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Contents
1. KYMCO 4 LUBRICATION SYSTEM ATV 50 LUBRICATION SYSTEM from ut p cam KYMCO 4 LUBRICATION SYSTEM ATV 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line e Do not attempt to disassemble the oil pump e Bleed air from the oil pump if there is air between the oil pump and oil line e If the oil is disconnected refill the oil line with motor oil before connecting it SPECIFICATIONS Recommended Motor Oil SAE20W20 2 stroke Motor Oil Capacity 1 liter 0 88 Imp qt 1 06 Us qt Light comes 0 25 liter 0 22 Imp qt 0 27 Us qt TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug e Oil pump not properly synchronized excessive oil Poor quality oil Engine overheating e Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston No oil in tank or clogged oil line e Oil pump not properly adjusted insufficient oiling e Air in oil line e Faulty oil pump Oil not flowing out of tank to engine e Clogged oil tank cap breather hole e Clogged oil filter 4 2 Downfooded fom amp KYMCO 4 LUBRICATION SYSTEM ATV 50 Oil Pump Oil Outlet Line OIL PUMP REMOVAL Do not allow foreig2. Faulty wire harness 2 Starter motor turns slowly or idles Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Signals operate Signals dim remain properly on or don t operate Weak or dead battery Connect starter motor directly to gt battery Starter motor Starter motor turns slowly turns normally _ Faulty starter relay Rotate crankshaft gt Turns easily to turn QO Seized cylinder Broken or shorted starter motor cable Faulty starter pinion 3 Starter motor does not stop turning Inspection Adjustment Symptom Probable Cause Turn ignition switch OFF 5 Not stopped Stopped I Faulty starter pinion Starter relay shorted or stuck closed Downfooded from KYMCO 2 FRAME COVERS EXHAUST MUFFLER ATV 50 oo OA FRAME COVERS EXHAUST MUFFLER SERVICE INFORMATION 2 1 TROUBLESHOOTING iniecto tenete tee 21 FRAME COVERS MX ER 50 228 HEADLIGHT REMOVAL MX ER 50 0 5 FASTENER REMOVAL pu FRAME C
3. Check carburetor air screw adjustment rings Normal Abnormal Q Blown cylinder head gasket compression compression Flaws in cylinder head Faulty reed valve Seized piston gt Not Clogged Clogged Clogged carburetor jets Correct timing Incorrect timing 1 31 Downfooded from amp coated p cam Correctly adjusted Incorrectly adjusted i Faulty CDI unit or generator Q A C G flywheel not aligned O Mixture too rich turn screw out Mixture too lean turn screw in KYMCO 1 GENERAL INFORMATION ATV 50 Inspection Adjustment Symptom Probable Cause Check carburetor gasket for air leaks O Carburetor not securely tightened No air leak Air leaks L 1 9 Faulty intake manifold gasket Deformed or broken carburetor O ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged Q Broken cable Not clogged Clogged Q Dirty auto bystarter Faulty auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching x circuit and then blow the hose with mouth Clogged Not Clogged 0 Faulty auto bystarter 1 32
4. LCD METER LED LGSBGRO Lye ack we jj nnde 1 Yo o L ye HORN SW Hofa Pusa O16 WIRING DIAGRAM MX ER 50 ROAD GO 2 STOP SW RH FR WINKER START SW sz E ere _ OTO coLon vin WINKER SW HORN SWWINKER SW STARTER SVQIMMER SW ENGINE STOP SW DIMMER SW TUBE BLAOK gt Hawt LOW e 5 9 FRAME 10 2 STARTER MOTOR 30W EARTH ENGINE STOP SW pes couor in RH RR WINKER 12V 10W TAIL STOP LIGHT 12V 5 21W cr LH RR WINKER 12V 10W WHELL RPM SENSOR IGN COIL SPARK PLUG COMB SW BarTiG E BAT2 OFF Ore YELLOW WHITE 1 26 ut p cam Downfooded fom 50 KYMCO 1 GENERAL INFORMATION G L HIGH BEAM 12V 1 2W W wW W L L L G Sn Se HEAD LIGHT 12V 35W 35W OIL INDI 12V 1 2W COLOR COMB GROUND MARKING WIRING DIAGRAM MX ER 50 OFF ROAD ENGINE STOP STARTER coLon FR LIGHTING SW COMB SW STOP SW 3 5 42V 3AH 1 S TC LHR bi X EG aid 2GE84 START BATTERY REG OIL
