KYMCO MXU 300 - User manual

OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

MXU 300/250

ON-ROAD

Issued: 21.02.2005

IMPORTANT NOTICES

READ THIS MANUAL CAREFULLY

AGE RECOMMENDATION

RIDER TRAINING

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.

The minimum recommended age for this ATV model is 16. Children under age 16

should never operate this vehicle.

Anyone who operates this vehicle should get proper instruction.

FOR ON-ROAD USE ONLY

This machine is designed and manufactured for ON-ROAD use only. It is illegal and unsafe to

operate this machine on any hills and rough or loose terrain.

This machine complies with all applicable ON-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 . 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 it is sold.

WARNING

PREFACE

Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a

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

operation 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.

WARNING

CONTROL FUNCTIONS....................18

IGNITION SWITCH..............................18

INSTRUMENTS AND INDICATOR........19

Multi-function display.......................21

HANDLEBAR SWITCHES....................28

Horn button.....................................28

THROTTLE LEVER.............................33

SPEED LIMITER.................................34

FRONT BRAKE LEVER.......................35

Turn signal switch............................28

Headlight dimmer switch..................29

Hazard switch.................................30

Start switch.....................................31

RECOIL STARTER..............................32

REAR BRAKE LEVER..........................35

BRAKE PEDAL...................................35

CONTENTS

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

SAFETY INFORMATION

DESCRIPTION AND MACHINE

IDENTIFICATION

...................1

......................5

................................10

IDENTIFICATION NUMBER

RECORDS..........................................10

KEY IDENTIFICATION NUMBER.........10

FRAME SERIAL NUMBER...................11

ENGINE SERIAL NUMBER..................11

PARTS LOCATION.............................12

Page Page

(Cont'd)

PARKING BRAKE...............................36

LOCKING STEERING.........................37

DRIVE SELECT LEVER.......................38

FUEL TANK CAP ................................39

FUEL VALVE......................................39

CHOKE KNOB....................................41

SEAT..................................................42

FLAG POLE BRACKET.......................43

TRAILER HITCH.................................43

STORAGE COMPARTMENT................44

ACCESSORY SOCKET SEAT...............44

PRE-OPERATION CHECKS.............46

DRIVE SELECT LEVER ......................47

Drive select lever adjustment.....49

FRONT AND REAR BRAKES................51

FUEL...............................................52

ENGINE, TRANSMISSION OIL AND

REAR FINAL GEAR CASE OIL .............54

CHAIN..............................................55

THROTTLE LEVER.............................55

FITTINGS AND FASTENERS...............55

LIGHTS..............................................55

SWITCHES.........................................55

TIRES................................................56

How to measure tire pressure ..............57

Tire wear limit ....................................58

COOLANT..........................................58

Page Page

(Cont'd)

RIDING YOUR ATV ............................73

GETTING TO KNOW YOUR ATV .........74

RIDE WITH CARE AND

APPAREL...........................................78

PRE-OPERATION CHECKS................80

LOADING AND ACCESSORIES..........82

Loading and operational guidelines...82

Accessories.....................................83

MODIFICATIONS................................84

DURING OPERATION.........................85

EXHAUST SYSTEM............................87

PRACTICING......................................88

TURNING YOUR ATV ..........................89

CLIMBING UP SLOPE..........................90

RIDING DOWN SLOPE.........................96

JUDGEMENT......................................75

GOOD

No modifications..............................84

PARKING...........................................97

WHAT TO DO IF ..................................98

WHAT TO DO ......................................98

OPERATION........................................60

STARTING A COLD ENGINE...............60

Using the recoil starter......................62

STARTING A WARM ENGINE..............63

WARMING UP.....................................63

DRIVE SELECT LEVER OPERATION

AND REVERSE DRIVING....................64

ENGINE BREAK-IN.............................67

ACCESSORIES ..................................70

PARKING..........................................68

Parking on a slope............................69

LOADING ...........................................71

Page Page

(Cont'd)

PERIODIC MAINTENANCE AND

ADJUSTMENT.....................................99

TOOL KIT...........................................99

PERIODIC MAINTENANCE/

LUBRICATION..................................101

ENGINE OIL .....................................103

TRANSMISSION OIL........................107

REAR FINAL GEAR CASE

OIL (MXU 300)...................................109

SPARK PLUG INSPECTION..............110

AIR FILTER CLEANING.....................112

AIR CLEANER HOUSING DRAIN

TUBE...............................................115

IDLE SPEED ADJUSTMENT .............116

THROTTLE LEVER ADJUSTMENT....117

VALVE CLEARANCE ADJUSTMENT..118

FRONT BRAKE PADS INSPECTION...115

REAR BRAKE PADS (MXU 250)

INSPECTION..................................119

REAR BRAKE PADS (MXU 300)

INSPECTION....................................120

BRAKE FLUID INSPECTION.............121

COOLING SYSTEM INSPECTION.....123

Engine overheating.......................124

DRIVE CHAIN SLACK

CHECK (MXU 250).............................125

Drive chain slack

Adjustment (MXU 250)........................125

DRIVE CHAIN CLEANING AND

LUBRICATION (MXU 250)..................127

REAR SWING ARM

LUBRICATION (MXU 250)............. ....127

DRAINING THE V-BELT

COMPARTMENT...............................128

CABLE INSPECTION AND

LUBRICATION..................................128

WHEEL REMOVAL............................129

Wheel installation.........................129

Page Page

(cont'd)

CLEANING AND STORAGE...........138

A. CLEANING ...................................138

B. STORAGE ....................................140

SPECIFICATIONS..................................142

INDEX...................................................148

NOISE REGULATION.............................146

MAINTENANCE RECORD.......................147

Page

BATTERY..........................................130

FUSE REPLACEMENT......................134

HEADLIGHT BEAM ADJUSTMENT....135

TROUBLESHOOTING .......................136

Troubleshooting chart...................137

Battery remove.............................131

Battery installation........................133

Page

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