KYMCO 150 MXU - Service Manual Download Page 1 | Manualshive

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KYMCO

SERVICE MANUAL

MXU 150

MX’er 150/125

Issued: 08.06.2005

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Summary of Contents for 150 MXU -

Page 1: ...KYMCO SERVICE MANUAL MXU 150 MX er 150 125 Issued 08 06 2005...

Page 2: ...WANG YANG Motor Co Ltd First Edition Jun 2005 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 LCA4 LLB1...

Page 3: ...shooting 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...

Page 4: ...______________________________ GENERAL INFORMATION SERIAL NUMBER 1 1 SPECIFICATIONS 1 2 SERVICE PRECAUTIONS 1 5 TORQUE VALUES 1 13 SPECIAL TOOLS 1 15 LUBRICATION POINTS 1 16 CABLE HARNESS ROUTING MX e...

Page 5: ...1 GENERAL INFORMATION 1 1 ATV 150 125 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number...

Page 6: ...1700 rpm Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 liter 0 88 lmp qt 1 06 US qt Oil exchanging capacity 0 9 lit...

Page 7: ...rpm Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 liter 0 88 lmp qt 1 06 US qt Oil exchanging capacity 0 9 liter 0...

Page 8: ...ion type Forced pressure Wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 liter 0 88 lmp qt 1 06 US qt Oil exchanging capacity 0 9 liter 0 79 lmp qt 0...

Page 9: ...ghtening 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...

Page 10: ...he 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 connecti...

Page 11: ...pecified 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 conn...

Page 12: ...ged 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 m...

Page 13: ...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...

Page 14: ...ontact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken sh...

Page 15: ...re with adjacent or surrounding parts in all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructio...

Page 16: ...symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Tra...

Page 17: ...kgf m N m lbf ft Remarks Stud bolt Oil filter screen cap Seat ball stopper bolt L cover Cam holder Tappet ADJ nut Pivot tensioner Lifter tensioner Lifter tensioner Right crankcase bolt Driver face Cl...

Page 18: ...rque kgf m N m lbf ft Remarks Steering stem nut Swing arm nut Rear wheel nut Front wheel nut Rear shock absorber upper mount bolt Front shock absorber upper mount bolt Front shock absorber lower mount...

Page 19: ...val installation Valve adjuster E012 Valve clearance adjustment Valve spring compressor E040 Cylinder head disassembly assembly Oil seal and bearing install E014 Universal holder E017 Clutch outer nut...

Page 20: ...oundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft right side oil seal Crankshaft one way clutch movable par...

Page 21: ...ot specified This will avoid abnormal noise and rise the durability of the motorcycle Steering knuckle Thrust Cover Bush Collar Steering Column Upper Rear Brake Cable Front Brake camshaft Oil Seal O r...

Page 22: ...1 GENERAL INFORMATION 1 18 ATV 150 125 Sprocket hub Rear Axle Hub Collar Oil Seal Bearing Rear Brake Cam Axle Hub Collar Oil Seal Bearing Driven Sprocket Swing arm Thrust Cover...

Page 23: ...1 GENERAL INFORMATION 1 19 ATV 150 125 CABLE HARNESS ROUTING MX er 150 125 Throttle Cable Rear Brake Cable Right Front Brake Cable Handlebar Switch Lead Front Brake Cable Left Front Brake Cable...

Page 24: ...1 GENERAL INFORMATION 1 20 ATV 150 125 Main Switch Inlet Hose Breather Hose C k Breather Hose CYL Head Cover...

Page 25: ...1 GENERAL INFORMATION 1 21 ATV 150 125 Wire Harness Fuse Breather Hose Rectifier Regulator Ignition Coil Outlet Hose...

Page 26: ...1 GENERAL INFORMATION 1 22 ATV 150 125 Battery Negative Cable Change Gear Control A C G Wire Connector Battery Starter Relay Positive Cable CDI Unit Fuse Breather Hose CYL Head Cover...

Page 27: ...Rear Right Turn Signal Light Connectors ON ROAD Taillight Wire Change Gear Control Unit Connectors Rectifier Regulator Rectifier Regulator Wires A C Generator Wire Change Gear Switch Wire Starter Moto...

Page 28: ...1 24 ATV 150 125 Front Brake Light Switch Wire Front Brake Cables Throttle Cable Rear Brake Cables Rear Brake Light Switch Wire Fuel Tank Breather Hose Handlebar Switch Wire Throttle Cable Fuel Hose A...

Page 29: ...Signal Light Wire ON ROAD Ignition Switch Wire Handlebar Switch Connector Front Left Brake Cable Front Right Brake Cable Rear Brake Hose Headlight Turn Signal Light Connectors ON ROAD Handlebar Switc...

Page 30: ...1 GENERAL INFORMATION 1 26 ATV 150 125 Rear Brake Hose RPM Sensor...

Page 31: ...1 GENERAL INFORMATION 1 27 ATV 150 125 Battery Fuse Box CDI Unit Change Gear Control Unit Starter Relay Starter Motor Cable Negative Battery Cable Positive Battery Cable...

Page 32: ...1 GENERAL INFORMATION 1 28 ATV 150 125 WIRING DIAGRAM MX er 150 125 ON ROAD...

Page 33: ...1 GENERAL INFORMATION 1 29 ATV 150 125 MX er 150 125 OFF ROAD...

Page 34: ...1 GENERAL INFORMATION 1 30 ATV 150 125 MXU 150 ON ROAD...

Page 35: ...1 GENERAL INFORMATION 1 31 ATV 150 125 MXU 150 OFF ROAD...

Page 36: ...iston and piston rings Leaking cylinder head gasket Air leaking through intake pipe Leaking intake manifold Incorrect ignition timing Incorrectly adjusted air screw Flooded carburetor Clogged air clea...

Page 37: ...bustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cause Engine spe...

Page 38: ...g Faulty CDI unit Faulty A C generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch Remove spark plug and install it into spark plug cap to test spark by connecting it...

Page 39: ...and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fuel suppl...

Page 40: ...ator rectifier coupler red wire and battery wire to engine ground and test voltage Inspection Adjustment Inspection Adjustment Symptom Symptom Probable Cause Probable Cause Normal voltage Battery has...

Page 41: ...ge gear control unit Faulty ignition coil Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnor...

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