5. 3 18 FRONT REAR SUSPENSION LUBRICATION 3 18 3 0 Downfooded from amp ut p cam KYMCO 3 INSPECTION ADJUSTMENT ATV 50 SERVICE INFORMATION GENERAL WARNING eBefore running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 1 4 mm 0 04 0 16 in Spark plug gap 0 6 0 7 mm 0 024 0 028 in Spark plug Standard NGK BR8HAS Idle speed 1800 100rpm Gear oil capacity MXU 50 MX ER 50 At disassembly 0 12 liter 0 11 Imp qt 0 13 Us qt At change 0 09 liter 0 08 Imp qt 0 1 Us qt Gear oil capacity MXU 50 REVERSE At disassembly 0 3 liter 0 26 Imp qt 0 32 Us qt At change 0 25 liter 0 22 Imp qt 0 26 Us qt Cylinder compression 1200 kPa 12 kgf cm 170 psi Ignition timing MXU 50 MX ER 50 BTDC 22 2000rpm MXU 50 REVERSE BTDC 13 5 1500rpm CHASSIS Front brake free play 10 20 mm 0 4 0 8 in Rear brake free play 10 20 mm 0 4 0 8 in TIRE PRESSURE Dll MX ER 50 1 Rider MXU 50 REVERSEMXU 50 1 Rider 33 kPa 0 33 kgf cm 4 7 p
6. Poor contact in fuel unit Check connectors for proper connection Pointer moves in accordance with float Pointer does not move in accord ance with float O Insufficient damping oil in fuel gauge 1 39 Downfooded from amp coated p cam Good Faulty 0 Loose or disconnected connector Broken or shorted wire in fuel gauge KYMCO 1 GENERAL INFORMATION ATV 50 STARTER MOTOR Starter motor won t turn Inspection Adjustment Symptom Probable Cause Check operation of stop switch by O Burned out fuse applying brake a dead Stoplight comes Loose of discounestad come on ee connector A gt or shorted ignition signals switch wire Signals operate Signals dim remain Faulty or weak battery Check operation of properly on or don t operate starter relay by depressing starter button Relay operates Relay does not _ Poor starter button connection properly operate Faulty starter relay Loose or disconnected Connect starter motor directly to gt battery Starter motor turns Starter does not turn Faulty starter motor
7. Bottom Y Inspect the top of the cylinder for warpage Service Limit 0 1 mm 0 004 in replace if over 7 7 Downloaded fom amp cantes fld p cam KYMCO 7 CYLINDER HEAD CYLINDER PISTON ATV 50 A Mark The cylinder has an A mark or no mark on it When replacing the cylinder with a new one use a cylinder having the same mark as the old one Measure the piston O D at a point 5 mm 0 2 in from the bottom of the piston skirt Service Limit 38 9 mm 1 56 in replace if below Measure the piston to cylinder clearance Service Limit 0 1 mm 0 004 in replace if over Measure the piston pin hole I D Service Limit 12 03 mm 0 481 in replace if over Measure the piston pin O D Service Limit 11 98 mm 0 479 in replace if below Measure the piston to piston pin clearance Service Limit 0 03 mm 0 0012 in replace if over 7 8 S caotes KYMCO 7 CYLINDER HEAD CYLINDER PISTON ATV 50 PISTON RING INSPECTION Measure each piston ring end gap Service Limits Top Second 0 4 mm 0 016 in replace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap NEN E CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for excessive play Measure the connecting road small end I D Service Limit 17 03 m
8. FRONT CENTER COVER REMOVAL INSTALLATION Remove the front cargo rack see page 2 8 Remove the two screws on the front cover two screws under the front cover and front center cover During removal do not pull the joint claws forcedly to avoid damage Installation is in the reverse order of removal HANDLEBAR COVER REMOVAL INSTALLATION Remove the front center cover see page 2 12 Disconnect the fuel tank breather hose from the handlebar cover Remove the two screws and raise the handlebar cover Disconnect the ignition switch connectors Fuel Tank Breather Hose instrument