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KYMCO MXU 300 -, User Manual

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KYMCO MXU 300 - User Manual Download Page 139

8

. CYLINDER/PISTON

 

8-8

     MXU 300/250

PISTON RING INSTALLATION

Install the piston rings onto the piston.

Apply engine oil to each piston ring.

Measure the connecting rod small end I.D.

Service Limit (replace if over):

17.06 mm (0.6824 in)

Measure the connecting rod to piston pin

clearance.

Service Limit (replace if over):

0.06 mm (0.0024 in)

Second

Side Rail

Top

Side Rail

Oil Ring

•

Be careful not to damage or break the

piston and piston rings.

•

All rings should be installed with the

markings facing up.

•

After installing the rings, they should

rotate freely without sticking.

＊

Summary of Contents for MXU 300 -

Page 1: ...WANG YANG Motor Co Ltd First Edition Apr 2005 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4121 LCA5 LDE9...

Page 2: ...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 OVERSE...

Page 3: ...________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION _____...

Page 4: ...1 GENERAL INFORMATION 1 1 MXU 300 250 SERIAL NUMBER 2 Location of Engine Serial Number 1 Location of Frame Serial Number...

Page 5: ...0 1 mm 0 004 in Idle speed rpm 1500rpm Lubrication type Forced pressure Wet sump Oil pump type Trochoid Oil filter type Full flow filtration Oil capacity 1 6 L 1 4 lmp qt 1 7 Us qt Oil exchanging cap...

Page 6: ...ust 0 1 mm 0 004 in Idle speed rpm 1600 rpm Lubrication type Forced pressure Wet sump Oil pump type Trochoid Oil filter type Full flow filtration Oil capacity 1 6 L 1 4 lmp qt 1 7 Us qt Oil exchanging...

Page 7: ...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 8: ...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 9: ...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 10: ...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 11: ...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 12: ...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 13: ...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 14: ...mbols 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 Trans...

Page 15: ...eat ball stopper bolt L cover bolt Cam shaft holder nut Tappet ADJ nut Pivot tensioner bolt Lifter tensioner bolt Lifter tensioner cap Mission case bolt Mission fill and drain bolt Driver face nut Clu...

Page 16: ...liper holder bolt MXU 250 Rear wheel shaft nut MXU 250 Rear swingarm pivot bolt MXU 250 Rearengineuppermountingbolt Rearenginelowermountingbolt Frontenginemountingbolt Exhaust muffler lock bolt frame...

Page 17: ...Universal holder E017 Drive face Clutch outer removal installation Flywheel holder E021 Flywheel removal Clutch spring compressor E034 Driven pulley disassembly Bearing puller E037 Nut wrench MXU 300...

Page 18: ...ngs 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 part Oil...

Page 19: ...frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the ATV Stee...

Page 20: ...1 GENERAL INFORMATION 1 17 MXU 300 250 Sprocket hub Rear Axle Hub Collar Oil Seal Bearing Driven Sprocket Rear Swing Arm Axle...

Page 21: ...Motor Fan Wire Thermostatic Switch Wire Left Front Brake Fluid Hose Right Front Brake Fluid Hose Thermostatic Sensor Wire Front Brake Fluid Hose Stop Switch Cord Throttle Cable Multi function Connecto...

Page 22: ...Motor Cable Radiator Overflow Tube A C G Wire REG REC Stop Switch Wire Turn Signal Relay Hazard Unit Horn ON ROAD Headlight Control Unit Gear Change Switch Wire A C G Connector Gear Change Switch Conn...

Page 23: ...e Handlebar Switch Wire Rear Brake Fluid Hose Harness Wire Blow By Hose Rear Brake Fluid Hose Start Motor Cable Battery Cable Crankcase Breather Hose Rear Brake Fluid Hose Ignition Coil Throttle Cable...

Page 24: ...1 GENERAL INFORMATION 1 21 MXU 300 250 Battery Negative Terminal Cable Positive Terminal Cable Ignition Control Module Starter Relay Starter Motor Cable Ground Wire Gear Change Control Unit Fuse Box...

Page 25: ...1 GENERAL INFORMATION 1 22 MXU 300 250 WIRING DIAGRAM MXU 250 OFF ROAD...

Page 26: ...1 GENERAL INFORMATION 1 23 MXU 300 250 WIRING DIAGRAM MXU 250 ON ROAD...

Page 27: ...1 GENERAL INFORMATION 1 24 MXU 300 250 WIRING DIAGRAM MXU 300 OFF ROAD...

Page 28: ...1 GENERAL INFORMATION 1 25 MXU 300 250 WIRING DIAGRAM MXU 300 ON ROAD...

Page 29: ...r piston 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 c...

Page 30: ...ild up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cau...

Page 31: ...g Faulty ignition 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 connecti...

Page 32: ...n 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 sup...

Page 33: ...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 34: ...ntrol unit Faulty ignition coil Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal N...

Page 35: ...___________________________________________________________________ __________________________________________________________________________________ _________________________________________________...

Page 36: ...2 FRAME COVERS EXHAUST MUFFLER 2 1 MXU 300 250...

Page 37: ...ay be damaged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler lock bolt 3 5 kgf m 35 Nm 25 lbf ft Exhaust muffler lock nut 3 5 kgf m 35 Nm...

Page 38: ...at at the rear Remove the seat INSTALLATION To install the seat align the tabs on the seat with the grommets on the frame and press the seat down until it locks FRONT CARGO RACK REMOVAL INSTALLATION R...

Page 39: ...LLATION Remove front cargo rack see page 2 3 Disconnect the right and left signal light connectors ON ROAD Remove the bolt from the right headlight case Remove the bolt from the left headlight case Re...

Page 40: ...nder the rear fender Remove the two mounting bolts from the rear cargo rack right left side under the rear fender Installation is in the reverse order of removal RIGHT LEFT FOOTBOARD REMOVAL INSTALLAT...

Page 41: ...eat see page 2 3 Remove the right left footboard see page 2 5 Remove the screw two mounting bolts and right side cover Remove the screw two mounting bolts and left side cover Installation is in the re...

Page 42: ...7 Disconnect the fuel tank breather tube from the handlebar cover Remove the two screws and raise the handlebar cover Disconnect the speedometer cable from the instrument Disconnect the instrument and...

Page 43: ...FRONT FENDER REMOVAL INSTALLATION Remove front carrier see page 2 4 front center cover see page 2 7 fuel tank cover see page 2 8 and right left side cover see page 2 6 Disconnect the right and left h...

Page 44: ...rear cargo rack see page 2 5 battery see chapter 16 and right left side cover Disconnect the right and left taillight connectors Remove the fuse box Remove the holder screw then remove the change gea...

Page 45: ...the rear fender Remove the two bolts under the rear fender right left side Loosen the air outlet hose band screw and disconnect the air outlet hose from the V belt compartment cover then remove the re...

Page 46: ...mounting bolt nut and exhaust muffler Inspect the gasket If the exhaust gas leaks the gasket should be replaced Installation is in the reverse order of removal Torque Exhaust muffler lock bolt 3 5 kg...

Page 47: ..._____________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 3 FUEL LINE THROTTLE OPERATION AIR CLEANER 3 4 AIR FILTER FOR DRIVE BELT 3 6 SECONDARY AUR SUPPLY SYSTEM SPARK PLUG 3 7 VALVE CLEAR...

Page 48: ...free play 1 4 mm 0 04 0 16 in Spark plug gap 0 6 0 7 mm 0 002 0 003 in Spark plug Standard DPR7EA 9 Valve clearance IN 0 1 mm 0 004 in EX 0 1 mm 0 004 in Idle speed MXU 250 1500 100 rpm MXU 300 1600...

Page 49: ...n timing BTDC 5 1 2000 rpm Tire pressure 1 Rider Front 0 28 kgf cm 28 Kpa 3 2 psi Rear 0 28 kgf cm 28 Kpa 3 2 psi Tire size Front 22 7 10 Rear 22 10 10 TORQUE VALUES Front wheel nut 4 5 kgf m 45 Nm 32...

Page 50: ...nsure more reliable vehicle operation and a longer service life The need for costly overhaul work will be greatly reduced This information applies to vehicles already in service ad well as new vehicle...

Page 51: ...throttle free play Slide the rubber sleeve back to expose the throttle cable adjuster Loosen the lock nut then turn the adjuster to obtain the correct free play 1 4 mm or 0 04 0 16 in Tighten the loc...

