KYMCO MXU 50 Owner's Manual
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KYMCO MXU 50 Owner's Manual

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OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 50
ON-ROAD
Issued: 08.JUL.2005

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  • Page 1 OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. MXU 50 ON-ROAD Issued: 08.JUL.2005...

  • Page 3: Important Notices

    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.
  • Page 4 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.
  • Page 5 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...

  • Page 6: Table Of Contents

    CONTENTS Page Page LOCATION OF THE WARNING AND Turn signal switch ........27 SPECIFICATION LABELS......1 Headlight dimmer switch ......28 Hazard switch........29 SAFETY INFORMATION......6 Stater switch........30 KICK STARTER........30 DESCRIPTION AND MACHINE THROTTLE LEVER.......31 IDENTIFICATION........11 SPEED LIMITER........32 IDENTIFICATION NUMBER RECORDS..11 FRONT AND REAR BRAKES....33 PARKING BRAKE........33 KEY IDENTIFICATION NUMBER....11...
  • Page 7 Page Page FRONT AND REAR BRAKES....40 RIDING YOUR ATV........57 FUEL...........41 GETTING TO KNOW YOUR ATV....58 ENGINE OIL...........42 RIDE WITH CARE AND GOOD TRANSMISSION OIL.......44 JUDGEMENT.........59 CHAIN...........45 AGE RECOMMENDATION.......60 THROTTLE LEVER.........45 NEVER CARRY PASSENGER ON THE FITTINGS AND FASTENERS....45 CARGO RACK........61 LIGHTS..........45 APPAREL..........62 SWITCHES......
  • Page 8 Page Page BRAKING..........74 FRONT BRAKE SHOES TURNING YOUR ATV ......75 INSPECTION........97 CLIMBING UP SLOPE......76 REAR BRAKE PADS INSPECTION..97 RIDING DOWN SLOPE ......82 FRONT BRAKE LEVER FREE PLAY PARKING..........83 ADJUSTMENT........98 WHAT TO DO IF........84 BRAKE FLUID INSPECTION....100 WHAT TO DO.........84 DRIVE CHAIN SLACK CHECK....102 Drive chain slack adjustment....102 PERIODIC MAINTENANCE AND DRIVE CHAIN CLEANING AND...
  • Page 9 Page CLEANING AND STORAGE....114 A. CLEANING ........114 B. STORAGE ........116 SPECIFICATIONS........118 NOISE REGULATION......122 MAINTENANCE RECORD.......123 INDEX...........124...

  • Page 10: Location Of The Warning And Specification Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 13 WARNING INFORMATION WARNING Your ATV comes with a hang tag and several labels containing important safety information. Anyone who rides the vehicle should read and understand this UNDER information before riding. Parents of young riders should make sure their Operating this ATV if you are under the youngsters read and understand the hang tag and label age of 6 increases your chance of severe information before allowing them to ride.
  • Page 14 CAUTION WARNING ． Never carry passenger Improper ATV use can result in SEVERE This carrier. INJURY or DEATH. ． ： Maximum load 15 Kg (33 lbs) ALWAYS USE AN NEVER USE WITH APPROVED HELMET AND ALCOHOL OR DRUGS CAUTION PROTECTIVE GEAR NEVER operate : ．...

  • Page 15: Safety Information

    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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 WARNING WHAT CAN HAPPEN Gasoline is poisonous and can cause POTENTIAL HAZARD injuries. Improper handling of gasoline. HOW TO AVOID THE HAZARD WHAT CAN HAPPEN If you should swallow some gasoline or Gasoline can catch fire and you could be inhale a lot of gasoline vapor, or get some burned.
  • Page 19 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.

  • Page 20: Description And Machine Identification

    DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION NUMBER RECORDS KEYS IDENTIFICATION NUMBER Record the keys identification number, frame The keys identification number is stamped on serial number, engine serial number and the hang tag as shown in the following model code information for assistance when illustration.

  • Page 21: Frame And Engine Serial Number

    FRAME AND ENGINE SERIAL NUMBER The engine serial number is stamped on the The frame serial number is stamped on the left crankcase. front of the frame. (1) Engine serial number (1) Frame serial number...