Connectors Disconnect the instrument connector then remove the handlebar cover and instrument Installation is in the reserve order of removal Downloaded fom p S caotes KYMCO 2 FRAME COVERS EXHAUST MUFFLER ATV 50 FUEL TANK COVER REMOVAL INSTALLATION Screws Screws Remove the four screws and two nuts from the fuel tank cover Remove the fuel tank cap by turning it counterclockwise and fuel tank seal then remove the fuel tank cover Put on the fuel tank cap after removing the cover to prevent dust mud etc from entering the fuel tank Installation is in the reverse order of removal MXU 50 REVERSE Remove the bolt and then remove the drive select lever grip FRONT FENDER REMOVAL INSTALLATION Remove front carrier see page 2 9 front center
9. KWANG YANG Motor Ltd First Edition Jan 2006 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T100LB10DE Downfooded from amp ut p cam This Service Manual describes technical features and servicing procedures for the KYMCO MXU 50 REVERSE MXU 50 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 19 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 The information and contents included in this manual may be different from the ATV in case specifications are changed KYMCO reserves the right to make changes at any time without notice and without incurring any obligation KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT
10. 1 33 Downfooded from amp coated p cam Engine overheats Q Poor quality fuel I 1 O Excessive carbon build up in combustion chamber _ Ignition timing too early m O Excessive carbon build up in Engine does not knock Engine knocks combustion chamber I Q Poor quality fuel r 9 Clutch slipping Mixture too lean KYMCO 1 GENERAL INFORMATION ATV 50 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Symptom Probable Cause Check ignition timing gt i mO Faulty CDI unit Correct timing Incorrect timing _ Faulty A C generator Check carburetor air screw adjustment 7 Mixture too rich turn screw Correctly adjusted Incorrectly adjusted out Mixture too lean turn screw in Check carburetor gasket for air leaks O Carburetor not securely i tightened AUC Faulty intake manifold gasket Remove spark plug and Deformed carburetor O ring install it into spark plug cap to test spark by connecting it to engine ground mO Faulty or fouled spark plug r Q Faulty CDI unit Good spark Weak or
11. Downfooded from amp coated p cam 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation Symptom Engine speed increases Check ignition timing using a timing light KYMCO ATV 50 Probable Cause Engine speed does not increase sufficiently m Clogged air cleaner O Clogged fuel filter I 1 O Clogged exhaust muffler Faulty auto bystarter Faulty charcoal canister Correct timing Incorrect timing O Faulty CDI unit Faulty A C generator Test cylinder compression using a compression gauge mO Worn cylinder and piston Normal Abnormal rings compression compression Blown cylinder head gasket L Faulty reed valve Check carburetor for clogging Not Clogged Clogged Clogged carburetor jets Remove spark plug and inspect d Plug not fouled or Plugfouled or Fouled spark plug discolored discolored Q Incorrect heat range plug Check if engine overheats r QO Mixture too lean Engine does not overheats Rapidly accelerate or run at high speed
