1.

GENERAL INFORMATION MXU 250

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GENERAL INFORMATION
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SERIAL NUMBER---------------------------------------------------------- 1- 1
SPECIFICATIONS ---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS ------------------------------------------------ 1- 3
TORQUE VALUES --------------------------------------------------------- 1-11
SPECIAL TOOLS ----------------------------------------------------------- 1-12
LUBRICATION POINTS -------------------------------------------------- 1-13
CABLE & HARNESS ROUTING ---------------------------------------- 1-16
WIRING DIAGRAM (OFF ROAD) -------------------------------------- 1-20
WIRING DIAGRAM (ON ROAD) --------------------------------------- 1-21
TROUBLESHOOTING----------------------------------------------------- 1-22

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1. GENERAL INFORMATION MXU 250

SERIAL NUMBER

(1) Location of Frame Serial Number

(2) Location of Engine Serial Number

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1. GENERAL INFORMATION MXU 250

SPECIFICATIONS
Name & Model No. LB50AD/AA Air cleaner type & No Wet type element

Fuel System
Motorcycle Name & Type MXU Fuel capacity 12.5 L (2.63 lmp gal,
Overall length 1810 mm (72.4 in) 3.25 US gal

Carburetor
Overall width (mm) 1050 mm (42 in) Type Piston valve
Overall height (mm) 1110 mm (44.4 in) Main jet NO. 98
Wheel base (mm) 1170 mm (46.8 in) Venturi dia. φ22 mm (φ0.88 in)
Engine type O.H.C. Throttle type PISTON
Displacement 249 cm3 (15.2 cu-in) Type Full transistor digital

Ignition System
Electrical Equipment
Fuel Used 92# nonleaded gasoline ignition
Front wheel 112 kg (246 lbs) Ignition timing 5°BTDC/1000rpm
Dry weight Rear wheel 102 kg (224 lbs) Contact breaker Non-contact point type
Total 214 kg (471 lbs) Spark plug DPR7EA-9
Front wheel 116 kg (255 lbs)
Curb weight Rear wheel 110 kg (242 lbs) Spark plug gap 0.6～0.7mm (0.002～
Total 226 kg (497 lbs) 0.003 in)
Front wheel 22*7-10 Battery Capacity 12V12AH
Tires Clutch Type Dry, centrifugal
Power Drive System

Rear wheel 22*10-10

automatic
Ground clearance 125 mm (5 in)
sion Gear Gear
Transmis- Reduction

Type Helical gear/spur gear

Min. turning radius 2900 mm (116 in)
Starting system Electric/Recoil starter Operation Automatic centrifugal
Type
Type Gasoline, 4-stroke
Type Chain drive
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere Reduction 1st 26.5
ratio 2nd 10.02
Valve arrangement O.H.C., chain drive
Bore x stroke (mm) 72.7 x 60 mm Reverse ratio 50.9
(2.9 x 2.4 in) FR/RR tire rolling 1759/1759 mm (71.8/71.8
Moving Device

Compression ratio 10.3:1 circumference in)

Compression pressure 16 kg/cm² (1600kPa,
227 psi) Tire pressure Front 0.28 kg/cm² (28 Kpa,
Rear 3.2 psi)
Intake Open 8.1° BTDC
Engine

Port (1mm) Close 41° ABDC Turning Left 40°

timing Exhaust Open 37° BBDC angle Right 40°
(1mm) Close 7.9° ATDC Brake system Rear Disk brake
Valve clearance Intake 0.1 mm (0.004 in) type Front Disk brake
(cold) Exhaust 0.1 mm (0.004 in)
Device
Damping

Front Double wishbone

Idle speed (rpm) 1500rpm Suspension
Lubrication type Forced pressure & type Rear Link suspension
System
Lubrication

Wet sump
Oil pump type Trochoid Frame type Double cradle
Oil filter type Full-flow filtration
Oil capacity 1.6 L (1.4 lmp qt, 1.7
Us qt)
Oil exchanging 1.4 L (1.23 lmp qt,
capacity 1.48 Us qt
Cooling Type Liquid cooled

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1. GENERAL INFORMATION MXU 250

SERVICE PRECAUTIONS
„ Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.

