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KYMCO MXU 250 User Manual

KYMCO MXU 250
352 pages
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By KWANG 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-S00

Table of Contents

Other manuals for KYMCO MXU 250

Questions and Answers:

KYMCO MXU 250 Specifications

General IconGeneral
BrandKYMCO
ModelMXU 250
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information and Specifications

Serial Number Identification

Location of frame and engine serial numbers.

Vehicle Specifications

Detailed technical specifications for MXU 250 and 300 models.

Service Precautions and Guidelines

Important safety and operational guidelines for servicing.

Standard Torque Values

Standard torque specifications for important fasteners.

Special Tools for Servicing

List of specialized tools required for maintenance.

Lubrication Points Guide

Specifies lubrication points for engine and frame components.

Cable and Harness Routing

Illustrates the correct routing of cables and wiring harnesses.

Wiring Diagrams

Electrical wiring diagrams for various models and conditions.

Troubleshooting Guides

Troubleshooting guides for common engine and system issues.

Frame Covers and Exhaust Muffler

Service Information and Torque Values

General service information and torque specifications for frame covers and exhaust mufflers.

Exhaust Muffler Troubleshooting

Troubleshooting common issues with exhaust mufflers.

Frame Cover Removal and Installation

Procedures for removing and installing various frame covers.

Exhaust Muffler Removal and Installation

Procedures for removing and installing the exhaust muffler.

Inspection and Adjustment Procedures

Service Information and Specifications

General service information and specifications for inspection and adjustment.

Maintenance Schedule

Recommended schedule for routine inspections and maintenance.

Fuel System Component Checks

Inspection and adjustment of fuel line, throttle, and air cleaner.

Air Filter for Drive Belt

Cleaning and inspection of the air filter for the drive belt.

Secondary Air Supply System and Spark Plug

Inspection of secondary air supply system and spark plug.

Valve Clearance Adjustment

Procedure for inspecting and adjusting valve clearance.

Idle Speed and Ignition Timing

Adjusting carburetor idle speed and checking ignition timing.

Cylinder Compression and Engine Oil

Checking cylinder compression and engine oil level.

Transmission and Final Gear Oil Replacement

Procedures for replacing transmission and final gear case oil.

Drive Belt and Brake Pad Inspection

Inspecting the drive belt and brake pads for wear.

Brake Fluid and Headlight Aim Checks

Inspecting brake fluid and adjusting headlight aim.

Steering System Inspection

Inspecting the steering system for play and wear.

Toe-In Adjustment

Procedure for adjusting front wheel toe-in.

Wheel and Tire Inspection

Inspecting wheels and tires for damage and checking pressure.

Drive Chain Slack Adjustment (MXU 250)

Adjusting drive chain slack for the MXU 250.

Drive Select Lever Adjustment

Adjusting the drive select lever mechanism.

Cable Inspection and Lubrication

Inspecting and lubricating control cables.

Rear Suspension Lubrication (MXU 250)

Lubricating the rear suspension components (MXU 250).

Cooling System Service

Inspecting and servicing the cooling system.

Spark Arrester Cleaning (Off Road)

Cleaning the spark arrester for off-road use.

Lubrication System

Service Information

General service information for the lubrication system.

Lubrication System Specifications

Specifications for oil pump components and clearances.

Lubrication System Troubleshooting

Troubleshooting common lubrication system issues.

Engine Oil and Oil Filter Procedures

Procedures for engine oil and oil filter replacement.

Oil Pump Service

Procedures for removing, disassembling, and inspecting the oil pump.

Fuel System

Service Information and Specifications

General service information and specifications for the fuel system.

Fuel System Troubleshooting

Troubleshooting common fuel system problems.

Fuel Tank Removal and Installation

Procedures for removing and installing the fuel tank.

Fuel Valve Service

Procedures for removing, disassembling, and inspecting the fuel valve.

Throttle Valve Service

Procedures for disassembling and assembling the throttle valve.

Carburetor Service

Procedures for removing, disassembling, and cleaning the carburetor.

Air Cleaner Housing Service

Procedures for removing and installing the air cleaner housing.

PAIR Solenoid Valve Service

Procedures for removing and installing the PAIR solenoid valve.

Engine Removal and Installation

Service Information

General service information regarding engine removal.

Engine Removal (MXU 250)

Step-by-step procedure for removing the engine from the MXU 250.

Engine Installation (MXU 250)

Step-by-step procedure for installing the engine on the MXU 250.

Engine Removal (MXU 300)

Step-by-step procedure for removing the engine from the MXU 300.

Engine Installation (MXU 300)

Step-by-step procedure for installing the engine on the MXU 300.

Cylinder Head and Valves

Service Information

General service information for cylinder head and valves.