  • Page 22: Parts Location

    PARTS LOCATION (01) Right front turn signal light (02) Headlight/Position light (03) Left front signal light (01) (02) (02) (03)
  • Page 23 (04) Left rear turn signal light (05) Taillight/Stop light/License light (06) Right rear turn signal light (04) (05) (06)
  • Page 24 (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...
  • Page 25 (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)
  • Page 26 (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.

  • Page 27: Control Functions

    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 (1) Ignition switch (2) Key parking brake, the engine can be started.

  • Page 28: Instruments And Indicator

    INSTRUMENTS AND INDICATOR (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.
  • Page 29 (4) Low oil level indicator " " (5) Right turn signal indicator The low level indicator lights when the 2- Flashes when the right turn signal operates. stroke engine oil level is low. NOTE: CAUTION: Both left and right turn signal indicator will flash at the meantime when the hazard switch is If the low oil level indicator comes on while operated and turn signal switch is turned off.

  • Page 30: Multi-Function Display

    Multi-function display (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.
  • Page 31 3. To set the hour, press the Mode/Adjust 4. Press the Mode/Adjust button (B). The minute button (A) until the desired hour. display will start flashing.
  • Page 32 5. To set minute, press the Mode/Adjust 6. To end the adjustment, press the button (A) until the desired minute. Mode/Adjust button (A) and Mode/Adjust button (B). The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 10 seconds.
  • Page 33 (2) Speedometer (3) Fuel gauge Shows riding speed in km/h or mph. The fuel gauge shows the approximate fuel supply available in a graduated display. The normal operating fuel range Press and hold Mode/Adjust button (B)for is with the section between the segment F more than 2 seconds to select km/h or and segment E.
  • Page 34 (4) Odometer/Tripmeter The odometer shows the total distance travelled in Km or in miles. The tripmeter shows the trip distance travellled in Km or in miles. Press and hold Mode/Adjust button (B)for more than 2 seconds to select km or mile. Press and hold Mode/Adjust button (A)for more than 2 seconds to select ODO or TRIP...
  • Page 35 To reset the tripmeter: 1. Press and hold Mode/Adjust button (A)for more than 2 seconds to select TRIP and do not release the Mode/Adjust button (A). 2. Press and hold the Mode/Adjust button (B) until the tripmeter is reset.

  • Page 36: Handlebar Switches

    HANDLEBAR SWITCHES (2) Turn signal switch Use the turn signal switch while turning to another direction or shifting to another lane. The turn signal light will flash when the switch is operated and ignition switch is ON. " " For turning to the " left ".

  • Page 37: Headlight Dimmer Switch

    (3) Headlight dimmer switch Turn the switch to the " " position to switch on the low beam. Turn the switch to the " " position to switch on the high beam. Turn the switch to the " " position to switch off the headlight.

  • Page 38: Hazard Switch

    CAUTION: (4) Hazard switch ． Turn on this switch when parking or there is a special condition. ． (4) Hazard switch After the hazard switch is turned on, it will not reset automatically. Be sure to reset it " "At this position, the right and left turn after use to avoid affecting the traffic signal lights wink together.

  • Page 39: Stater Switch

    KICK STARTER The kick starter cranks the engine when the kick starter is operated. CAUTION: See starting instructions prior to starting engine (see page 49 for details). (5) Start switch (5)Start switch " " The start switch is used for starting the engine.

  • Page 40: Throttle Lever

    THROTTLE LEVER It is operated by the thumb. Pressing the WARNING lever opens the throttle. When pressure is POTENTIAL HAZARD released, spring tension automatically closes the throttle. Regulate the speed of the Malfunction of throttle. machine by varying the throttle position. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow...

  • Page 41: Speed Limiter

    SPEED LIMITER The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power Always make sure the throttle lever free available and decreases the maximum speed play is adjusted to 1.0~4.0 mm (0.04~0.16 of the ATV.

  • Page 42: Front And Rear Brakes

    PARKING BRAKE FRONT AND REAR BRAKES To set the parking brake, squeeze the front The front and rear brakes are operated by brake lever and lock it with the lock pin. squeezing the brake levers. Always set the parking brake when parking and before starting the engine.

  • Page 43: Fuel Tank Cap

    FUEL TANK CAP WARNING After refueling, be sure to tighten the fuel POTENTIAL HAZARD tank cap until it clicks. Improper use of the parking brake. Insert the breather tube into the handlebar cover hole. WHAT CAN HAPPEN To refuel refer to page 41~42. The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine.

