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MXU 300(250)(150) OFF ROAD-000-002_v1

1. 1 Fuel valve MXU 300 250 2 Fuel valve MXU 150 43 OFF With the lever and A mark in this position fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever A mark in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever A mark to this position THEN FILL THE FUEL TANKAT THE FIRST OPPORTUNITY After refueling return the fuel valve lever to the ON position NOTE After refueling do not operate the ATV with the fuel valve in the RES position If you run out of fuel there will be no reserve supply OFF ON RES CHOKE KNOB Starting a cold engine requires a richer air fuel mixture Aseparate starter circuit supplies this mixture Move in direction A to turn on the choke knob Move in direction B to turn off the choke knob Refer to starting a cold engine for proper operation See page 66 e 1 Fully open 2 Half open 3 Closed A ON position B OFF position CAUTION e Extended use of the choke may impair piston e Pushing the choke knob too hard to the OFF and cylinder wall lubrication and shorten the life of the engine position may dislodge the choke cable boot If this happens water and dirt may enter the choke cable and cause corrosion If the choke is hard to actuate or feels lik
2. 7 1 MXU 300 250 8 1 MXU 250 A CAUTION Never Carry passenger on N WARNING Exceeding vehicle towing limit could lead to an accident Reduce speed when towing a trailer This carrier Maximum load 20 Kg 44 Ibs Read owner s manual for details MAXIMUM TOWING CAPACITY 150kg 331 Ibs TONGUE WEIGHT 14kg 30 Ibs 7 2 MXU 150 A CAUTION 8 2 MXU 150 WARNING Exceeding vehicle towing limit could lead to an Never carry passenger on This carrier Maximum load 15 Kg 33 Ibs accident Reduce speed when towing a trailer Read owner s manual for details MAXIMUM TOWING CAPACITY 100kg 220 Ibs 8 1 MXU 300 WARNING Exceeding vehicle s towing limit could cause an accident Reduce speed when towing a trailer Read operator s manual for details MAXIMUM TONGUE WEIGHT 35 Ibs 16 kg MAXIMUM TOWING CAPACITY 500 Ibs 227 kg 1411 102 A SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars An accident can occur quickly even during routine maneuvers suchas turning andriding onhills orover obstacles if youfailto take proper pre cautions SEVERE INJURY OR DEATH can result if you do not follow these instructions e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper training or instruction B
3. e Do not remove this Owner s Manual from this ATV according to the guidelines and agreement with the U S Consumer Product Safety Commission e Read this manual carefully It contains important safety information 44 WARNING Operation of this ATV by children under the age of 14 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 14 to operate this ATV 1411 377 44 WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 1411 804 OWNER S MANUAL MXU 150 250 300 orr roap KYMCO is certificated to 1509001 15013485 15014001 OHSAS18001 etc and accredited to SO1 025 Details at http www kymco com IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner s Manual contains important information on safety operation and maintenance Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle AGE RECOMMENDATION The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle RIDER TRAINING Anyone who operates this vehicle should get proper instruction FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only This machine is designed and manufactured for OFF ROAD us
4. COOLING SYSTEM INSPECTION MXU 300 250 1 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature The coolant level should be between the maximum and minimum marks 2 If the level is low remove the coolant reservoir cap and then add coolant or distilled water to raise it to the specified level 3 If your ATV overheats see page 161 for details 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark CAUTION Hard water or salt water is harmful to the engine You may use distilled water if rou can not get soft water NOTE 1 If water is added have a KYMCO dealer check the antifreeze content of the coolant as soon as possible 2 The radiator fan operation is completely automatic It is switched on or off according to the coolant temperature in the radiator 160 Engine overheating A WARNING If your ATV overheat wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is low check the cooling system for leakage Ask a KYMCO Add coolant dealer to inspect See NOTE and repair the cooling system POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN Level is OK You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool befo
5. MXU 150 The front brake lever free play should be adjusted to 10 20 mm 0 4 0 8 in at the tip of the brake lever If the free play is incorrect adjust as follows AO NE MTN 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 2 Loosen the lower locknut 3 3 Turn the lower adjusting bolt 4 until specified free play is obtained A Free play 10 20 mm 0 4 0 8 in Specified free play 10 20 mm 0 4 0 8 in 1 Loosen the upper locknut 1 and fully turn in the upper adjusting bolt 2 4 Tighten the lower locknut 158 5 While applying the front brake turn out the upper adjusting bolt until the upper and lower cable lengths are equal The cable joint 5 will become vertical e 3 Ka 2 I bk E mu VK A R C Xi mmm ee EECH Fal rd EEE EN ET AA J ZE ae Ecg M i AO BS 1 Cable joint A Cable length 6 Tighten the upper locknut 159 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by KYMCO dealer
6. MXU 300 250 3 2 MXU 150 8 2 MXU 150 8 1 MXU 300 250 2 Warning information Anyone whorides the vehicle should read and understand this information before riding They contain importantinformation forsafe and proper operation of yourAT V Thelabels should be considered as permanentparts of the vehicle Ifalabel comes off orbecomes hard toread contact yourKYMCOdealerforreplacements 1 3 1 MXU 250 300 AA WARNING Improper tire pressure or overloading can cause loss of control WARNING NEVER ride as a passenger Passengers can cause a loss of control SEVERE INJURY Loss of control can result in severe iii injury or death e Cold tire pressure e Front 4 0 psi 27 6 kPa 2 MXU 150 MXU 250 300 2 Rear 3 5 psi 24 1 kPa e Maximum weight capacity 400 Ibs 182 kg 44 WARNING 44 WARNING Operation of this ATV by children under the age of 14 increases the risk of severe injury or death 1411 805 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death Adult supervision required for children under age 16 NEVER operate this ATV if you are under age 16 NEVER permit children under age 14 to operate this ATV 1411 377 3 2 MXU 150 AA WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires c
7. POSITION EIGHT Eeer 20 PREFACE tiese eie nie ee E nee ee Ee C PRE OPERATION CHECKG 51 88 Cont d 200 Page R REAR FINAL GEAR CASE OIL 59 136 REAR SWING ARM LUBRICATION 165 RECOIL SIARTER esse ne dees ei 35 RIDING DOWNHILL 113 RIDING OVER ROUGH TERRAIN 117 RIDING YOUR ATV 8 1 S SAFETY INFORMATION T SEAT E 46 47 SLIDING AND SKIDDING ss sos ES SE EE 105 SPARK ARRESTER CLEANING 180 SPARK PLUG INSPECTION 140 SPECIAL MESSAGES sesse ees seed sees ESE B SPECIFICATIONS sees ee ee ee ee 188 192 SPEED LIMITER ane ss eege 38 89 STARTING ENGINE 66 68 69 70 Stater DUTTON sae deca ES EER EE Ge ie EE le 32 STORAGE EER EE Se DE GE ee 186 STORAGE COMPARTMENT 49 VE os EE ER siah 60 201 Page T THROTTLE LEVER as iN EE 37 60 150 TIRE EE 61 63 TOOL KT este eee oe ig oe ee oe 122 TRAILER FUT Cis osse see ie ede oes 48 TRANSMISSION OIL 0008 59 135 TROUBLESHOOTING ia os es Ges OD ie EE 182 Troubleshooting chart GER 183 TURNING YOUR AF ooo sis ones dese bei 103 W WARMING UP 70 Ve ee en ee re ee er ee ees 169 V VALVE CLEARANCE ADJUSTMENT 152 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kaohsiung Taiwan Republic of China Telephone 886 7 3822926 FAX 886 7 3950021 By KWANG YANG Motor Co Ltd Second Edition May 2008 All rights reserved Any reproduction or unaut
8. eCheck coolant leakage Coolant MXU 300 250 eReplace if necessary eReplace coolant every 24 months eCheck specific gravity Battery eCheck breather hose for proper operation eCorrect if necessary eCheck leakage Exhaust system eRetighten if necessary eReplace gasket if necessary eCheck and adjust slack alignment clean lube i l eCheck bearing assembly for looseness damage Wheel bearings eReplace if damaged eCheck operation eReplace if damaged eCheck toe in eAdjust if necessa Knuckle shaf Re el ubricate every 6 months Ed eCheck all chassis fittings and fasteners Fittings and Fasteners sCorrect if necessary Steering system E eCheck balance damage runout Wheels eReplace if necessary It is recommended that these items be serviced by a KYMCO dealer Lithium soap base grease Kk 126 ENGINE OIL MXU 300 250 1 Engine oil level measurement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Check the oil level through the inspection window 1 D The oil level should be between the maximum H and minimum L marks If the level is low add oil to raise it to the proper level NOTE Wait a few minutes until the oil level settles before checking ER a WEE ES A 1 Engine oil inspection window 2 Maximum level mark H 3 Minimum level mark L 126 2 1 Engine oil replacement and oil filter cleaning
9. 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 64 A WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Should be serviced by your authorized KYMCO dealer when changing the coolant 65 OPERATION A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your KYMCO dealer STARTING A COLD ENGINE A WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Set the parking brake 2 Turn the fuel lock to ON 3 Turn the main switch to ON position and the engine stop switch to 4 Shift the drive select lever to neutral 66 NOTE The engine can be started only whe
10. Improperly operation in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly ENGINE BREAK IN There is never a more important period in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a KYMCO dealer 74 1 0 10 hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of the machine from time to time Do not operate it at full throttle position 2 10 20 hours Avoid prolon
11. Liquid cooled 4 stroke OHC Single cylinder 270 cm 16 5 cu in 72 7X65 2 mm 2 9X2 6 in 10 3 1 Electric Recoil starter Wet sump 188 1810 mm 72 in 1050 mm 42 in 1110 mm 44 in 32 in 810 mm 1170 mm 47 in 285 mm 11 in 2900 mm 113 in 226kg 497 Ibs Liquid cooled 4 stroke OHC Single cylinder 249 cm 15 2 cu in 72 7X60 mm 29 1X2 4 in 10 3 1 Electric Recoil starter Wet sump Engine oil transmission oil rear final gear case oil Type Engine oil classification Transmission oil classification Rear final gear case oil classification Quantity Engine oil Periodic oil change Total amount Transmission oll Periodic oil change Total amount Rear final gear case oil Periodic oil change Total amount 0 0 API Service SE D D D D D D Gel SAE 10W 30 Ed EER EE SAE 10W 40 SAE 20W 40 SAE 20W 50 10 20 30 40C SF SG type or higher SEA 90 SAE 90 1 4 L 1 23 Imp qt 1 48 US qt 1 6 L 1 41 Imp qt 1 69 US qt 0 5 L 0 43 Imp qt 0 53 US qt 0 6 L 0 52 Imp qt 0 64 US qt 0 1 L 3 56 Imp oz 3 33 US oz 0 15 L 5 33 Imp oz 5 US oz 189 0 3 L 0 26 Imp qt 0 32 US qt 0 4 L 0 35 Imp qt 0 42 US qt Air filter for engine Wet type element for V belt compartment Dry type element Fuel Type UNLEADED FUEL Tank capacity 12 5 L 2 7 Imp gal 3 2 US gal Reserve amount 1 8L 0 4 Imp gal 0 47 US gal Carbure
12. Quantity Engine oil Periodic oil change 0 9 L 0 79 Imp qt 0 95 US qt Total amount 1 L 0 88 Imp qt 1 06 US qt Transmission oil Periodic oil change 0 2 L 0 18 Imp qt 0 21 US qt Total amount 0 4 L 0 35 Imp qt 0 42 US qt 193 Air filter for engine Wet type element for V belt compartment Dry type element Fuel Type UNLEADED FUEL Tank capacity 8 1L 1 7 Imp gal 2 11 US gal Reserve amount 1L 0 21 Imp gal 0 26 US gal Carburetor Type Spark plug Type DR 8EA Gap 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automatic Brake Front brake type Drum brake Rear brake type Disk brake 194 Suspension Front Rear Shock absorber Front Rear Electrical Ignition system Generator system Battery type Tire Type Size Front Rear Bulb voltage wattage X quantity Headlight Stop light Taillight Position light Swing axle Swing arm Coil spring Oil damper Coil spring Oil damper C D I C D I Magneto 12V 8AH Tubeless 21X7 10 22X10 10 12V35W 35W X2 12V21W 5W X1 12V5WX2 195 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Some local laws and regulations prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or de
