMENT................................... |
118 |
TOOL KIT.......................................... |
118 |
PERIODIC MAINTENANCE/ |
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LUBRICATION.................................. |
120 |
ENGINE OIL (MXU 250) ..................... |
122 |
ENGINE OIL (MXU 150) ..................... |
126 |
TRANSMISSION OIL......................... |
130 |
SPARK PLUG INSPECTION.............. |
133 |
AIR FILTER CLEANING..................... |
134 |
AIR CLEANER HOUSING DRAIN |
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TUBE (MXU 250/150)........................ |
142 |
IDLE SPEED ADJUSTMENT ............. |
144 |
THROTTLE LEVER ADJUSTMENT.... |
145 |
VALVE CLEARANCE ADJUSTMENT..147 |
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FRONT AND REAR BRAKE PADS |
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INSPECTION (MXU 250)................... |
147 |
FRONT BRAKE SHOES |
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INSPECTION (MXU 150/50)............... |
149 |
REAR BRAKE PADS |
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INSPECTION (MXU 150/50)............... |
149 |
BRAKE FLUID INSPECTION............. |
150 |
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Page |
FRONT BRAKE LEVER FREE PLAY |
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ADJUSTMENT (MXU 150/50)............. |
152 |
REAR BRAKE LEVER FREE PLAY |
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ADJUSTMENT (MXU 150).................. |
154 |
BRAKE PEDAL |
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ADJUSTMENT (MXU 150).................. |
155 |
COOLING SYSTEM |
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INSPECTION (MXU 250).................... |
159 |
Engine overheating........................ |
160 |
DRIVE CHAIN SLACK CHECK............. |
161 |
Drive chain slack |
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adjustment (MXU 250).................. |
161 |
Drive chain slack |
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adjustment (MXU 150/50).............. |
163 |
DRIVE CHAIN CLEANING AND |
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LUBRICATION.................................. |
164 |
REAR SWING ARM |
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LUBRICATION (MXU 250).................. |
164 |
KNUCKLE SHAFT & REAR SWING |
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ARM LUBRICATION (MXU 150/50)..... |
165 |
(cont'd)
G
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Page |
BRAKE LEVER LUBRICATION........... |
166 |
CABLE INSPECTION AND |
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LUBRICATION.................................. |
166 |
DRAINING THE V-BELT |
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COMPARTMENT (MXU 250/150)........ |
167 |
WHEEL REMOVAL............................ |
168 |
Wheel installation......................... |
168 |
BATTERY.......................................... |
169 |
Battery remove (MXU 250)............ |
170 |
Battery installation (MXU 250)....... |
172 |
Battery remove (MXU 150/50)........ |
173 |
Battery installation (MXU 150/50)... |
173 |
FUSE REPLACEMENT (MXU 250)...... |
174 |
FUSE REPLACEMENT (MXU 150/50).175 |
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HEADLIGHT BEAM ADJUSTMENT.... |
178 |
TROUBLESHOOTING ....................... |
179 |
Troubleshooting chart................... |
180 |
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Page |
CLEANING AND STORAGE |
...........181 |
A. CLEANING ................................... |
181 |
B. STORAGE .................................... |
183 |
SPECIFICATIONS (MXU 250/150)........... |
185 |
SPECIFICATIONS (MXU 50)................... |
189 |
NOISE REGULATION............................. |
193 |
MAINTENANCE RECORD....................... |
194 |
INDEX................................................... |
195 |
H
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LOCATION OF THE WARNING AND |
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SPECIFICATION LABELS |
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(1-1): MXU 250 |
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(4-1): MXU 250 |
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(1-2): MXU 150/50 (2) |
(3) |
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(4-2): MXU 150/50 |
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(6-1): |
MXU 250/150 |
(5-1): |
MXU 250 |
(7-1): MXU 250 |
(8): MXU 50 |
(6-2): |
MXU 50 |
(5-2): |
MXU 150/50 |
(7-2): MXU 150 |
|
1
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.
(1-1): MXU 250
CAUTION
Never carry passenger on This carrier.
Maximum load 20 Kg (44 lbs)
(1-2): MXU 150/50
CAUTION
Never carry passenger on This carrier.
Maximum load 15 Kg (33 lbs)
(2)
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
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NEVER USE |
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ALWAYS USE |
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AN |
WITH DRUGS |
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APPROVED |
OR ALCOHOL |
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HELMET AND |
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PROTECTIV |
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E GEAR |
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NEVER operate :
Without proper training or instruction.At speeds too fast for your skills or
the conditions.
Do not operate the vehicle after consuming ALCOHOL OR DRUGS.
ALWAYS :
Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns.
For your safety, wear gear to include helmet gloves and foot protection.
Gasoline is flammable shut off engine, avoid sparks and open flame when refueling.
READ OWNER'S MANUAL, FOLLOW ALL INSTRUCTIONS AND WARNINGS.
2
(3)
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.
(4-1): MXU 250
CAUTION
Never carry passenger on This carrier.