  • Page 44: Fuel Valve

    FUEL VALVE The fuel valve supplies fuel from the fuel tank to the carburetor. The fuel valve has three positions. OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this position when the engine is not running.

  • Page 45: Seat

    SEAT To install the seat, align the tabs on the seat To remove the seat, pull upward the seat lock with the grommets on the frame and press the lever and pull up the seat the rear. seat down until it locks. NOTE: Make sure that the seat is securely fitted.

  • Page 46: Flag Pole Bracket

    FLAG POLE BRACKET STORAGE COMPARTMENT Flag poles are optional equipment available The storage compartment is located under from your KYMCO dealer. To mount a flag the seat. To remove the seat, see page 36. pole in the bracket to make you more visible. The owner's manual should be stored in the storage compartment.

  • Page 47: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ROUTINE PAGE ITEM Check operation, condition, free play (drum brake) and brake fluid level (disk brake). ～ 40, 97 101 Brake Adjust (drum brake) if necessary. Fill with DOT 4 brake fluid (disk brake) if necessary.
  • Page 48 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.

  • Page 49: Front And Rear Brakes

    FRONT AND REAR BRAKES WARNING 1. Drum brake: Check for correct free play in the brake levers. If the free play is POTENTIAL HAZARD incorrect, adjust it. (See pages 98~99.) Riding with improperly operating brakes. Check operation of the levers. They should move smoothly and there should WHAT CAN HAPPEN be a firm feeling when the brake is...

  • Page 50: Fuel

    FUEL Your KYMCO engine has been designed to Fill the fuel tank when necessary and make use regular unleaded gasoline with a pump sure there is sufficient gasoline in the tank. octane number of 86 or higher, or research Check for leaks. octane number of 91 or higher.

  • Page 51: Engine Oil

    ENGINE OIL WARNING Oil level POTENTIAL HAZARD When the low oil level indicator lights (see Improper care when refueling. page 20), it means the oil level in the oil tank is low; stop the engine and fill the oil tank as WHAT CAN HAPPEN soon as possible.
  • Page 52 To fill, lift seat (see page 36), remove the cap from the oil tank, and fill with the recommended oil up to the upper level mark (do not overfill the oil tank neck). NOTE: When filling, do not let dirt or other foreign materials enter the tank.

  • Page 53: Transmission Oil

    TRANSMISSION OIL Make sure the transmission oil and rear final gear case oil at the specified level. Add oil as necessary. (See page 89~91.) Check for leaks. Recommended oil classification: Transmission oil: SAE #90 Oil quantity: Transmission oil: Periodic oil change: 0.11 L (0.10 lmp qt, 0.12 US qt) Total amount: 0.12 L (0.11 lmp qt, 0.13 US qt...

  • Page 54: Chain

    CHAIN LIGHTS Check the general condition of the chain and Check the position light and taillight/stop light check the chain slack before every ride. to make sure they are in working condition. Repair as necessary for proper operation. Lubricate and adjust the chain as necessary. (See pages 102~104 for details.) SWITCHES THROTTLE LEVER...

  • Page 55: Tires

    HOW TO AVOID THE HAZARD 3.Tire pressure below the minimum 1.The tires listed below have been specified could cause the tire to approved by Kwang Yang Motor Co., dislodge from the rim under severe Ltd. for this model. Other tire riding conditions.

  • Page 56: How To Measure Tire Pressure

    Set pressure tires cold. 4.Higher pressures may cause the tire to Set tire pressures to the following burst. Inflate the tires very slowly and specifications: carefully. Fast inflation could cause the tire to burst. Recommended Minimum Maximum pressure 25 kpa 28 kpa 30 kpa How to measure tire pressure...

  • Page 57: Tire Wear Limit

    Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. A. 3mm (0.12 in)

  • Page 58: Operation

    OPERATION STARTING ENGINE WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating ATV without being familiar Freezing control cables in cold weather. with all controls. WHAT CAN HAPPEN WHAT CAN HAPPEN You could be unable to control the ATV, Loss of control, which could cause an which could lead to an accident or accident or injury.
  • Page 59 4.Completely close the throttle lever and 5. Be sure to keep the throttle closed and the start the engine by pushing the start switch. parking brake locked while starting and warming up the engine. 6. Allow the engine warm up before riding. NOTE: If the engine fails to start, release the start switch, then push the start switch again.