13. Accessories can affect the handling and control of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories e Choose only accessories designed for your ATV Your KYMCO dealer has a variety of genuine KYMCO accessories Other accessories may also be available on the market However itis not possible for KYMCO to test all non KYMCO accessories nor have any control over the quality or suitability of them Choose a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV 78 Do not mount an accessory where it could interfere with your ability your to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding anATV with accessories The ATV may handle differently than it does without accessories LOADING As originally equipped this ATV can carry cargo or tow a trailer you must use common sense and good judgment Keep the following points in mind Never exceed the weight limit shown An overloaded ATV can be unstable e Maximum load MXU 300 250 Trailer
14. Digital clock Coolant temperature gauge MXU 300 250 Fuel gauge 2 High beam indicator The ignition switch is at the At position the high beam indicator lamp will light when the headlight switch to select high beam 20 1 Multi function display 2 High beam indicator NOTE 3 Low gear indicator MXU 300 The headlight can be turned on only when the 4 Neutral indicator engine is running 5 Reverse indicator 6 Mode Adjust button A 3 Low gear indicator MXU 300 7 Mode Adjust button B The low gear indicator will light when the transmission is in low gear and the ignition switch is ON EN 4 Neutral indicator The neutral indicator will light when the transmission is in neutral and the ignition switchis ON 5 Reverse indicator The reverse indicator will light when the transmission is in reverse and the ignition switch is ON 22 6 7 Mode Adjust buttons These buttons is used to select the tripmeter the odometer the km h the mph the km or the mile These buttons is also used to adjust the time and reset the tripmeter Multi function display MXU 300 250 Multi function display MXU 150 1 Digital clock 1 Digital clock 2 Coolant temperature gauge 2 Speedometer 3 Speedometer 3 Fuel gauge 4 Fuel gauge 4 Odometer Tripmeter 5 Odometer Tripmeter 23 1 Digital clock 3 To set the hour press the Mode Adjust button Show the time hours and minute
15. Drain tube 2 Air cleaner housing 3 Clip 147 To clean the drain tube MXU 150 1 Remove the drain plug 1 by removing the clip 2 2 Drain the deposits 3 Reinstall the drain plug securing it with the clip 1 Drain plug 2 Clip 148 IDLE SPEED ADJUSTMENT NOTE A diagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 1 Throttle stop screw 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to decrease engine speed Specified idle speed MXU 300 250 1 400 1 600 r min MXU 150 1 600 1 800 r min 149 THROTTLE LEVER ADJUSTMENT NOTE Adjust the engine idling speed before adjusting the throttle lever free play To adjust throttle free play MXU 300 250 1 Slide the rubber sleeve 1 back to expose the throttle cable adjuster 2 Loosen the lock nut 3 then turn the adjuster 2 to obtain the correct free play 3 5 mm or 0 12 0 2 in 1 Rubber sleeve 2 Cable adjuster 3 Tighten the locknut and reinstall the sleeve 3 Locknut 4 Throttle lever A 3 5 mm 0 12 0 2 in Other checks Check the throttle cable for kinks and signs of wear that could
16. MXU 150 Front 25 kpa 0 25 kgf cm 3 5 psi Rear 25 kpa 0 25 kgf cm 3 5 psi 4 Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst 28 kpa 25 kpa 30 kpa 0 28 kgficm 0 25 kgf cm 0 3 kgf cm 3 92 psi 3 5 psi 4 2 psi 28 kpa 25 kpa 30 kpa Front 0 28 kgf cm 0 25 kgf cm 0 3 kgf cm 3 92 psi 3 5 psi 4 2 psi 62 How to measure tire pressure Tire wear limit Use the low pressure tire gauge Tool kit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire NOTE The low pressure tire gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect A Standard 3mm 0 12 in 1 Low pressure tire gauge 63 COOLANT MXU 300 250 Check the coolant level in the reservoir tank when the engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if itis between the FULL and LOW marks on the tank If the coolant level is at or below the LOW level add tap water soft water to bring the level up to FULL Change the coolant every two years See page 160 161 for details CAUTION Hard water or salt water is harmful to the engine You may use distilled water if rou can not get soft water
17. available from your KYMCO dealer The owner s manual should be stored in the The accessory socket s rated capacity is DC storage compartment 12V 10Watts 0 8A or less Be careful not to flood this area when washing your ATV or riding through water and never put any electric conduction material in the storage compartment 1 Owner s manual 1 Accessory socket seat 49 CAUTION Do not plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket e Do not add electrical equipment that will exceed the accessory socket capacity otherwise you may blow the fuse 0 8A in the accessory socket Using non KYMCO accessory socket may drain the battery or blow a fuse in this ATV s electrical system Be carful not to flood this accessory socket when washing yourATV When you have done using an accessory unplug it and cover the socket with cap The accessory socket connector is located under left side of front fender If the accessory socket is not equipped always plug the connector with the plug 1 Connector 2 Plug 50 PRE OPERATION CHECKS Before using this machine check the following points ITEM ROUTINE PAGE DRIVE SELECT LEVER e Check the lever for proper operation 52 56 e Check operation condition and brake fluid level Ss Fill with DOT 4 brake fluid if necessary i wee FUEL Check fuel level 57 58 e Fill with fue
18. before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible 114 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slippery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel A WARNING 115 POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the si
19. cause stretching or failure Lubricate the throttle cable witha commercially available lubricant to prevent premature wear and corrosion 150 To adjust throttle free play MXU 150 1 Slide the rubber sleeves 1 back to expose the throttle cable adjuster 2 Loosen the lock nut 3 then turn the adjuster 2 to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear that could cause stretching or failure Lubricate the throttle cable witha commercially available lubricant to prevent premature wear and corrosion 151 SS A W N 1 1 Rubber sleeve 2 Cable adjuster 3 Locknut 4 Throttle lever A 3 5 mm 0 12 0 2 in VALVE CLEARANCE ADJUSTMENT FRONT AND REAR BRAKE PADS The correct valve clearance changes with use INSPECTION MXU 300 250 resulting in improper fuel air supply or engine A wear indicator is provided on each brake The noise To prevent this the valve clearance must indicators allows checking of brake pads be adjusted regularly This adjustment however wear Check the position of the indicator Ifthe should be left to a professional KYMCO service indicator reaches the wear limit line ask a technician KYMCO dealer to replace the pads 1 Wear indicator 2 R L Front brake 152 Rear brake pads MXU 250 inspection A wear indicator is provided on each brake
20. d Page CLEANING AND STORAGE 184 A GEA le LEE 184 E STORAGE ss pes deeg 186 SPECIFICATIONS MXU 300 250 188 SPECIFICATIONS MXU 150 192 NOISE KESLEATION ss ne n SEE DE 196 MAINTENANCE RECORD 197 LOCATION OF THE WARNING AND SPECIFICATION LABELS 2 CERTIFICATE LABEL OF SVIA HANG TAG_GENERAL USE 1 DECAL OF EPA NOT HS WEN we REMOVE 4 WARNING improper ATV use can result in SEVERE INJURY or DEATH DAG ALWAYS USE NEVERUSE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH ORUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads 3 collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid ATV overturns om hills and rough terrain and in tums wold paved surtaces pavement may seriowsly affect handling and control LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS MXU 300 VEHICLE EMISSION CONTROL INFORMATION N ENGINE DISPLACEMENT 0 271L ENGINE FAMILY 7KYMXO 27LD9 THIS VEHICLE IS CERTIFIED TO OPERATE ON GASOLINE THIS VEHICLE CONFORMS TO US EPA REGULATIONS OF 1 5 G KM HC NOX 35 G KM CO CALIFORNIA REGULATIONS OF 1 2 G KM HC 15 G KM CO FOR 2007 MODEL Y
21. lose control If you are unable to continue up the hill dismount the ATV on the uphill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT use the rear brake to stop The ATV could easily tip over backwards Instead dismount the ATV immediately on the uphill side A WARNING 110 POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual 111 If the hillis not too steep and you have good footing you may be able to walk the AT V back down the hill Make sure your intended path is clear in case you lose control of the ATV If you decide you can walk the ATV safely 1 Stand with your body facing downhill beside the vehicle so you can reach the front brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check yo
22. motorcycle ae helmet increases your chances of a severe head injury or death in Helmet the event of an accident You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket Long pants Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident 85 Do not operate after consuming alcohol or drugs Operator s performance capability is reduced by the influence of alcohol or drugs 86 A WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could resultin an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV This machine is designed to carry operator only passengers prohibited A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation Itis not for carrying passengers 87 PRE OPERATION CHECKS Always perform the pro operation checks listed on page 51 before
23. nut POTENTIAL HAZARD Installing wheels improperly Wheel installation When reinstalling a wheel tighten the wheel WHAT CAN HAPPEN nuts in a crisscross rather than a circular A wheel may come loose possibly leading pattern to an accident Wheel nut torque HOW TO AVOID THE HAZARD Carefully follow the instructions in this Owner s Manual when installing Front 45 Nm 4 5 m kg 32 ft lb Rear 45 Nm 4 5 m kg 32 ft lb 169 BATTERY Your ATV battery is located in a compartment under the seat The battery is sealed so it is not necessary to check the electrolyte level or add distilled water If the battery seems weak see your authorized KYMCO dealer for information on recharging or replacement If you replace the battery choose one that is sealed and equivalent to the original Be sure to read and follow all safety precautions indicated on the battery CAUTION Do not attempt to remove the caps from the battery cells as this may damage the battery e Although the battery is sealed it vents explosive gases and should be handled with appropriate care 170 A WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery WHAT CAN HAPPEN Gases may explode and possibly cause injury HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery NOTE e When the ATV is to be stored for an extended period remove the battery from the vehicle and charge it full
24. regular unleaded gasoline with a pump octane number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Use unleaded fuel only because it produces fewer engine and spark plug deposits and extends the life of the exhaust system Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank 58 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot ENGINE TRANSMISSION OILAND REAR FINAL GEAR CASE OIL Make sure the engine transmission oil and rear final gear case oil at the specified level Add oil as necessary See page 126 139 Check for leaks i 30 0 110 F eme 30 LU men emp emm Mm MK end SAE 20VV 50 10 0 10 20 30 40 C Recommended engine transmission oil classification A
25. s electrical system capacity A blown fuse could cause a loss of lights or engine power MODIFICATIONS No Modifications Modifying this ATV or removing original A WARNING equipment may render the vehicle unsafe or POTENTIAL HAZARD illegal Spark arresters and mufflers are Operating this ATV with improper required in most areas Don t modify your modifications exhaust system or emission control system components Remember excessive noise WHAT CAN HAPPEN bothers everyone and creates a bad image for Improper installation of accessories or off road vehicles modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction If you have question consult an authorized ATV dealer 92 EXHAUST SYSTEM The exhaust on the machine is very hot during and following operation To prevent burns avoid touching the exhaust system Park the machine in a place where pedestrians or children are not likely to touch it A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not touch the hot exh
