MXer50 Cap 01 (General In Format On)

8/2/2019 MXer50 Cap 01 (General In Format On)

1/33

1. GENERAL INFORMATION

1-1

MXer 50

1

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

GENERAL INFORMATION__________________________________________________________________________________

SERIAL NUMBER------------------------------------------------------ 1- 2

SPECIFICATIONS------------------------------------------------------ 1- 3

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

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

SPECIAL TOOLS ------------------------------------------------------- 1-13

LUBRICATION POINTS----------------------------------------------- 1-13

CABLE & HARNESS ROUTING ------------------------------------- 1-16

WIRING DIAGRAM ---------------------------------------------------- 1-20TROUBLESHOOTING ------------------------------------------------- 1-22

1


2/33


1-2

MXer 50

SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number


3/33


1-3

MXer 50

SPECIFICATIONS

Name & Model No. LA10AD

Motorcycle Name & Type MXer

Overall length (mm) 1685

Overall width (mm) 980

Overall height (mm) 1030

Wheel base (mm) 1120

Engine type Air cooled 2-stroke

Displacement (cc) 49.4

Fuel Used 92# nonleaded gasoline

Front wheel 67

Net weight (kg) Rear wheel 73

Total 140Front wheel 73

Gross weight(kg) Rear wheel 77

Total 150

Front wheel 20*7-8

Rear wheel 22*10-8

Ground clearance (mm) 130

Perform

-

Breaking distance(m)(ANSI) 20.6 below

AnceMin. turning radius (m) 2.5

Starting systemStarting motor &

kick starter

Type Air cooled 2-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke (mm) 39 x 41.4

Compression ratio 7.2:1Compression pressure(kg/cm_) 12.0

Max. output (ps/rpm) 4.3/6000Max. torque (kg m/rpm) 0.55/5500

Intake Open Automatic controlled

Port (1mm) Close Automatic controlledtiming

Exhaust Open

(1mm) Close

Valve clearance Intake

(cold) (mm) Exhaust

Idle speed (rpm) 2000rpm

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Air cleaner type & No Sponge

Fuel capacity 8.1 liters

Type PB

Main jet No. 80

Venturi dia.(mm) f14

Throttle type VALVE PISTON

Type CDI

Ignition timing 22/2000rpm

Spark plug

NGK

BR8HAS

Spark plug gap 0.6_ 0.7mm

Battery Capacity 12V4AH

Clutch Type CVT

Operation Automatic centrifugalType

Type Chain drive

Reduction 1st

ratio 2nd

Final gear ratio 23.678

Front Caster angle

Axle Trail length

Tire ressure Front 0.35(kg/cm_) Rear 0.35

Turning Left 44

angle Right 44

Brake s stem Rear Disk brake

type Front Drum brakeSus ension Front Swingtype Rear Swing arm

Shock Front Swing

type Rear Swing arm

Frame type SP pipe

Tires

Engine

FuelSystem

Carburetor

Electrical

IgnitionSystem

PowerDriveS

ystem

Reduct

ion

Gear

MovingDevice

Damping

Device


4/33


1-4

MXer 50

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,

circlips, cotter pins, etc. whenreassembling.

nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torque

diagonally.

n Use genuine parts and lubricants.

nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.

n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oil

before reassembly.


5/33


1-5

MXer 50

n Apply or add designated greases andlubricants to the specified lubrication

points.

n After reassembly, check all parts forproper tightening and operation.

nWhen two persons work together, payattention to the mutual working safety.

n Disconnect the battery negative (-) terminalbefore operation.

nWhen using a spanner or other tools, makesure not to damage the motorcycle surface.

n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.

nWhen connecting the battery, the positive(+) terminal must be connected first.

n After connection, apply grease to thebattery terminals.

n Terminal caps shall be installed securely.


6/33


1-6

MXer 50

n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

n After operation, terminal caps shall beinstalled securely.

nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.

n Hold the connector body when connectingor disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,protruding or loose.

ConfirmCapacity


7/33


1-7

MXer 50

n The connector shall be insertedcompletely.

n If the double connector has a lock, lockit at the correct position.

n Check if there is any loose wire.

n Before connecting a terminal, check fordamaged terminal cover or loose negativeterminal.

n Check the double connector cover forproper coverage and installation.

n Insert the terminal completely.

n Check the terminal cover for propercoverage.

n Do not make the terminal cover openingface up.

n Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.