  • Page 60: Engine Break-In

    ENGINE BREAK-IN To start the engine without the electric starter. There is never a more important period in the life of your machine than the period between A. Follow steps 1 through 3. zero and 20 hours. B. With the throttle closed, operate the kick For this reason, we ask that you carefully starter (see page 30) with a rapid, read the following material.

  • Page 61: Parking

    1. 0~10 hours: PARKING Avoid continuous operation above half When parking, stop the engine. Turn the fuel lock to "OFF" and apply the parking brake. throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to Make sure the lock pin into the locked time.

  • Page 62: Parking On A Slope

    Parking on a slope 1. Bring the machine to a stop by applying the WARNING brakes. POTENTIAL HAZARD 2. Stop the engine. Parking on a slope or other incline. 3. With the brake applied, apply the parking brake. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident.

  • Page 63: Accessories

    ACCESSORIES Do not mount an accessory where it could Accessories can affect the handling and interfere with your ability your to control the control of your ATV. Keep the following in ATV. Examples include (but are not limited mind when considering an accessory or to) a heavy or bulky object attached to the operating an ATV which has accessories.

  • Page 64: Loading

    LOADING As originally equipped, this ATV can carry Load cargo on the cargo racks as close to cargo or tow a trailer, you must use common the center of the vehicle as possible. Put sense and good judgment. Keep the following cargo at the rear of the front cargo rack points in mind:...
  • Page 65 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.

  • Page 66: Riding Your Atv

    RIDING YOUR ATV...

  • Page 67: Getting To Know Your Atv

    WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This Owner's Manual completely and understand section, riding your ATV, provides general ATV riding instructions for recreational riding. the operation of the controls.

  • Page 68: Ride With Care And Good Judgement

    RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Become familiar with this ATV at slow Get training if you are inexperienced. speeds first, even if you are an Beginners and inexperienced riders should experienced operator. get proper instruction on how to operate this Do not attempt to operate at maximum ATV.

  • Page 69: Age Recommendation

    AGE RECOMMENDATION HOW TO AVOID THE HAZARD A child under 6 should never operate this The minimum recommended age for this ATV ATV. model is 6. For safety, never let children Never allow a child under 16 to operate under 6 years old operate this vehicle. an ATV without adult supervision and Children under 16 should be supervised by never allow continued use of t e ATV by a...

  • Page 70: Never Carry Passenger On The Cargo Rack

    NEVER CARRY PASSENGER ON THE CARGO RACKS WARNING POTENTIAL HAZARD Carrying a passenger on the cargo racks WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.

  • Page 71: Apparel

    APPAREL WARNING POTENTIAL HAZARD Operating without protective clothing Operating this ATV without wearing an increases your chances of severe injury approved motorcycle helmet, eye in the event of an accident. protection and protective clothing. WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating without Always wear an approved motorcycle an approved...

  • Page 72: Do Not Operate After Consuming Alcohol Or Drugs

    DO NOT OPERATE AFTER CONSUMING WARNING ALCOHOL OR DRUGS. POTENTIAL HAZARD Operator's performance capability is reduced Operating this ATV after consuming by the influence of alcohol or drugs. alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.

  • Page 73: Pre-Operation Checks

    PRE-OPERATION CHECKS Always perform the pre-operation checks WARNING listed on page 38 before riding for safety and POTENTIAL HAZARD proper care of the machine. Operating this ATV with improper tires, or with improper or uneven tire pressure. WARNING WHAT CAN HAPPEN POTENTIAL HAZARD Failure to inspect the ATV before Use of improper tires on this ATV, or...
  • Page 74 Do not operate at speeds too fast for your Speed limiter skills or the conditions. For riders inexperienced with this model, this model is equipped with a speed limiter in the WARNING throttle lever housing. The speed limiter limits the power and top speed of the POTENTIAL HAZARD machine.

  • Page 75: Loading And Accessories

    LOADING AND ACCESSORIES Use extra caution when riding the machine Loading and operational guidelines with additional loads, such as accessories or Carrying cargo will affect how your ATV cargo. handles and greatly reduce its ability in The machine's handling may be adversely accelerating, braking and making turns and affected.