12. Ground deans 162mm 65 Mimi ooo mm Starting motor amp 39 x 41 4 mm 1 56 x 1 656 in Compression ratio 72 1 12 kgf cm 1200 kPa 170 4 psi Intake Automatic controlled Port timing Exhaust Open utomatic controlled Valve clearance take Exhaust Lubrication type Separate type Oil pump type Oil filter type Bore x stroke Compression pressure Downfooded fom amp ut p cam UulojsAg ond eornoo qd V g lt oO lt a 8 Brake system KYMCO ATV 50 Q Type 3 3pPB J 80 0 Type CD I Spark plug NGK BR8HAS Spark plug gap 0 6 0 7mm Automatic centrifugal Type system system 1 2 3 5 Secondary reduction 20 12 ratio 46 11 pee kgf cm 28 kPa 4 Tire pressure psi kgf cm 28 kPa 4 psi JoyoIngs uous Operation Turning angle 1 4 1 GENERAL INFORMATION SERVICE PRECAUTIONS B Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally E Use genuine parts and lubricants When servicing the motorcycle be sure to use special tools for removal and installation After disas
13. z protruding or loose x x 1 7 Downfooded from ut p cam B When taking out connector lock on 1 GENERAL INFORMATION The connector shall be inserted completely If the double connector has a lock lock it at the correct position B Check if there is any loose wire E Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation B Insert the terminal completely B Check the terminal cover for proper coverage E Do not make the terminal cover opening face up Secure 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 Downfooded fom KYMCO 50 mu x eet Snapping mol EE 1 8 1 GENERAL INFORMATION B After clamping check each wire to make sure it is secure E Do not squeeze wires against the weld or its clamp B After clamping check each harness to make sure that it is not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat B Route wire harnesses to avoid sharp edges orcorners Avoid the projected ends of bolts and screws Bi Route wire harnesses passing through the
14. side of bolts and screws Avoid projected ends of bolts and screws 1 9 Downfooded fom amp ut p cam KYMCO A ATV 50 E i nn n 1 GENERAL INFORMATION B Route harnesses so they are neither pulled tight nor have excessive slack B Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner E When rubber protecting cover is used to protect the wire harnesses it shall be installed securely E Do not break the sheath of wire If a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires Downfooded fom amp KYMCO 50 4 ipt amp tight a d 1 10 1 GENERAL INFORMATION After routing check that the wire harnesses are not twisted or kinked Wire harnesses routed along with handlebar should not be pulled tight have excessive Slack or interfere with adjacent or surrounding parts in all steering positions B When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions E Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before connecting 1
15. 13 5 1 5 BTDC 1500rpm ep Mark 3 7 Downloaded fom 3 INSPECTION ADJUSTMENT ATV 50 CYLINDER COMPRESSION Warm up the engine before compression test Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 1200 12kgf cm 170psi If the compression is low check for the following Leaky valves Valve clearance too small Leaking cylinder 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 Compression Gauge Oil Check Bolt r FINAL REDUCTION GEAR OIL MXU 5 50 7 ia MXU 50 MX ER 50 Gear Oil Lever The gear oil level shall be at the oil check bolt hole If the oil level is low add the specified oil to the proper level Specified Gear Oil SAE1OW90 Install and tighten the oil check bolt Torque 1 3 kgf m 13 N m 9 4 Start the engine and check for oil leaks 3 8 Downloaded fom KYMCO 3 INSPECTION ADJUSTMENT ATV 50 Oil Filler Bolt MXU 50 MX ER 50 GEAR OIL CHANGE Remove the oil filler bolt Removes the oil drains bolt and drain the oil thoroughly Install the oil drain bolt Torque 1 3 kgf m 13 N m 9 4 Ibf ft Make sure that sealin