Page 52: ...ng Remove the screw and remove the air cleaner assembly from the air cleaner holder Remove the air cleaner and air cleaner screen from the air cleaner body Remove the air cleaner net from the air clea...

Page 53: ...the drain tube securing it with the clip AIR FILTER FOR DRIVE BELT To clean the air filter Remove front center cover See page 2 7 Remove air filter Tap the element lightly to remove most of the dust a...

Page 54: ...nsiderable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water Check the AICV air injection control valve hoses between the AICV control solenoid valve and cyl...

Page 55: ...index mark on the right crankcase cover to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Inspect and adjust the valve clearance Valve Clearance...

Page 56: ...djust the air screw IGNITION TIMING Remove the timing hole cap Check the ignition timing with a timing light When the engine is running at idle speed the ignition timing is correct if the F mark on th...

Page 57: ...linder head gasket Worn piston rings Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head ENGINE OIL OIL LEV...

Page 58: ...ue 2 5 kgf m 25 Nm 18 lbf ft Fill the engine with oil and install the oil fill cap Oil Capacity At disassembly 1 6 liter 1 4 lmp qt 1 7 Us qt At change 1 4 liter 1 23 lmp qt 1 48 Us qt ENGINE OIL REPL...

Page 59: ...oil filter cap to specification Torque 1 5 kgf m 15 Nm 11 lbf ft Fill the engine with oil and install the oil fill cap Oil Capacity At disassembly 1 6 liter 1 4 lmp qt 1 7 Us qt At change 1 4 liter 1...

Page 60: ...t 0 42 Us qt At change 300 cc 0 26 lmp qt 0 32 Us qt Oil Capacity MXU 300 At disassembly 600 cc 0 52 lmp qt 0 64 Us qt At change 500 cc 0 43 lmp qt 0 53 Us qt Install the oil filler bolt and tighten t...

Page 61: ...the oil has completely drained reinstall and tighten the drain plug to specified torque Torque 2 kgf m 20 Nm 15 lbf ft Fill the gear case with the recommended oil SAE 90 Oil Capacity MXU 300 At disass...

Page 62: ...Measure the V belt width Service limit 22 mm 0 88in Replace the drive belt if out of specification BRAKE PADS INSPECTION A wear indicator is provided on each brake The indicators allows checking of br...

Page 63: ...the lower level mark through the inspection window HEADLIGHT AIM Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim ad...

Page 64: ...xcessive play Check the tie rod ends Turn the handlebar to the left and or right until it stops completely then slightly move the handlebar from left to right Replace the tie rod ends if tie rod end h...

Page 65: ...e exactly opposite Measure the width B between the marks Calculate the toe in using the formula given below Toe in B A Toe in 0 15 mm 0 0 6 in If the toe in is incorrect adjust the toe in Adjust the t...

Page 66: ...h tie rod are turned the same amount If not the machine will drift tight or left even though the handlebar is positioned straight which may lead to mishandling and accident After setting the toe in to...

Page 67: ...wear or damage Tire wear limit 3 mm 0 12 in WHEEL INSPECTION Inspect the wheel Replace if damage or bends Always balance the wheel when a tire or wheel has been changed or replaced Rear Axle Nut Neve...

Page 68: ...e the machine on a level place Check drive chain slack Adjust if out of specification Drive chain slack A 30 40 mm 1 2 1 6 in Adjust drive chain slack Loosen the caliper holder bolt and two axle hub h...

Page 69: ...e ATV forward To loosen the chain pull the ATV backward Retighten the two axle hub holder bolt and caliper holder bolt to the specification Torque Axle hub holding bolt 4 kgf m 40 Nm 29 lbf ft Caliper...

Page 70: ...screwdriver and pass the standard phillips screwdriver through the shift arm into the index hole at the transmission case cover Turn the rod clockwise or counterclockwise until the drive select lever...

Page 71: ...oting parts of each lever REAR SUSPENSION LUBRICATION MXU 250 Inject grease into the nipples using a grease gun until slight over flow is observed from the thrust covers Nipple Damaged cable sheath ma...

Page 72: ...in bolt to drain the coolant Drain the coolant in the reserve tank Reinstall the drain bolt Coolant capacity 1400 cc 1232 lmp qt 1484 Us qt Radiator capacity 1100 cc 968 lmp qt 1166 Us qt Reserve tank...

Page 73: ...eaning the spark arrester 1 Remove the bolt 1 2 Remove the tailpipe 2 by pulling it out of the muffler 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arr...

Page 74: ...___________________________________________________________________ __________________________________________________________________________________ _________________________________________________...

Page 75: ...4 LUBRICATION SYSTEM 4 1 MXU 300 250 LUBRICATION SYSTEM Oil Pump Oil Filter Screen Crankshaft Rocker Arm Shaft...

Page 76: ...t reaches its service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS Unit mm in Item Standard Service Limit Inner rotor to outer rotor clearance 0 15 0 006 0 2 0 00...

Page 77: ...filter cleaning OIL PUMP REMOVAL Remove the right crankcase cover and the A C generator flywheel Refer to the A C GENERATOR FLYWHEEL section in the chapter 16 Remove the starter clutch gear Refer to...

Page 78: ...ket Remove the two oil pump bolts for remove the oil pump OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump INSPECTION Measure the rotor end to pump body clearance Service Limit 0 12...

Page 79: ...ump cover by aligning the hole in the cover with the dowel pin Tighten the screw to the specified torque Torque 0 2 kgf m 2 Nm 1 5 lbf ft INSTALLATION Reverse the OIL PUMP REMOVAL procedures Outer Rot...

Page 80: ...4 LUBRICATION SYSTEM 4 6 MXU 300 250 Make sure that the pump shaft rotates freely without binding Install oil pump driven sprocket and drive chain circlip and oil separator cover Pump Shaft...

Page 81: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUE...

Page 82: ...5 FUEL SYSTEM 5 1 MXU 300 250...

Page 83: ...uretor air and fuel jets the O rings and diaphragm must be removed first to avoid damage Then clean with compressed air When the motorcycle is not used for over one month drain the residual gasoline f...

Page 84: ...ottle operation Float level too low Intake air leak Engine idles roughly stalls or runs poorly Clogged fuel tank cap breather hole Excessively used choke Kinked or restricted fuel line Ignition malfun...

Page 85: ...nk then remove the fuel tank INSTALLATION Reverse the FUEL TANK REMOVAL procedures FUEL VALVE REMOVAL Remove the screw and then remove control switch Disconnect all fuel tubes and remove the two screw...

Page 86: ...the rubber gasket from the fuel valve body INSPECTION Inspect the fuel valve body for dirt and clog Clean if necessary Replace the rubber gasket with new ones if they are damaged or deteriorated Repl...

Page 87: ...ring INSTALLATION Reverse the FUEL VALVE REMOVEAL procedures Connect all fuel tube Aligning the tab on the control shaft with the outlet duct in the fuel valve body Aligning the tab on the retaining...

Page 88: ...LVE DISASSEMBLY Remove the fuel tank Refer to FUEL TANK section in the chapter 5 Remove the carburetor cap Pull out the throttle valve Compress the spring to disconnect the throttle cable by hand Carb...

Page 89: ...Check the throttle valve and jet needle for wear or damage ASSEMBLY Reverse the DISASSEMBLY procedures Install the throttle valve into the carburetor body Throttle Valve Needle Retainer Spring Jet Nee...

Page 90: ...he screw on the lock plate for disconnect the choke cable Loosen the air cleaner connecting tube band screw Remove the two bolts at the air cleaner case Disconnect the air cleaner connecting tube from...

Page 91: ...00 250 Check the O ring for damage Replace with new ones if necessary DISASSEMBLY Remove the float chamber attaching three screws and remove the float chamber Remove the baffle plate Baffle plate Scre...

Page 92: ...crew Slow Jet Main Jet Throttle Stop Screw Spring Washer O ring Air Screw Throttle Stop Screw Spring Be careful not to damage the jets and jet holder when removing them Before removal turn the throttl...

Page 93: ...Remove the two screws and the air cut off valve cover Remove the spring diaphragm and O rings Inspect the diaphragm and spring for wear or damage Spring Screws Diaphragm Slow Jet Main Jet Needle Jet...