„ When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

„ Use genuine parts and lubricants.

„ When servicing the motorcycle, be sure

to use special tools for removal and
installation.

„ After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil
before reassembly.

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1. GENERAL INFORMATION MXU 250

„ Apply or add designated greases and

lubricants to the specified lubrication
points.

„ After reassembly, check all parts for

proper tightening and operation.

„ When two persons work together, pay

attention to the mutual working safety.

„ Disconnect the battery negative (-)

terminal before operation.
„ When using a spanner or other tools,
make sure not to damage the motorcycle
surface.

„ After operation, check all connecting

points, fasteners, and lines for proper
connection and installation.
„ When connecting the battery, the positive
(+) terminal must be connected first.
„ After connection, apply grease to the
battery terminals.
„ Terminal caps shall be installed securely.

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1. GENERAL INFORMATION MXU 250

„ If the fuse is burned out, find the cause

and repair it. Replace it with a new one Confirm
according to the specified capacity. Capacity

„ After operation, terminal caps shall be

installed securely.

„ When taking out the connector, the lock

on the connector shall be released before
operation.

„ Hold the connector body when

connecting or disconnecting it.
„ Do not pull the connector wire.

„ Check if any connector terminal is

bending, protruding or loose.

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1. GENERAL INFORMATION MXU 250

„ The connector shall be inserted

completely.
„ If the double connector has a lock, Snapping!
lock it at the correct position.
„ Check if there is any loose wire.

„ Before connecting a terminal, check

for damaged terminal cover or loose
negative terminal.

„ Check the double connector cover for

proper coverage and installation.

„ Insert the terminal completely.

„ Check the terminal cover for proper
coverage.
„ Do not make the terminal cover opening
face up.

„ Secure wire harnesses to the frame with

their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

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1. GENERAL INFORMATION MXU 250

„ After clamping, check each wire to make

sure it is secure.

„ Do not squeeze wires against the weld or

its clamp.

„ After clamping, check each harness to

make sure that it is not interfering with
any moving or sliding parts.

„ When fixing the wire harnesses, do not

make it contact the parts which will No Contact !
generate high heat.

„ Route wire harnesses to avoid sharp

edges or corners. Avoid the projected
ends of bolts and screws.
„ Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.

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1. GENERAL INFORMATION MXU 250

„ Route harnesses so they are neither

pulled tight nor have excessive slack. Do not pull
too tight!

„ Protect wires and harnesses with

electrical tape or tube if they contact a
sharp edge or corner.

„ When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

„ Do not break the sheath of wire.

„ If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.

„ When installing other parts, do not press

or squeeze the wires. Do not press or
squeeze the wire.

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1. GENERAL INFORMATION MXU 250

„ After routing, check that the wire

harnesses are not twisted or kinked.

„ Wire harnesses routed along with

handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

„ When a testing device is used, make sure

to understand the operating methods Do you understand
the instrument? Is the
thoroughly and operate according to the instrument set
operating instructions. correctly?

„ Be careful not to drop any parts.

„ When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting. Remove Rust !

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1. GENERAL INFORMATION MXU 250

„ Symbols:
The following symbols represent the
servicing methods and cautions included
in this service manual.

: Apply engine oil to the

specified points. (Use
designated engine oil for
Engine Oil lubrication.)

: Apply grease for

lubrication.
Grease

: Transmission Gear Oil

(90#)
Gear Oil

Special : Use special tool.

: Caution

: Warning

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1. GENERAL INFORMATION MXU 250

TORQUE VALUES
STANDARD TORQUE VALUES
Torque Torque
Item Item
kgf-m (N-m, lbf-ft) kgf-m (N-m, lbf-ft)
5mm bolt and nut 0.5 (5, 3.6) 4mm screw 0.3 (3, 2.2)
6mm bolt and nut 1 (10, 7.2) 5mm screw 0.4 (4, 2.9)
8mm bolt and nut 2.2 (22, 16) 6mm screw, SH bolt 0.9 (9, 6.5)
10mm bolt and nut 3.5 (35, 25) 6mm flange bolt and nut 1.2 (12, 9)
12mm bolt and nut 5.5 (55, 40) 8mm flange bolt and nut 2.7 (27, 20)
14mm bolt and nut 7 (70, 50) 10mm flange bolt and nut 4 (40, 29)
Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia. Torque Remarks