26. the pivot points using a grease gun 166 BRAKE LEVER LUBRICATION CABLE INSPECTION AND LUBRICATION Lubricate the pivoting parts of the brake levers A WARNING POTENTIAL HAZARD Damaged control cables Recommended lubricant Lithium soap based grease All purpose grease WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a KYMCO dealer to replace them Recommended lubricant KYMCO chain and cable lube or SAE 10W40 motor oil 167 DRAINING THE V BELT COMPARTMENT If water leaks into V belt compartment such as when the machine is drive in water remove the drain screw on the bottom of compartment and drain the water Be sure to drive slowly until the V belt becomes dry If slipping is noticed aska KYMCO dealer to inspect 1 Drain bolt MXU 300 250 1 Drain bolt MXU 150 168 WHEEL REMOVAL Be sure the tapered side of the wheel nuts 1 1 Elevate the wheel by placing a suitable stand face the wheel rim 2 under the frame 2 Remove the nuts from the wheel S 1 OK 3 Remove the wheel assembly 2 1 Wheel nut 2 Wheel rim Ss d A WARNING 1 Wheel
27. 00 250 Kick starter MXU 150 Rear wheel ED N Ter Tse 18 19 21 17 27 28 29 24 23 22 30 31 32 33 Parking brake Front brake fluid reservoir MXU 300 250 Instrument and indicators Accessory socket seat MXU 300 250 Rear brake fluid reservoir Headlight dimmer switch Starter button Engine stop switch Passing signal switch 28 Left operator footpeg 29 Ignition switch Headlight switch Position light switch 0 Fuel fill cap 1 Throttle lever 2 Right operator footpeg 3 Rear brake pedal MXU 300 250 Ne 31 Flag pole bracket NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual 31 CONTROL FUNCTIONS IGNITION SWITCH HEADLIGHT amp POSITION LIGHT SWITCH Functions of the respective switch positions are as follows OFF position All electrical circuits are switched off The key can be removed in this position ON position With the engine stop switch at run O and the transmission in neutral and set the parking brake the engine can be started The key can not be removed u Ar ae keng em dy position The ignition switch is ON while the position light and taillight will light The key can not be removed 20 INSTRUMENTS AND INDICATOR 1 Multi function display The display includes the following functions Speedometer Odometer Tripmeter
28. 50 VALVE CLEARANCE ADJUSTMENT 152 FRONT AND REAR BRAKE PADS INSPECTION MXU 300 250 152 FRONT BRAKE SHOES INSPECTION MXU 180 eege dereen 155 Page REAR BRAKE PADS INSPECTION MXU 150 155 BRAKE FLUID INSPECTION 156 FRONT BRAKE LEVER FREE PLAY ADJUSTMENT MXU 150 158 COOLING SYSTEM INSPECTION MXU Eege is 160 Engine overheating 161 DRIVE CHAIN SLACK CHECK MXU 2507 150 nss RE EE DA EE 162 Drive chain slack adjustment MXU 250 ee ee ee ee 162 Drive chain slack adjustment MXU 150 ee ee ee see ee 164 DRIVE CHAIN CLEANING AND LUBRICATION MXU 250 150 165 REAR SWING ARM LUBRICATION MXU 250 165 KNUCKLE SHAFT amp REAR SWING ARM LUBRICATION MXU 150 166 BRAKE LEVER LUBRICATION 167 CABLE INSPECTION AND B IER ME 167 DRAINING THE V BELT COMPARTMENT 0cceeeeeeeeeees 168 WHEEL REMOVAL ies sere eN NG SEE 169 Wheel installatiON esse sesse ee ee 169 BATTERY osse sesse in des He gs Se EDE 170 Battery remove MXU 300 250 171 Battery installation MXU 300 250 173 Battery remove MXU 150 174 Battery installation MXU 150 174 FUSE REPLACEMENT MXU 300 230 oe SE EE Ee 175 FUSE REPLACEMENT MXU 150 176 HEADLIGHT BEAM ADJUSTMENT 179 SPARK ARRESTER CLEANING 180 TIROUBLESHOOTIING 182 Troubleshooting chart iss N 183 Cont
29. 5LCA THIS VEHICLE IS CERTIFIED TO OPERATE ON GASOLINE THIS VEHICLE CONFORMS TO US EPA REGULATIONS OF 1 5 G KM HC NOX 35 G KM CO CALIFORNIA REGULATIONS OF 1 2 G KM HC 15 G KM CO FOR 2007 MODEL YEAR NEW ATV S ENGINE EXHAUST CONTROL SYSTEM EM ENGINE TUNEUP SPECIFICATIONS IGNITION TIMING 15 DEG BTDC 1700 RPM IDLE SPEED 1700 RPM IN NEUTRAL IDLE MIXTURE NOT ADJUSTABLE SPARK PLUG NEK DRBEA SPARK PLUG GAP 0 6 0 7mm FUEL UNLEADED GASOLINE ONLY 82 2M gctane OIL SAE30 MANUFACTURED 05 2006 MONTH YEAR KWANG YANG MOTOR CO LTD TAIWAN Kymco IMPORTER STRINC MOTORSPORTS DIVISION KYMCO USA INMAN SC ADDRESS 1770 CAMPTON RD INMAN SC 29303 KYMCO certifies that this ATV complies with the American National Standard for Four Wheel All Terrain Vehicles ANSI SVIA 1 2007 Standard 87666 PVA1 M35 For US KYMCO certifie que ce quadricyle V T T est conforme a la norme nationale am ricaine ANSI SVIA 1 2007 des v hicules tout terrain a 4 roues 87666 PVA1 MG5 For France 7 1 MXU 300 250 4 1 MXU 300 250 7 2 MXU 150 6 5 4 2 MXU 150 A FR O I 2 Es N EA alle B Ss SY gt e e Bel ma I 1 i IAN Ke dT KS LF SN SS ss 5 Es N od S be i l EE R ss at ji aa d CO SIG r Ca e g ma TA ES y WAecast ie i mm 7 Ae AUT AE Se oi 2 3 1
30. A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and oil filter cap 2 to drain the oil CAUTION Be sure no foreign material enters the crankcase CAUTION When removing the oil filter cap the compression spring oil strainer and O ring will fall out Take care not to lose these parts 2 Oil filter cap 127 E Clean the oil strainer with solvent H Fill the engine with oil and install the oil fill F Inspect the O ring and replace if damaged cap G Reinstall the O ring oil strainer compression spring and oil filter cap Tighten the oil filter cap to specification Oil quantity Periodic oil change 1 4L 1 23 Imp qt 1 47US qt Total amount 1 6L 1 41 Imp qt 1 68US gt Recommended oil see page 189 CAUTION Before reinstalling the drain plug be sure to install the O ring compression spring and oil strainer CAUTION Be sure no foreign material enters the crankcase Tightening torque Oil filter cap engine 14 7 Nm 1 5 m kg 11 ft lb Warm up the engine for several minutes at idle speed Check for oil leakage while warming up CAUTION If oil leakage is found stop the engine immediately and check for the cause 128 2 2 Engine oil replacement A Place the machine on a level place B Warm up the engine for several minutes and stop
31. ARM ENGINE To start a warm engine refer to the Starting a cold engine section The choke knob should not be used The throttle should be opened slightly WARMING UP To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the choke knob turned off DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged MXU 250 150 Se 1 Drive select lever N Neutral 1 Shifting F Forward R Reverse forward MXU 250 150 A Bring the machine to a complete stop and return the throttle lever to the closed osition B A ly the parking brak MOIE E EE RE Make sure that the lever is completely shifted NOTE into position If the drive select lever is shifted into forward Ee D Open the throttle lever gradually or reverse while the engine is running the C Shift the gear from neutral to forward by moving the shift lever along the shift guide engine will stop unless the parking brake is applied 71 forward MXU 300 A Bring the machine to a complete stop and NOTE return the throttle lever to the closed Make sure that the lever is completely position shifted into p
32. Allow extra room for starting stopping and turning whenever you carry cargo or pulla trailer 5 Avoid riding on steep slopes when carrying cargo or pilling a trailer Never cross a slope when toeing a trailer ROND A I WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling stability and braking which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer J1 Accessories Genuine KYMCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and using non KYMCO accessories Always follow the loading instructions above plus the following 1 Carefully inspect the accessory to make sure it does not block any lights reduce ground clearance or limit suspension travel steering travel or other controls 2 Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls 3 Do not add electrical equipment that will exceed the vehicle
33. CHES 1 Headlight switch MXU 300 250 Headlight dimmer switch Turn the switch to the ZD position to switch on the low beam Turn the switch to the p position to switch on the high beam Turn the switch to the position to switch off the headlight 31 1 Headlight switch MXU 150 NOTE The headlight can be turned on only when the ignition switch is in the ZX position and engine is running The illumination of headlight will be available fully only when the engine speed is more than 2000 rpm Do not turn on the headlight when the engine is not running because it can drain the battery and without charging in this AT V s electrical system Ka i e 2 Starter button MXU 300 250 2 Starter button MXU 150 Stater button To starter the engine press the starter button with the transmission in neutral the ignition NOTE switch ON and the engine stop switch at RUN Q If the starter switch is pushed with the ignition switch ON and the engine stop switch Ga the starter motor will be activated but the CAUTION See starting instructions prior to starting engine see page 66 for details engine will not start To start the engine be sure to position the engine stop switch at OT 32 3 Engine stop switch MXU 300 250 Engine stop switch When the switch is in the RUN Q position the engine will operate When the switch is in OFF X positi
34. E geet 38 ENGINE SERIAL NUMBER 14 FRONT BRAKE EE 39 PARTS LOCATION 15 REAR BRAKE iese eed ies ves ie eed gede 39 Cont d Page PARKING BRARE eee 40 DRIVE SELECT LEVER sesse issie 41 FUEL TANK CA 42 FUEL VALVE oe ee ee EG ee ei 43 CHOKE KNOB wi se onse oi ee 45 SEAT MXU 20012p01 ee 46 SEAT MXU 150 47 FLAG POLE BRACKET 48 TRAILER AIT O ese NES Doe Se DE ee 48 STORAGE COMPARTMENT 49 ACCESSORY SOCKET SEAT MXU 200 2p0 49 PRE OPERATION CHECKG 51 DRIVE SELEGT LEVER sissies 52 Drive select lever adjustment 54 FRONT AND REAR BRAKEG 56 SEI EE 57 ENGINE TRANSMISSION OIL AND REAR FINAL GEAR CASE OIL 59 CERAIN ER ER 60 THROTTLE LEVER siese nss E ss oe ie 60 FITTINGS AND FASTENERG 60 MEE RE EN N NE EE 60 SWITEHES sasies osse EE EE n Gie De 60 ds IE EE EA N EE 61 How to measure tire pressure 63 Tire wear limit sasies ss EE SR DE EE 63 COOLANT MXU 300 250 esse 64 Page OPERATION see ee ee 66 STARTING A COLD ENGINE 66 Using the recoil starter MXU 300 250 68 Using the kick starter MXU 150 69 STARTING A WARM ENGINE 70 WARMING UR 70 DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING 71 ENGINE BREAK IN esse ese see 74 PARKING MXU 300 250 795 PARKING MXU 180 eegen ss ss se ed es Ee 76 Parking on a SIODE sei ES
35. E tied tee Tf ACCESSORIES sos ER EE Ee drone 78 LOADING ies cones ve AD OE 79 RIDING YOUR ATV ee ee ee 81 GETTING TO KNOW YOUR ATV 82 RIDE WITH CARE AND GOOD PUD GE ME NT iseer ee Ee Se n 83 APPARE L iss ee Ee se EE Ee Ene De 85 PRE OPERATION CECR eisers 88 Speed IMEL EE EE AE GE SE 89 LOADING AND ACCESSORIEG 90 Load LI HS esse EE EE OE oi 90 Loading and Operational Guidelines 90 ACCESSOFIES ee ee RR EE RE RR Re Ee ee Ee 91 MODIFICATIONS ie icc Se SG ee Ge ee Ek 92 No Modttcatons sees see see ee see 92 EXHAUST SvGIENM ees see esse esse 93 BE CARFUL WHERE YOU RIDE 94 FOR OFF ROAD USE ONLY 99 DURING OPRERATION 101 TURNING vOURATIVM eee 103 SLIDING AND SKIDDING 105 CLIMBING TT UE ie esse essensies de 107 RIDING DOWNHILL esse esse ee ee ee 113 Page CROSSING A SLOPE osse es ie 115 RIDING OVER ROUGH TERRAIN 117 CROSSING TROUGH SHALLOW EE de EN tote ape EER 118 PIR ISIN Le 119 WHAT TO DO IF tei ee 120 WHAT TO DO sessies Ee ee EE EE De 120 Page PERIODIC MAINTENANCE AND ADJUSTMENT eee 122 TOOL KIT 122 PERIODIC MAINTENANCE LUBRICATION 124 ENGINE OIL MXU 20012p01 126 ENGINE OIL MXU 150 130 TRANSMISSION OI 135 REAR FINAL GEAR CASE OIL MXU 2001 138 SPARK PLUG INSPECTION 140 AIR FILTER CLEANING 141 AIR CLEANER HOUSING DRAIN TUBE ee ee ee ee 147 IDLE SPEED ADJUSTMENT 149 THROTTLE LEVER ADJUSTMENT 1
36. EAR NEW ATV S ENGINE EXHAUST CONTROL SYSTEM EM ENGINE TUNEUP SPECIFICATIONS IGNITION TIMING 5 DEG BTDC 1500 RPM IDLE SPEED 1500 RPM IN NEUTRAL IDLE MIXTURE NOT ADJUSTABLE SPARK PLUG NGK DPR7EA9 SPARK PLUG GAP 0 6 0 7mm REM FUEL UNLEADED GASOLINE ONLY 92 OCTANE OIL SAE30 MANUFACTURED 05 2006 MONTH YEAR KWANG YANG MOTOR CO LTD TAIWAN IMPORTER STR INC MOTORSPORTS DIVISION KYMCO USA INMAN SC ADDRESS 1770 CAMPTON RD INMAN SC 29303 MXU 250 VEHICLE EMISSION CONTROL INFORMATION N ENGINE DISPLACEMENT 0 249 L ENGINE FAMILY 7KYMXO 25LB5 THIS VEHICLE IS CERTIFIED TO OPERATE ON GASOLINE THIS VEHICLE CONFORMS TO US EPA REGULATIONS OF 1 5 G KM HC NOX 35 G KM CO CALIFORNIA REGULATIONS OF 1 2 G KM HC 15 G KM CO FOR 2007 MODEL YEAR NEW ATV S ENGINE EXHAUST CONTROL SYSTEM EM ENGINE TUNEUP SPECIFICATIONS IGNITION TIMING 5 DEG BTDC 1500 RPM IDLE SPEED 1500 RPM IN NEUTRAL IDLE MIXTURE NOT ADJUSTABLE SPARK PLUG NEK DPR7EA9 SPARK PLUG GAP 0 6 0 7mm FUEL UNLEADED GASOLINE ONLY 92 P M OCTANE OIL SAE30 MANUFACTURED 05 2006 MONTH YEAR KWANG YANG MOTOR CO LTD So TAIWAN bed IMPORTER STR INC MOTORSPORTS DIVISION KYMCO USA INMAN SC ADDRESS 1770 CAMPTON RD INMAN SC 29303 MXU 150 VEHICLE EMISSION CONTROL INFORMATION ENGINE DISPLACEMENT 0 150L ENGINE FAMILY 7KYMXO 1