Snapping!


8/33


9/33


1-9

MXer 50

n Route harnesses so they are neitherpulled tight nor have excessive slack.

n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge or

corner.

nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.

n Do not break the sheath of wire.

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

nWhen installing other parts, do not press orsqueeze the wires.

Do not pull tootight!

Do not press orsqueeze the wire.


10/33


1-10

MXer 50

n After routing, check that the wire harnessesare not twisted or kinked.

nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent or

surrounding parts in all steering positions.

nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

n Be careful not to drop any parts.

nWhen rust is found on a terminal, removethe rust with sand paper or equivalent

before connecting.

Do you understandthe instrument? Isthe instrument setcorrectly?

Remove Rust !


11/33


1-11

MXer 50

n Symbols:

The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Use special tool.

: Caution

: Warning

Engine Oil

Grease

Special


12/33


1-12

MXer 50

TORQUE VALUES

STANDARD TORQUE VALUESItem Torque (kgf-m) Item Torque (kgf-m)

5mm bolt, nut

6mm bolt, nut

8mm bolt, nut

10mm bolt, nut

12mm bolt, nut

14mm bolt, nut

0.45_ 0.6

0.8_ 1.2

1.8_ 2.5

3.0_ 4.0

5.0_ 6.0

6.0_ 8.0

4mm screw

5mm screw

6mm screw, SH bolt

6mm flange bolt and nut



0.15_ 0.4

0.3_ 0.5

0.7_ 1.1

1.0_ 1.4

2.4_ 3.0

3.5_ 4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item Qty Thread dia.(mm) Torque (kgf-m) Remarks

Cylinder head bolt

Clutch drive plate nut

Drive face nut

Clutch outer nut

A.C.G flywheel nut

Oil check bolt

Exhaust muffler joint lock nut

Exhaust muffler lock boltSpark plug

4

1

1

1

1

1

2

2

BF7X115

39

12

NH10

10

8

NC6mm

BF8X35

1.5_ 1.7

5.0_ 6.0

3.5_ 4.0

3.5_ 4.0

3.5_ 4.0

1.0_ 1.5

1.0_ 1.4

3.0_ 3.61.1_ 1.7

FRAME

Item Qty Thread dia.(mm) Torque (kgf-m) Remarks

Steering stem nut

Swing arm nut

Rear wheel nut

Front wheel nut

Rear shock absorber upper mount bolt

Front shock absorber upper mount bolt

Front shock absorber lower mount bolt

Rear fork axle

Rear hub nut

Rear wheel shaft nut

Rear engine bracket up bolt

Rear engine bracket bolt

Engine hanger bracket bolt

1

4

4

4

1

2

2

1

4

2

1

2

1

14

10

14

14

10

10

10

14

12

32

10

10

10

6.0_ 8.0

4.0_ 5.0

6.0_ 8.0

6.0_ 8.0

3.5_ 4.5

3.5_ 4.5

3.5_ 4.5

6.0_ 8.0

6.0_ 8.0

11.0_ 13.0

3.5_ 4.5

3.5_ 4.5

4.0_ 5.0


13/33

1. SPECIFICATIONS

1-13

MXer 50

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page

Flywheel puller E001

Oil seal and bearing install E014

Universal holder E017

Clutch spring compressor E034

Bearing puller E037

Crankshaft install E016

Crankshaft & crankcase install E024

Crankcase puller E026

Crankshaft Bearing puller E030ut wrench F010

Float level gauge

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Crankcase sliding & movable parts

Cylinder movable parts

Transmission gear (final gear)

Kick starter spindle bushing

Drive pulley movable parts

Starter pinion movable parts

JASO-FC or API-TC

JASO-FC or API-TC

Gear oil: SAE90#

Grease

Grease

Grease


14/33


1-14

MXer 50

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 avoidabnormal noise and rise the durability of the motorcycle.