Cylinder Head and Valve Specifications

Specifications for cylinder head, valve clearance, and camshaft.

Cylinder Head Component Torque Values

Torque values for cylinder head components.

Special Tools for Cylinder Head Service

Special tools for cylinder head and valve service.

Cylinder Head and Valve Troubleshooting

Troubleshooting common cylinder head and valve issues.

Cylinder Head Cover Service

Procedures for removing and installing the cylinder head cover.

Camshaft and Camshaft Holder Service

Procedures for removing and inspecting the camshaft and camshaft holder.

Cylinder Head Service

Procedures for removing, disassembling, and inspecting the cylinder head.

Cylinder and Piston

Service Information

General service information for cylinder and piston.

Cylinder and Piston Specifications

Specifications for cylinder, piston, and piston rings.

Cylinder and Piston Troubleshooting

Troubleshooting common cylinder and piston issues.

Cylinder and Piston Removal and Disassembly

Procedures for removing and disassembling the cylinder and piston.

Piston Ring and Piston Inspection

Inspecting piston rings, piston pins, and piston walls.

Cylinder Inspection and Service

Inspecting the cylinder bore for wear and measuring clearances.

Piston Ring Installation

Procedures for installing piston rings onto the piston.

Piston and Cylinder Installation

Procedures for installing the piston and cylinder.

Drive and Driven Pulleys

Service Information

General service information for drive and driven pulleys.

Drive and Driven Pulley Specifications

Specifications for pulley components and drive belt.

Pulley Component Torque Values

Torque values for pulley and clutch components.

Special Tools for Pulley Servicing

Special tools for pulley and clutch servicing.

Drive and Driven Pulley Troubleshooting

Troubleshooting common drive and driven pulley issues.

Left Crankcase Cover Service

Procedures for removing and installing the left crankcase cover.

Drive Pulley and Driven Pulley Service

Procedures for removing, inspecting, and assembling pulleys.

Final Reduction and Transmission System

Service Information and Specifications

General service information and specifications for the transmission system.

Transmission Component Torque Values

Torque values for transmission components.

Transmission System Troubleshooting

Troubleshooting common transmission system issues.

Transmission Case Cover Service (MXU 250)

Procedures for removing and disassembling the transmission case cover (MXU 250).

Transmission Service (MXU 250)

Procedures for removing and inspecting the transmission (MXU 250).

Speedometer Gear Service

Procedures for removing and inspecting the speedometer gear.

Transmission Case Cover and Driven Bevel Gear Service (MXU 300)

Procedures for removing and disassembling the transmission case cover and driven bevel gear (MXU 300).

Transmission Service (MXU 300)

Procedures for removing and inspecting the transmission (MXU 300).

Secondary Gear Shim Adjustment (MXU 300)

Adjusting and inspecting secondary gear shims for backlash (MXU 300).

Crankcase, Crankshaft, and Balance Shaft

Service Information

General service information for crankcase, crankshaft, and balance shaft.

Crankcase, Crankshaft, and Balance Shaft Troubleshooting

Troubleshooting common crankcase, crankshaft, and balance shaft issues.

Crankcase, Crankshaft, and Balance Shaft Removal

Procedures for removing crankcase, crankshaft, and balance shaft.

Crankshaft Inspection

Inspecting crankshaft for wear, runout, and bearing play.

Crankcase and Balancer Installation

Procedures for installing the balance shaft and crankshaft into the crankcase.

Cooling System Service

Service Information

General service information for the cooling system.

Special Tool for Cooling System

Special tool for mechanical seal driver.

Water Pump Torque Values

Torque values for water pump components.

Cooling System Troubleshooting

Troubleshooting common cooling system issues.

Cooling System Testing

Testing the cooling system, including radiator cap.

Radiator Service

Procedures for inspecting, removing, and installing the radiator.

Coolant Replacement and Air Bleeding

Procedures for replacing coolant and bleeding the system.

Water Pump Service

Procedures for inspecting, removing, and replacing the water pump.

Thermosensor Service

Procedures for removing, inspecting, and installing the thermosensor.

Thermostat Service

Procedures for removing, inspecting, and installing the thermostat.

Brake System

Service Information and Specifications

General service information and specifications for the brake system.

Brake System Troubleshooting

Troubleshooting common brake system issues.

Front Hydraulic Brake Service

Procedures for front hydraulic brake pad removal.

Front Brake Fluid Change and Air Bleed

Procedures for changing front brake fluid and bleeding the system.

Brake Master Cylinder Service

Procedures for disassembling and assembling the brake master cylinder.

Front Brake Caliper Service

Procedures for removing, disassembling, and assembling the front brake caliper.