37. ION Be sure no foreign material enters the crankcase When removing the drain plug the compression spring oil strainer and O ring will fall out Take care not to lose these parts 1 Dipstick oil filler cap 2 Oil filter cap 131 E Clean the oil strainer with solvent H Fill the engine with oil and install the oil filler F Inspect the O ring and replace if damaged cap G Reinstall the O ring oil strainer compression spring and drain plug Tighten the drain plug to specification Recommended oil see page 189 Oil quantity Engine oil Periodic oil change 0 9L 0 79 Imp gt 0 95 US qt Total amount 1L 0 88 Imp at 0 1 06 US qt CAUTION Before reinstalling the drain plug be sure to install the O ring compression spring and oil strainer CAUTION Be sure no foreign material enters the crankcase Tightening torque Oil filter cap engine 14 7 Nm 1 5 m kg 10 6 ft lb Warm up the engine for several minutes at idle speed Check for oil leakage while warming up CAUTION If oil leakage is found stop the engine immediately and check for the cause 132 2 2 Engine oil replacement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil filler cap 1 and drain plug 2 to drain the oil 2 Drain plug E Reinstall the drain plug and tighten the dr
38. Improper use ofthe parking brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the parking brake before you begin to ride 41 DRIVE SELECT LEVER The drive select lever is used for driving the machine either forward or in reverse Refer to page 52 56 and 71 73 for drive select lever adjustment and operation MXU 250 150 1 Drive select lever R For reverse drive N Neutral F For forward drive FUEL TANK CAP After refueling be sure to tighten the fuel tank cap until it clicks Insert the breather tube into the handlebar cover hole To refuel refer to page 5 58 p gt MXU 300 1 Drive select lever R For reverse drive 1 Fuel tank cap N Neutral 2 Breather tube H For forward drive in high gear 3 Handlebar cover hole L For forward drive in low gear 42 FUEL VALVE The fuel valve supplies fuel from the fuel tank to the carburetor The fuel valve has three positions Ai ER SEE OF AAV AM ae Gi Ce GA e ET e D LI
39. MXU 300 250 Rear cargo rack 30 kg 66 Ibs Maximum towing capacity Front cargo rack 20 kg 44 Ibs 150 kg 331 Ibs Tongue weight 14kg 30 Ibs tts e Maximum load MXU 150 e Trailer MXU 150 Rear cargo rack 20 kg 44 Ibs Maximum towing capacity Front cargo rack 15 kg 33 Ibs 100 kg 220 Ibs RE Em gt ME CH ww 1 Rear cargo rack 2 Front cargo rack 3 Trailer 79 Load cargo on the carriers as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around e A shifting load can cause an accident e Make sure the load does not interfere with controls or your ability to see where you are going e Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier vehicle takes longer to stop e Avoid making sharp turns unless at very slow speeds e Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV 80 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load ca
40. PI Service SE SF SG type or higher 59 CAUTION Besuretousemotoroilsthatdonotcontain anti friction modifiers Passengercarmotor oils often labeled Energy Conserving containanti friction additives which will cause Starterclutchslippage resultingin reducedcomponentlifeand poorengine performance Oil quantity Engine oil see page 189 193 Transmission oil see page 189 193 Rear final gear case oil MXU 300 See page 189 CHAIN Check the general condition of the chain and check the chain slack before every ride Lubricate and adjust the chain as necessary See pages 162 165 for details THROTTLE LEVER Check to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as necessary for proper operation FITTINGS AND FASTENERS Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a KYMCO dealer or refer to the Service Manual for correct tightening torque LIGHTS Check the headlight and taillight to make sure they are in working condition Repair as necessary for proper operation SWITCHES Check the operation of the headlight switch engine stop switch and any other switches Repair as necessary for proper operation 60 TIRES A WARNING 2 The tires should be set to the recommended pressure Recommended tire pressure MXU POTENTIAL HAZARD Operating this ATV with improper t
41. RD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces Troubleshooting chart Supply fuel Check if there is fuel in the fuel Turn the fuel Restart engine Some fuel valve to RES tank Clean filter element and fuel tank Water or dirt mixed in fuel Turn the fuel valve to Turn the fuel valve to OFF Wa the fuel valve Check fuel flow Remove the fuel There is fuel Engine t r Clean fuel valve 2 Battery bied Check fluid recharge check connections over slowly Use electric starter Engine turns Batt over duickly ele gers Ask a KYMCO dealer to inspect 3 Ignition Wet Wipe clean with dry mag just pl Remove plug and cloth seed ee check electrode Ee F 1 e I ach plug cap an Use electric Spark weak ground to chassis Pe WE Spark good Ignition system normal Use electric starter Ask a KYMCO dealer to inspect to see if there is ee Compression normal 183 4 Compression CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the machine A Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used B Make sure
42. The indicators allows checking of brake pads wear Check the position of the indicator Ifthe indicator reaches the wear limit line aska KYMCO dealer to replace the pads 1 Rear brake pads cover Rear brake lever 1 Rear brake pads cover Rear brake pedal 2 Rear brake pads Rear brake lever 2 Rear brake pads Rear brake pedal 3 Wear indicator 3 Wear indicator 153 Rear brake pads MXU 300 inspection A wear indicator is provided on each brake The indicators allows checking of brake pads wear Check the position of the indicator Ifthe indicator reaches the wear limit line aska KYMCO dealer to replace the pads 1 Rear brake 2 Wear indicator 154 FRONT BRAKE SHOES INSPECTION MXU 150 A wear indicator 1 is provided on each front brake The indicators allows checking of brake shoe wear without disassembling the brake Apply the brake and check the position of the indicator If the indicator reaches the wear limit line 2 ask aKYMCO dealer to replace the shoes as a set SE ae Eeer sd a oe C N REAR BRAKE PADS INSPECTION MXU 150 A wear indicator is provided on each brake The indicators allows checking of brake pads wear Check the position of the indicator Ifthe indicator reaches the wear limit line ask a KYMCO dealer to replace the pads 1 Wear indicator 2 Rear brake 155 BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the ins
43. V without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain 83 HOW TO AVOID THE HAZARD Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum performance until you are totally familiar with the machine s handling and performance characteristics Riding your machine requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Not recommended for children under 16 year of age A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc 84 APPAREL A WARNING Operating without protective clothing increases your chances of severe injury in the event of an accident POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet eye protection and protective clothing HOW TO AVOID THE HAZARD Always wear an approved motorcycle WHAT CAN HAPPEN helmet that fits properly Operating without an approved
44. ain plug to specification F Fill the engine with oil and install the oil filler cap i We G Warm up the engine for several minutes at 1 Dipstick oil filler cap idle speed Check for oil leakage while warming up CAUTION Be sure no foreign material enters the crankcase 133 Tightening torque Drain plug engine 30 Nm 3 0 m kg 21 6 ft lb CAUTION Be sure no foreign material enters the crankcase Recommended oil see page 189 Oil quantity see page 189 134 TRANSMISSION OIL Transmission oil replacement 1 MXU 300 250 Remove 6 screws nuts 4 bolts and right footboard Page 54 Place the machine on a level place Place a container under the engine Remove the oil filler bolt 2 3 4 h 3 1 Oil filler bolt 135 5 Remove the drain plug 2 to drain the oil 6 Reinstall the drain plug and tighten to Specification Tightening torque Drain plug 20 Nm 2 m kg 15 ft lb 2 Drain plug MXU 150 2 Drain plug 136 7 Fill the engine with oil and install the oil filler bolt Recommended oil SEA 90 Oil quantity Periodic oil change MXU 300 0 5L 0 43 Imp gt 0 53 US qt MXU 250 0 3L 0 27 Imp gt 0 31 US qt MXU 150 0 2 L 0 18 Imp at 0 21 US qt CAUTION Be sure no foreign material enters the crankcase Tightening torque Oil filler bolt 20 Nm 2 m kg 15 ft lb 8 Start the engine and warm up for a fe
45. arrester portion of the tailpipe 1 Bolt 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the screw holes 5 Install the bolt and tighten it 180 A WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system 181 TROUBLESHOOTING Although KYMCO machines receive a rigid inspection before shipment from the factory trouble may occur during operation Any systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a KYMCO dealer The skilled technicians ata KYMCO dealership have the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills A WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZA
46. aust system Do not park the machine in a place where others might be likely to touch it 93 BE CAREFUL WHERE YOU RIDE This machine is designed for off road use only Riding on paved surfaces can cause loss of control A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATV are designed for off road use only le Paved surfaces may seriously affect J Ge G i handling and control of the ATV and may d cause the vehicle to go out of control 1 e HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets 94 Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states itis illegal to operate ATVs on public streets roads and highways 95 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the machine to upset AA WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bum
47. bles are routed correctly 4 Disconnect the negative terminal lead 4 from the battery first then disconnect the positive terminal lead 5 5 Remove the battery 3 ie ep ee ee eee Be 3 Battery 4 Positive terminal lead 5 Negative terminal lead Fa 1 Mount bolt 2 Battery cover 174 FUSE REPLACEMENT MXU 300 250 2 Remove the seat page 46 The fuse box stored in the battery compartment 3 Open the fuse box cap 3 under the seat The fuse box contains a spare A Pull the old fuse out of the fuse holder fuse The specified fuse is 15A 5 Push the new fuse in to the fuse holder 6 Close the fuse box cap and install seat To replace a fuse 1 Make sure the ignition switch is OFF WARNING POTENTIAL HAZARD Using an improper fuse CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse 1 Spare fuse 2 Fuse box 3 Fuse box cap 175 FUSE REPLACEMENT MXU 150 When frequent fuse failure occurs it usually indicates a short circuit or an overload in the electrical system See your authorized KYMCO dealer for repair CAUTION To prevent accidental short circuiting turn o
48. de of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the 116 RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident Be sure to keep your feet firmly mounted on the footboards at all time Avoid jumping the ATV as loss of control and damage to the ATV may result A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have The ATV can be used to cross slow moving reduced stopping ability Test your brakes shallow water of up to a maximum of 20 cm 7 9 after leaving water If necessary apply inches in depth Before entering the water them several times to let friction dry out the choose your path carefully Enter where there is pads or lining no sharp drop off and avoid rocks or other obstacles which
49. dicator lamp comes on 3 If the neutral indicator lamp does not come on then see page 54 56 for adjustment WARNING POTENTIAL HAZARD Operating with improperly adjusted drive select lever WHAT CAN HAPPEN You may lose control of the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N position and neutral indicator lamp comes on before start the engine 1 Drive select lever N Neutral 53 Drive select lever adjustment 1 Turn the ignition switch is ON and make sure the engine stop switch in the OFF Ga position 2 Remove 6 screws nuts 4 bolts and the right footboard 1 Right footboard 54 3 Loosen the locknuts 1 of rod 2 Shift the gear to neutral by moving the shift lever and or turn the rod The neutral indicator lamp comes on 4 MXU 300 250 Provide standard phillips screwdriver 3 tool kit and pass the standard phillips screwdriver through the shift arm 4 into the index hole 5 at the transmission case cover 1 Locknuts 3 Standard phillips 2 Rod screwdriver tool kit 4 Shift arm 5 Index hole 55 5 Turn the rod 2 clockwise or counterclockwise until the drive select lever 6 into the N position of the shift guide and tighten the locknuts then pull out the standard phillips screwdriver 6 After adjustment start the engine and test ride the ATV to be sure the drive select lever is operating pro