Steering knuckle/ThrustCover/Bush/Collar

Steering Column Upper

Rear Brake Cable

Front Brakecamshaft/OilSeal/O-ring

Throttle Cable

Front Brake Cable

Steering Column Lower

Front WheelOil Seal

Front Arm Bush

Front Brakecamshaft/OilSeal/O-ring

Front Wheel

Oil Seal

Steering knuckle/ThrustCover/Bush/Collar

Front Arm Bush


15/33

1. SPECIFICATIONS

1-15

MXer 50

Sprocket hub/Rear

Axle Hub Collar/OilSeal/Bearing

Rear Brake Cam/ AxleHub Collar/OilSeal/Bearing

Driven Sprocket

Swing arm ThrustCover


16/33


1-16

MXer 50

CABLE & HARNESS ROUTING

Throttle Cable

Rear Brake Cable

Right Front Brake Cable

Handlebar Switch Lead

Front Brake Cable

Left Front Brake Cable

A.C.G WireStarter Motor WireAuto BystarterWire


17/33

1. SPECIFICATIONS

1-17

MXer 50

Throttle Cable

Rear Brake Cable

Ignition Coil Wire

Fuel Tube

Fuel Filter

Oil Meter Wire

Right Front Brake CableLeft Front Brake Cable


18/33


1-18

MXer 50

Wire Harness Rectifier/Regulator

Oil Tube

Resistor

Ignition Coil

Right Front Brake Cable


19/33

1. SPECIFICATIONS

1-19

MXer 50

Battery

Starter Relay

CDI UnitFuse

Rear Brake Cable

Breather Hose

Oil Meter Wire

Positive Cable

egative Cable

Main Switch


20/33


1-20

MXer 50

WIRING DIAGRAM (ON ROAD)


21/33

1. SPECIFICATIONS

1-21

MXer 50

WIRING DIAGRAM (OFF ROAD)


22/33


1-22

MXer 50

TROUBLESHOOTINGENGINE WILL NOT START OR IS HARD TO START

Empty fuel tank Clogged float valve Clogged charcoal

canister Clogged fuel filter Faulty auto fuel valve

Faulty spark plug Fouled spark plug Faulty CDI unit Faulty A.C. generator Broken or shorted

ignition coil Broken or shorted

exciter coilFaulty ignition switch

Burned or worncylinder piston

Faulty reed valve Blown cylinder head

gasket Leaking crankcase Faulty crankcase oil

seal

Incorrectly adjusted idlespeed

Air leaking throughintake pipe

Incorrect ignitiontiming

Flooded carburetor Throttle valve

excessively open

Faulty auto bystarter

Check if fuel reachescarburetor byloosening drain screw.

Remove spark plugand install it intospark plug cap to testspark by connecting it

to engine ground.

Inspection/Adjustment Symptom Probable Cause

Fuel reachescarburetor

Spark jumps

Dry spark plug

Not clogged

Normalcompression

Engine does notfire

Fuel does notreach carburetor

Weak or no spark

Wet spark plug

Clogged

Low or nocompression

Engine fires butdoes not start

Test cylindercompression.

Remove spark plug andinspect again.

Wait for 30 minutesand then remove thecarbu-retor auto chokecircuit hose and blowthe hose with mouth.

Start engine by follow-ing normal startingprocedure.


23/33

1. SPECIFICATIONS

1-23

MXer 50

ENGINE STOPS IMMEDIATELY AFTER IT STARTS

Empty fuel tank Clogged float valve Clogged charcoal

canister Clogged fuel filter Faulty auto fuel valve

Fouled spark plug

Incorrect heat rangeplug

Fouled spark plug Faulty CDI unit Faulty A.C. generator Faulty ignition coil Broken or shorted high

tension wire Faulty ignition switch

Worn cylinder andpiston rings Blown cylinder head

gasket Flaws in cylinder head Faulty reed valve Seized piston

Clogged carburetor jets

Faulty CDI unit or A.C.generator

A.C.G. flywheel notaligned

Mixture too rich (turnscrew out)

Mixture too lean (turnscrew in)

Check if fuel reachescarburetor byloosening drain screw.


Fuel reachescarburetor

Good spark

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground.

Correct timing

Correctly adjusted

Plug not fouled or

discolored

Normalcompression

Not Clogged

Fuel does notreach carburetor

Weak or inter-mittent spark

Incorrect timing

Incorrectly adjusted

Plug fouled or

discolored

Abnormalcompression

Clogged

Test cylindercompression (using acompression gauge).

Check carburetor forclogging.

Check ignition timing.

Check carburetor airscrew adjustment.



24/33


1-24

MXer 50

Carburetor not securelytightened

Faulty intake manifoldgasket

Deformed or brokencarburetor O-ring

Broken cable Dirty auto bystarter Faulty auto bystarter



No air leak

Not clogged

Clogged

Air leaks

Clogged

Not Clogged

Check carburetorgasket for air leaks.

