Kymco MXU 50 User Manual

OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

MXU 50

ON-ROAD

Issued: 08.JUL.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 6. Children under age 6 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.

		Indicates a strong possibility that serious injury or death
	WARNING
		may 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

WARNING

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	Page

LOCATION OF THE WARNING AND
SPECIFICATION LABELS...........................	1
SAFETY INFORMATION.............................	6
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................	11
IDENTIFICATION NUMBER RECORDS....	11
KEY IDENTIFICATION NUMBER..............	11
FRAME AND ENGINE SERIAL
NUMBER...............................................	12
PARTS LOCATION..................................	13
CONTROL FUNCTIONS........... ................	18
IGNITION SWITCH/HEADLIGHT &
POSITION LIGHT SWITCH......................	18
INSTRUMENTS AND INDICATOR............	19
Multi-function display.................... ........	21
HANDLEBAR SWITCHES........................	27
Horn button.................................. ........	27

Turn signal switch ................................	27
Headlight dimmer switch ......................	28
Hazard switch.. . ..................................29
Stater switch.. . ....................................30
KICK STARTER...................................	30
THROTTLE LEVER...............................	31
SPEED LIMITER.... ................................	32
FRONT AND REAR BRAKES...................	33
PARKING BRAKE...................................	33
FUEL TANK CAP.....................................	34
FUEL VALVE . ........................................	35
SEAT.....................................................	36
FLAG POLE BRACKET...........................	37
STORAGE COMPARTMENT....................	37
PRE-OPERATION CHECKS......................	38

(Cont'd)

D

	Page
FRONT AND REAR BRAKES...................	40
FUEL...................................................	41
ENGINE OIL...........................................	42
TRANSMISSION OIL...............................	44
CHAIN...................................................	45
THROTTLE LEVER.................................	45
FITTINGS AND FASTENERS...................	45
LIGHTS.................................................	45
SWITCHES........................ ....................	45
TIRES............................ .......................	46
How to measure tire pressure.................	47
Tire wear limit........................................	48
OPERATION............................................	49
STARTING ENGINE................................	49
ENGINE BREAK-IN.................................	51
PARKING..............................................	52
Parking on a slope.................................	53
ACCESSORIES......................................	54
LOADING...............................................	55

	Page
RIDING YOUR ATV...................................	57
GETTING TO KNOW YOUR ATV..............	58
RIDE WITH CARE AND GOOD
JUDGEMENT.........................................	59
AGE RECOMMENDATION.......................	60
NEVER CARRY PASSENGER ON THE
CARGO RACK........................................	61
APPAREL..............................................	62
DO NOT OPERATE AFTER CONSUMING
ALCOHOL OR DRUGS............................	63
PRE-OPERATION CHECKS....................	64
LOADING AND ACCESSORIES...............	66
Loading and operational guidelines.........	66
Accessories.........................................	67
NO MODIFICATIONS..............................	68
DURING OPERATION.............................	69
EXHAUST SYSTEM................................	71
PRACTICING.........................................	72
SPEED LIMITER FOR NEW RIDERS........	73

(Cont'd)

E

	Page
BRAKING..............................................	74
TURNING YOUR ATV .............................	75
CLIMBING UP SLOPE.............................	76
RIDING DOWN SLOPE ...........................	82
PARKING...............................................	83
WHAT TO DO IF.....................................	84
WHAT TO DO.........................................	84
PERIODIC MAINTENANCE AND
ADJUSTMENT.........................................	85
Tool kit...................................................	85
PERIODIC MAINTENANCE/
LUBRICATION.......................................	87
TRANSMISSION OIL..............................	89
SPARK PLUG INSPECTION...................	91
AIR FILTER CLEANING.........................	92
IDLE SPEED ADJUSTMENT....................	95
THROTTLE LEVER ADJUSTMENT.........	96

	Page
FRONT BRAKE SHOES
INSPECTION........................................	97
REAR BRAKE PADS INSPECTION.........	97
FRONT BRAKE LEVER FREE PLAY
ADJUSTMENT.......................................	98
BRAKE FLUID INSPECTION................	100
DRIVE CHAIN SLACK CHECK..............	102
Drive chain slack adjustment..............	102
DRIVE CHAIN CLEANING AND
LUBRICATION....................................	104
CABLE INSPECTION AND
LUBRICATION....................................	104
KNUCKLE SHAFT AND REAR SWING
ARM LUBRICATION.............................	105
WHEEL REMOVAL...............................	106
Wheel installation...............................	106
BATTERY...........................................	107
FUSE REPLACEMENT.........................	109
HEADLIGHT BEAM ADJUSTMENT.......	111
TROUBLESHOOTING.........................	112
Troubleshooting chart.........................	113

(Cont'd)

F

	Page
CLEANING AND STORAGE	....................114
A. CLEANING .....................................	114
B. STORAGE ......................................	116
SPECIFICATIONS..................................	118
NOISE REGULATION.............................	122
MAINTENANCE RECORD.......................	123
INDEX...................................................	124

G

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

(1)		(2)			(3)		(4)

1

(5)			(6)

2

(7)

3

WARNING INFORMATION

Your ATV comes with a hang tag and several labels containing important safety information. Anyone who rides the vehicle should read and understand this information before riding.

Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride.

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

(2)

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.