Page 94: ...FLOAT FLOAT VALVE INSPECTION Inspect the float valve seat for wear or damage Inspect the float for damage or fuel level inside the float chamber FUEL RESERVOIR O RING CHECK Remove the O ring INSPECTI...

Page 95: ...at level with the float level gauge while the float pin just contacts with float valve Float Level 14 8mm When adjusting carefully bend the float pin Check the float for proper operation Install the j...

Page 96: ...d disconnect the crankcase breather hose from the crankcase Loosen the carburetor to air cleaner connecting tube band screw Remove the intake air duct trim clip Remove the mounting bolts and then remo...

Page 97: ...INSTALLATION Remove the two nuts and electrical holder Disconnect air supply hose and vacuum hose from the air solenoid valve then remove the air solenoid valve Installation is in the reverse order o...

Page 98: ..._____________________________________ __________________________________________________________________________________ _______________________________________________________________________________...

Page 99: ...jack or other adjustable support is required to support and maneuver the engine Be careful not to damage the machine body cables and wires during engine removal Use shop towels to protect the machine...

Page 100: ...the air solenoid valve refer to chapter 5 Remove the spark coil refer to chapter 17 Disconnect the crankcase breather from the cylinder head cover Disconnect the vacuum hose from the inlet pipe Discon...

Page 101: ...he two mounting nuts and drive select shift Disconnect the speedometer cable Remove the three bolts at the drive sprocket cover and then remove the drive sprocket cover Remove the two bolts on the dri...

Page 102: ...re nut for disconnect the starter motor wire Remove the bolt at the starter motor for disconnect the ground wire lead Remove the A C Generator ignition pulse generator and gear change switch connector...

Page 103: ...and then disconnect the outlet hose from the left crankcase cover Remove the rear lower mounting bolt and nut Remove the rear upper mounting bolt and nut Remove the front mounting bolts and nuts Remov...

Page 104: ...6 ENGINE REMOVAL 6 6 MXU 300 250 Remove the engine assembly to the left side of the machine...

Page 105: ...loosely install then tighten the engine mounting nuts to the specified torque Torque 40 N m 4 kgf m 29 lbf ft The brackets bolts front engine mounting bolt and loosely install then tighten the bolts...

Page 106: ...buretor Refer to chapter 5 Disconnect the spark plug from the cylinder head Disconnect the spark coil connectors from the spark coil then remove the two bolts and spark coil Disconnect the speedometer...

Page 107: ...mounting nuts and drive select shift Remove the bolt and thermostat Remove the two nuts and electrical holder Disconnect air supply hose and vacuum hose from the air solenoid valve then remove the ai...

Page 108: ...er pump Remove the A C Generator ignition pulse generator and gear change switch connectors Straight the clamp and remove the bolt then disconnect the engine ground cable Band Water Hose Ignition Puls...

Page 109: ...nut for disconnect the starter motor wire Loosen the inlet hose band screw and then disconnect the inlet hose from the left crankcase cover Loosen the outlet hose band screw and then disconnect the o...

Page 110: ...MOVAL 6 12 MXU 300 250 Remove the four bolts for remove the left and right engine brackets Remove the rear upper mounting bolt and nut Remove the rear lower mounting bolt and nut Brackets Bolts Nut Bo...

Page 111: ...d screw on the swingarm side Remove the joint boot from the swingarm Rise the engine front side and move the engine forward then remove the engine from the frame by disengaging the countershaft from t...

Page 112: ...6 ENGINE REMOVAL 6 14 MXU 300 250 Turn the engine rear side to frame left side Lower the cylinder head to turn the cylinder head to frame left side...

Page 113: ...6 ENGINE REMOVAL INSTALLATION 6 15 MXU 300 250 Move the engine to a rubber mat...

Page 114: ...6 MXU 300 250 Remove the two bolts and intake manifold may more easy to move engine Bolts Intake Manifold Be careful not to damage choke knob cable and holder plate when the engine is moved Holder Pla...

Page 115: ...haft case Slide the joint boot front to expose the secondary driven bevel gear shaft Install the engine the frame Move the engine rearward and engage the secondary driven bevel gear shaft into the uni...

Page 116: ...nt engine mounting bolt and loosely install then tighten the bolts on the brackets to the specified torque Torque 22 N m 2 2 kgf m 16 lbf ft Tighten the front engine mounting bolt and nut to the speci...

Page 117: ...__________________________________________________ __________________________________________________________________________________ __________________________________________________________________...

Page 118: ...7 CYLINDER HEAD VALVES 7 1 MXU 300 250...

Page 119: ...m Standard Service Limit IN 0 1 0 004 EX 0 1 0 004 MXU 250 15 2 kgf cm 1500 kPa 213 psi Cylinder head compression MXU 300 16 2 kgf cm 1600 kPa 227 psi Cylinder head warpage 0 05 0 0002 IN 34 287 1 371...

Page 120: ...alve stem seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve...

Page 121: ...over then remove the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts Torque 1 kgf m 10 N...

Page 122: ...to tighten it Remove the four camshaft holder nuts and washers Remove the camshaft holder and dowel pins Remove the camshaft gear from the cam chain and remove the camshaft Nuts Washers Camshaft Diago...

Page 123: ...discoloration or grooves If any defects are found replace the rocker arm shaft with a new one then inspect lubrication system Inspect the rocker arm bore cam lobe contact surface and adjuster surface...

Page 124: ...ecification Service limits 0 1 mm 0 004 in Check the stop plate spring for damage Replace the stop plate assembly with a new one if the spring is damage CAMSHAFT HOLDER ASSEMBLY Reverse the CAMSHAFT H...

Page 125: ...defects are found replace the camshaft with a new one then inspect lubrication system INSTALLATION Reverse the CAMSHAFT REMOVAL procedures Note the following points 1 Turn the flywheel so that the T...

Page 126: ...t 2 Turn the cam chain tensioner screw counter clockwise to release it Apply engine oil to a new O ring and install it Tighten the cam chain tensioner cap bolt 3 Adjust the valve clearance Refer to th...

Page 127: ...ct the thermostat Remove the two cylinder head bolts Remove the cylinder head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats oil seals and valves using a valv...

Page 128: ...in the stem to guide clearance Service limits replace if over IN 0 06 mm 0 0024 in EX 0 08 mm 0 0032 in CYLINDER HEAD INPECTION Check the spark plug hole and valve areas for cracks Check the cylinder...

Page 129: ...e compressed force valve spring and installed length Replace if out of specification Standard IN 10 20 11 84kg at 18 05mm EX 19 14 22 02kg at 21 5mm Measure the spring tilt Replace if out of specifica...

Page 130: ...tems gently with a plastic hammer for 2 3 times to firmly seat the cotters INSTALLATION Install the dowel pins and a new cylinder head gasket Reverse the CYLINDER HEAD REMOVAL procedures After camshaf...

Page 131: ...____________________________________________________________________________ __________________________________________________________________________________ ________________________________________...

Page 132: ...8 CYLINDER PISTON 8 1 MXU 300 250...

Page 133: ...check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muff...

Page 134: ...iston Ring end gap Second 0 3 0 45 0 012 0 018 0 65 0 026 Piston ring Oil ring 0 2 0 7 0 008 0 028 0 9 0 036 Piston O D 72 67 72 69 2 9068 2 9076 72 6 2 904 Piston O D measuring position 10mm from bot...

Page 135: ...inder head gasket and cam chain guide Unscrew the clamp and disconnect the water hose Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface...

Page 136: ...the piston wall for wear scratches damage If any defects are found replace the piston with a new one Install the piston rings onto the piston and measure the piston ring to groove clearance Service L...

Page 137: ...ring end gap Service Limit replace if over Top 0 5 mm 0 02 in 2nd 0 65 mm 0 026 in Oil ring 0 9 mm 0 036 in Measure the piston pin hole I D Service Limit replace if over 17 04 mm 0 6816 in Measure th...

Page 138: ...and Y directions Cylinder I D Service Limit replace if over 72 8 mm 2 912 in Measure the cylinder to piston clearance Service Limit repair or replace if over 0 1 mm 0 004 in The true roundness is the...

Page 139: ...Service Limit replace if over 17 06 mm 0 6824 in Measure the connecting rod to piston pin clearance Service Limit replace if over 0 06 mm 0 0024 in Second Side Rail Top Side Rail Oil Ring Be careful n...