Connect auto bystarterwire to battery. Waitfor 5 minutes, thenconnect a hose to fuelenriching circuit andthen blow the hosewith mouth.

Remove auto bystarterconnecting wire and

check if bypass fuelline is clogged.


25/33

1. SPECIFICATIONS

1-25

MXer 50

ENGINE LACKS POWER

Clogged air cleaner Clogged fuel filter Clogged exhaust

muffler Faulty auto bystarter Faulty charcoal canister

Faulty CDI unit Faulty A.C. generator

Worn cylinder andpiston rings Blown cylinder head

gasket Faulty reed valve

Clogged carburetor jets

Fouled spark plug Incorrect heat range

plug

Mixture too lean Poor quality fuel Excessive carbon build-

up in combustion chamber Ignition timing too

early

Excessive carbon build-up in combustion chamber

Poor quality fuel

Clutch slipping Mixture too lean


Engine speedincreases

Engine overheats

Correct timing

Engine does notknock

Plug not fouled ordiscolored

Normalcompression

Not Clogged

Engine speed doesnot increasesufficiently

Engine does notoverheats

Incorrect timing

Engine knocks

Plug fouled ordiscolored

Abnormalcompression

Clogged

Start engine andaccelerate lightly forobservation.

Check ignition timing(using a timing light).

Rapidly accelerate orrun at high speed

Test cylindercompression (using acompression gauge)

Check carburetor forclogging

Remove spark plugandinspect

Check if engineoverheats


26/33


1-26

MXer 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unit Faulty A.C. generator

Mixture too rich (turnscrew out)

Mixture too lean (turnscrew in)

Carburetor not securelytightened

Faulty intake manifoldgasket

Deformed carburetorO-ring

Faulty or fouled sparkplug Faulty CDI unit Faulty A.C. generator Faulty ignition coil Broken or shorted high

tension wire Faulty ignition switch

Broken auto bystarterwire



Clogged Not clogged




Remove auto bystarterconnecting wire andcheck if bypass fuel

line is clogged.

Check carburetorgasket for air leaks.

Check carburetor air

screw adjustment.

Correct timing Incorrect timing

Correctly adjusted Incorrectly adjusted

No air leak Air leaks

Good spark Weak or inter-mittent spark

Not clogged Clogged


27/33

1. SPECIFICATIONS

1-27

MXer 50

POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unit

Loose A.C.G. stator Faulty A.C. generator

Empty fuel tank Clogged fuel tube or

filter Clogged charcoal

canister

Clean and unclog

Broken auto bystarterwire




Clogged Not clogged



Remove auto bystarterconnecting wire andcheck if bypass fuelline is clogged.

Check carburetor jetsfor clogging.

Check auto fuel valvefor fuel supply.

Correct timing Incorrect timing

Fuel flows freely Fuel flow

Not clogged Clogged

Not clogged Clogged


28/33


1-28

MXer 50

CLUTCH, DRIVE AND DRIVEN PULLEYS

Worn or slipping drive belt Broken ramp plate Broken driven face spring Separated clutch lining Damaged driven pulley shaft

splines Damaged final gear

Seized final gear

Broken shoe spring Clutch outer and clutch weight

stuckSeized pivot

Worn or slipping drive belt Worn weight rollers

Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley

bearings

Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley

bearings

Oil or grease fouled drive belt Worn drive belt

Weak driven face spring Worn or seized driven pulley

bearings

Engine starts butmotor-cycle does notmove

Engine lacks power atstart of a grade (poorslope performance)

Symptom Probable Cause

Engine lacks power athigh speed

There is abnormal

noiseor smell while running

Motorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheelrotates when engineidles)


29/33

1. SPECIFICATIONS

1-29

MXer 50

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

Steering stem nut too tight Broken steering steel balls

Excessive wheel bearing play Bent rim Loose axle nut

Misaligned front and rear wheels Bent front fork

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)

Weak shock spring

Excessive load Shock damper oil leaking

Bent fork tube or shock rod Fork slider and tube binding

Fork tube and spring binding Fork slider and tube binding

Steering is heavy

Suspension is too soft

Front or rear wheel iswobbling

Symptom

Symptom

Probable Cause

Probable Cause

Steering handlebar pullsto one side

Suspension is too hard

Suspension is noisy


30/33


1-30

MXer 50

POOR BRAKE PERFORMANCE

(Adjust brake according to standards)