  • Page 76: Accessories

    Accessories WARNING Genuine KYMCO accessories have been POTENTIAL HAZARD specifically designed for and tested on this vehicle. Because KYMCO cannot test all Overloading this ATV or carrying or other accessories, you are personally towing cargo improperly. responsible for properly selecting, installing, and using non-KYMCO accessories.

  • Page 77: No Modifications

    NO MODIFICATIONS No Modifications WARNING Modifying this ATV or removing original equipment may render the vehicle unsafe or POTENTIAL HAZARD illegal. Spark arresters and mufflers are Operating this ATV with improper modifications. required in most areas. Don't modify your exhaust system or emission control system WHAT CAN HAPPEN components.

  • Page 78: During Operation

    DURING OPERATION WARNING Always keep your feet on the footboards POTENTIAL HAZARD during operation. Otherwise your feet may Removing hands from handlebars or feet contact the rear wheels. from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg, your foot or leg may come...
  • Page 79 Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.

  • Page 80: Exhaust System

    EXHAUST SYSTEM The exhaust on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system...

  • Page 81: Practicing

    PRACTICING With the engine idling, return the starter knob Select a flat area to become familiar with your to the closed position and shift the drive ATV. Make sure that this area is free of select lever into the forward position. Then obstacles and other riders.

  • Page 82: Speed Limiter For New Riders

    SPEED LIMITER FOR NEW RIDERS Your ATV has an adjustable throttle limiter. The screw and locknut in the lower throttle housing can be adjusted to limit throttle lever movement. To adjust the throttle limiter: 1. Loosen the lock nut (2). 2.

  • Page 83: Braking

    BRAKING Pulling one or both brake levers or/and Practice starting and stopping at slow depressing brake pedal too hard may cause speeds. Gradually work up to faster starts the front and/or rear wheels to skid or slide and stops. out of control. If this happens, release all pressure on the lever(s) immediately.

  • Page 84: Turning Your Atv

    TURNING YOUR ATV To achieve maximum traction while riding on-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. When approaching a corner or turn, close the throttle fully, and slow the ATV down by applying both front and rear brakes at the same time.

  • Page 85: Climbing Up Slope

    CLIMBING UP SLOPE WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on slopes. Be sure that you can Operating on excessively steep slopes. maneuver your ATV well on flat ground before attempting any incline and then practice WHAT CAN HAPPEN riding first on gentle slopes.
  • Page 86 WARNING An obstacle or a sharp drop could be on the other side of the slope. POTENTIAL HAZARD Climbing slopes improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing slopes as described in this Owner's Manual.
  • Page 87 If you are climbing a slope and you find that When crossing the side of a slope: you have not properly judged your ability to Always follow proper procedures as make it to the top, you should turn the ATV described in the Owner's Manual.
  • Page 88 If your ATV has stalled or stopped and you WARNING believe you can continue up the slope, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or wheels which could cause you to lose control. improperly dismounting while climbing a If you are unable to continue up the slope, slope.
  • Page 89 Apply the front brake. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on up slope side or to a side if pointed straight up slope. Turn the ATV around and remount, following the procedure described in the Owner's Manual.
  • Page 90 If the slope is not too steep and you have good footing, you may be able to walk the ATV back down the slope . Make sure your intended path is clear in case you lose control of the ATV. If you decide you can walk the ATV safely: 1.

  • Page 91: Riding Down Slope

    RIDING DOWN SLOPE WARNING When riding your ATV down slope, shift your POTENTIAL HAZARD weight as far to the rear and up slope side of Going down a slope improperly. the ATV as possible. Move back on the seat and sit with your arms straight. Improper WHAT CAN HAPPEN braking may cause a loss of traction.

  • Page 92: Parking

    PARKING Always choose a level place to park. After bringing your ATV to a stop, hold the brakes while you shift into neutral. Then set the parking brake and turn the ignition switch OFF. If you're through riding for the day, also turn the fuel valve OFF.

  • Page 93: What To Do If

    WHAT TO DO IF If your ATV can't make it up a slope you are This section is designed to be a reference trying to climb: guide only. Be sure to read each section on riding techniques completely. Turn the ATV around if you still have forward speed.