Rear Hydraulic Brake Service

Procedures for replacing rear brake pads.

Rear Brake Master Cylinder Service

Procedures for disassembling and assembling the rear brake master cylinder.

Rear Brake Caliper Service

Procedures for removing, disassembling, and assembling the rear brake caliper.

Front Wheel, Suspension, and Steering System

Service Information and Specifications

General service information and specifications for the front wheel, suspension, and steering system.

Front Component Torque Values

Torque values for front wheel, suspension, and steering components.

Special Tools for Front System Service

Special tools for front suspension and steering servicing.

Front System Troubleshooting

Troubleshooting common front wheel, suspension, and steering issues.

Front Wheel Removal and Inspection

Procedures for removing, inspecting, and installing the front wheel.

Front Wheel Hub Service

Procedures for removing, disassembling, and assembling the front wheel hub.

Front Suspension Service

Procedures for removing, inspecting, and installing the front suspension components.

Tie-Rod Service

Procedures for removing, inspecting, and adjusting tie-rods.

Handlebar Removal and Installation

Procedures for removing, inspecting, and installing the handlebar.

Steering Column Service

Procedures for removing, inspecting, and installing the steering column.

Rear Wheel, Axle, Suspension, and Driving Mechanism

Service Information and Specifications

General service information and specifications for the rear wheel, axle, suspension, and driving mechanism.

Rear Component Torque Values

Torque values for rear wheel, axle, suspension, and driving components.

Special Tools for Rear Axle Service

Special tools for rear axle and nut servicing.

Rear System Troubleshooting

Troubleshooting common rear wheel, axle, suspension, and driving mechanism issues.

Rear Wheel and Hub Service

Procedures for removing, inspecting, and installing the rear wheel and hub.

Rear Axle and Hub Service (MXU 250)

Procedures for removing, inspecting, and installing the rear axle and hub (MXU 250).

Rear Shock Absorber Service

Procedures for removing, inspecting, and installing the rear shock absorber.

Swingarm Service (MXU 250)

Procedures for removing, inspecting, and installing the swingarm (MXU 250).

Rear Driving Mechanism Service (MXU 300)

Procedures for removing and inspecting the rear driving mechanism (MXU 300).

Final Drive Shim Adjustment and Gear Case Disassembly (MXU 300)

Adjusting final drive shims and disassembling the final gear case (MXU 300).

Final Gear Case Assembly (MXU 300)

Procedures for assembling the final gear case (MXU 300).

Swingarm Bearing Replacement (MXU 300)

Procedures for inspecting and replacing swingarm bearings (MXU 300).

Rear Driving Mechanism Installation (MXU 300)

Procedures for installing the rear driving mechanism (MXU 300).

Battery, Charging System, and A.C. Generator

Service Information and Specifications

General service information and specifications for the battery and charging system.

Battery Torque and Special Tools

Torque value for flywheel nut and special tools for flywheel service.

Battery and Charging System Troubleshooting

Troubleshooting common battery and charging system issues.

Battery Removal, Installation, and Testing

Procedures for removing, installing, and testing the battery.

Charging System Inspection

Inspecting the charging system for current leakage and voltage.

Regulator/Rectifier and A.C. Generator Inspection

Inspecting the regulator/rectifier and A.C. generator for proper function.

Ignition System

Service Information

General service information for the ignition system.

Ignition System Specifications

Specifications for spark plug, ignition coil, and pulser coil.

Ignition System Testing Instrument

Commercially available electric tester specifications.

Ignition System Troubleshooting

Troubleshooting ignition system faults.

Ignition Unit and Change Gear Control Inspection

Inspecting the ignition unit and change gear control.

Ignition Coil Inspection

Inspecting the ignition coil for continuity and resistance.

Pulser Coil Inspection

Inspecting the pulser coil for resistance.

Starting System

Service Information

General service information for the starting system.

Starting System Troubleshooting

Troubleshooting common starting system issues.

Starter Motor Service

Procedures for removing, disassembling, and inspecting the starter motor.

Starter Relay Inspection

Procedures for inspecting the starter relay and its voltage.

Starter Clutch Service

Procedures for removing and inspecting the starter clutch components.

Recoil Starter Rope Replacement

Procedures for replacing the recoil starter rope.

Lights and Switches

Service Information

General service information for lights and switches.

Bulb Removal and Replacement

Procedures for removing and replacing headlight, tail/brake, and signal light bulbs.

Horn (On Road) Service

Procedures for removing and installing the horn.

Ignition Switch Service

Procedures for inspecting and replacing the ignition switch.

Handlebar Switch Inspection

Procedures for inspecting handlebar switches.

Neutral/Reverse Switch Service

Procedures for inspecting and replacing neutral and reverse switches.

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