Page 140: ...bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Intake Side Guide Exhaust Side Guide Apply proper clean engine oil arou...

Page 141: ...9 DRIVE AND DRIVEN PULLEYS 9 0 MXU 300 250 9 DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 2 LEFT CRANKCASE COVER 9 3 DRIVE PULLEY DRIVEN PULLEY 9 4 9...

Page 142: ...9 DRIVE AND DRIVEN PULLEYS 9 1 MXU 300 250...

Page 143: ...h outer I D 153 153 2 6 12 6 128 153 5 6 14 Driven face spring free length 131 5 24 Driven face O D 39 965 39 985 1 5986 1 5994 39 94 1 5976 Movable driven face I D 40 40 025 1 6 1 601 40 06 1 6024 We...

Page 144: ...move the recoil starter cover Remove the dowel pins and gasket Disconnect drive belt air inlet and outlet hose from left crankcase cover see page 6 5 Remove the left crankcase cover bolts and left cra...

Page 145: ...nd tighten the bolts Connect the drive belt air inlet and outlet hose and tighten band screws Install the recoil starter cover and outlet hose cover DRIVE PULLEY DRIVEN PULLEY REMOVAL Remove the left...

Page 146: ...e the drive pulley Refer to the DRIVE PULLEY REMOVAL section in the chapter 9 Hold the clutch outer with the universal holder and remove the clutch outer nut Special tool Universal Holder E017 Remove...

Page 147: ...ND DRIVEN PULLEYS 9 6 MXU 300 250 Remove the movable drive face assembly and drive pulley collar DISASSEMBLY Remove the ramp plate Remove the six weight rollers Drive Pulley Collar Drive Face Ramp Pla...

Page 148: ...ow 22 8 mm 0 912 in Measure the movable drive face bushing I D Service Limit replace if over 27 06 mm 1 0824 in ASSEMBLY Install the weight rollers into the movable drive face Install the ramp plate C...

Page 149: ...r or damage Measure the clutch outer I D Service Limit replace if over 153 5 mm 6 14 in CLUTCH DRIVEN PULLEY DISASSEMBLY Hold the clutch driven pulley assembly with the clutch spring compressor Specia...

Page 150: ...r and disassemble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Remove the oil seal from...

Page 151: ...ickness Service Limit replace if below 0 5 mm 0 02 in INSPECTION Measure the driven face spring free length Service Limit replace if below 131 mm 5 24 in Check the driven face for wear or damage Measu...

Page 152: ...Drive the inner needle bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into t...

Page 153: ...ring into the driven face Special tool Oil Seal And Bearing Install E014 CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch CLUTCH DRIVEN PULLEY ASSEMBLY Circlip Retai...

Page 154: ...guide rollers and guide roller pins and then install them into the holes of the driven face Install the seal collar Remove any excessive grease Set the driven pulley assembly driven face spring and cl...

Page 155: ...d collar Install the clutch driven pulley and driven belt onto the drive shaft Install the clutch outer collar Hold the clutch outer with the flywheel holder Install and tighten the clutch outer nut T...

Page 156: ...5 Nm 68 lbf ft When installing the drive pulley face compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened Make sure the ratchet into the spl...

Page 157: ...___________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION TRANSMISSION SYSTEM _____________________...

Page 158: ...10 FINAL REDUCTION TRANSMISSION SYSTEM 10 1 MXU 300 250 MXU 250...

Page 159: ...10 FINAL REDUCTION TRANSMISSION SYSTEM 10 2 MXU 300 250 MXU 300...

Page 160: ...ONS Specified Oil GEAR OIL SAE 90 Oil Capacity MXU 250 At change 0 3 liter 0 264 lmp qt 0 318 US qt At disassembly 0 4 liter 0 352 lmp qt 0 424 US qt Oil Capacity MXU 300 At change 0 5 liter 0 44 lmp...

Page 161: ...bolts and then remove the washer and drive sprocket see page 6 3 Remove the bolt and then disconnect the drive shift arm from the shift shaft see page 6 3 Disconnect the speedometer cable see page 6 3...

Page 162: ...earing Inspect the bearing for allow play in the transmission case cover or the bearing turns roughly If any defects are found replace the bearing with a new one Inspect the drive axle gear teeth for...

Page 163: ...ace the bearing with a new one ASSEMBLY Install the needle bearing Install the oil seal and bearing Install the bearing circlip Install the drive axle and drive axle cirelip TRANSMISSION MXU 250 REMOV...

Page 164: ...10 FINAL REDUCTION TRANSMISSION SYSTEM 10 7 MXU 300 250 Remove the shift shaft Remove the stopper plug Remove spring washer and shift cam stopper Shift Shaft Plug Shift Cam Stopper Washer Spring Plug...

Page 165: ...10 FINAL REDUCTION TRANSMISSION SYSTEM 10 8 MXU 300 250 Remove the transmission guide bar Remove shift cam Remove the shift fork Guide Bar Shift Fork Shift Cam...

Page 166: ...cation Replace Service Limit Less than 0 03 mm 0 0012 in Inspect the shift fork cam follower and shift fork pawl Scoring beads wear Replace Check the shift cam groove and shift cam gear Wear or damage...

Page 167: ...ft shaft gear Damage Replace Inspect shift shaft Damage bends wear Replace Remove the main axle MAIN AXLE DISASSEMBLY Remove the washers collar primary driven gear bush and clutch dog Collar Washer Pr...

Page 168: ...300 250 Remove the circlip and then remove the washers reverse wheel gear and needle bearing Washers Primary Driven Gear Clutch Dog Collar Main Axle Bush Circlip Washer Reverse Wheel Gear Washers Cir...

Page 169: ...oration pitting wear Replace Inspect the mated dogs Rounded edges cracks missing portions Replace MAIN AXLE ASSEMBLY Reverse the MAIN AXLE DISASSEMBLY procedures Washer Circlip Needle Bearing Reverse...

Page 170: ...Inspect the gear teeth Blue discoloration pitting wear Replace PRIMARY DRIVE AXLE REMOVAL Remove the clutch driven pulley Refer to the chapter 9 Remove the oil seal circlip bolts and plates Remove the...

Page 171: ...or the bearing turns roughly If any defects are found replace the bearing with a new one INSTALLATION Reverse the TRANSMISSION REVOVAL section procedures Install the main drive axle Reverse the MAIN...

Page 172: ...ion case cover bolt Torque 2 7 kgf m 27 Nm 20 lbf ft Fill the engine with oil and install the oil filler bolt Refer to the TRANSMISSION OIL REPLACEMENT section in the chapter 3 Specified Gear Oil KYMC...

Page 173: ...le see page 6 3 Remove the speedometer gear plug washer and speedometer gear shaft INSPECTION Inspect the speedometer gear teeth pitting wear Replace Remove the transmission case cover see page 10 4 I...

Page 174: ...NAL REDUCTION TRANSMISSION SYSTEM 10 17 MXU 300 250 Inspect the oil seal for wear or damage If any defects are found replace the oil seal with a new one INSTALLATION Reverse the REMOVAL procedures Oil...

Page 175: ...EPLACEMENT section in the chapter 3 Remove the engine assembly Refer to the ENGINE REMOVAL section in the chapter 6 or remove the rear swingarm page 15 21 Loosen the joint boot band screw and remove t...

Page 176: ...eter gear plug washer and speedometer gear Using a chisel unlock the nut Hold the clutch outer see page 9 3 to remove the left crankcase cover with the universal holder and remove the secondary drive...

Page 177: ...im Remove the two dowel pins SECONDARY DRIVEN BEVEL GEAR CASE DISASSEMBLY Using a chisel unlock the nut Fit the universal joint onto the driven bevel gear shaft Remove the driven bevel gear shaft nut...

Page 178: ...vel gear shaft from case TRANSMISSION CASE COVER BEARING OIL SEAL REPLACEMENT Inspect the shift shaft oil seal and speedometer gear oil seal for wear or damage If any defects are found replace the oil...

Page 179: ...ools Special tools Bearing puller E037 Bearing Oil seal install E014 Install a new driveshaft bearing and a new countershaft bearing with special tool Special tools Bearing Oil seal install E014 Insta...

Page 180: ...RY DRIVEN BEVEL GEAR SHAFT CASE BEARING OIL SEAL REPLACEMENT Remove the secondary driven bevel gear shaft oil seal Remove the snap ring Remove the outer bearing Remove the snap ring Remove the inner b...