16. 202 4 Ibs 94 kg 206 8 Ibs 186 kg 409 2 lbs 21 7 10 22 10 10 165 mm 6 6 in 2900 mm 116 in Starting motor amp 39 x 41 4 mm 1 56 x 1 656 in Compression ratio 72 1 12 kgf cm 1200 kPa 170 4 psi Intake Automatic controlled Port timing Exhaust Open utomatic controlled Valve clearance Exhaust Idle speed rpm 1800 Lubrication type Separate type Oil pump type Plunger type Oil filter type Full flow filtration 1 3 Bore x stroke Compression pressure Downfooded fom amp ut p cam 84 ond eornoo qd V g lt Cc lt a Brake system KYMCO ATV 50 Q Type 3 3pPB J 80 0 Type CD I Spark plug gap 0 6 0 7mm Operation J032Jnq uous Automatic centrifugal Type DN M 23 678 psi psi angle Type w uononpoy Final gear ratio Tire pressure 1 GENERAL INFORMATION Model No LB10 MXU 50 REVERSE 1786 mm 71 in 958 mm 38 in 1010 mm 40 in 1105 mm 44 in Air cooled 2 stroke 49 4 cm 2 964 cu in Front wheel Rear wheel Front wheel Rear wheel Front wheel Tires Rear wheel 78 kg 171 6 Ibs 80 kg 176 Ibs 158 kg 347 6 Ibs 83 kg 182 6 Ibs 84 kg 184 8 Ibs 167 kg 36734 Ibs 21 7 10 22 10 10
17. 50 Wire Connector OIL TANK OIL TANK REMOVAL Remove the seat 42 3 or 2 8 Remove the oil meter connector Remove the one bolt and one nut from the oil tank see page 2 14 Disconnect the oil inlet line Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence is the reverse of removal Connect oil line properly e Bleed air from the oil pump after installation The oil tube clip at the oil tank side must be locked from inside of the oil tube joint 4 6 fom P S caotes KYMCO 5 FUEL SYSTEM ATV 50 FUEL SYSTEM SERVICE INFORMA TION 22 ee ae 5 2 TROUBLESHOOTING 52 THROTTLE VALVE DISASSEMBLY CARBURETOR REMOVAL 5 3 AUTO BYSTARTER sic 5 6 FLOAT FLOAT VALVE JETS FLOAT CHAMBER 5 8 CARURETOR INSTALLATION 5 11 ATR SCREW ADIUSTMENT auctae eet ei 5 12 5 13 FURL TANE see 5 14 VALVE REMOVA Lers 5 15 AR TI ae ee 5 15 5 0 Downfooded from amp coated p cam 50 KYMCO 5 FUEL SYSTEM 5 S caotes fud p 5 1 Downfooded fom KYMCO 5 FUEL SYSTEM ATV 50 SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disa
18. 9 1 1 RELAY REC LEVEL M Ly YRBRYW L P B d 799 RYWG a TL RBRY WL P BAG R RYW B hy GHG T B x 29 EJ B 5 E 7 a 3 99 oF s Y WR Y Xx W I P ul 6 AUTO a 4 B S ME RR STOP SW l CDI PULSER UNIT d tl 5 9 FRAME 10 2 STARTER MOTOR 30W EARTH 5W LIGHTING SW cr RE LO Hi COMB SW STARTER SW ENGINE STOP SW L BAT IG E 2 coo BR W L e GY BR 5 BR TAIL STOP LIGHT 12V 5 21W IGN COIL SPARK PLUG 1 27 Downfooded from 50 KYMCO 1 GENERAL INFORMATION WIRING DIAGRAM MXU 50 ON ROAD B Y L Ww P V HEAD LIGHT 12V 35W 35W FR POSITION 12V 5W BR w we BR w we uB BR HEAD LIGHT 12V 35WI35W FR POSITION 12V SW WIRE COLORS GROUNG MARKING BLACK YELLOW BLUE ORANGE RED WHITE PINK BR BROWN LG LIGHT GREEN GR GRAY SB SKY BLUE uU TEL BW BERG R ojs bd E RAN Gv s A sp by LY BBRGR aye T B GR E Rw c FUSE 20A RH FR WINKER REAR 12V FUEL 12V10WFR FR COMB SW STARTER MOTOR STOP SW oil Saar UNIT STOP SW LEVEL RELAY HAZARD WINKER RELAY E 5 9 S 5 5 E B i V
19. Bleed air from the oil pump Oil Inlet Line Control 4 4 S caotes KYMCO 4 LUBRICATION SYSTEM ATV 50 Oil Outlet Line OIL PUMP BLEEDING Air in oil lines will block oil flow and result in severe engine damage e Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines Oil Pump OIL INLET LINE OIL PUMP BLEEDING Fill the oil tank with recommended oil Place a shop towel around the oil pump Disconnect the oil inlet line from the oil pump and clip it Fill the oil pump with oil by squirting clean oil through the joint About 3cc 0 003 Imp qt 0 003 Us qt Fill the oil line with oil and connect it to the oil pump Bleed air from oil inlet line first then bleed air from the oil outlet line OIL OUTLET LINE BLEEDING 1 Disconnect the oil outlet line and bend it into shape Force air out of the tube by filling it with oil 2 Start the engine and allow it to idle with the oil control lever in the fully open position Visually check the oil flow 3 If there is no oil flowing out within 1 minute bleed air from the oil inlet line and oil pump Oil Outlet Line e Never run the engine in a closed area e Do not increase the engine speed at will 4 5 Downfooded from P KYMCO 4 LUBRICATION SYSTEM ATV