  • Page 94: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND Have KYMCO dealer perform service if ADJUSTMENT you are not familiar with machine Periodic inspection, adjustment and lubrication will keep your machine in the Tool kit safest and most efficient condition possible. A tool kit is provide with your ATV. Safety is an obligation of the machine owner.
  • Page 95 The tools in the kit are sufficient to perform WARNING routine maintenance and simple repairs. Any extensive work requiring additional tools POTENTIAL HAZARD should be performed by your authorized Operating this ATV with improper KYMCO dealer. modifications. The tool kit includes the following items: WHAT CAN HAPPEN Air pressure gauge Spark plug wrench...

  • Page 96: Periodic Maintenance/Lubrication

    PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH Check oil level/oil leakage Transmission oil Replace every 12 months. Check oil level/oil leakage Rear final gear case oil Replace every 12 months. Check operation. *V-belt Replace if damage or excessive wear. Every 20~40 hours Clean.
  • Page 97 INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH Check slack/aligment/clean/lube. Drive chain Adjust slack if necessary. Check specific gravity. Battery Check breather hose for proper operation. Correct if necessary. Check leakage. *Exhaust system Retighten if necessary. Replace gasket if necessary. Check operation.

  • Page 98: Transmission Oil

    TRANSMISSION OIL 1. Transmission oil measurement A. Place the machine on a level place. B. Remove the oil filler bolt (1) and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level.
  • Page 99 2. Transmission oil replacement A. Place the machine on a level place. B. Place a container under the engine. C. Remove the oil filler bolt (1) and drain plug (2) to drain the oil. D. Reinstall the drain plug and tighten to Specification.

  • Page 100: Spark Plug Inspection

    SPARK PLUG INSPECTION The spark plug is an important engine CAUTION: component and is easy to inspect. The Be sure no foreign material enters the condition of the spark plug can indicate the crankcase. condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air F.

  • Page 101: Air Filter Cleaning

    AIR FILTER CLEANING Before installing the spark plug, measure the electrode gap with a feeler gauge and adjust The air cleaner accumulates dust and must to specification. be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned Spark plug gap: at more frequent intervals than specified in 0.6~0.7 mm (0.024~0.028 in)
  • Page 102 2. Remove the air filter element, and separate it from the box. To clean the air cleaner: 1. Remove the air filter case cover. (1) Air filter element 3. Wash the element gently but thoroughly in solvent. (1) Air filter case cover...
  • Page 103 5. Inspect the element. If damaged, replace WARNING POTENTIAL HAZARD 6. Apply quality foam air filter oil to the Using low flash point solvents or element. If foam air filter oil is not gasoline to clean the air filter element. available, motor oil may be used.

  • Page 104: Idle Speed Adjustment

    IDLE SPEED ADJUSTMENT NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

  • Page 105: Throttle Lever Adjustment

    THROTTLE LEVER ADJUSTMENT NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. To adjust throttle free play: 1. Slide the rubber sleeves (1) back to expose the throttle cable adjuster (2). 2. Loosen the lock nut (3), then turn the adjuster to obtain the correct free play.

  • Page 106: Front Brake Shoes Inspection

    FRONT BRAKE SHOES INSPECTION REAR BRAKE PADS INSPECTION A wear indicator is provided on each brake. A wear indicator (1) is provided on each front brake. The indicators allows checking of The indicators allows checking of brake pads wear. Check the position of the indicator. If brake shoe wear without disassembling the brake.

  • Page 107: Front Brake Lever Free Play Adjustment

    FRONT BRAKE LEVER FREE PLAY ADJUSTMENT The front brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the of the brake lever. If the free play is incorrect, adjust as follows: (1) Upper locknut (2) Upper adjusting bolt (3) Lower locknut (4) Lower adjusting bolt 2.
  • Page 108 5. While applying the front brake, turn out the WARNING upper adjusting bolt until the upper and POTENTIAL HAZARD lower cable lengths are equal. The cable Operating with improperly serviced or joint (5) will become vertical. adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.

  • Page 109: Brake Fluid Inspection

    BRAKE FLUID INSPECTION LOWER Check if the fluid level is below the lower level mark through the inspection window. WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation. (1) Lower level mark HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes.
  • Page 110 NOTE: CAUTION: As the brake pads wear, brake fluid level To prevent damage to the brake system, drops, automatically compensating for use only fluid from a sealed container. wear. There are no adjustments to Never allow contaminants (dirt, water, perform, but fluid level and pad wear must etc.) to enter the brake fluid reservoir.