Page 181: ...tools Bearing Oil seal install E014 Install a new outer bearing with special tool Special tools Bearing Oil seal install E014 Apply the oil to a new oil seal lip and then install the oil seal with the...

Page 182: ...el gear shaft for blue discoloration pitting or wear Inspect the bevel gears and speedometer gear for blue discoloration pitting or wear SECONDARY DRIVEN BEVEL GEAR ASSEMBLY Apply engine oil to the se...

Page 183: ...Install the shim and driven bevel gear Fit the universal joint onto the driven bevel gear shaft Tighten the driven bevel gear nut to the specified torque Torque 100 N m 10 kgf m 72 5 lb ft Stake the...

Page 184: ...tighten the bolts to the specified torque Torque 2 7 kgf m 27 Nm 20 lbf ft Install the shim and drive bevel gear Hold the clutch out and tighten the drive bevel gear nut to the specified torque Torqu...

Page 185: ...case cover Then while rotating the driven bevel gear shaft tighten the bolts in a crisscross pattern in several steps Install the speedometer gear and washer Install the plug and tighten it O ring Mar...

Page 186: ...l KYMCO SIGMA GEAR OIL 90 Oil Capacity MXU 300 At disassembly 0 6 liter 0 528 lmp qt 0 636 US qt At change 0 5 liter 0 44 lmp qt 0 53 US qt TRANSMISSION MXU 300 REMOVAL Remove the shift shaft Remove t...

Page 187: ...move the lower shift fork Remove the countershaft and driveshaft as an assembly Disassemble the countershaft and the driveshaft Countershaft Driveshaft Guide Bar Upper Shift Fork Washer Plug Shift Cam...

Page 188: ...pect the shift fork cam follower and shift fork pawl Scoring beads wear Replace Check the shift cam groove and shift cam gear Wear or damage Replace Inspect shift shaft gear Damage Replace Inspect shi...

Page 189: ...ar clutch dog Clutch dog Check the gear dogs gearshifter groove for wear or damage Remove the snap ring then remove washer Remove the high drive gear then remove washer High drive gear Inspect the dog...

Page 190: ...TERSHAFT DISASSEMBLYN procedures to assemble all parts into their original positions Washer Countershaft Washer Snap Ring High Drive Gear Counter Gear Countershaft High Gear Clutch Dog Washer Low Driv...

Page 191: ...ar Reverse gear Inspect the dog holes and teeth for damage or wear Remove the washer Remove the reverse low gear clutch dog Clutch dog Check the gear dogs gearshifter groove for wear or damage Remove...

Page 192: ...e the DRIVESHAFT DISASSEMBLYN procedures to assemble all parts into their original positions Washer Low Driven Gear Reverse Gear Clutch Dog Washers High Driven Gear Washer Snap Ring Low Driven Gear Co...

Page 193: ...tes Remove the primary drive axle If the bearing is left on the drive axle remove it with the special tool Special tool Universal bearing puller E030 TRANSMISSION CASE BEARING REPLACEMENT Remove the t...

Page 194: ...ith special tool Special tools Bearing Oil seal install E014 INASTALLATION Apply engine oil to the following parts Countershaft Driveshaft Gear teeth Assemble the countershaft and driveshaft Install t...

Page 195: ...the upper gearshift fork into the clutch dog main axle groove and install the upper gearshift fork pawl into the shift cam groove with its LCD9R mark facing down Install the guide bar Install the shi...

Page 196: ...in specification the shim must be changed and the backlash should be rechecked until correct Refer to the chart a at the page 10 41 for appropriate shim thickness Bevel gear backlash Standard 0 03 0 1...

Page 197: ...o be correct example 2 then to complete installation 1 Incorrect contact at tooth top 2 Correct 3 Incorrect contact at tooth root If tooth contact is found to be incorrect examples 1 and 3 the shim th...

Page 198: ...03 in E 0 8 mm 0 032 in F 0 85 mm 0 034 in G 0 9 mm 0 036 in H 0 95 mm 0 038 in I 1 mm 0 04 in J 1 05 mm 0 042 in K 1 1 mm 0 044 in L 1 15 mm 0 046 in Driven bevel gear shims A 0 85 mm 0 034 in B 0 9...

Page 199: ...___________________________________________________________________ __________________________________________________________________________________ _________________________________________________...

Page 200: ...11 CRANKCASE CRANKSHAFT BALANCE SHAFT 11 1 MXU 300250...

Page 201: ...driven pulleys Chapter 9 A C generator Chapter 16 Starter clutch Chapter 18 Oil pump Chapter 4 SPECIFICATIONS Unit mm in Item Standard Service Limit Connecting rod big end side clearance 0 05 0 4 0 0...

Page 202: ...L Remove the timing chain from right crankcase Remove the left and right crankcase attaching bolts Separate the left and right crankcase halves Remove the gasket and dowel pins Remove the crankshaft f...

Page 203: ...300 250 Remove balance shaft from the left crankcase Clean off all gasket material from the crankcase mating surfaces Inspect the balance shaft gear teeth Burrs chips roughness wear Replace Balance Sh...

Page 204: ...06 mm 0 6824 in Measure the connecting rod small end free play A Out of specification 0 8 1 mm 0 032 0 04 in Replace the crankshaft Measure the crankshaft run out B Service Limit replace if over 0 1...

Page 205: ...2 mm 0 008 in Radial 0 05 mm 0 002 in CRANKCASE BALANCER INSTALLATION Install the balance shaft and crankshaft into the left crankcase Install the dowel pins and new gasket Install the right crankcas...

Page 206: ...___________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLIN...

Page 207: ...water as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 1 2 kgf m 12 Nm 8 6 lbf ft Left...

Page 208: ...3 1 041 1 038 1 035 1 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 0...

Page 209: ...sure 0 75 1 05 kgf cm 75 105 kPa 10 65 14 91 psi Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the wat...

Page 210: ...the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Remove the front fender page 2 8 Remove the radiator cap Remove the drain bolt and drain the coolant from the system Disc...

Page 211: ...diator forward and raise the radiator from frame Disconnect the thermostatic switch wire connectors Disconnect the fan motor connector Loosen the hose bands and disconnect the coolant hoses from the r...

Page 212: ...tor by battery CHECK THERMOSTATIC SWITCH When coolant temperature lower then 85 90 the thermostatic switch OFF When coolant temperature over 85 90 the thermostatic switch ON RADIATOR ASSEMBLY Install...

Page 213: ...maintenance schedule Mix only distilled low mineral water with the antifreeze Mix only distilled low mineral water with the antifreeze Recommended mixture 1 1 Distilled water and antifreeze REPLACEME...

Page 214: ...th the recommended coolant through the filler opening up to the filler neck Bleed air from the system as follow 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle three to four tim...

Page 215: ...and replace the mechanical seal WATER PUMP IMPELLER REMOVAL Drain the coolant page 12 7 Loosen the screw and disconnect the coolant inlet hose Remove the four bolts and the water pump cover Remove th...

Page 216: ...nnect the water hose from the right crankcase cover Remove the twelve bolts attaching the right crankcase cover Remove the water pump bearing snap ring from the water pump assembly Remove the water pu...

Page 217: ...seal out of the water pump assembly from the inside Drive in a new mechanical seal using a mechanical seal driver Inner Bearing Apply sealant to the right crankcase cover fitting surface of a new mec...

Page 218: ...case cover Tighten the twelve bolts to secure the right crankcase cover WATER PUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Instal...

Page 219: ...r over a burner and measure the resistance through the sensor as the water heats up Temperature 50 80 100 120 Resistance 154 52 27 16 THERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivale...

Page 220: ...the water hose from the thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Remove the two screws and...

Page 221: ...T INSTALLATION The installation sequence is the reverse of removal Fill the cooling system with the specified coolant page 12 7 O ring Thermosensor Thermostat Thermometer Do not let the thermostat tou...

Page 222: ...___________________________________________________________ __________________________________________________________________________________ BRAKE SYSTEM ____________________________________________...

Page 223: ...13 BRAKE SYSTEM 13 1 MXU 300 250...

Page 224: ...fluid with a clean towel Do not wipe the machine with a towel contaminated by brake fluid Make sure to use recommended brake fluid Use of other unspecified brake fluids may cause brake failure Inspect...