20. Generator Wire Connectors 1 e L Soe y Pulser Wire Connectors Downfooded fom gt S caotes KYMCO 6 ENGINE REMOVAL INSTALLATION ATV 50 Starter Motor Wire Connector zy Auto Bystarter Wire Connector Spark Plug Cap Remove the spark plug cap Disconnect the oil pump control cable from Oil Outlet Carburetor Lock Nuts the pump body Disconnect the oil inlet and outlet line from the oil pump After the oil inlet line is disconnected plug the oil line opening to prevent oil from flowing out Remove the two carburetor lock nuts Remove the carburetor ee Oil Inlet Line Control Cable Downfooded fom P uiti cantes fud p cam KYMCO 6 ENGINE REMOVAL INSTALLATION ATV 50 Drive Select Rod Neutral Switch Connectors a 175 gt MXU 50 REVERSE Disconnect the neutral switch connectors Remove the bolt nut at drive select rod then remove the drive select rod from drive select arm MXU 50 REVERSE Remove the three bolts at the drive sprocket cover then remove the protector cover Drive Sprocket Cover Drive Chain Gear Remove the rear drive chain gear on the bolts Remove the drive chain gear Pownfooded from P S caotes 6 ENGINE REMOVAL INSTALLATION ATV 50 Bolt Nut Remove the engine any connector thing Remove the re
21. NUMBER Location of Frame Serial Number gt 57 ES P Location of Engine Serial Number 1 1 Downfooded fom Edit 1 GENERAL INFORMATION SPECIFICATIONS Wheel base gasoline 1 56 x 1 656 in Compression pressure pressure Compression kgf cm 1200 kPa 170 4 psi Intake Automatic controlled s ee controlled Valve clearance L me C n type Oil pump type Oil filter type Engine type Displacement Fuel Used Tires Bore x stroke Downfooded Pim amp ut p cam KYMCO ATV 50 S 2 MamjeNo 80 Type Spark plug 0 6 0 7mm Operation UulojsAg ond JO032Jn QE uous eornoo qd Automatic centrifugal Type REC RM 23 678 pens kgf cm 35 kPa 4 97 psi Rear 10 35 kgf cm 35 kPa u E angle Brake system Type 0191545 w uononpow Final gear ratio Tire pressure 1 GENERAL INFORMATION Model No Fuel Used Front wheel Dry weight Rear wheel Front wheel Rear wheel Front wheel Rear wheel Min turning radius LB10 MXU 50 1775 mm 71 in 950 mm 38 in 1040 mm 41 6 in 1120 mm 44 8 in Air cooled 2 stroke 49 4 cm 2 964 cu in 92 nonleaded gasoline 87 kg 191 4 lbs 89 kg 195 8 155 176 kg 387 2 lbs 92 kg
22. Not clogged Clogged 0O Faulty auto bystarter x 1 30 1 GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Check if fuel reaches carburetor by loosening drain screw Symptom Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Fuel reaches carburetor Fuel does not reach carburetor KYMCO ATV 50 Probable Cause O Empty fuel tank Clogged float valve Remove spark plug and install it into spark plug to test spark connecting it to engine ground Plug not fouled discolored Plug fouled or discolored Test cylinder compression using a compression gauge Good spark Check carburetor for clogging Weak or inter mittent spark Check ignition timing Clogged charcoal canister Clogged fuel filter Faulty auto fuel valve Ep Fouled spark plug Incorrect heat range plug O Fouled spark plug Faulty CDI unit Faulty A C generator I 7 Faulty ignition coil Broken or shorted high tension wire 9 Faulty ignition switch mO Worn cylinder and piston