(mm) kgf-m (N-m, lbf-ft)
Stud bolt 4 8 0.9 (9, 6.5)
Oil filter screen cap 1 30 1.5 (15, 11)
Seat ball stopper bolt 1 14 4.8 (48, 35)
L cover bolt 10 6 1.2 (12, 8.6)
Cam shaft holder nut 4 8 2.5 (25, 18) Apply oil
Tappet ADJ nut 2 5 0.9 (9, 6.5) Apply oil
Pivot tensioner bolt 1 8 1 (10, 7.2)
Lifter tensioner bolt 2 6 1.2 (12, 8.6)
Lifter tensioner cap 1 6 0.4 (4,2.9)
Mission case bolt 9 8 2.7 (27, 20)
Mission fill bolt 1 12 2.5 (25, 18)
Driver face nut 1 14 9.5 (95, 68) Apply oil
Clutch outer nut 1 12 5.5 (55, 40)
Drive plate nut 1 28 5.5 (55, 40)
Oneway clutch bolt 3 8 2.0 (20, 14) Apply thread lock
ACG flywheel nut 1 14 6.0 (60, 43)
Spark plug 1 12 1.8 (18, 13)
Water pump impeller 1 7 1.2 (12, 8.6)
Drain plug 1 12 2.5 (25, 18)
Oil pump screw 1 3 0.15 (15, 10.8)
Head CYL stud bolt (IN pipe) 2 6 0.9 (9, 6.5)
Head CYL stud bolt (EX pipe) 2 8 0.9 (9, 6.5)
A.C.G Startor 3 5 0.9 (9, 6.5)

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1. GENERAL INFORMATION MXU 250

FRAME
Thread dia. Torque
Item Q‘ty Remarks
(mm) Kgf-m (N-m, lbf-ft)
Steering stem nut 1 14 7 (70, 50)
Front swing arm nut 8 10 4.5 (45, 32)
Front wheel nut 8 12 4.5 (45, 32)
Rear wheel nut 8 12 4.5 (45, 32)
Front wheel hub nut 2 14 7 (70, 50)
Rear wheel hub nut 2 16 10 (100, 72)
Front shock absorber upper mount bolt 2 10 4 (40, 29)
Front shock absorber lower mount bolt 2 10 4 (40, 29)
Rear shock absorber upper mount bolt 1 10 4 (40, 29)
Rear shock absorber lower mount bolt 1 10 4 (40, 29)
Rear swing arm axle 1 14 7 (70, 50)
Rear hub nut 2 10 4 (40, 29)
Rear wheel shaft nut 2 40 12 (120, 86)
Rear engine bracket upper bolt 1 10 4 (40, 29)
Rear engine bracket lower bolt 1 10 4 (40, 29)
Engine hanger bracket bolt 1 10 4 (40, 29)
Exhaust muffler lock bolt (frame) 2 8 4 (40, 29)
Exhaust muffler lock nut (engine) 2 8 2 (20, 14.4)

SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Flywheel puller E003
Valve adjuster E012
Valve spring compressor E040
Oil seal and bearing install E014
Universal holder E017
Flywheel holder E021
Clutch spring compressor E034
Bearing puller E037
Nut wrench F010
Ball join remover F012

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1. GENERAL INFORMATION MXU 250

LUBRICATION POINTS

ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part •Genuine KYMCO Engine Oil (SAE15W-40)
Cam lobes •API SG Engine Oil
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft right side oil seal
Crankshaft one-way clutch movable part
Oil pump drive chain
Balance gear
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip
Transmission gear and movable parts Gear oil: SAE90#

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1. GENERAL INFORMATION MXU 250

FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the ATV.