50. e chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings B STORAGE Before storing your ATV for an extended time be sure you thoroughly check the vehicle for needed repairs and have them corrected Otherwise the repairs may be forgotten by the time you remove the vehicle from storage In addition extended storage requires that you take the following steps to reduce the effects of deterioration from non use of the vehicle 1 Change the engine oil 2 Drain the fuel tank and carburetor Be sure to drain the fuel in a well ventilated area notina garage 186 A WARNING POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite HOW TO AVOID THE HAZARD Always refuel this ATV and handle fuel ina well ventilated area with the engine off Do not smoke or allow flames or sparks in the area where fuel is handled Do not overfill the tank Be careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting he engine A WARNING 4 REMENE the battery page 171 STRENG store itin an area protected from freezing POTENTIAL HAZARD l l temperatures and direct sunlight and out of Prolonged contact of fuel with the skin the reach of childre
51. e itis sticking check the cable boot SEAT MXU 300 250 To remove the seat pull right the seat lock lever and pull up the seat at the rear To install the seat align the tabs on the seat with the grommets on the frame and press the seat down until it locks NOTE Make sure that the seat is securely fitted se EA EA 1 Seat lock lever 46 SEAT MXU 150 To install the seat align the tabs on the seat with To remove the seat pull upward the seat lock the grommets on the frame and press the seat lever and pull up the seat the rear down until it locks 1 Seat lock lever 47 FLAG POLE BRACKET Flag poles are optional equipment available from your KYMCO dealer To mount a flag pole in the bracket to make you more visible NOTE Flag poles are required in some riding areas Check local regulations before riding 1 Flag pole bracket TRAILER HITCH The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball as specified by the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and operational guidelines see page 9 80 48 3 Trailer STORAGE COMPARTMENT ACCESSORY SOCKET SEAT MXU 300 250 The storage compartment is located under the The accessory socket is optional equipment seat To remove the seat see page 46 47
52. e only It is illegal and unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle For your safety and the safety of others pay special attention to all warnings preceded by this alert symbol A Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH Indicates a strong possibility that serious injury or death may result if instructions are not followed CAUTION Indicates a possibility that equipment or property damage could result if instructions are not followed Note Gives helpful information The Owner s Manual should be considered a permanent part of your ATV It should remain with the vehicle at all times and stay with the ATV if itis sold PREFACE Congratulations on your purchase of the KYMCO ATV KYMCO take pride ina worldwide reputation for quality in research design production and service For replacement parts and accessories we recommend genuine KYMCO products They ve been specially designed for your vehicle and manufactured to meet KYMCO s demanding standards This manual will provide you with a good basic understanding of the features and opera
53. ed adjuster out more than 8 mm 0 32 in Always make sure the throttle lever free play is adjusted to 3 5 mm 0 12 0 2 in See page 150 FRONT BRAKE REAR BRAKE The front brakes are operated by squeezing the MXU 300 250 front brake lever The rear brake is operated either by depressing the brake pedal or by squeezing the rear brake lever near left handgrip MXU 150 The rear brake is operated by squeezing the rear brake lever near left handgrip 1 Front brake lever 2 Rear brake lever 3 Rear brake pedal MXU 300 250 39 PARKING BRAKE Parking brake MXU 300 250 To set the parking brake squeeze the front brake lever and lock it with the lock lever Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the front brake lever until the lock lever releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position See page 75 Parking brake MXU 150 To set the parking brake squeeze the front brake lever and lock it with the lock pin Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the front brake lever until the lock pin releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position See page 76 1 Lock lever MXU 300 250 1 Lock pin MXU 150 A WARNING POTENTIAL HAZARD
54. eginners should receive training from a certified instructor Always follow the age recommendation An operator over 14 years old or older under adult supervision could be permitted for operating an ATV with engine size greater than 150cc e Never carry a passenger on an ATV e Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets e Never operate an ATV on any public street road or highway even a dirt or gravel one e Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants e Never consume alcohol or drugs before or while operating this ATV e Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Never attempt wheel jump or other stunt Always inspect your ATV each time you use it to make Sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual e Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Nev
55. embly 4 from the air cleaner housing 4 Unscrew the clamp 5 141 3 Screw 4 Air cleaner assembly 5 Clamp 5 Remove the screw 6 and remove the air cleaner assembly from the air cleaner holder 6 Remove the air cleaner 7 and air cleaner screen 8 from the air cleaner guide 9 7 Remove the air cleaner screen from the air cleaner 7 Air cleaner 8 Air cleaner screen 9 Air cleaner guide 6 Screw 142 8 Gently wash the air cleaner in clean non 9 Soak the air cleaner an equivalent gear oil flammable high flash point solvent such as SAE 80 90 until saturated then squeeze out kerosene not gasoline Allow the air cleaner the excess oil to dry throughly before applying oil Awet air cleaner will not fully absorb the oil NOTE The element should be wet but not dripping A WARNING CAUTION POTENTIAL HAZARD BE the air cleaner when squeezing out Using gasoline or low flash point solvents excess oil could damage the air cleaner for cleaning ATV parts 10 Reassemble by reversing the disassembly WHAT CAN HAPPEN sequence A fire or explosion could result HOW TO AVOID THE HAZARD Use only a nonflammable or high flash point solvent to clean ATV parts 143 To clean the air cleaner MXU 150 1 2 Remove the seat See page 47 Remove the four screw 1 and remove the air cleaner housing cover 2 Remove the air filter element 3 from the air cleane
56. er operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible e Never operate the ATV on hills too steep Pract
57. familiar with machine service Periodic inspection adjustment and lubrication will keep your machine in the safest and most TOOL e efficient condition possible Safety is an A tool kit is provide with your ATV obligation of the machine owner The most You are recommended to put the tool kit in the important points of machine inspection vinyl bag and always carry them on the seat adjustment and lubrication are explained onthe reverse side following pages I WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD 1 Tool kit 2 Rubber band Turn off the engine when performing maintenance unless otherwise specified 122 The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer The tool kit includes the following items 1 Air pressure gauge 2 Spark plug wrench 3 10 12 mm wrench 4 Standard Phillips screwdriver 5 Screwdriver handle 6 Tool bag 7 Rubber band 5 4 3 2 1 A WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in s
58. ff the ignition switch before checking or replacing a fuse There is a spare fuse under the battery cover The specified fuse is 7A A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating 1 Spare fuse Never use a material in place of the proper fuse 176 Fuse box The fuse box is located in the storage box under To replace a fuse the seat 1 Make sure the ignition switch is OFF The specified fuses are 7A 2 Remove the seat page 47 3 Remove the fuse box cap 1 1 Fuse box cap 177 4 Pull the old fuse out of the fuse box 5 Push the new fuse in to the fuse box 6 Reinstall the fuse box cap and install seat 1 Fuse 7A 178 HEADLIGHT BEAM ADJUSTMENT CAUTION Itis advisable to have a KYMCO dealer make this adjustment To adjust Turn the ignition switch at position and start the engine Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting screws 1 Adjusting screws 179 SPARK ARRESTER CLEANING Be sure the exhaust pipe and muffler are cool 2 Remove the tailpipe by pulling it out of the before cleaning the spark arrester muffler 1 Remove the bolt 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark
59. ged operation above 3 4 throttle Revthe machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally PARKING MXU 300 250 When parking stop the engine and shift into neutral Turn the fuel lock to OFF and apply the parking brake The front brake lever has three locked position that allow it to be used as a parking brake To set the parking brake see page 40 1 Locked position 3 Certainly locked position 2 Lock lever 19 PARKING MXU 150 When parking stop the engine Turn the fuel lock to OFF and apply the parking brake Make sure the lock pin into the locked position To set the parking brake see page 40 1 Locked position 76 Parking on a slope A WARNING POTENTIAL HAZARD Parking ona hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily cf 1 Bring the machine to a stop by applying the brakes 2 Stop the engine 3 With the rear brake applied apply the rear parking brake ACCESSORIES
60. horized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4121 LB60 50 30AA U00 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH BOGS ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OPERATOR S MANUAL Part No 4121 LB60 50 30AA U00 FOLLOW ALL INSTRUCTIONS AND WARNINGS Issed 20 May 2008
61. ice on smaller hills before attempting larger hills Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual e Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type tires specified in this manual Always maintai
62. ighten the chain pull the ATV backward 4 Retighten the two axle hub holder bolt and hub stopper bolt to the specification Tightening torque Axle hub holding bolt 40 Nm 4 0 m kg 29 ft Ib Hub stopper bolt 12 Nm 1 2 m kg 9 ft lb 5 Pull out the standard phillips screwdriver 3 Driven sprocket holder 5 Standard phillips tool kit 163 4 Axle hub Drive chain slack adjustment MXU 150 1 Loosen the upper and lower axle holding bolts 1 2 Turn the adjusting nut 2 to decrease or increase chain slack 3 Retighten the upper and lower axle holding bolts Tightening torque Axle holding bolts upper 70 Nm 7 0 m kg 48 ft Ib CAUTION Too little of chain slack will overload the engine and other important parts Keep the slack within the specified limit 2 Adjust nut 164 DRIVE CHAIN CLEANING AND LUBRICATION REAR SWING ARM LUBRICATION MXU 250 MXU 250 150 Lubricate the pivot points using a grease gun The drive chain is equipped with rubber O rings between the chain plates Steam cleaning high pressure washes and certain solvents can damage these O rings Use only kerosene to clean the drive chain Wipe it dry and thoroughly lubricate it with SAE 30 50 motor oil Do not use any other lubricants on the drive chain They may contain solvents that could damage the O rings 1 O rings 165 KNUCKLE SHAFT amp REAR SWING ARM LUBRICATION MXU 150 Lubricate