Page 225: ...rom the brake caliper Remove the two bolts attaching the brake caliper and then remove brake caliper Compress the brake caliper holder and remove brake pads A wear indicator is provided on each brake...

Page 226: ...ce a new one 3 2 kgf m 32 Nm 25 lbf ft FRONT BRAKE FLUID CHANGE AIR BLEED BRAKE FLUID DRAINING Place the machine on the level ground and set the handlebar upright Remove the two screws attaching the b...

Page 227: ...nded Brake Fluid DOT 4 BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake lever after continuously pull it several times Then loosen the bleed valve nut to b...

Page 228: ...emove the master cylinder Remove the brake lever bolt and the brake lever Remove the piston rubber cover and snap ring from the brake master cylinder Snap Ring Snap Ring Pliers Close Fluid Tube Bolt S...

Page 229: ...the inside of the master cylinder and brake reservoir with brake fluid INSPECTION Check the cylinder inside wall and spring for scratch corrosion or other abnormal condition If any abnormal condition...

Page 230: ...ue 1 2 kgf m 12 Nm 8 6 lbf ft Install the brake fluid tube with the attaching bolt and two sealing washers then tighten the bolt Torque 3 5 kgf m 35 Nm 25 lbf ft Connect the front stop switch wire con...

Page 231: ...caliper Remove the brake caliper DISASSEMBLY Remove the brake pads page 13 3 Remove the brake pad spring plate Remove the piston from the brake caliper If necessary use compressed air to squeeze out t...

Page 232: ...ndition is noted replace the caliper ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seals Lubricate the brake caliper cylinder inside wall with brake fluid Install the oil...

Page 233: ...lts and brake caliper mounting bolts Torque Brake pad pin bolt 1 8 kgf m 18 Nm 13 lbf ft Brake caliper mounting bolt replace a new one 3 2 kgf m 32 Nm 25 lbf ft Fill the brake reservoir with the speci...

Page 234: ...DS REMOVAL procedures REAR BRAKE PADS MXU 300 Replacement Remove the left rear wheel page 15 4 The rear and front brake pads are replaced the same page 13 3 Brake Pad Cover Cotter Pin Brake Pad Pin Sp...

Page 235: ...nt hose to the brake caliper bleed valve and then loosen the bleed valve nut Use a syringe to draw the brake fluid out through the hose Use shop towels to cover plastic parts and coated surfaces to av...

Page 236: ...ir bubbles in the hose Then tighten the bleed valve nut Torque 0 6 kgf m 6 Nm 4 32 lbf ft Recommended Brake Fluid DOT 4 Reservoir Protection Cover Reservoir Cover Pedal Reservoir Pedal Bleed Valve Fro...

Page 237: ...nuously pull it several times Then loosen the bleed valve nut to bleed air from the brake system Repeat these steps until the brake system is free of air Brake Pedal Bleed Valve Pedal When bleeding ai...

Page 238: ...THE REAR BRAKE PEDAL DISASSEMBLY Remove the brake reservoir cover Drain the brake fluid from the hydraulic brake system page 13 13 Loosen the upper and lower nuts Hold the lower nut to turn clockwise...

Page 239: ...fluid inlet duct Check the O ring for wear or damage and replace if necessary Remove the two nuts and remove the seal boot Remove the circlip and then pull out the push rod washer piston and spring Fl...

Page 240: ...ake fluid to all removed parts Reverse the MASTER CYLINDER ON THE REAR BRAKE PEDAL DISASSEMBLY procedures Connect the brake fluid tube to the master cylinder with the fluid bolt and new sealing washer...

Page 241: ...ow gun pressurize the caliper fluid chamber to push out the piston To prevent brake fluid from splashing on the parts nearby cover the parts with cloth Slightly loosen the caliper housing bolts before...

Page 242: ...ratch corrosion or other damages If any abnormal condition is noted replace the caliper BRAKE DISK Measure the brake disk thickness Service Limit 3 0 mm 0 12 in Measure the brake disk run out Service...

Page 243: ...aliper and tighten the two mounting bolts Torque Brake caliper mounting bolt replace a new one 3 2 kgf m 32 Nm 25 lbf ft With the tube ends contacted to the caliper and install the washers and tighten...

Page 244: ...300 250 REMOVAL INSPECTION ASSEMBLY INSTALLATION MXU 300 Remove the rear left wheel page 15 4 The rear and calipers are all the same removal inspection assembly installation Bolts Bolts Caliper Pedal...

Page 245: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRO...

Page 246: ...14 FRONT WHEEL FRONT SUSPENSION STEERING SYSTEM 14 1 MXU 300 250...

Page 247: ...wheel hub nut 7 kgf m 70 Nm 50 lbf ft Castle nut Knuckle ball joint nut 3 kgf m 30 Nm 22 lbf ft Castle nut Tie rod ball joint nut 2 kgf m 20 Nm 15 lbf ft Castle nut Front shock absorber mount bolt 4...

Page 248: ...and under the frame Measure the wheel run out Replace wheel or check bearing play if out of specification Rim run out limits Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in INSTALLATION When reinstalling a...

Page 249: ...ove the cotter pin Remove nut from the front wheel hub and then remove front wheel hub DISASSEMBLY Remove the outside collars Inspect the dust seals for wear or damage If any defects are found replace...

Page 250: ...STEERING SYSTEM 14 5 MXU 300 250 Inspect the bearings for allow play in the front wheel hub or the wheel turns roughly If any defects are found replace the bearings Remove the bearings using a general...

Page 251: ...wheel hub ASSEMBLY Install the left new bearing and dust seal into the front wheel hub Special tool Oil seal and bearing install E014 Install the distance collar Distance Collar Be sure the tapered s...

Page 252: ...pin Do not loosen the wheel hub nut after torque tightening If the wheel hub nut groove is not aligned with the cotter pin hole align groove with the hole by tightening up on the wheel hub nut Always...

Page 253: ...l according to the following instructions Special tool Tie rod ball join remover F011 Apply grease to the ball joint remover at the point shown This will ease installation of the tool and prevent dama...

Page 254: ...ll ease installation of the tool and prevent damage to the pressure bolt threads Insert the jaws carefully making sure that you do not damage the ball joint boot Adjust the jaw spacing by turning the...

Page 255: ...shock absorber and bush Inspect the shock absorber rod Bends damage Replace the shock absorber assembly Inspect the shock absorber Oil leaks Replace the shock absorber assembly Inspect the spring of...

Page 256: ...play by moving it from side to side If side play noticeable replace the inner collars and bushes as a set Check the front arm vertical movement by moving it up and down If vertical movement is tight...

Page 257: ...tightening torque of the front arms securing nuts Torque 4 5 kgf m 45 Nm 32 lbf ft Check the lower front arm side play by moving it from side to side If side play noticeable replace the inner collar a...

Page 258: ...two nuts and two bolts attaching the lower front arm then remove the lower front arm and bushes Inspect the lower front arm Cracks bends damage Replace Inspect bushes Wear damage Replace Bolts Bushes...

Page 259: ...nd tighten the nuts Torque 3 kgf m 30 Nm 22 lbf ft Install the tie rod and washer onto the steering knuckle and tighten the nut Torque 2 kgf m 20 Nm 15 lbf ft Install the all cotter pins and band ends...

Page 260: ...n washer and nut attaching the tie rod and steering knuckle Then remove tie rods using the special tool page 14 8 Special tool Tie rod ball join remover F011 Inspect the tie rod Bend damage Replace Ch...

Page 261: ...here the indentation surface of the tie rod is parallel to the rod end shaft and then tighten the lock nut Torque 3 kgf m 30 Nm 22 lbf ft Set the other rod end knuckle arm side in an angle as shown ri...

Page 262: ...he steering knuckle and steering column then tighten the nuts Torque Steering knuckle side 2 kgf m 20 Nm 15 lbf ft Steering column side 2 kgf m 20 Nm 15 lbf ft Install the all cotter pins and band end...

Page 263: ...NDERS section in the CHAPTER 2 Remove the right and left master cylinder and remove bands then disconnect the rear and front fluid tube from the handlebar Remove the two screws and remove the handleba...

Page 264: ...bar and handlebar holder then tighten the four bolts Torque 2 5 kgf m 25 Nm 18 lbf ft Be sure the upper handlebar holder mark face to front First tighten the bolts on the front side of the handlebar h...

