KYMCO MXU 50 REVERSE Manuale utente

By KWANG YANG Motor Co., Ltd.

First Edition, Jan 2006

unauthorized use without the written permission of

KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T100LB10DE

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO MXU 50

REVERSE/MXU 50/MX’ER 50.

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 19 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/CYLINDER/PISTON 7

A.C. GENERATOR 8

KICK STARTER/DRIVE

PULLEY/CLUTCH/DRIVEN PULLEY 9

FINAL REDUCTION

(MXU 50/MX’ER 50) 10

FINAL REDUCTION/TRANSMISSION

SYSTEM (MXU 50 REVERSE) 11

CRANKCASE/CRANKSHAFT 12

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION/STEERING

SYSTEM 13

REAR WHEEL /SWING

ARM/HYDRAULIC BRAKE 14

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR 15

IGNITION SYSTEM 16

STARTING SYSTEM 17

LIGHTS/SWITCHES 18

ONLY ATV ON ROAD AVAILABLE 19

The information and contents included in

this manual may be different from the

ATV in case specifications are changed.

KYMCO reserves the right to make

changes at any time without notice and

without incurring any obligation.

ENGINE CHASSIS ELECTRICAL

EQUIPMENT

1. GENERAL INFORMATION

1-0

ATV50

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

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

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

SERVICE PRECAUTIONS------------------------------------------------ 1- 5

TORQUE VALUES --------------------------------------------------------- 1-13

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

LUBRICATION POINTS -------------------------------------------------- 1-14

CABLE & HARNESS ROUTING (MX’ER 50) ------------------------ 1-17

CABLE & HARNESS ROUTING (MXU 50 REVERSE/MXU 50) - 1-21

WIRING DIAGRAM (MX’ER 50 ON ROAD) ------------------------- 1-26

WIRING DIAGRAM (MX’ER 50 OFF ROAD) ------------------------ 1-27

WIRING DIAGRAM (MXU 50 ON ROAD)---------------------------- 1-28

WIRING DIAGRAM (MXU 50 REVERSE ON ROAD)-------------- 1-29

TROUBLESHOOTING----------------------------------------------------- 1-30

1. GENERAL INFORMATION

1-1

ATV50

SERIAL NUMBER

Location of Frame Serial Numbe

Location of Engine Serial Numbe

1. GENERAL INFORMATION

1-2

ATV50

SPECIFICATIONS

Model No. LA10

Name MX’ER 50

Overall length 1685 mm (67.4 in)

Overall width 980 mm (39.2 in)

Overall height 1030 mm (41.2 in)

Wheel base 1120 mm (44.8 in)

Engine type Air cooled 2-stroke

Displacement 49.4 cm3(2.964 cu-in)

Fuel Used 92# nonleaded

gasoline

Front wheel 67 kg (147.4 lbs)

Dry weight Rear wheel 73 kg (160.6 lbs)

Total 140 kg (308 lbs)

Front wheel 73 kg (160.6 lbs)

Curb weight Rear wheel 77 kg (169.4 lbs)

Total 150 kg (330 lbs)

Front wheel 20*7-8

Tires Rear wheel 22*10-8

Ground clearance 130 mm (5.2 in)

Min. turning radius 2500 mm (100 in)

Starting system Starting motor &

kick starter

Type Air cooled 2-stroke

Cylinder arrangement Single cylinder

Combustion chamber typ

Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke 39 x 41.4 mm

(1.56 x 1.656 in)

Compression ratio 7.2:1

Compression pressure 12 kgf/c

2(1200 kPa,

170.4 psi)

Open

Port Intake Close Automatic controlled

timin

Open

Exhaust Close Automatic controlled

Intake －

Valve clearance Exhaus

－

Idle speed (rpm) 1800

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Air cleaner type Sponge

Fuel capacity 8.1 liters

Type PB

Main jet No. 80

Venturi dia φ14 mm (φ0.56 in)

Throttle type Valve piston

Type CDI

Ignition timing 22°/2000 rpm

Spark plug NGK-BR8HAS

Spark plug gap 0.6～0.7mm

Battery Capacity 12V4AH

Clutch Type CVT

Operation Automatic centrifugal

Type

Type Chain drive

Reduction 1st －

ratio 2nd －

Final gear ratio 23.678

Front Caster angle －

Axle Trail length －

Front 0.35 kgf/cm2(35 kPa,

4.97 psi)

Tire pressure Rear 0.35 kgf/cm2(35 kPa,

4.97 psi)

Turning Left 44°

angle Right 44°

Brake system Rear Disk brake

type Front Drum brake

Suspension Front Swing

type Rear Swing arm

Shock

Front Swing

type Rear Swing arm

Frame type SP pipe

Engine

Fuel S

stem

Carbureto

Electrical Equipment

nition S

stem

Power Drive System

Reduction

Gear

Moving Device Damping

Device

1. GENERAL INFORMATION

1-3

ATV50

Model No. LB10

Name MXU 50

Overall length 1775 mm (71 in)

Overall width 950 mm (38 in)

Overall height 1040 mm (41.6 in)