Steering Column Upper

Throttle Cable

Front Swing Arm Bush

Front Swing Arm

Steering Column Lower

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1. GENERAL INFORMATION MXU 250

Rear Swing Arm

Axle

Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing
Driven Sprocket

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1. GENERAL INFORMATION MXU 250

CABLE & HARNESS ROUTING

Multi-function Connector
Throttle Cable

Stop Switch Cord Handlebar Switch Wire

Rear Brake Fluid Hose

Front Brake Fluid Hose
Speed Cable
Thermostatic Sensor
Wire
Harness Wire
Ignition Switch
Connector Motor Fan Wire/
Horn (ON ROAD) Thermostatic Switch Wire

Front Right Turn

Signal Light (ON
ROAD)/Headlight Front Left Turn Signal Light
Connectors (ON ROAD)/Headlight
Connectors

Right Front Brake Fluid Hose

Left Front Brake Fluid Hose

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1. GENERAL INFORMATION MXU 250

Turn Signal Light/Stop Main Wire Harness

Light Connectors (ON
ROAD)
REG.REC
A.C.G Connector

A.C.G Wire
Coolant Reservoir
Breather Hose
Gear Change Temperature Sensor Wire
Switch Wire

License Light Turn Signal Relay

Connector Ground Wire
(ON ROAD)
Hazard Unit

Horn (ON
ROAD)

Right Turn Water Hose

Signal Light Gear Change
(ON Switch Connector
ROAD)/Tail Carburetor Headlight Control Unit
Light Drain Tube
Connector Radiator Overflow
Tube

Start Motor
Cable Inlet Water Hose
Stop Switch Wire

Outlet Water Hose

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1. GENERAL INFORMATION MXU 250

Ignition Coil

Rear Brake Fluid Hose Crankcase Breather Hose

Harness Wire Start Motor Cable

Handlebar Switch Wire
Battery Cable
Blow By Hose

Motor Fan Wire

Throttle Cable Left Turn Signal Light (ON

Rear Brake Fluid Hose ROAD)/ Tail Light Connector

Rear Brake Fluid Hose

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1. GENERAL INFORMATION MXU 250

Gear Change Control Unit Ignition Control Module

Fuse Box Starter Relay Positive Terminal Cable

Ground Wire

Battery
Starter Motor Cable
Negative Terminal Cable

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1. GENERAL INFORMATION MXU 250

WIRING DIAGRAM (OFF ROAD)

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1. GENERAL INFORMATION MXU 250

WIRING DIAGRAM (ON ROAD)

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1. GENERAL INFORMATION MXU 250

TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment Symptom Probable Cause

Check if fuel reaches

carburetor by loosening
drain screw Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Fuel does not Clogged float oil passage
Fuel reaches Clogged fuel tank cap breather
carburetor reach carburetor hole
Clogged fuel filter
Clogged fuel valve passage
Remove spark plug and
install it into spark plug
cap to test spark by Faulty spark plug
connecting it to engine Fouled spark plug
ground Faulty ignition unit
Faulty change gear control unit
Spark jumps Weak or no spark Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery
Test cylinder
compression
Faulty starter clutch
Valve clearance too small
Valve stuck open
Normal Low or no Worn cylinder, piston and piston
compression compression rings
Leaking cylinder head gasket

Start engine by follow-

ing normal starting
procedure
Air leaking through intake pipe
Engine does not Engine fires but Leaking intake manifold
fire does not start Incorrect ignition timing
Incorrectly adjusted air screw

Remove spark plug and

inspect again

Flooded carburetor
Dry spark plug Wet spark plug Clogged air cleaner
Throttle valve excessively open

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1. GENERAL INFORMATION MXU 250

ENGINE LACKS POWER

Inspection/Adjustment Symptom Probable Cause

Start engine and
accelerate lightly for
observation Clogged air cleaner
Engine speed Engine speed does not Restricted fuel flow
increases increase sufficiently Clogged fuel tank cap breather hole
Clogged exhaust muffler
Check ignition timing Carburetor fuel level too low
(using a timing light)
Faulty ignition unit
Correct timing Incorrect timing
Faulty pulser coil
Check valve clearance
Improper valve clearance
Correct Incorrect adjustment
Excessively worn valve seat
(protruded valve stem)
Test cylinder compression
Improper valve and seat contact
Normal Abnormal Worn cylinder and piston rings
compression compression Leaking cylinder head gasket
Improper valve timing
Check carburetor for
clogging