63. ing or running the engine ina closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation 12 DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION NUMBER RECORDS KEY IDENTIFICATION NUMBER Record the key identification number frame The key identification number is stamped on serial number engine serial number and the hang tag as shown in the following model code information for assistance when illustration order replacement parts KEY NO FRAME NO ENGINE NO MODEL CODE 1 Key identification number 13 FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the The engine serial number is stamped on the left crankcase front of the frame 1 Frame serial number 2 Engine serial number 14 PARTS LOCATION 03 05 04 03 02 01 Rear cargo Rear brake lever Headlight Position light Front cargo Front brake lever 15 10 09 08 07 06 Drive select lever Fuel valve MXU 300 250 Seat Battery MXU 150 Taillight Stop light Battery MXU 300 250 Reservoir water tank MXU 300 250 Rear brake pedal fluid reservoir MXU 300 250 11 12 13 16 17 16 15 14 Exhaust system Tool kit Fuel valve MXU 150 Choke knob Front wheel Recoil starter MXU 3
64. ires or di 300 250 with improper or uneven tire pressure Front 25 32 kpa 0 25 0 32 kgf cm WHAT CAN HAPPEN 3 5 4 5 psi Use of improper tires on this ATV or Rear 25 32 kpa 0 25 0 32 kgf cm operation of this ATV with improper or 3 5 4 5 psi uneven tire pressure may cause loss of control increasing your risk of accident Recommended tire pressure MXU 150 Front 25 30 kpa 0 25 0 3 kgf cm HOW TO AVOID THE HAZARD 3 5 4 2 psi 1 The tires listed below have been Rear 25 30 kpa 0 25 0 3 kgf cm approved by Kwang Yang Motor Co Ltd 3 5 4 2 psi for this model Other tire combinations are not recommended e Check and adjust tire pressures when the tires are cold Size Type Tire pressures must be equal on both MXU 300 250 22X7 10 sides Front Tubeless MXU 150 21X7 10 MXU 300 250 22X10 10 Tubeless MXU 150 61 3 Tire pressure below the minimum Set pressure tires cold specified could cause the tire to dislodge Set tire pressures to the following from the rim under severe riding MXU 300 Recommended RE We MXU 250 pressure aximum conditions 28 kpa 25 kpa 32 kpa Front 0 28 kgficm 0 25 kgf cm 0 32 kgf cm 3 92 psi 3 5 psi 4 5 psi 28 kpa 25 kpa 32 kpa 0 28 kgf cm 0 25 kgf cm 0 32 kgf cm 3 92 psi 3 5 psi 4 5 psi pressure The following are minimums MXU 300 250 Front 25 kpa 0 25 kgf cm 3 5 psi Rear 25 kpa 0 25 kgf cm 3 5 psi
65. it C Place a container under the engine D Remove the oil fill cap 1 and drain plug 2 to drain the oil E Reinstall the drain plug and tighten the drain plug to specification F Fill the engine with oil and install the oil fill cap Tightening torgue Drain plug engine 30 Nm 3 0 m kg 22 ft lb CAUTION Be sure no foreign material enters the crankcase Recommended oil see page 189 ba Oil quantity see page 189 2 Drain sis 129 ENGINE OIL MXU 150 1 Engine oil level measurement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Remove the dipstick 1 and wipe it off with a Clean rag Insert the dipstick in the filler hole without screwing it in D Remove the dipstick and inspect the oil level E The oil level should be between the maximum 2 and minimum marks 3 If the level is low add oil to raise it to the proper level NOTE Wait a few minutes until the oil level settles before checking 2 Maximum level mark 1 Dipstick oil filler cap 3 Minimum level mark CAUTION Be sure no foreign material enters the crankcase 130 2 1 Engine oil replacement and oil filter cleaning A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil filler cap 1 and oil filter cap 2 to drain the oil CAUT
66. kidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control 106 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes Try more difficult climbs only after you have developed your skill In all cases avoid inclines with slippery or loose surfaces or obstacles that might cause you to lose control A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills Itis important when climbing a hill to make sure that tour weight is transferred forward on the ATV This can be accomplished by leaning forward and steeper inclines standing on the footboards and leaning forward over the handlebars 107 A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as desc
67. l if necessary ENGINE TRANSMISSION OIL e Check oil level AND REAR FINAL GEAR Fill with oil if necessary CASE OIL e Check chain slack and condition DRIVE CHAIN Adjust if necessary 60 162 165 THROTTLE Check for proper throttle cable operation GO WHEELS AND TIRES e Check tire pressure wear and damage 61 63 169 FITTINGS AND Ss FASTENERS Check all fitting and fasteners ew SWITCHES e Check for proper function ET N LIGHTS e Check for proper operation 60 179 COOLANT MXU 300 250 EE 64 65 160 161 e Fill with coolant if necessary 1 5 59 126 139 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibillty of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 52 DRIVE SELECT LEVER CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged Check operation of the lever before start the engine 1 Make sure moving the shift lever into the N position of the shift guide 2 Turn the ignition switch to ON and check the neutral in
68. lever 36 THROTTLE LEVER lt is operated by the thumb Pressing the lever opens the throttle When pressure is released spring tension automatically closes the throttle Regulate the speed of the machine by varying the throttle position 1 Throttle lever 37 A WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a KYMCO dealer if you can t find or solve the problem yourself SPEED LIMITER The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV 1 Adjuster 2 Locknut A MXU 300 250 13mm 0 52in MXU 150 8mm 0 32in 38 A WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD e MXU 300 250 Do not turn the speed adjuster out more than 13 mm 0 52 in e MXU 150 Do not turn the spe
69. livery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 196 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty The chart below is printed only asa reminder to you that the maintenance work is required It is not acceptable proof of maintenance work DATE MAINTENACE OF MONTH SERVICING DEALER REMARKS INTERVAL SERVICE NAME AND ADDRESS 150 km 1000 km 2000 km 3000 km 4000 km 6000 km 7000 km 8000 km 9000 km 10000 km 197 INDEX Page A PASO RE osse ES aeons 78 90 91 ACCESSORY SOCKET SEAT sesse ed ss ses 49 AGERECOMMENDATION ee ee ees ee ee A AIR CLEANER HOUSING DRAIN TUBE 147 AIR FILTER CLEANING eee 141 APPAREL carte sane tun EG SE ewe Ge On Ges ie ed 85 B sek eege 170 171 173 174 BRAKEG 39 56 152 155 156 158 167 C CABLE INSPECTION AND LUBRICATION 8 CHOKE eege ind CLEANING ss rere te CLIMBING UPHEIEL issie de EC RRC RE CONTROL FUNCTIONG CROSSING THROUGH SHALLOW WATER 198 D DRAINING THE V BELT COMPAR TINE NT es
70. may be slippery or upset the ATV Drive slowly and carefully A WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual 118 Test your brakes after leaving the water Do not PARKING continue to ride your ATV without verifying that Always choose a level place to park After you have regained proper braking ability bringing your ATV to a stop hold the brakes while you shift into neutral Then set the parking brake and turn the ignition switch OFF If you re through riding for the day also turn the fuel valve OFF 119 WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding techniques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footpeg to the outside of the turn Position your weight over the front wheels for better control See pages 101 102 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 103 104 If your ATV star
71. n slow charge the battery Breathing fuel vapor once a month A WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery WHAT CAN HAPPEN The fuel can cause skin irritation Fuel vapor could cause lung damage HOW TO AVOID THE HAZARD Avoid repeated or prolonged contact of fuel WHAT CAN HAPPEN with the skin or breathing of fuel vapor Gases may explode and possibly cause injury KEEP OUT OF REACH OF CHILDREN HOW TO AVOID THE HAZARD 3 Remove the spark plug and pour one Do not allow open flames or sparks near the tablespoon 15 20 cc of clean engine oil into battery the cylinder Operate the starter for a few seconds to distribute the oil then reinstallthe 2 Wash and dry the ATV and wax all painted spark plug Make sure the engine stop switch surfaces is OFF KX before pressing the starter 6 Inflate the tires to their recommended button pressures 7 Place the ATV on blocks to raise all four tires off the ground 187 SPECIFICATIONS MXU 300 250 Dimension Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank Engine Type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system 1810 mm 72 in 1050 mm 42 in 1110 mm 44 in 810 mm 32in 1160 mm 46 in 125 mm 5 in 3200 mm 128 in 227 kg 499 Ibs
72. n at faster speeds Do not turn at speeds too fast for your skills or the conditions Do not turn at excessive speeds As you approach a Curve slow down and begin A PHIRI to turn the handlebars in the desired direction POTENTIAL HAZARD As you do so put your weight on the footpeg to Turning improperly the outside of the turn opposite your desired direction and lean your upper body into the WHAT CAN HAPPEN turn Use the throttle to maintain an even speed ATV could go out of control causing a through the turn This maneuver will let the collision or overturn wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly 103 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves de ok Improper riding procedures such as abrupt outer footboard throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are This procedure should be practiced at slow thoroughly familiar with the operation of your speed many times in a large off road area with ATV no obstacles If an incorrect technique is used your ATV may con
73. n proper tire pressure as described in this manual e Never modify an ATV through improper installation or use of accessories e Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo Allow greater distance for braking 10 A WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure itis kept upright and that the fuel valve is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank 11 WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes A WARNING POTENTIAL HAZARD Start
74. n the drive select lever is in neutral e When the select lever is in neutral the neutral indicator light should come on If the light does not come on ask aKYMCO dealer to inspect it 5 Use the starter choke in reference to the figure Position Cold engine start ambient temperature below 5C 40F Position Cold engine start ambient temperature at OC 30F 30C 90F and warming up position Position Cold engine start ambient temperature above 25C 80F and warm engine start position 67 AMBIENT TEMP STARTER CHOKE POSITION 1 Fully open 2 Half open 3 Closed a Starter choke 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails to start release the start switch then push the start switch again Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 If the engine is started with the starter choke in position 0 the starter choke should be returned to position to warm up the engine If the engine is started with the starter choke in position keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position before riding 68 Using the recoil starter MXU 300 250 The recoil starter is used to start the engine when the battery i
75. nced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiter limits the power and top speed of the machine Turning the screw in decreases top speed and turning it out increases top speed lL se a y iii vg L 1 Adjuster 2 Locknut LOADING AND ACCESSORIES Load Limits There are limits to how much weight can be carried on your ATV NOTE The following weight limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits MXU 300 250 MAXIMUM TOWING CAPACITY 150kg 331 Ibs TONGUE WEIGHT 14kg 30 Ibs MAXIMUM LOADING LIMIT REAR CARGO RACK 30 kg 66 lbs FRONT CARGO RACK 20 kg 44 lbs MXU 150 MAXIMUM TOWING CAPACITY 100kg 220 Ibs MAXIMUM LOADING LIMIT REAR CARGO RACK 20 kg 44 Ibs FRONT CARGO RACK 15 kg 33 Ibs Loading and Operational Guidelines This ATV is not designed to carry or tow a trailer If you decide to add accessories to allow you to carry cargo or tow a trailer use common sense Carrying cargo will affect how your ATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers Be sure to observe the weight limits and follow these guidelines Never ride with a passenger Do not tow another vehicle Make sure all cargo is secured before riding
76. ng permission 99 Select a large flat area off road to become familiar with your ATV Make sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 66 70 to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position and shift the drive select lever into the forward position Then release the parking brake Apply the throttle slowly and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in aloss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of yourATV When slowing down or stopping release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident 100 Always keep your feet on the footpegs during POTENTIAL HAZARD operation Otherwise yo