Wheel base 1120 mm (44.8 in)

Engine type Air cooled 2-stroke

Displacement 49.4 cm3(2.964 cu-in)

Fuel Used 92# nonleaded

gasoline

Front wheel 87 kg (191.4 lbs)

Dry weight Rear wheel 89 kg (195.8 lbs)

Total 176 kg (387.2 lbs)

Front wheel 92 kg (202.4 lbs)

Curb weight Rear wheel 94 kg (206.8 lbs)

Total 186 kg (409.2 lbs)

Front wheel 21*7-10

Tires Rear wheel 22*10-10

Ground clearance 165 mm (6.6 in)

Min. turning radius 2900 mm (116 in)

Starting system Starting motor &

kick starter

Type Air cooled 2-stroke

Cylinder arrangement Single cylinder

Combustion chamber typ

Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke 39 x 41.4 mm

(1.56 x 1.656 in)

Compression ratio 7.2:1

Compression pressure 12 kgf/c

2(1200 kPa,

170.4 psi)

Open

Port Intake Close Automatic controlled

timin

Open

Exhaust Close Automatic controlled

Intake －

Valve clearance Exhaus

－

Idle speed (rpm) 1800

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Air cleaner type Sponge

Fuel capacity 8.1 liters

Type PB

Main jet No. 80

Venturi dia φ14 mm (φ0.56 in)

Throttle type Valve piston

Type CDI

Ignition timing 22°/2000 rpm

Spark plug NGK-BR8HAS

Spark plug gap 0.6～0.7mm

Battery Capacity 12V8AH

Clutch Type CVT

Operation Automatic centrifugal

Type

Type Chain drive

Reduction 1st －

ratio 2nd －

Final gear ratio 23.678

Front Caster angle －

Axle Trail length －

Front 0.28 kgf/cm2(28 kPa, 4

psi)

Tire pressure Rear 0.28 kgf/cm2(28 kPa, 4

psi)

Turning Left 40°

angle Right 40°

Brake system Rear Disk brake

type Front Drum brake

Suspension Front Swing

type Rear Swing arm

Shock

Front Swing

type Rear Swing arm

Frame type SP pipe

Engine

Fuel S

stem

Carbureto

Electrical Equipment

nition S

stem

Power Drive System

Reduction

Gear

Moving Device Damping

Device

1. GENERAL INFORMATION

1-4

ATV50

Model No. LB10

Name MXU 50 REVERSE

Overall length 1786 mm (71 in)

Overall width 958 mm (38 in)

Overall height 1010 mm (40 in)

Wheel base 1105 mm (44 in)

Engine type Air cooled 2-stroke

Displacement 49.4 cm3(2.964 cu-in)

Fuel Used 92# nonleaded

gasoline

Front wheel 78 kg (171.6 lbs)

Dry weight Rear wheel 80 kg (176 lbs)

Total 158 kg (347.6 lbs)

Front wheel 83 kg (182.6 lbs)

Curb weight Rear wheel 84 kg (184.8 lbs)

Total 167 kg (36734 lbs)

Front wheel 21*7-10

Tires Rear wheel 22*10-10

Ground clearance 162 mm (6.6 in)

Min. turning radius 2900 mm (116 in)

Starting system Starting motor &

kick starter

Type Air cooled 2-stroke

Cylinder arrangement Single cylinder

Combustion chamber typ

Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke 39 x 41.4 mm

(1.56 x 1.656 in)

Compression ratio 7.2:1

Compression pressure 12 kgf/c

2(1200 kPa,

170.4 psi)

Open

Port Intake Close Automatic controlled

timin

Open

Exhaust Close Automatic controlled

Intake －

Valve clearance Exhaus

－

Idle speed (rpm) 1800

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Air cleaner type Sponge

Fuel capacity 8.1 liters

Type PB

Main jet No. 80

Venturi dia φ14 mm (φ0.56 in)

Throttle type Valve piston

Type CDI

Ignition timing 13.5°/1500 rpm

Spark plug NGK-BR8HAS

Spark plug gap 0.6～0.7mm

Battery Capacity 12V8AH

Clutch Type CVT

Operation Automatic centrifugal

Type

Primary reduction

system Helical gear/spur gear

Secondary reduction

system Chain drive

Primary reduction ratio 1.2 – 3.5

Secondary reduction

ratio 20.12

Reverse ratio 46.11

Front Caster angle －

Axle Trail length －

Front 0.28 kgf/cm2(28 kPa, 4

psi)

Tire pressure Rear 0.28 kgf/cm2(28 kPa, 4

psi)

Turning Left 40°

angle Right 40°

Brake system Rear Disk brake

type Front Drum brake

Suspension Front Swing

type Rear Swing arm

Shock

Front Swing

type Rear Swing arm

Frame type SP pipe

Engine

Fuel S

stem

Carbureto

Electrical Equipment

nition S

stem

Power Drive System Moving Device Damping

Device

1. GENERAL INFORMATION

1-5

ATV50

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

1-6

ATV50

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

1-7

ATV50

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.

Confir

Capacity

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