Not clogged Clogged Clean and unclog

Remove spark plug and

inspect

Plug not fouled or Plug fouled or Fouled spark plug

discolored discolored Incorrect heat range plug
Remove oil dipstick and
check oil level and condition
Incorrect or Oil level too high
Correct and not Oil level too low
contaminated contaminated
Oil not changed
Remove cylinder head oil
pipe bolt and inspect
Valve train not Clogged oil line
Valve train lubricated
properly lubricated properly Faulty oil pump

Check if engine overheats Coolant level too low

Worn cylinder and piston rings
Mixture too lean
Engine does not Engine overheats Poor quality fuel
overheats Excessive carbon build-up in
combustion chamber
Ignition timing too early
Rapidly accelerate or run
at high speed
Excessive carbon build-up in
combustion chamber
Engine does not knock Engine knocks Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early

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1. GENERAL INFORMATION MXU 250

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Faulty ignition unit

Correct timing Incorrect timing
Faulty pulser coil

Check carburetor air

screw adjustment

Mixture too rich (turn screw

Correctly adjusted Incorrectly adjusted out)
Mixture too lean (turn screw in)

Check carburetor gasket

for air leaks
Deteriorated O-ring
Carburetor not securely
No air leak Air leaks tightened
Damaged insulator rubber

Remove spark plug and

install it into spark plug
cap to test spark by
connecting it to engine
ground
Faulty or fouled spark plug
Faulty ignition unit
Weak or inter- Faulty A.C. generator
Good spark mittent spark Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch

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1. GENERAL INFORMATION MXU 250

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Faulty ignition unit

Correct timing Incorrect timing
Faulty pulser coil

Check valve clearance

Improperly adjusted valve

Correctly adjusted Incorrectly adjusted clearance
Worn valve seat
Check fuel pump for
fuel supply
Empty fuel tank
Clogged fuel tube or filter
Fuel flows freely Fuel flow restricted
Clogged Fuel tank cap breather
Check carburetor jets hole
for clogging

Not clogged Clogged Clean and unclog

Check valve timing

Correct Incorrect Cam timing gear aligning marks

not aligned

Check valve spring

tension

Not weakened Weak spring Faulty spring

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1. GENERAL INFORMATION MXU 250

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Inspection/Adjustment Symptom Probable Cause

Start engine and test

limit voltage of battery
terminals
Voltage does not Dead battery
Normal voltage
increase Faulty battery

Measure resistance
between AC generator
coil terminals
Faulty A.C. generator coil
Normal Resistance too high Broken yellow wire
Shorted pink and yellow
Connect battery (+) wire wires
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage
Normal voltage No voltage Broken red wire

Check regulator/rectifier
coupler for loose
connection
Faulty regulator/rectifier
Normal Abnormal
Poorly connected coupler

Faulty A.C. generator

Overcharging

Inspection/Adjustment Symptom Probable Cause

Connect battery (+) wire

to regulator/rectifier
coupler green wire and
battery (-) wire to engine
ground and test voltage
Battery has voltage Battery has no
with ignition voltage with ignition Broken green wire
switch “ON” switch “ON”

Check regulator/rectifier
coupler for loose
connection

Normal Abnormal Poorly connected coupler

Faulty regulator/rectifier

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1. GENERAL INFORMATION MXU 250

NO SPARK AT SPARK PLUG

Inspection/Adjustment Symptom Probable Cause

Replace with a new

spark plug and inspect
again

Weak or no spark Good spark Faulty spark plug

Check spark plug cap

and high-tension wire
for looseness

Not loose Loose Loose spark plug cap

Check ignition unit

coupler for looseness

Good Good Poorly connected coupler

Measure resistance
between terminals of
ignition unit coupler

Normal Abnormal

Check related parts

Faulty ignition switch

Weak battery
Normal Abnormal Faulty pulser coil
Faulty ignition coil
Faulty charging system
Broken wire harness
Poorly connected coupler

Check ignition unit

with a ignition unit
tester
Faulty ignition unit
Normal Abnormal Faulty change gear control
unit

Check ignition coil with

a ignition unit tester

Abnormal Faulty ignition coil

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