Page 265: ...bar and then tighten the two screws Place the right and left brake master cylinder on the handlebar and install the master cylinder holder with the UP mark facing up aligning the punch mark on the han...

Page 266: ...er lip with the mark in the handlebar and then install the lower holder and tighten the two screws STEERING COLUMN REMOVAL AND INSPECTION Remove handlebar page 14 18 Remove the two bolts and remove th...

Page 267: ...nnect the tie rods from the steering column Remove the cotter pin and nut attaching the steering column under the frame body then remove steering column and collar Inspect the collar dust seals snap r...

Page 268: ...tall the cotter pin and band ends of cotter pin Assembly the steering column and tighten the two bolts Torque 2 2 kgf m 22 Nm 16 lbf ft Install the tie rods and washer then tighten the nut Torque 2 kg...

Page 269: ...________________________________________________________________________ REAR WHEEL AXLE SUSPENSION DRIVING MECHANISM __________________________________________________________________________________...

Page 270: ...15 REAR WHEEL AXLE SUSPENSION DRIVING MECHANISM 15 1 MXU 300 250 MXU 250...

Page 271: ...15 REAR WHEEL AXLE SUSPENSION DRIVING MECHANISM 15 2 MXU 300 250 MXU 300...

Page 272: ...wingarm pivot bolt MXU 250 7 kgf m 70 N m 52 lbf ft Rear wheel hub nut 10 kgf m 100 N m 72 lbf ft Rear wheel shaft nut MXU 250 12 kgf m 120 N m 86 lbf ft Caliper holder bolt MXU 250 1 kgf m 10 N m 7 2...

Page 273: ...rear wheels Remove the nut cap Remove the cotter pin and then remove nut Remove the rear wheel hub Inspect the rear wheel hub Cracks damage Replace Inspect the rear wheel hub splines Wear damage Repla...

Page 274: ...el hub onto the axle Apply grease to the rear wheel hub nut threads and setting surfaces Install the hub nut onto the axle and tighten the hub nut to the specified torque and further tighten until its...

Page 275: ...the rear caliper Refer to the REAR BRAKE CALIPER REMOVAL section in chapter 13 Remove the rear wheels page 15 4 Use the nut wrench to loosen two rear axle nuts inner and outer of the rear axle Special...

Page 276: ...spect the brake disk splines Wear damage Replace Loosen the driven chain refer to the DRIVE CHAIN SLACK ADJUSTMENT section in the chapter 3 and remove the two bolts at the drive sprocket refer to the...

Page 277: ...AXLE SUSPENSION DRIVING MECHANISM 15 8 MXU 300 250 Remove the rear axle from right side REAR AXLE DISASSEMBLY Driven Sprocket Rear Axle Tap the axle and with a rubber hammer this will avoid damage th...

Page 278: ...ocket clip at the rear axle and then remove the driven sprocket Remove the four nuts attaching the driven sprocket holder at the driven sprocket and then remove driven sprocket Inspect the drive sproc...

Page 279: ...atched excessively damage Replace Inspect the splines and threads of the rear axle Wear damage Replace Measure the rear axle run out Service limit less than 1 5 mm 0 06 in Out of specification Replace...

Page 280: ...older Remove the two bolts attaching the rear axle hub at the rear fork Remove the circlip at the caliper holder and then remove the caliper holder and collar Inspect the O ring for damage Apply greas...

Page 281: ...urns roughly Replace Dust seals is wear damage Replace Axle hub is cracks bend damage Replace REAR AXLE HUB DISASSEMBLY Bearing and dust seal replacement steps Clean the outside of the rear axle hub R...

Page 282: ...e disk collar inner nut washer and outer nut Dust Seal Dust Seal Bearing Rear Axle Hub Distance Collar Do not strike the center race or balls of the bearing Contact should be made only with the outer...

Page 283: ...ten the two rear axle nuts inner and outer Special tool Nut wrench F010 Torque 12 kgf m 120 Nm 86 lbf ft Adjust drive chain slack Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 Dri...

Page 284: ...unting bolt nut Remove the upper mounting bolt nut and nut and the shock absorber Inspect the shock absorber rod Bends damage Replace the shock absorber assembly Inspect the shock absorber Oil leaks R...

Page 285: ...ace Elevate the rear wheels by placing a suitable stand under the rear of frame Remove the rear wheels rear axle and rear hub Refer to the REAR AXLE HUB MXU 250 REMOVAL AND INSPECTION section in chapt...

Page 286: ...e inner collar bearing bushing and thrust cover or adjust the shim Check the swingarm vertical movement by moving it up and down If vertical movement is tight binding or rough check the inner collar b...

Page 287: ...ECHANISM 15 18 MXU 300 250 Remove the nut and pivot bolt then remove rear swingarm and drive chain Remove the four bolts from the lower guard and then remove the lower guard Remove the thrust covers P...

Page 288: ...end damage Replace Roll the pivot bolt on a flat surface to inspect the pivot shaft Bends Replace Inspect the thrust covers collar and bushes Wear damage Replace Inspect the drive chain stiffness Stif...

Page 289: ...nd thrust cover Install the swingarm and drive chain Install the pivot bolt and tightening the nut and pivot bolt Torque 7 kgf m 70 Nm 50 lbf ft Install the shock absorber page 15 15 Install the rear...

Page 290: ...lacing a suitable stand under the rear of frame Remove the rear wheels and rear hubs page 15 4 Drain the final gear case oil page 3 13 Remove the rear brake calipers page 13 12 Remove the rear brake d...

Page 291: ...m side Remove the joint boot from the swingarm Remove the rear shock absorber page 15 15 Remove the bolt and band then disconnect the rear brake fluid hoses from the swingarm Remove the swingarm pivot...

Page 292: ...pivot lock nut using the special tool Special tool Lock nut wrench F013 Remove the left pivot adjusting bolt Remove the swingarm then take spring out from the swingarm Disengage the universal joint f...

Page 293: ...versal joint from the drive shaft splines UNIVERSAL JOINT INSPECTION If the splines are damaged check the pinion and universal joint splines also DRIVE SHAFT INSPECTION Check the splines of the drive...

Page 294: ...de end Remove the final gear case assembly and rear axle by driving them from the left side using a rubber mallet Place the rear axle right side end on the rubber mat Remove the final gear case assemb...

Page 295: ...R CASE INSPECTION Turn the pinion gear and check that the gear turns smoothly and quietly without binding If the gears do not turn smoothly or quietly the gears and or bearing may be damaged or faulty...

Page 296: ...08 in If the difference in measurements exceeds the service limit it indicates that the bearing is not installed squarely or the case is deformed Inspect the bearings and case If the backlash is too s...

Page 297: ...at the left side shim was changed if the left shim was replaced with a 0 03 mm 0 0012 in thicker shim replace the right shim with one that is 0 03 mm 0 0012 in thinner FINAL GEAR CASE DISASSEMBLY Chec...

Page 298: ...ng gear shim BEARING INSPECTION Turn the inner race of each bearing in the gear case and case cover with your finger The bearings should turn smoothly and quietly Also check that the bearing outer rac...

Page 299: ...ase Install the case cover Install and tighten the case cover bolts in several steps until the cover evenly touches the gear case Then while rotating the pinion gear tighten the bolts to the specified...

Page 300: ...g and pinion gear must be changed and the tooth contact re checked until correct Tooth contact Shim adjustment Contact at tooth top 1 Decrease shim thickness Contact at tooth root 3 Increase shim thic...

Page 301: ...it if necessary Remove the oil seal from the gear case Remove the lock nut using the special tool Special tool Lock nut wrench F015 Install the special tools onto the pinion gear shaft and gear case...

Page 302: ...from the shaft with a commercially available bearing puller Remove the pinion shim Install the shim and bearing onto the pinion gear Drive the bearing with the marked side facing up When the gear set...

Page 303: ...E BEARING REPLACEMENT CASE BEARING Remove the oil seal Drive the ring gear bearing out of the case CASE COVER BEARING Remove the oil seal Drive the ring gear bearing out of the case cover Drive each b...

Page 304: ...r case to 80 176 F and remove needle bearing Drive the needle bearing into the case Install the snap ring Apply molybdenum disulfide grease to the needle bearing PINION GEAR INSTALLATION Drive he pini...