Maximum load 30 Kg (66 lbs)
(4-2): MXU 150/50
CAUTION
Never carry passenger on This carrier.
Maximum load 20 Kg (44 lbs)
(5-1): MXU 250
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 : 25~32kpa, (0.25~0.32kgf/cm2), 3.5~4.5psi REAR : 25~32kpa, (0.25~0.32kgf/cm2), 3.5~4.5psi
Never set tire pressure below recommended.
(5-2): MXU 150/50
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.
3
(6-1): MXU 250/150
WARNING
Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 16.
(6-2): MXU 50
WARNING
UNDER
6
Operating this ATV if you are under the age of 6 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 6.
(7-1): 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)
(7-2): 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)
(8): MXU 50
4
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or instruction. Beginners should receive training from a certified instructor.
Always follow the age recommendation:
-A child under 6 years old should never operate an ATV with engine size greater than 70cc.
-A child under 12 years old should never operate an ATV with engine size greater than 90cc.
-A child under 16 years old should never operate an ATV with engine size greater than 90cc.
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
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.
5
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 go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain.
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 the ATV on hills.
Always follow proper procedures for climbing slopes as described in this manual. Check the terrain carefully before you start up any slope. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a slope at high speed.
6
Always follow proper procedures for going down slopes and for braking on slopes as described in this manual. Check the terrain carefully before you start down any slope. Shift your weight backward. Never go down a slope at high speed. Avoid going down slope at an angle that would cause the vehicle to lean sharply to one side. Go straight down the slope where possible.
Never attempt to turn the ATV around on any slope until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep slope if possible.
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.
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.
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 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.
7
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 cock 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.
8
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.
9
DESCRIPTION AND MACHINE IDENTIFICATION
IDENTIFICATION NUMBER RECORDS
Record the keys identification number, frame serial number and engine serial number information for assistance when order replacement parts.
IGNITION SWITCH KEY NO.
MXU 250/150: STEERING LOCK KEY NO.
FRAME NO.
ENGINE NO.
KEYS IDENTIFICATION NUMBER
The keys identification number is stamped on the hang tag as shown in the following illustration.
(1)
(2)
(1)Ignition switch key identification number
(2)MXU 250/150: Steering lock key identification
number
10
FRAME SERIAL NUMBER |
ENGINE SERIAL NUMBER (MXU 250/150) |
The frame serial number is stamped on the |
The engine serial number is stamped on the left |
front of the frame. |
crankcase. |
(1)
(2)
(1) Frame serial number |
(2) Engine serial number |
11
ENGINE SERIAL NUMBER (MXU 50)
The engine serial number is stamped on the right crankcase. 
(2)
(2) Engine serial number
12
PARTS LOCATION (MXU 250)
(03) |
(02) |
(02) |
(01) |
(01) Rear brake lever
(02) Headlights/Position lights
(03) Front brake lever
(04) Right front turn signal light
(05) Steering handlebar lock
(06) Left front turn signal light
(04) |
(05) |
(06) |
13
(10)(08) (09) (08)(07)
(07) Right rear turn signal light
(08) Taillights/Stop lights
(09) Instrument and indicators
(10) Left rear turn signal light
(11) Exhaust system
(12) Trailer hitch
(13) License light
(14) Battery
(11) (12) (13) (14)
14
(18) |
(17) |
(16) |
(15) |
(15) Drive select lever
(16) Fuel valve
(17) Seat
(18) Tool kit
(19) Reservoir water tank
(20) Brake pedal fluid reservoir
(19) (20)
15
(22) |
(21) |
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(21) Exhaust system
(22) Choke knob
(23) Recoil starter
(23)
16
(30) |
(29) |
(28) |
(27) |
(26) |
(25) |
(24) |
(24) Front brake lever/Parking brake
(25) Front cargo rack
(26) Front brake fluid reservoir
(27) Ignition switch
(28) Rear brake fluid reservoir
(29) Accessory socket seat
(30) Rear brake lever
(31) Headlight dimmer switch Starter button
Hazard switch Turn signal switch Horn switch
(32) Left footpeg
(33) Fuel fill cap
(34) Throttle lever
(35) Right footpeg
(36) Rear brake pedal
(31) |
(32) |
(33) |
(34) |
(35) |
(36) |
17
(37) Rear cargo rack
(38) Flag pole bracket
NOTE:
The machine you have purchased may differ slightly from those shown in the figures of this manual.
(37)(38)
18
PARTS LOCATION (MXU 150/50)
(03) |
(02) |
(02) |
(01) |
(01) Rear brake lever
(02) Headlights/Position lights
(03) Front brake lever/Parking brake
(04) Right front turn signal light
(05) MXU 150: Steering handlebar lock
(06) Left front turn signal light
(04) |
(05) |
(06) |
19
(09) |
(08) |
(07) |
(07) Right rear turn signal light
(08) Instrument and indicators
(09) Left rear turn signal light
(10) Exhaust system
(11) MXU 150: Trailer hitch
(12) License light/Taillights/Stop lights
(10) (11) |
(12) |
20
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