(1)

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 : 25~30 kpa, (0.25~0.3 kgf/cm2 ), 3.5~4.2 psi REAR : 25~30 kpa, (0.25~0.3 kgf/cm2 ), 3.5~4.2 psi

Never set tire pressure over the recommended.

(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

(4)

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH.

			NEVER USE WITH
ALWAYS USE AN
APPROVED HELMET AND			ALCOHOL OR DRUGS
PROTECTIVE GEAR

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.

(5)

CAUTION

Never carry passenger on This carrier.

Maximum load 15 Kg (33 lbs)

(6)

CAUTION

Never carry passenger on This carrier.

Maximum load 20 Kg (44 lbs)

(7)

5

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.

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.

6

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.

7

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.

8

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.

9

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.

10

DESCRIPTION AND MACHINE IDENTIFICATION

IDENTIFICATION NUMBER RECORDS

Record the keys identification number, frame serial number, engine serial number and model code information for assistance when order replacement parts.

KEYS IDENTIFICATION NUMBER

The keys identification number is stamped on the hang tag as shown in the following illustration.

IGNITION SWITCH KEY NO.

FRAME NO.
					(1)
ENGINE NO.			(1) Ignition switch key identification number

11

FRAME AND ENGINE SERIAL NUMBER

The frame serial number is stamped on the front of the frame.

(1)

(1) Frame serial number

The engine serial number is stamped on the left crankcase.

(1)

(1) Engine serial number

12

PARTS LOCATION

(01) Right front turn signal light

(02) Headlight/Position light

(03) Left front signal light

(01)

(02)

(02)

(03)

13

(04) Left rear turn signal light

(05) Taillight/Stop light/License light

(06) Right rear turn signal light

(04)

(05)

(06)

14

(13)

(12)

(11)

(10)

(09) (08) (07)

(07) Front brake lever

(08) Parking brake

(09) Speed limiter

(10) Fuel filler cap

(11) Instrument and indicators

(12) Rear brake fluid reservoir

(13) Rear brake lever

(14) Headlight dimmer switch Starter button

Hazard switch Turn signal switch Horn switch

(15) Ignition switch/Headlight switch

(16) Throttle lever

(14)

(15)

(16)

15

(19)

(18)

(17)

(17) Rear cargo rack

(18) Seat

(19) Front cargo rack

(20) Front wheel

(21) Kick starter

(22) Air cleaner

(23) Rear wheel

(20)

(21)

(22)

(23)

16

(24) (25) (26)

(24)Storage compartment/Oil tank/Tool kit

(25)Battery/Fuse

(26)Flag pole bracket

NOTE:

The machine you have purchased may differ slightly from those shown in the figures of this manual.

17

CONTROL FUNCTIONS

IGNITION SWITCH/HEADLIGHT & POSITION LIGHT SWITCH

Functions of the respective switch positions are as follows:

"OFF" position:

All electrical circuits are switched off except hazard light. The key can be removed in this position.

"ON" position :

With the transmission in neutral and set the parking brake, the engine can be started.

The key can not be removed.

" " position:

The ignition switch is ON while the position light and taillight will light.

The key can not be removed.

ON

OFF

(1)

(2)

(1) Ignition switch

(2) Key

18

INSTRUMENTS AND INDICATOR

(4)
(3)
(2)		(5)
(1)	(7)	(6)

(1)Multi-function display

(2)Left turn signal indicator

(3)High beam indicator

(4)Low oil level indicator lamp

(5)Right turn signal indicator

(6)Mode/Adjust button (A)

(7)Mode/Adjust button (B)

(1) Multi-function display

The display includes the following functions: Speedometer

Odometer/Tripmeter Digital clock

Fuel gauge

(2) Left turn signal indicator

Flashes when the left turn signal operates.

NOTE:

Both left and right turn signal indicator will flash at the meantime when the hazard switch is operated and turn signal switch is turned off.

(3) High beam indicator

The ignition switch is at the "" position, the high beam indicator lamp will light when the headlight switch to select high beam () .

NOTE:

The headlight can be turned on only when the engine is running.

19

(4)Low oil level indicator ""

The low level indicator lights when the 2- stroke engine oil level is low.

CAUTION:

If the low oil level indicator comes on while riding, stop riding and shut the engine off. Fill the oil tank to the upper level mark with the recommended oil (see page 43). Continuing to ride with a low oil level may lead to engine failure that could result in an accident.

(5) Right turn signal indicator

Flashes when the right turn signal operates.

NOTE:

Both left and right turn signal indicator will flash at the meantime when the hazard switch is operated and turn signal switch is turned off.

(6) (7) Mode/Adjust buttons

These buttons is used to select the tripmeter, the odometer, the km/h, the

mph, the km or the mile.

These buttons is also used to adjust the time and reset the tripmeter.

20

Multi-function display			(1) Digital clock
			Show the time (hours and minutes) while the
	(2)	(3)	ignition is ON.
			To adjust the time manually, proceed as
			follows:
			1. Turn the ignition switch ON.
			2. Press and hold both the Mode/Adjust
			button (A) and Mode/Adjust button (B) for
			more than 2 seconds. The clock will be set
			in the adjust mode with the hour display
(1)		(4)	flashing.

(1)Digital clock

(2)Speedometer

(3)Fuel gauge

(4) Odometer/Tripmeter

(B) (A)

21