23. cover see page 2 12 fuel tank cover see page 2 13 and right left side cover see page 2 10 Disconnect the right and left headlight connectors 2 13 Downloaded from P KYMCO 2 FRAME COVERS EXHAUST MUFFLER ATV 50 Bolt REAR FENDER l REMOVAL INSTALLATION Remove seat see page 2 8 battery see page 15 5 rear cargo rack see page 2 10 and right left footboard see page 2 10 Remove one bolt and one nut then remove the oil tank Remove the three bolts from the rear fender Raise the rear fender and pass the fuse battery cables start relay through out the rear fender W 8 bj re Dem ami Disconnect the rear right and left signal light connectors Installation is in the reserve order of removal of Connector 2 14 Downfooded fom P S caotes EXHAUST MUFFLER 50 REMOVAL Remove the two nuts attaching the exhaust muffler Remove the two nuts attaching the exhaust pipe Muffler Remove the exhaust muffler lock bolts Remove the exhaust muffler and them remove exhaust pipe When installing first install the exhaust pipe onto the engine and then install the exhaust muffler Torque Exhaust muffler lock bolt 3 3 kgf m 33 N m 24 Exhaust muffler joint lock nut 1 2 kgf m 12 N m 9 Ibf ft Be sure to install a new exhaust muffler gasket Gasket Exhaust Pipe Gasket 2 15 Pownfood
24. holder Install the air screw and throttle stop screw according to the rotations recorded If the air screw must be replaced be sure to perform the air screw adjustment again Throttle Stop Screw Air Screw Float Pin Install the float valve float and float pin Tighten the float screw securely FLOAT LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm Float Level 8 6 mm 0 34 in Replace the float if the level is out of the specified level range Install the O ring Check the operation of the float and install the float chamber Tighten the screws Downfooded fom P S caotes KYMCO 5 FUEL SYSTEM ATV 50 CARBURETOR INSTALLATION O rings When installation do not allow foreign particles to enter the carburetor Check the carburetor insulator and O ring for wear or damage Insulator Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts Connect the fuel tube and auto bystarter wire connector Route the auto bystarter wire correctly and properly Fuel Tube Carburetor Cap Install the carburetor cap 35 3 Install the fuel tube Install the air cleaner onto the carburetor and tighten the band screw 5 11 Pownfooded from P 5 FUEL SYSTEM ATV 50 AIR SCREW ADJUSTM
25. 11 Downfooded fom amp ut p cam KYMCO ATV 50 Do you understand the instrument Is the instrument set correctly gt KYMCO 1 GENERAL INFORMATION ATV 50 B Symbols The following symbols represent the servicing methods and cautions included in this service manual D Apply engine oil to the Engine Oil specified points Use designated engine oil for lubrication Grease Apply grease for lubrication i Caution V Warning 1 12 Downfooded fom ut p cam KYMCO 1 GENERAL INFORMATION ATV 50 TORQUE VALUES STANDARD TORQUE VALUES Yeti Torque iis Torque kgf m N m Ibf ft kgf m N m Ibf ft 5mm bolt and nut 0 5 5 3 6 4mm screw 6mm bolt and nut 1 10 7 2 5mm screw 8mm bolt and nut 2 2 22 16 6mm screw SH bolt 10mm bolt and nut 3 5 35 25 6mm flange bolt and nut 1 2 12 9 12mm bolt and nut 5 5 55 40 8mm flange bolt and nut 2 7 27 20 14mm and nut 7 70 50 10mm flange bolt and nut 14 40 29 Torque specifications listed below are for important fasteners Torque Q ty Thread dia mm kgf m N m Remarks Cylinder head bolt 1 6 16 11 5 Clutch drive plate nut Drive face nut Clutch outer nut A C G flywheel nut check filler bolt MXU 50 MX ER 50 Oil drain plug Oil filler bolt MXU 50 REVERSE Exhaust muffler joint lock nut Exhaust muffler lo