Page 305: ...s and install it into the gear case until it is fully seated FINAL GEAR CASE MXU 300 ASSEMBLY Clean the mating surface of the gear case and cover being careful not to damage them Blow compressed air t...

Page 306: ...0 mm bolts Install and tighten the case cover bolts in several steps until the cover evenly touches the gear case Then while rotating the pinion gear tighten the bolts to the specified torque in a cri...

Page 307: ...RM INSPECTION BEARING REPLACEMENT Inspect the dust seal for wear or damage If any damages are found replace them with new ones Remove the dust seals Remove the swingarm bearing Inspect the swingarm be...

Page 308: ...ller E014 Apply grease to the swingarm bearing and lips of dust seals then install them into the swingarm with the special tool Special tool Oil seal bearing installer E014 Remove the three bolts and...

Page 309: ...ng installer E014 Pack 3 g 0 1 oz of grease into bearing cavity REAR DRIVING MECHANISM MXU 300 INSTALLATION Apply grease to new O ring and install it into the groove in the swingarm Install the dust p...

Page 310: ...xle into the axle housing from swingarm right side and install final gear case Install and tighten the mounting bolts in several steps to the specified torque Torque 55 N m 5 5 kgf m 40 lbf ft Apply m...

Page 311: ...of grease into each bearing cavity Apply grease to the new dust seal lips and install them into the swingarm pivot until they are flush Apply molybdenum disulfide grease to the universal joint splines...

Page 312: ...imes to seat the pivot bearings Retighten the pivot bolts to the same torque Install the left pivot lock nut Tighten the lock nut while holding the left pivot adjusting bolt to the specitied torque Sp...

Page 313: ...ING MECHANISM 15 44 MXU 300 250 Apply molybdenum disulfide grease to the disk holder splines and the rear axle splines Install the rear brake disk Install the brake calipers page 13 22 Install the rea...

Page 314: ...__________________________________________ __________________________________________________________________________________ __________________________________________________________________________...

Page 315: ...16 BATTERY CHARGING SYSTEM A C GENERATOR 16 1 MXU 300 250 CHARGING CIRCUIT Fuse Battery Regulator Rectifier A C Generator...

Page 316: ...charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rect...

Page 317: ...nnection Disconnected battery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch lighting system Low power Charging system failure Weak...

Page 318: ...e sure the ignition switch is OFF 2 Pull right the lock lever and pull up the seat at the rear 3 ON ROAD Hang license light holder 1 by removing the left mount bolt 2 and loosen the right mount bolt 3...

Page 319: ...attery INSTALLATION 1 Installation is in the reverse order of removal 2 Make sure the battery is installed upright as shown 3 Check all bolts and other fasteners are secure 4 After installing the batt...

Page 320: ...y negative terminal Charging current Standard 1 2A Quick 3 0A Charging time Standard 5 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min Keep flames and sparks away from a chargi...

Page 321: ...ine and warm it up to operating temperature stop the engine Connect the multi meter between the positive and negative terminals of the battery With the headlight on high beam restart the engine Measur...

Page 322: ...Continuity Probe Probe I Yellow Green II Red White Yellow Reverse Direction No Continuity Probe Probe I Green Yellow II Yellow Red White VOLTAGE REGULATION TEST Connect a voltmeter across the battery...

Page 323: ...ove the right crankcase cover Refer to the WATER PUMP SHAFT REMOVAL section in the chapter 12 Remove the pulser coil screws and then remove the A C generator wire set plate Remove the A C generator bo...

Page 324: ...and tighten the nut Torque 6 kgf m 60 Nm 43 lbf ft Install the oil through guide and spring Install the A C generator onto the right crankcase cover and tighten the bolts Torque 0 9 kgf m 9 Nm 6 5 lb...

Page 325: ...______________________________________ __________________________________________________________________________________ ______________________________________________________________________________...

Page 326: ...17 IGNITION SYSTEM 17 1 MXU 300 250 IGNITION CIRCUIT ON ROAD Ignition Unit Change Gear Control A C Generator Pulser Coil Ignition Coil...

Page 327: ...ignition unit A C generator change gear control and replace any faulty parts Inspect the ignition unit with a ignition unit tester Loose connector and poor wire connection are the main causes of faul...

Page 328: ...istance over 10M CDV TROUBLESHOOTING High voltage too low No high voltage Weak battery or low engine speed Faulty ignition switch Loose ignition system connection Faulty ignition unit Faulty ignition...

Page 329: ...Unit Change Gear Control Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings Use...

Page 330: ...h a new one CHANGE REAR CONTROL INSPECTION Testing Range at 20 C Note The readings in this table are taken with a YF 3501 Tester Probe Probe Green Yellow Brown Light Green Red Green Pink Green Yellow...

Page 331: ...stance between the ignition coil primary coil terminals Resistance 3 4 4 1 20 C Remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and the primary coil ter...

Page 332: ...a new one PULSER COIL INSPECTION Remove the front fender Refer to the chapter 2 Disconnect the pulser coil wire coupler and measure the resistance between the blue yellow and green white wire terminal...

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Page 334: ...18 STARTING SYSTEM 18 1 MXU 300 250 STARTING CIRCUIT Fuse Battery Starter Relay Starter Button Stop Switches Starter Motor...

Page 335: ...urned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter...

Page 336: ...front cover motor case and other parts INSPECTION Inspect the removed parts for wear damage or discoloration and replace if necessary Clean the commutator if there is metal powder between the segment...

Page 337: ...ments and the armature shaft There should be no continuity STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front...

Page 338: ...e dust seal for wear or damage ASSEMBLY Apply grease to the dust seal in the front cover Install the brushes onto the brush holders Apply a thin coat of grease to the two ends of the armature shaft In...

Page 339: ...he starter motor cable connector and properly install the waterproof rubber jacket Check the O ring for wear or damage and replace if necessary Apply grease to the O ring and install the starter motor...

Page 340: ...und circuit Check for continuity between the starter relay yellow red and green red wire terminals STARTER RELAY VOLTAGE INSPECTION Connect a 12V battery across the starter relay yellow red and green...

Page 341: ...UMP SHAFT REMOVAL section in the chapter 12 Remove the flywheel Refer to the A C GENERATOR FLYWHEEL REMOVAL section in the chapter 16 Inspect the starter one way clutch for wear or damage Remove the s...

Page 342: ...damage INSTALLATION Reverse the REMOVAL procedures Install the starter idle gear and shaft Install the starter driven gear Install flywheel and right crankcase cover Refer to the A C GENERATOR FLYWHE...

Page 343: ...Insert the rope into the hook part of the friction plate reel the rope clockwise five times with the rope then cut the rope Hook the rope onto the groove of the recoil starter case Remove the plug of...

Page 344: ...250 Insert the rope into recoil starter grip and washer Reinstall the cap Pull the rope and check that the ratchet is pushed out Refer to the chapter 9 to remove ratchet Inspect the ratchet splines We...

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Page 346: ...ing tabs that must be released before disconnecting and must be aligned when reconnecting To isolate an electrical failure check the continuity of the electrical path through the part A continuity che...

Page 347: ...ulb and replace with a new one Install the bulb aligning the bulb socket groove with the bulb tab and set the lock clips Connect headlight wire connector Install the rubber boot Install the front fend...

Page 348: ...e the bulb Install the bulb in the reverse order of removal TURN SIGNAL LIGHT ON ROAD FRONT Remove the rubber boot from the turn signal light case Remove the bulb socket by turning it counterclockwise...

Page 349: ...der of removal LICENCE LIGHT BULB ON ROAD Remove the two screws and licence light cover Remove the bulb Install the bulb in the reverse order of removal HORN ON ROAD REMOVAL Disconnect the horn wire l...

Page 350: ...ire clips on the steering shaft holder frame pipe Remove the handlebar cover see page 2 7 Remove the ignition switch from the cover while pushing in the two stoppers Install a new ignition switch by a...

Page 351: ...19 LIGHTS SWITCHES 19 6 MXU 300 250 ON ROAD OFF ROAD Start Switch Light Switch Horn Switch Winker Switch Hazard Switch Kill Switch Start Switch Dimmer Switch Pass Switch...

Page 352: ...th it in any gear except neutral REVERSE SWITCH There should be continuity with the transmission in reverse and no continuity with it in any gear except reverse REPLACEMENT Remove drive and driven pul...

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