  • Page 111: Drive Chain Slack Check

    DRIVE CHAIN SLACK CHECK Drive chain slack adjustment Inspect the drive chain while all tires are touching the ground. Check the slack at the 1.Loosen the upper and lower axle holding position shown in the figure. The normal bolts (1). vertical deflection is approximately 10~20 mm (0.4~0.8in).
  • Page 112 2.Turn the adjusting nut (2), to decrease or 3.Retighten the upper and lower axle holding increase chain slack. bolts. Tightening torque: Axle holding bolts (upper): 70 Nm (7.0 m-kg, 48 ft-lb) CAUTION: Too little of chain slack will overload the engine and other important parts.

  • Page 113: Drive Chain Cleaning And Lubrication

    CABLE INSPECTION AND LUBRICATION DRIVE CHAIN CLEANING AND LUBRICATION WARNING The drive chain is equipped with rubber O- POTENTIAL HAZARD rings between the chain plates. Steam Damaged control cables. cleaning, high-pressure washes, and certain solvents can damage these O-rings. Use only WHAT CAN HAPPEN kerosene to clean the drive chain.

  • Page 114: Knuckle Shaft And Rear Swing Arm Lubrication

    KNUCKLE SHAFT & REAR SWING ARM LUBRICATION Lubricate the pivot points using a grease gun.

  • Page 115: Wheel Removal

    WHEEL REMOVAL Be sure the tapered side of the wheel nuts (1) 1. Elevate the wheel by placing a suitable face the wheel rim (2). stand under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. (1) Wheel nut (2) Wheel rim WARNING...

  • Page 116: Battery

    BATTERY WARNING Your ATV battery is located in a compartment POTENTIAL HAZARD under the seat. The battery is sealed, so it is not Allowing open flames or sparks near the necessary to check the electrolyte level or add battery. distilled water. If the battery seems weak, see your authorized KYMCO dealer for information on WHAT CAN HAPPEN Gases may explode and possibly cause...
  • Page 117 Battery remove Battery installation 1. Make sure the ignition switch is OFF. 1. Install in the reverse order of removal. 2. Remove the seat (page 36) 2. Check all bolts and other fasteners are secure. 3. Remove the battery cover (1), by removing the 3.

  • Page 118: Fuse Replacement

    FUSE REPLACEMENT When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the CAUTION: electrical system. See your authorized To prevent accidental short-circuiting, KYMCO dealer for repair. turn off the ignition switch before checking or replacing a fuse. There is a spare fuse under the battery cover.
  • Page 119 Fuse box: To replace a fuse: The fuse box is located in the storage box 1. Make sure the ignition switch is OFF. under the battery cover. The specified fuses are: 20 A 2. Remove the battery cover (page 108). 3.

  • Page 120: Headlight Beam Adjustment

    HEADLIGHT BEAM ADJUSTMENT CAUTION: It is advisable to have a KYMCO dealer NOTE: make this adjustment. Adjust the headlight beam as specified by local laws and regulations. To adjust: Turn the ignition switch at " " position and start the engine. Adjust the headlight beam vertically by turning the vertical beam adjuster.

  • Page 121: Troubleshooting

    TROUBLESHOOTING WARNING Although KYMCO machines receive a rigid POTENTIAL HAZARD inspection before shipment from the factory, Checking the fuel system while smoking trouble may occur during operation. Any or near an open flame. systems can cause poor starting and loss of power.

  • Page 122: Troubleshooting Chart

    Troubleshooting chart Clean filter element Water or dirt mixed in fuel. and fuel tank. 1. Fuel Supply fuel. No fuel. Turn the fuel Check if there is Check fuel flow. Turn the fuel valve to fuel in the fuel Restart engine. Some fuel.

  • Page 123: Cleaning And Storage

    CLEANING AND STORAGE A. CLEANING CAUTION: Frequent, thorough cleaning of your machine Excessive water pressure may cause will not only enhance its appearance but will water seepage and deterioration of wheel improve its general performance and extend bearings, brakes, transmission seals and the useful life of many components.
  • Page 124 7. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after washing. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.