26. 3 kgf m 30 N m 22 Ibf ft Tie rod End Nuts Be sure that both tie rod turned 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 e After setting the toe in to specification run the machine slowly for some distance with hands placed lightly on the handlebar and check that the handlebar responds correctly If not turn either the right or left tie rod within the toe in specification 3 14 Downfooded from fud p cam KYMCO 3 INSPECTION ADJUSTMENT ATV 50 WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure Tire pressure should be checked when tires are cold TIRE PRESSURE MX ER 50 MXU 50 TIRE SIZE MXU 50 REVERSE MXUS0 Front 21 7 10 Rear 22 10 10 MX ER 50 Front 20 7 8 Rear 22 10 8 Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the specified torque Torque Front 7 kgf m 70 N m 50 Ibf ft Rear 7 kgf m 70 N m 50 Ibf ft WHEEL INSPECTION Inspect the tire surfaces Replace if wear or damage Tire wear limit 3 mm 0 1 in It is dangerous to ride with a worn out tire When a tire wear is out of specification replace the tire immediately 3 15 Teunnfoaded fom 3 m
27. C GENERATOR 8 3 GENERATOR INSTALLATION euge dier Eve 8 4 8 Downfooded from amp ut p cam KYMCO 8 A C GENERATOR ATV 50 8 1 Downfooded fom amp KYMCO 8 A C GENERATOR 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e All A C generator maintenance and inspection can be made with the engine installed e Refer to Section 15 16 for A C generator inspection TORQUE VALUE Flywheel nut 3 8 kgf m 38 N m 27 4 Ibf ft SPECIAL TOOLS Flywheel puller A120E00001 Universal holder A120E00017 Pannfanded
28. Disconnect the throttle cable from the throttle valve Throttle Valve Carburetor Cap Rubber Seal Remove the throttle valve spring carburetor cap and rubber seal 5 3 Downloaded fom uite S caotes KYMCO 5 FUEL SYSTEM ATV 50 Remove the jet needle by removing the needle clip Needle Cli Check the jet needle and throttle valve for 2 wear damage Needle Retainer 2nd Notch STD Jet Needle lt Throttle Valve Carburetor Cap Rubber Seal THROTTLE VALVE INSTALLA TION Install the jet needle on the throttle valve and secure with the needle clip Install the rubber seal on the throttle cable and then install the carburetor cap and throttle valve spring Connect the throttle cable to the throttle valve Throttle Valve Throttle Cable 5 4 Downloaded fom P R 5 FUEL SYSTEM ATV 50 Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw Tighten the carburetor cap After installation perform the following adjustments and inspections Throttle cable free play 43 3 Idle speed adjustment 3 7 Throttle Cable Bystarter Fuel Tube gt S CARBURETOR REMOVAL Remove the air cleaner by removing the air cleaner band screw and attaching bolts Disconnect the fuel tube Loosen the drain bolt to drain fuel from the carburetor
29. ENT Turn the air screw clockwise until it seats lightly and back it to the specification given Do not force air screw against its seat to prevent damage Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Air Screw Throttle Stop Screw Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1800 100 rpm Air Screw Opening 2 1 2 turns Slightly increase the engine speed and make sure that the engine does not miss or run erratic If the adjustment of the air screw within the range of 1 2 turn makes no difference to the engine performance check other related items 5 12 fom P S caotes 5 FUEL SYSTEM ATV 50 REED VALVE REMOVAL Remove the four intake manifold bolts and gasket Remove the reed valve and gasket Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary Do not disassemble or bend reed stopper To do so can cause loss of engine power and engine damage If any of the stopper reed or valve seat is faulty replace them as unit Reed Valve Seat INSTALLATION Install the reed valve in the reverse order of removal Install a new gasket with gasket indentation alig
30. NJ ju Disconnect the auto bystarter wire 24 connector M AH Drain Bolt 5 5 Downfooded from KYMCO 5 FUEL SYSTEM ATV 50 Remove the two carburetor lock nuts Remove the carburetor AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 5Q 10 minutes minimum after stopping the engine If the resistance exceeds 5Q replace the auto bystarter with a new one After the engine