77. nuous use while the indicator is flashing may cause damage to the engine ieee 1 Segment C 2 Segment H 27 3 Speedometer Shows riding speed in km h or mph Press and hold Mode Adjust button B for more than 2 seconds to select km h or mph 4 Fuel gauge The fuel gauge shows the approximate fuel supply available in a graduated display The normal operating fuel range is with the section between the segment F and segment E When the segment E or the fuel indicator flashes fuel will be low and you should refill the tank as soon as possible Ki er SMS IF si N E 1 2 f E 1 Segment F 2 Segment E 3 Fuel indicator 28 5 Odometer Tripmeter The odometer shows the total distance travelled in Km or in miles The tripmeter shows the trip distance travellled in Km or in miles Press and hold Mode Adjust button B for more than 2 seconds to select km or mile Press and hold Mode Adjust button A for more than 2 seconds to select ODO or TRIP S T O Q N O lt ob O O gt D O E a O DO v dp oO La A To reset the tripmeter O O O a of H O 0b dip O J OI O C O O 0 dip ON D Be mar D US O d B A not release the Mode Adjust button 2 Press and hold the Mode Adjust button until the tripmeter is reset A B 30 HANDLEBAR SWIT
78. old e Recommended FRONT 25 30kpa 0 25 0 3kgf cm 3 5 4 2psi REAR 25 30kpa 0 25 0 3kgf cm 3 5 4 2psi Never set tire pressure below recommended LOADING e Maximum Vehicle Load 100Kg 220 Ibs Including weight of operator cargo and accessories 4 1 MXU 300 250 5 A CAUTION Never carry passenger on This carrier Maximum load 30 Kg 66 Ibs A CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged 4 2 MXU 150 CAUTION Never Carry passenger on This carrier Maximum load 20 Kg 44 Ibs 6 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH BOGS ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS
79. ome situation could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized KYMCO dealer PERIODIC MAINTENANCE LUBRICATION INITIAL EVERY WHICHEVER COMES FIRST mi 100 600 1200 wan le Sen Repco Warm engine tore dann NNNNNNNNNNEN 7 eClean Oil strainer eReplace if necessary a eCheck oil level oil leakage Transmission oil eReplace every 12 months Rear final gear case oil eCheck oil level oil leakage MXU 300 eReplace every 12 months R eCheck operation V belt eReplace if damage or excessive wear Air filter element eClean Every 20 40 hours for engine and V belt Repi if 150 300km 100 200mi compartment ER ARIE More often in wet or dusty areas eCheck idle speed starter operation Poarburetor agustitnecessay OF OL OO preatnersystam ss OL O breather system eReplace if necessary eCheck condition me EFES lelolo eReplace if necessary eCheck fuel hose for cracks or damage patt L es iech FOL OO f eCheck valve clearance rvenes Jil odolo R eCheck operation and brake fluid Brake Repiacotvakepaditnoessay TOIOIO 124 NITIAL EVERY WHICHEVER COMES FIRST mi monte tf ef ie
80. on the engine will not operate This switch is intended primarily as a safety or emergency control and it should normally remain in the RUN position ge P A L ke ll F kan WW Te ME d F 33 3 Engine stop switch MXU 150 NOTE If you stop your ATV by turning the engine stop switch OFF Sal be sure to turn the ignition switch OFF to prevent battery discharge 4 Passing signal switch MXU 300 250 4 Passing signal switch MXU 150 Passing signal switch When passing if there are cars coming from the opposite direction press and release the passing signal switch and the headlight will wink to warn the coming vehicles 34 RECOIL STARTER MXU 300 250 The recoil starter is on the left side of the ATV It 1 Turning starter grip counterclockwise to is used to start the engine when the battery is unlock and grasp the starter grip firmly then low pull it out slowly until it seats lightly See using the recoil starter page 68 2 Pull the grip up briskly and fully 1 Recoil starter 35 KICK STARTER MXU 150 The kick starter cranks the engine when the kick 3 After the engine starts allow the starter grip starter is operated to return slowly and turning it clockwise to lock NOTE CAUTION Do not allow water enter the V belt See starting instructions prior to starting compartment always lock the recoil starter engine see page 69 for details 1 Start kick
81. on problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the machine to a KYMCO dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the proper type Standard spark plug MXU 300 250 DPR7EA 9 MXU 150 DR 8EA Before installing the spark plug measure the electrode gap with a feeler gauge and adjust to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in A Spark plug gap When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten to the specified torque Tightening torque Spark plug 17 2 Nm 1 72 m kg 13 ft Ib 140 AIR FILTER CLEANING The air cleaner accumulates dust and must be cleaned periodically If the ATV is ridden in dusty areas the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner MXU 300 250 1 Remove the seat See page 46 2 Unlatch the four retainer clips 1 and remove the air cleaner housing cover 2 3 Loosen the screw 3 and remove the air cleaner ass
82. osition B Apply the parking brake NOTE D Open the throttle lever gradually If the drive select lever is shifted into forward or reverse while the engine is running the engine will stop unless the parking brake is applied C Shift the gear from neutral to forward in high or low gear by moving the shift lever along the shift guide CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged 1 Drive select lever R For reverse drive N Neutral H For forward drive in high gear L For forward drive in low gear 72 2 Shifting reverse A Bring the machine to a complete stop and return the throttle lever to the closed position B Apply the parking brake C Shift the gear from neutral to reverse and by moving the shift lever along the shift guide NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a KYMCO dealer to inspect the machine D Check behind for people or obstacles then release the parking brake E Open the throttle lever gradually and continue to watch to the rear while backing 13 NOTE If the drive select lever is shifted into reverse while the engine is running the engine will stop unless the parking brake is applied A WARNING POTENTIAL HAZARD
83. pacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Riding Your ATV e A 81 Indicates a strong possibility that serious injury or death may result if instructions are not followed 82 GETTING TO KNOW YOUR ATV This ATV is for recreation use This section riding yourATV provides general ATV riding instructions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But itis essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owne s Manual completely and understand the operation of the controls Pay particular attention to the safety information on pages 7 12 Please also read all caution and warning labels on yourATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners and inexperienced riders should get proper instruction on how to operate this ATV I WARNING POTENTIAL HAZARD Operating this AT
84. pection window A WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes WHAT CAN HAPPEN May cause irritation HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed A j Ren Gg a We ene cA 1 Lower level mark Hand Brake lever 1 MXU 300 250 Lower level mark Foot brake pedal 156 NOTE As the brake pads wear brake fluid level drops automatically compensating for wear There are no adjustments to perform but fluid level and pad wear must be inspected periodically The system must be inspected frequently to ensure there are no fluid leaks If the brake lever travel become excessive and the brake pads are not worn beyond the recommended limit page 152 155 There is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service 157 CAUTION To prevent damage to the brake system use Brake fluid can damage paint and plastic so Use only DOT 4 brake fluid from a sealed only fluid from a sealed container Never allow contaminants dirt water etc to enter the brake fluid reservoir handle the fluid with care When adding brake fluid be sure the reservoir is horizontal before removing the cover to prevent accidental spilling container FRONT BRAKE LEVER FREE PLAY ADJUSTMENT
85. perly See page 71 73 1 Locknuts 6 Drive select lever 2 Rod N Neutral 3 Standard phillips screwdriver 56 FRONT AND REAR BRAKES 1 Make sure there is no brake fluid leakage 2 Check operation of the levers and pedal They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a KYMCO dealer 3 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear See page 152 159 A WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the ATV inspected by a KYMCO dealer FUEL Fill the fuel tank when necessary and make sure there is sufficient gasoline in the tank Check for leaks 1 Fuel neck Recommended fuel UNLEADED FUEL Fuel tank capacity MXU 300 250 Total 12 5L 2 64 Imp gal 3 19 US gal Reserve 1 8L 0 38 Imp gal 0 46 US gal MXU 150 Total 8 1L 1 74 Imp gal 2 08 US gal Reserve 1L 0 22 Imp gal 0 26 US gal 57 Your KYMCO engine has been designed to use
86. ps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 96 A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 97 When riding in an area where you might not easily be seen such as desert terrain mounta caution flag on the machine DO NOT use the flag pole bracket as atrailer hitch A WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mounta caution flag on the machine to make you more visible Watch carefully for other vehicles 98 FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only Do not ride in areas posted no trespassing Do not ride on private property without getti
87. r housing 144 3 Air filter element 4 Remove the screw 4 and separate air filter A WARNING element from the element guide 5 POTENTIAL HAZARD Using gasoline or low flash point solvents for cleaning ATV parts WHAT CAN HAPPEN A fire or explosion could result HOW TO AVOID THE HAZARD Use only anonflammable or high flash point solvent to clean ATV parts 4 Screw 5 Element guide 5 Gently wash the air cleaner in clean non flammable high flash point solvent such as kerosene not gasoline Allow the air cleaner to dry throughly before applying oil Awet air cleaner will not fully absorb the oil 145 6 Soak the air cleaner an equivalent gear oil SAE 80 90 until saturated then squeeze out the excess oil NOTE The element should be wet but not dripping CAUTION Twisting the air cleaner when squeezing out excess oil could damage the air cleaner 7 Reassemble by reversing the disassembly sequence 146 AIR CLEANER HOUSING DRAIN TUBE The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the drain tube MXU 300 250 1 Remove the drain tube 1 by removing the clip 2 Drain the deposits 3 Reinstall the drain tube securing it with the clip 3 1
88. re removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Should be serviced by your authorized KYMCO dealer when changing the coolant Restart the engine If the engine overheats again ask aKYMCO dealer to inspect and or repair the cooling system NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible 161 DRIVE CHAIN SLACK CHECK MXU 250 150 Drive chain slack adjustment MXU 250 Inspect the drive chain while all tires are 1 Loosen the hub stopper bolt 1 and two axle touching the ground Check the slack at the hub holding bolts 2 position shown in the figure H l MXU 250 The normal vertical deflection is approximately 30 40 mm 1 18 1 57in If the deflection exceeds 40 mm 1 57 in adjust the chain slack MXU 150 The normal vertical deflection is approximately 10 20 mm 0 39 0 79in If the deflection exceeds 20 mm 0 79 in adjust the chain slack 1 Hub stopper bolt 2 Axle hub holder bolt A MXU 250 30 40 mm 1 18 1 57in MXU 150 10 20 mm 0 39 0 79in 162 2 Provide standard phillips screwdriver 5 tool kit and pass the standard phillips screwdriver through the axle hub 4 and driven sprocket holder 3 holes 3 To loosen the chain push the ATV forward To t
89. ribed in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed 108 An obstacle a sharp drop or another vehicle or person could be on the other side ofthe hill If you are climbing a hill and you find that you When crossing the side of a hill have not properly judged your ability to make it Always follow proper procedures as to the top you should Hain die ATV around while described inthe Owner lt Manual you still have forward motion provided you have the room to do so and go down the hill Avoid hills with excessively slippery or loose surfaces A WARNING Shift your weight to the uphill side of the POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if 109 If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to
