KYMCO MX 125 Manuale utente

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO MX’er

125/150.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before starting any

operation.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part,

starting from periodic maintenance.

Sections 4 through 17 give instructions

for disassembly, assembly and

inspection of engine, chassis frame and

electrical equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1

FRAME COVERS/EXHAUST MUFFLER 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

FUEL SYSTEM 5

ENGINE REMOVAL/INSTALLATION 6

CYLINDER HEAD/VALVES 7

CYLINDER/PISTON 8

DRIVE AND DRIVEN PULLEYS 9

FINAL REDUCTION/TRANSMISSION

SYSTEM 10

CRANKCASE/CRANKSHAFT/

BALANCE SHAFT 11

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION/STEERING

SYSTEM 12

REAR WHEEL /SWING

ARM/HYDRAULIC BRAKE 13

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR 14

IGNITION SYSTEM 15

STARTING SYSTEM 16

LIGHTS/SWITCHES 17

ONLY ATV ON ROAD AVAILABLE 18

ENGINE CHASSIS

ELECTRICAL

EQUIPMENT

The information and contents included

in this manual may be different from

the motorcycle in case specifications

are changed.

1. GENERAL INFORMATION

1-0

MX’er SYSTEM

__________________________________________________________________________________

____________________________________________________________________

GENERAL INFORMATION

____________________________________________________________________

SERIAL NUMBER---------------------------------------------------------- 1- 1

SPECIFICATIONS---------------------------------------------------------- 1- 2

SERVICE PRECAUTIONS------------------------------------------------ 1- 4

TORQUE VALUES --------------------------------------------------------- 1-12

SPECIAL TOOLS ----------------------------------------------------------- 1-14

LUBRICATION POINTS -------------------------------------------------- 1-15

CABLE & HARNESS ROUTING ---------------------------------------- 1-18

WIRING DIAGRAM-------------------------------------------------------- 1-22

TROUBLESHOOTING----------------------------------------------------- 1-23

1. GENERAL INFORMATION

1-1

MX’er SYSTEM

SERIAL NUMBER

Location of Frame Serial Numbe

Location of Engine Serial Numbe

1. GENERAL INFORMATION

1-2

MX’er SYSTEM

SPECIFICATIONS

Name & Model No. LA30AA, AB

Motorcycle Name & Type MX’er

Overall length (mm) 1600

Overall width (mm) 980

Overall height (mm) 990

Wheel base (mm) 1120

Engine type O.H.C.

Displacement (cc) 149.4

Fuel Used 92# nonleaded gasoline

Front wheel 74

Net weight (kg) Rear wheel 78

Total 152

Front wheel 80

Gross weight(kg) Rear wheel 82

Total 162

Front wheel 20*7-8

Rear wheel 22*10-8

Ground clearance (mm) 130

Perform- Breaking distance

(m)(ANSI) 20.6 below

ance Min. turning radius (m) 3

Starting system Starting motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke (mm) 62 x 49.5

Compression ratio 9.7:1

Compression pressure

(kg/cm²) 16.0

Max. output (ps/rpm) 11/7500

Max. torque (kg m/rpm) 1.1/5500

Intake

Open 5.5°BTDC

Port (1mm) Close 27.5°ABDC

timing Exhaust Open 36°BBDC

(1mm)

Close 4°ATDC

Valve clearance Intake 0.06

(cold) (mm) Exhaust 0.06

Idle speed (rpm) 1700rpm

Lubrication type Forced pressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.0 liter

