KYMCO MXU 50 ON-ROAD User Manual
MXU 50
Issued: 08.JUL.2005
OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
ON-ROAD
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.
WARNING
Indicates a strong possibility that serious injury or death
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:
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 Page
LOCATION OF THE WARNINGAND
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 Page
FRONT AND REAR BRAKES...................40
FUEL...................................................41
ENGINE OIL.........................
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
..................42
RIDING YOUR ATV...................................57
GETTING TO KNOW YOUR ATV..............58
RIDE WITH CARE AND
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
GOOD
(Cont'd)
E
Page 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
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) (4)(3)
1
(5) (6)
2
(7)
3
WARNING INFORMATION
(2)
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
(1) (3)
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/cm ), 3.5~4.2 psi
REAR :
25~30 kpa, (0.25~0.3 kgf/cm ), 3.5~4.2 psi
Never set tire pressure over the recommended.
2
2
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
WARNING
UNDER
6
Operating this ATV if you are underthe
age of 6 increases your chance of severe
injury or death.
NEVER
age 6.
operate this ATVif you are under
CAUTION
.
4
(4)
(5)
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH.
ALWAYS USE AN
APPROVED HELMET AND
PROTECTIVE GEAR
NEVER operate :
Without proper training or instruction.
At speeds too fast for your skills
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.
NEVER USE WITH
ALCOHOL OR DRUGS
or
CAUTION
．
Never carry passenger
This carrier.
．：
Maximum load 15 Kg (33 lbs)
on
(6)
CAUTION
．
Never carry passenger
This carrier.
．：
Maximum load 20 Kg (44 lbs)
(7)
on
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 anATV 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 anATV 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 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 theATV
during operation.
Always go slowly and be extra careful when operating on unfamiliar terrain.Always be alert
to changing terrain conditions when operating theATV.
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
WARNING
ON
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.
IGNITION SWITCH KEY NO.
FRAME NO.
KEYS IDENTIFICATION NUMBER
The keys identification number is stamped on
the hang tag as shown in the following
illustration.
(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)
The engine serial number is stamped on the
left crankcase.
(1)
(1) Engine serial number
(1) Frame serial number
12
PARTS LOCATION
(01) Right front turn signal light
(02)
Headlight/Position light
(03) Left front signal light
(03)(02)(01) (02)
13
(04) Left rear turn signal light
(05) Taillight/Stop light/License light
(06) Right rear turn signal light
(04)
(06)(05)
14
(11) (10)(12)(13) (09) (07)(08)
(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
(15)(14)
(16)
15
(21) (22)(20) (23)
(17)(18)(19)
(17) Rear cargo rack
(18) Seat
(19) Front cargo rack
(20) Front wheel
(21) Kick starter
(22) Air cleaner
(23) Rear wheel
16
(25) (26)(24)
(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
OFF
"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.
(1)
(2)
(1) Ignition switch (2) Key
18
INSTRUMENTS AND INDICATOR
(4)
(3)
(2)
(7)(1)
(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)
(6)
(1) Multi-function display
The display includes the following functions:
Speedometer
Odometer/Tripmeter
Digital clock
Fuel gauge
(2) Left turn signal indicator
(5)
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 2stroke 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)
(1) Digital clock
(2) Speedometer
(3) Fuel gauge
(4) Odometer/Tripmeter
(2)
(4)
(3)
(1) Digital clock
Show the time (hours and minutes) while the
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
flashing.
21
(B)
(A)
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