90. riding for safety and proper care of the machine I WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect tour ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 88 AA WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle on pages61 63 Always maintain proper tire pressure as described in the Owner s Manual on page Do not operate at speeds too fast your skills or the conditions A WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can resultin an accident HOW TO AVOID THE HAZARD Always go ata speed that is proper for the terrain visibility and operating conditions and your experience 89 Speed limiter For riders inexperie
91. s while the A until the desired hour ignition is ON To adjust the time manually proceed as follows 1 Turn the ignition switch ON 2 Press and hold both the Mode Adjust button A and Mode Adjust button B for more than 2 seconds The clock will be set in the adjust mode with the hour display flashing 24 5 To set minute press the Mode Adjust button A until the desired minute 25 4 Press the Mode Adjust button B The minute display will start flashing Di xE be H L 6 To end the adjustment press the Mode Adjust button A and Mode Adjust button B The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 10 seconds 26 2 Coolant temperature gauge MXU 300 250 Overheating message The coolant temperature gauge shows When the coolant is over specified temperature coolant temperature the coolant temperature gauge flashing If this occurs stop the engine and check the reserve tank coolant level Read page 161 and The normal operating temperature range is to not ride the ATV until the problem has been within the section between the segment C corrected and segment H oy HE H Ke E Leg SE ANT EE 1 I A EA CH D cin K CAUTION 1 The engine may overheat if the ATV is overloaded If this happens reduce the load to specification 2 Restart after making sure that the indicator is out Conti
92. s low 1 Recoil starter To start the engine without the electric starter MXU 300 250 1 Follow steps 1 through 5 2 With the throttle closed turning starter grip counterclockwise to unlock and grasp the starter grip firmly then pull it out slowly until it seats lightly 3 Pull the grip up briskly and fully 4 After the engine starts allow the starter grip to return slowly and turning it clockwise to lock NOTE Do not allow water enter the V belt compartment always lock the recoil starter 5 Follow steps 7 through 8 69 Using the kick starter MXU 150 The kick starter is used to start the engine when the battery is low 1 Start kick lever To start the engine without the electric starter MUX 150 1 Follow steps 1 through 5 2 With the throttle closed operate the kick starter with a rapid continuous motion CAUTION Do not allow the kick starter to snap back freely against the pedal stop as engine case damage could result Raise the kick starter pedal after the kick starter lever is returned to the stop 3 Follow steps 7 through 8 If you cannot restart a warm engine 1 Follow steps 1 through 4 2 Open the throttle slightly 1 8 1 4 while starting the engine If the throttle limiter Is adjusted as delivered open the throttle fully 70 CAUTION See the engine break in section prior to operating engine for the first time STARTING A W
93. the spark plug and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprockets or wheel axles 3 Rinse the dirt and degreaser off witha garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Dry the chain and lubricate it to prevent rust 184 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it A WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing th
94. tinue to go straight If the ATV doesn t turn come to a stop and then practice the procedure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Lean towards inside of turn 104 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide If unexpected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide 105 With practice over a period of time skill at A WARNING controlled sliding can be developed The terrain should be chosen carefully before attempting POTENTIAL HAZARD such maneuvers since both stability and control Skidding or sliding improperly are reduced Bear in mind that sliding maneuvers should always be avoided on WHAT CAN HAPPEN extremely slippery surfaces such as ice since You may lose control of this ATV You may all control may be lost also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control s
95. tion of this machine This manual includes important safety information It provides information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a KYMCO dealer We wish you many years of safe and enjoyable riding While reading this manual remember Indicates a strong possibility that serious injury or death may result if instructions are not followed All information in this publication is based on the latest product information available at the time of approval for printing KWANG YANG MOTOR CO LTD reserves the right to make changes at any time without notice and without incurring any obligation CONTENTS Page Page LOCATION OF THE WARNING AND CONTROL FUNCTIONS 20 SPECIFICATION LABELG 1 IGNITION SWITCH HEADLIGHT amp POSITION LIGHT SWITGH sesse 20 INSTRUMENTS AND INDICATOR 21 Multi function deplay 23 SAFETY INFORMATION if HANDLEBAR SWITCHES 34 Headlight dimmer switch 31 Start DUNO soek ek De am 32 DESCRIPTION AND MACHINE Engine stop switch 33 Passing signal swimtch 34 IDENTIFICATION 13 RECOIL STARTER MXU 300 250 E IDENTIFICATION NUMBER RECORDS ee ee seat E De 13 EARE E A O ai EN KEY IDENTIFICATION NUMBER 43 THROTTLE LEVER see Ee 37 FRAME SERIAL NUMBER 14 SPEED Ee VU
96. tor Type Spark plug Type DPR7EA 9 Gap 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automatic Brake Front brake type Disk brake Rear brake type Disk brake 190 Suspension Front Rear Shock absorber Front Rear Electrical Ignition system Generator system Battery type Tire Type Size Front Rear Bulb voltage wattage quantity Headlight Stop light Taillight Position light 191 Dual swing A arm Swing arm Coil spring Oil damper Coil spring Oil damper C D I C D I Magneto 12V 12AH Tubeless 22X7 10 22X10 10 12V35W 35W X2 12V21W 5W X2 12V5WX2 SPECIFICATIONS MXU 150 Dimension Overall length 1775 mm 70 in Overall width 950 mm 37 1 in Overall height 1040 mm 40 6 in Seat height 750 mm 29 3 in Wheel base 1115 mm 43 7 in Minimum ground clearance 155 mm 6 in Minimum turning radius 3000 mm 117 in Basic weight With oil and full fuel tank 185kg 407 Ibs Engine Type Air cooled 4 stroke OHC Cylinder arrangement Single cylinder Displacement 149 cm 9 1 cu in Bore x stroke 62X49 5 mm 2 48X1 98 in Compression ratio 9 7 1 Starting system Electric Kick starter Lubrication system Wet sump 192 Engine oil transmission oil T e SAE 5W yP SAE 10W 30 Engine oil classification SAE 10W 40 SAE 20W 40 SAE 20W 50 og 10 20 30 40 C API Service SE SF SG type or higher Transmission oil classification SEA 90
97. ts seisoene oni os es 168 Mee Ir ME 60 162 164 165 DRIVESELECT LEVER se mas 41 52 54 71 E ENGINE BREAK AN es Es ed Ee Dee 74 ENGINE Ode is ee dio 59 126 130 Engine stop SWIG ese de n SE NN De 33 EXHAUST SYSTEM esse ks se sed seke ses dd sd 93 Page F FITTINGS AND FASTENERG 60 FLAG POLE BRACKET 48 ze MR EE EE EE N 57 FUEL TANK GAF osse EER EEN ESE Ne Ein 42 FUEC VALVE seide A eie ee de 43 FUSE REPLACEMEN Tis ccsonssenseasess 175 176 H HANDLEBAR SWITCHES onoinonnnnnonnnnnnnnn 31 HEADLIGHT BEAM ADJUSTMENT 179 Headlight dimmer switchen 31 HEADLIGHT SWITGH EE 20 Cont d 199 Page IDENTIFICATION NUMBER 13 IDLE SPEED ADJUSTMENT ia ese 149 IGNITMON SE MITE Es sae ese ee EE od 20 IMPORTANT NOTICES ese ees ee se ee ee A INDICA Ke 21 INSTRUMENTS sessie ens or sb Ve ei ee 21 K KICA SAA ACE ees tees EE Ge n oe Ge 36 KNUCKLE SHAFT LUBRICATION 166 L LABEL tne MT HE RE N OR AU OE 1 di al AA EA OE DO EA 60 OADINGE eras Ee EG ee 79 90 M MODIPIGAT tie isme osse ee eie 92 Multi function displaY ede SR RS Ee 23 O OPERATION iese es ins ei oe De NE 66 101 P PARKING ee ee ee ee se ee ee 75 76 77 119 PARKING BRAKE cccccceneeeae eee eens 40 PARTS OC AION sasatasatdessnseaceatosessdatesses 15 Passing signal SWIG sie EE ei ae ds 34 PERIODIC MAINTENANCE LUBRICATION EE 124 PERIODIC MAINTENANCE AND RE RK E 122
98. ts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the Slide See pages 103 106 If yourATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See pages 107 112 120 If yourATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See pages 115 116 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See pages 117 119 Indicates astrong possibility that serious injury or death may result if instructions are not followed 121 PERIODIC MAINTENANCE AND Have KYMCO dealer perform service if you ADJUSTMENT are not
99. ur feet may contact the rear wheels Removing hands from handlebars or feet from footboards during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footpegs of your ATV during operation 101 Avoid wheelies and jumping You may lose control of the machine or overturn I WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 102 TURNING YOURATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off Always follow proper procedures for road the two rear wheels are mounted solidly turning as described in this Owner s on one axle and turn together at the same Manual speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning Aspecial turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed Practice turning at low speeds before attempting to tur
100. ur footing 4 Then slowly and carefully back the ATV down the hill using the front brake lever to control speed 5 If you lose control of the ATV for your safety get away from the vehicle If the hill is too steep or too slippery or if you have any doubt whether you can safely walk the ATV back down the hill leave the vehicle where it is and get help If possible block the wheels so the vehicle Won t roll backwards 112 RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms Straight Improper braking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction Whenever possible ride your ATV straight downhill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear 113 A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully
101. w minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause 137 REAR FINAL GEAR CASE OIL MXU 300 Change the oil in the rear final gear case when specified by the Maintenance Schedule Change the oil with the final gear case warm and the ATV on level ground to assure complete and rapid draining Rear final gear oil replacement 1 To drain the oil first place an oil drain pan under the oil drain plug 1 2 Remove the oil filler cap 2 1 Oil drain plug 4 Oil filler cap 138 3 Remove the drain plug 4 After the oil has completely drained reinstall the drain plug Tightening torque Drain plug 20 Nm 2 m kg 15 ft lb 5 Fill the gear case with the recommended oil Recommended oil SAE 90 Oil quantity Periodic oil change 0 1L 3 56 Imp oz 3 33 US oz Remove the oil level check bolt 3 Make sure the oil level reaches the oil level check hole 6 Install the oil filler cap and oil level check bolt Tightening torque Oil filler cap 14 7 Nm 1 5 m kg 11 ft lb Oil level check bolt 20 Nm 2 m kg 15 ft lb 3 Oil level check bolt 139 SPARK PLUG INSPECTION The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an intake air leak or carbureti
102. y Then store it in a cool dry place If the battery is to be left on the vehicle disconnect the negative cable from the battery terminal Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Battery remove MXU 300 250 1 Make sure the ignition switch is OFF 2 Remove the seat page 46 3 Remove the battery cover 1 by removing the screws 2 4 Release the rings and remove the rubber band 3 171 3 Rubber band 5 Shift the battery 4 and the terminal leads face yourself 6 Disconnect the negative terminal lead 5 from the battery first then disconnect the positive terminal lead 6 7 Remove the battery d Le Gees e 4 Battery 5 terminal lead 6 terminal lead 172 Battery installation MXU 300 250 1 Install 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 battery check to see if the battery cables are routed correctly 173 Battery remove MXU 150 Battery installation MXU 150 1 Make sure the ignition switch is OFF 1 Install in the reverse order of removal 2 Remove the seat page 47 2 Check all bolts and other fasteners are secure 3 Remove the battery cover 2 by removing the 3 After installing the battery check to see if the mount bolts 1 battery ca

MXU 300(250)(150) OFF ROAD-000-002_v1

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