Worn brake linings Worn brake cam contacting area

onbrake shoes Worn brake cam Worn brake drum

Worn brake linings Foreign matter on brake linings Rough brake drum contacting area

Sluggish or elongated brake cables Brake shoes improperly contact

brake drum Water and mud in brake system Oil or grease on brake linings

Faulty brake master cylinder Faulty brake caliper Oil or grease on brake disk Deformed brake disk Leaking brake fluid tube

Brake squeaks


Brake performance ispoor

Index mark on brakepanel aligns with wearindicator arrow

ExpandingBrake

HydraulicBrake


31/33

1. SPECIFICATIONS

1-31

MXer 50

Faulty

OIL METER

1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON)

Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected

connector Broken wire harness

Burned out bulb

Loose wire connector Broken wire harness Incorrectly connected

wire

Faulty float Broken or shorted wire

in

meter

2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)

Loose or disconnectedconnector

Broken wire harness Incorrectly connected

wire

Faulty float Broken or shorted wire

in meter

Damaged oil tank Foreign matters in oil

tank

Inspection/Adjustment Symptom

Inspection/Adjustment

Probable Cause


Signals operateproperly

Signals dim, remainon or dont

Bulb lights Bulb does not light

Good Faulty

Remove oil meter andcheck operation ofindicator light bymoving float

Check connectors for proper connection.

Good

Good Faulty

Remove oil meter andcheck operation ofindicator light bymoving float

Check connectors for proper operation.

Connect indicatorlight bulb to batteryfor bulb inspection.

Check battery circuitby operating turnsignals.

Good Faulty

Float up = Light off

Float down = Light on

Float up = Light offFloat down = Light on


32/33


1-32

MXer 50

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON)



Faulty float

Broken or shorted fuelunit wire


Incorrectly connectedconnector

Broken or shorted wirein fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON)



Poor contact in fuelunit

Insufficient damping oilin fuel gauge

Loose or disconnected

connector Broken or shorted wirein fuel gauge



Symptom

Symptom





Pointer does notmove


Good

Good

Pointer moves

Pointer moves

Pointer moves

Pointer does notmove in accord-ance with float

Faulty

Faulty


Pointer moves inaccordance withfloat

Probable Cause

Probable Cause

Remove fuel unit andcheck operation ofpointer by movingfloat up and down.

Check battery circuitby operating turnsignals.

Check operation ofpointer by opening

and shorting fuel unitterminal on wireharness side.


Remove fuel unit andcheck operation ofpointer by movingfloat up and down.

Check battery circuitby operating turnsignals and horn.

Move float up anddown rapidly (1 round/sec.) to check theoperation of pointer.



33/33

1. SPECIFICATIONS MXer 50STARTER MOTOR

1. Starter motor wont turn

Burned out fuse Weak or dead battery Faulty stop switch Loose or disconnected

connector Broken or shorted

ignition switch wire

Faulty or weak battery

Poor starter button

connection Faulty starter relay Loose or disconnected

connector

Faulty starter motor

Faulty wire harness

2. Starter motor turns slowly or idles

Weak or dead battery


Faulty starter relay

Seized cylinder

Broken or shortedstarter motor cable

Faulty starter pinion3. Starter motor does not stop turning

Faulty starter pinion

Starter relay shorted orstuckclosed




Symptom

Symptom

Symptom





Stoplight does notcome on

Starter motor

Turns easily

Not stopped

Stoplight comes

Starter does not

Hard to turn

Stopped

Relay operates

properly

Starter motorturns slowly

Probable Cause

Probable Cause

Probable Cause

Relay does not

operate

Starter motorturns normally

Check operation ofstop switch byapplying brake.

Check batterycircuit by operatingturn signals.

Check batterycircuit by operatingturn signals.

Turn ignition switchOFF.

Check operation ofstarter relay bydepressing starterbutton.

Connect startermotor directly tobattery.

Connect startermotor directly tobattery.

Rotate crankshaft.

Date post:	06-Apr-2018
Category:	Documents
Upload:	ritchieau
View:	216 times
Download:	0 times

MXer50 Cap 01 (General In Format On)

Documents