Oil exchanging

capacity 0.9 liter

Cooling Type Forced air cooling

Air cleaner type & No Sponge

Fuel capacity 8.1 liters

Type PD

Float lever 14.8mm

Venturi dia.(mm) φ25

Throttle type PISTON

Type CDI

Ignition timing 15°BTDC/1700rpm

Contact breaker Non-contact point type

Spark plug

NGK

CR8E

Spark plug gap 0.60.7mm

Battery Capacity 12V8AH

Clutch Type CVT

Type Helical gear

Operation Automatic centrifugal

type

Type Chain drive

Reduction 1st 2.8-0.95

ratio 2nd 7.226

Counter gear ratio 26.902

Front Caster angle

Axle Trail length

Tire

ressure Fron

0.2

(kg/cm²) Rear 0.25

Turning Left 44°

angle Right 44°

Brake s

ste

Rea

Disk brake Drum brake

type Front Drum brake

Sus

ension Fron

Swin

type Rear Swing arm

Shock Front Swing

type Rear Swing arm

Frame type SP pipe

Fuel S

stem

Carbureto

Electrical Equipment

nition S

stem

Tires

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device

Engine

Damping

Device

Lubrication

stem

1. GENERAL INFORMATION

1-3

MX’er SYSTEM

SPECIFICATIONS

Name & Model No. LA25AB

Motorcycle Name & Type MX’er

Overall length (mm) 1685

Overall width (mm) 980

Overall height (mm) 990

Wheel base (mm) 1120

Engine type OHC

Displacement (cc) 124

Fuel Used 92# nonleaded gasoline

Front wheel 74

Net weight (kg) Rear wheel 78

Total 152

Front wheel 80

Gross weight(kg) Rear wheel 82

Total 162

Front wheel 20*7-8

Rear wheel 22*10-8

Ground clearance (mm) 130

Perform- Breaking distance

(m)(ANSI) 20.6 below

ance Min. turning radius (m) 2.5

Starting system Starting motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H..C., chain drive

Bore x stroke (mm) 56.5 x 49.5

Compression ratio 9.2:1

Compression pressure

(kg/cm²) 14.0

Max. output (ps/rpm) 9.8/7500

Max. torque (kg m/rpm) 0.98/5500

Intake

Open 5.5°BTDC

Port (1mm) Close 27.5°ABDC

Timi

Exhaust Open 36°BBDC

(1mm)

Close 4°ATDC

Valve clearance Intake 0.06

(cold) (mm) Exhaust 0.06

Idle speed (rpm) 1700rpm

Lubrication type Forced pressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.0 liter

Oil exchanging

capacity 0.9 liter

Cooling Type Forced air cooling

Air cleaner type & No Sponge

Fuel capacity 8.1 liters

Type PD

Piston dia. (mm) 14.8mm

Venturi dia.(mm) φ25

Throttle type PISTON

Type CDI

Ignition timing 15°BTDC/1700rpm

Contact breaker Non-contact point type

Spark plug NGK

CR8E

Spark plug gap 0.60.7mm

Battery Capacity 12V8AH

Clutch Type CVT

Type Helical gear

Operation Automatic centrifugal

type

Type Chain drive

Reduction 1st 2.8-0.95

ratio 2nd 7.226

Counter gear ratio 26.902

Front Caster angle

Axle Trail length

Tire

ressure Fron

0.2

(kg/cm²) Rear 0.25

Turning Left 44°

angle Right 44°

Brake s

ste

Rea

Disk brake Drum brake

type Front Drum brake

Sus

ension Fron

Swin

type Rear Swing arm

Shock Front Swing

type Rear Swing arm

Frame type SP pipe

Fuel S

stem

Carbureto

nition S

stem

Electrical Equipment

Tires

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device

Engine

Damping

Device

Lubrication

stem

1. GENERAL INFORMATION

1-4

MX’er SYSTEM

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure

to use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

1. GENERAL INFORMATION

1-5

MX’er SYSTEM

Apply or add designated greases and

lubricants to the specified lubrication

points.

After reassembly, check all parts for

proper tightening and operation.

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-)

terminal before operation.

When using a spanner or other tools,

make sure not to damage the motorcycle

surface.

After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-6

MX’er SYSTEM

If the fuse is burned out, find the cause

and repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock

on the connector shall be released before

operation.

Hold the connector body when

connecting or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is

bending, protruding or loose.

Confirm

Capacity

1. GENERAL INFORMATION

1-7

MX’er SYSTEM

The connector shall be inserted

completely.

If the double connector has a lock,

lock it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check

for damaged terminal cover or loose

negative terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

Sna

1. GENERAL INFORMATION

1-8

MX’er SYSTEM

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with

any moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp

edges or corners. Avoid the projected

ends of bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

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