KYMCO MX'er 125 Bedienungsanleitung

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO MX’er

125/150.

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 1

FRAME COVERS/EXHAUST MUFFLER 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

FUEL SYSTEM 5

ENGINE REMOVAL/INSTALLATION 6

CYLINDER HEAD/VALVES 7

CYLINDER/PISTON 8

DRIVE AND DRIVEN PULLEYS 9

FINAL REDUCTION/TRANSMISSION

SYSTEM 10

CRANKCASE/CRANKSHAFT/

BALANCE SHAFT 11

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION/STEERING

SYSTEM 12

REAR WHEEL /SWING

ARM/HYDRAULIC BRAKE 13

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR 14

IGNITION SYSTEM 15

STARTING SYSTEM 16

LIGHTS/SWITCHES 17

ONLY ATV ON ROAD AVAILABLE 18

The information and contents included

in this manual may be different from

the motorcycle in case specifications

are changed.

CHASSIS

ELECTRICAL

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

MX’er SYSTEM

__________________________________________________________________________________

GENERAL INFORMATION

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

SPECIFICATIONS------------------------------------------------------------- 1-2

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

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

SPECIAL TOOLS -------------------------------------------------------------- 1-14

LUBRICATION POINTS----------------------------------------------------- 1-15

CABLE & HARNESS ROUTING------------------------------------------- 1-18

WIRING DIAGRAM----------------------------------------------------------- 1-22

TROUBLESHOOTING ------------------------------------------------------- 1-23

1. GENERAL INFORMATION

MX’er SYSTEM

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

1. GENERAL INFORMATION

MX’er SYSTEM

SPECIFICATIONS

Name & Model No. LA30AA, AB

Motorcycle Name & Type MX’er

Overall length (mm) 1600

Overall width (mm) 980

Overall height (mm) 990

Wheel base (mm) 1120

Engine type O.H.C.

Displacement (cc) 149.4

Fuel Used 92# nonleaded gasoline

Front wheel

Net weight (kg) Rear wheel

Total 152

Front wheel

Gross weight(kg)

Rear wheel

Total 162

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) 3

Starting system Starting motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke (mm) 62 x 49.5

Compression ratio 9.7:1

Compression pressure

(kg/cm²)16.0

Max. output (ps/rpm) 11/7500

Max. torque (kg m/rpm) 1.1/5500

Intake Open 5.5°BTDC

Port (1mm) Close 27.5°ABDC

timing

Exhaust Open 36°BBDC

(1mm) Close 4°ATDC

Valve

clearance Intake 0.06

(cold) (mm) Exhaust 0.06

Idle speed (rpm) 1700rpm

Lubrication type Forced pressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.0 liter

Oil exchanging

capacity 0.9 liter

Cooling Type Forced air cooling

Air cleaner type & No

Sponge

Fuel capacity 8.1 liters

Type PD

Float lever 14.8mm

Venturi dia.(mm) φ25

Throttle type PISTON

Type CDI

Ignition timing 15°BTDC/1700rpm

Contact breaker Non-contact point type

Spark plug

NGK

CR8E

Spark plug gap 0.6 0.7mm

Battery Capacity 12V8AH

Clutch

Type CVT

Type Helical gear

Operation Automatic centrifugal

type

Type Chain drive

Reduction

1st 2.8-0.95

ratio 2nd

7.226

Counter gear ratio 26.902

Front Caster angle

Axle Trail length

re pressure

Front

0.2

(kg/cm²)Rear 0.25

Turning Left 44°

angle Right 44°

Brake system

Rear

Disk brake

Drum 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

Lubrication

System

Fuel System

Carbureto

Electrical

Equipment

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

MX’er SYSTEM

SPECIFICATIONS

Name & Model No. LA25AB

Motorcycle Name & Type MX’er

Overall length (mm) 1685

Overall width (mm) 980

Overall height (mm) 990

Wheel base (mm) 1120

Engine type OHC

Displacement (cc) 124

Fuel Used 92# nonleaded gasoline

Front wheel

Net weight (kg) Rear wheel

Total 152

Front wheel

Gross weight(kg)

Rear wheel

Total 162

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

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H..C., chain drive

Bore x stroke (mm) 56.5x 49.5

Compression ratio 9.2:1

Compression pressure

(kg/cm²)14.0

Max. output (ps/rpm) 9.8/7500

Max. torque (kg m/rpm) 0.98/5500

Intake Open 5.5°BTDC

Port (1mm) Close 27.5°ABDC

Timin

Exhaust Open 36°BBDC

(1mm) Close 4°ATDC

Valve

clearance Intake 0.06

(cold) (mm) Exhaust 0.06

Idle speed (rpm) 1700rpm

Lubrication type Forced pressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.0 liter

Oil exchanging

capacity 0.9 liter

Cooling Type Forced air cooling

Air cleaner type & No

Sponge

Fuel capacity 8.1 liters

Type PD

Piston dia. (mm) 14.8mm

Venturi dia.(mm) φ25

Throttle type PISTON

Type CDI

Ignition timing 15°BTDC/1700rpm

Contact breaker Non-contact point type

Spark plug NGK

CR8E

Spark plug gap 0.6 0.7mm

Battery Capacity 12V8AH

Clutch

Type CVT

Type Helical gear

Operation Automatic centrifugal

type

Type Chain drive

Reduction

1st 2.8-0.95

ratio 2nd

7.226Counter gear ratio 26.902

Front Caster angle

Axle Trail length

re pressure

Front

0.2

(kg/cm²)Rear 0.25

Turning Left 44°

angle Right 44°

Brake system

Rear

Disk brake

Drum brake

type Front Drum brake

Suspension

Front

Swing

type Rear Swing arm

Shock absorber

Front Swing

type Rear Swing arm

Frame type SP pipe

Lubrication

System

Tires

Engine

Fuel System

Carbureto

Electrical

Equipment

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

oving Device

Damping

Device

1. GENERAL INFORMATION

MX’er SYSTEM

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.

1. GENERAL INFORMATION

MX’er SYSTEM

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.

1. GENERAL INFORMATION

MX’er SYSTEM

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

1. GENERAL INFORMATION

MX’er SYSTEM

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!

1. GENERAL INFORMATION

MX’er SYSTEM

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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