KYMCO MX'ER 50 Manuel utilisateur

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO MX’er 50.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before starting any

operation.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part,

starting from periodic maintenance.

Sections 4 through 17 give instructions

for disassembly, assembly and

inspection of engine, chassis frame and

electrical equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

FRAME COVERS/EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/CYLINDER/PISTON

A.C.GENERATOR

KICK STARTER/DRIVE

PULLEY/CLUTCH/FRIVEN PULLEY

FINAL REDUCTION/TRANSMISSION

SYSTEM

CRANKCASE/CRANKSHAFT

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION/STEERING

SYSTEM

REAR WHEEL /SWING

ARM/HYDRAULIC BRAKE

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/SWITCHES

ONLY ATVON ROAD AVAILABLE

The information and contents

included in this manual may be

different from the motorcycle in case

specifications are changed.

CHASSIS EQUIPMENT

ENGINE

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1. GENERAL INFORMATION

1-1

MX’er 50

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

SERIAL NUMBER ------------------------------------------------------ 1- 2

SPECIFICATIONS ------------------------------------------------------ 1- 3

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

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

SPECIAL TOOLS ------------------------------------------------------- 1-13

LUBRICATION POINTS----------------------------------------------- 1-13

CABLE & HARNESS ROUTING ------------------------------------- 1-16

WIRING DIAGRAM ---------------------------------------------------- 1-20

TROUBLESHOOTING ------------------------------------------------- 1-22

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1. GENERAL INFORMATION

1-2

MX’er 50

SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number

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1. GENERAL INFORMATION

1-3

MX’er 50

SPECIFICATIONS

Name & Model No.

LA10AD

Motorcycle Name & Type

MX’er

Overall length (mm)

1685

Overall width (mm)

980

Overall height (mm)

1030

Wheel base (mm)

1120

Engine type

Air cooled 2-stroke

Displacement (cc)

49.4

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

Total

140

Front wheel

Gross weight(kg)

Rear wheel

Total

150

Front wheel

20*7-8

Rear wheel

22*10-8

Ground clearance (mm)

130

Perform

Breaking distance

(m)(ANSI)

20.6 below

Ance

Min. turning radius (m)

2.5

Starting system

Starting motor &

kick starter

Type

Air cooled 2-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

Reed valve & piston

Bore x stroke (mm)

39 x 41.4

Compression ratio

7.2:1

Compression pressure

(kg/cm_)

12.0

Max. output (ps/rpm)

4.3/6000

Max. torque (kg m/rpm)

0.55/5500

Intake

Open

Automatic controlled

Port

(1mm)

Automatic controlled

timin

Exhaust

Open

°–

(1mm)

°–

Valve clearance

Intake

°–

(cold) (mm)

Exhaust

°–

Idle speed (rpm)

2000rpm

Lubrication type

Separate type

Oil pump type

Plunger type

Oil filter type

Full-flow filtration

Air cleaner type & No

Sponge

Fuel capacity

8.1 liters

Type

Main jet No.

Venturi dia.(mm)

f14

Throttle type

VALVE PISTON

Type

CDI

Ignition timing

22°/2000rpm

Spark plug

NGK

BR8HAS

Spark plug gap

0.6_0.7mm

Battery

Capacity

12V4AH

Clutch

Type

CVT

Operation

Automatic centrifugal

Type

Chain drive

Reduction

1st

°–

ratio

2nd

°–

Final gear ratio

23.678

Front

Caster angle

°–

Axle

Trail length

°–

Tire pressure

Front

0.35

(kg/cm_)

Rear

0.35

Turning

Left

44°

angle

Right

44°

Brake system

Rear

Disk brake

type

Front

Drum brake

Suspension

Front

Swing

type

Rear

Swing arm

Shock

absorber

Front

Swing

type

Rear

Swing arm

Frame type

SP pipe

Tires

Engine

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Reduction

Gear

Moving Device Damping

Device

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1. GENERAL INFORMATION

1-4

MX’er 50

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

nWhen tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

nUse genuine parts and lubricants.

nWhen servicing the motorcycle, be sure to

use special tools for removal and

installation.

nAfter disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

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1. GENERAL INFORMATION

1-5

MX’er 50

nApply or add designated greases and

lubricants to the specified lubrication

points.

nAfter reassembly, check all parts for

proper tightening and operation.

nWhen two persons work together, pay

attention to the mutual working safety.

nDisconnect the battery negative (-) terminal

before operation.

nWhen using a spanner or other tools, make

sure not to damage the motorcycle surface.

nAfter operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

nWhen connecting the battery, the positive

(+) terminal must be connected first.

nAfter connection, apply grease to the

battery terminals.

nTerminal caps shall be installed securely.

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1. GENERAL INFORMATION

1-6

MX’er 50

nIf the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

nAfter operation, terminal caps shall be

installed securely.

nWhen taking out the connector, the lock on

the connector shall be released before

operation.

nHold the connector body when connecting

or disconnecting it.

nDo not pull the connector wire.

nCheck if any connector terminal is bending,

protruding or loose.

Confirm

Capacity

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1. GENERAL INFORMATION

1-7

MX’er 50

nThe connector shall be inserted

completely.

nIf the double connector has a lock, lock

it at the correct position.

nCheck if there is any loose wire.

nBefore connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

nCheck the double connector cover for

proper coverage and installation.

nInsert the terminal completely.

nCheck the terminal cover for proper

coverage.

nDo not make the terminal cover opening

face up.

nSecure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

Snapping!

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1. GENERAL INFORMATION

1-8

MX’er 50

nAfter clamping, check each wire to make

sure it is secure.

nDo not squeeze wires against the weld or

its clamp.

nAfter clamping, check each harness to make

sure that it is not interfering with any

moving or sliding parts.

nWhen fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

nRoute wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

nRoute wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

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1. GENERAL INFORMATION

1-9

MX’er 50

nRoute harnesses so they are neither

pulled tight nor have excessive slack.

nProtect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

nWhen rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

nDo not break the sheath of wire.

nIf a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

nWhen installing other parts, do not press or

squeeze the wires.

Do not pull too

tight!

Do not press or

squeeze the wire.

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