  • Page 125: Storage

    B. STORAGE WARNING Before storing your ATV for an extended time, POTENTIAL HAZARD be sure you thoroughly check the vehicle for Refueling this ATV or handling fuel needed repairs and have them corrected. improperly. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage.
  • Page 126 4. Remove the battery (page 108) and store it WARNING in an area protected from freezing POTENTIAL HAZARD temperatures and direct sunlight and out of Prolonged contact of fuel with the skin. the reach of children, slow charge the battery once a month. Breathing fuel vapor.

  • Page 127: Specifications

    SPECIFICATIONS MXU 50 Model Dimension: 1775 mm (71 in) Overall length Overall width 950 mm (38 in) Overall height 1040 mm (41.6 in) 750 mm (30 in) Seat height Wheel base 1120 mm (44.8 in) Minimum ground clearance 165 mm (6.6 in)
  • Page 128 Model MXU 50 Engine oil/transmission oil: Type 2-stroke engine oil Engine oil classification: Transmission Oil classification: SAE 90# Quantity Engine oil: 2-stroke engine oil 1 L (0.9 lmp qt, 1.1 US qt) over Transmission oil: Periodic oil change 0.11 L (0.1 lmp qt, 0.12 US qt) Total amount 0.12 L (0.11 lmp qt, 0.13 US qt)
  • Page 129 Model MXU 50 Air filter: for engine Wet type element Fuel: Type UNLEADED FUEL Tank capacity 8.1 L(1.74 lmp gal, 2.08 US gal) Reserve amount 1 L(0.22 lmp gal, 0.26 US gal) Carburetor: Type Spark plug: Type NGK BR8 HAS 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
  • Page 130 Model MXU 50 Suspension: Front Swing axle Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Battery type 12V8AH Tire: Type Tubeless Size: Front/Rear 21X7-10/22X10-10 Bulb voltage, wattage*quantity:...

  • Page 131: Noise Regulation

    NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 132: Maintenance Record

    MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

  • Page 133: Index

    INDEX Page Page DO NOT OPERATE AFTER CONSUMING ACCESSORIES......54, 66, 67 ALCOHOL OR DRUGS......63 AGE RECOMMENDATION....A, 60 DRIVE CHAIN......45, 102, 104 AIR FILTER CLEANING ......92 DURING OPERATION......69 APPAREL..........62 ENGINE BREAK-IN........51 ENGINE OIL..........42 BATTERY..........107 ENGINE SERIAL NUMBER.......12 BRAKES.......33, 40, 74, 97, 98, 100 EXHAUST SYSTEM.........71 CABLE INSPECTION AND LUBRICATION........104...
  • Page 134 Page Page IDENTIFICATION NUMBER RECORDS..11 FASTENERS..........45 IDLE SPEED ADJUSTMENT.....95 FITTINGS..........45 IGNITION SWITCH........18 FLAG POLE BRACKET......37 IMPORTANT NOTICES......A FOR ON-ROAD USE ONLY......A INDICATOR..........19 FRAME SERIAL NUMBER......12 INSTRUMENTS........19 FUEL............41 FUEL TANK CAP........34 FUEL VALVE..........35 FUSE REPLACEMENT......109 KEY IDENTIFICATION NUMBER ....11 KICK STARTER........30 KNUCKLE SHAFT LUBRICATION....105 GETTING TO KNOW YOUR ATV....58...
  • Page 135 Page Page READ THIS MANUAL CAREFULLY.....A Multi-function display........21 REAR SWING ARM LUBRICATION..105 RIDE WITH CARE AND GOOD JUDGEMENT...........59 NEVER CARRY PASSENGER ON THE RIDER TRAINING........A CARRIER..........61 RIDING DOWN SLOPE......82 NO MODIFICATIONS.......68 RIDING YOUR ATV........57 OPERATION ........... 49 SAFETY INFORMATION......6 SEAT ............36 SPARK PLUG INSPECTION.....91 PARKING ..........
  • Page 136 Page THROTTLE LEVER....... 31, 45, 96 TIRES.............46 TOOL KIT..........85 TRANSMISSION OIL ......44, 89 TROUBLESHOOTING ......112 Troubleshooting chart......113 Turn signal switch........27 TURNING YOUR ATV........75 WHAT TO DO...........84 WHAT TO DO IF........84 WHEEL..........106...
  • Page 137 NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. First Edition, Jul 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.
  • Page 140 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN NEVER USE APPROVED HELMET WITH DRUGS AND PROTECTIVE OR ALCOHOL 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.

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