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MXer50 cap 01 (info generali) .pdf



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1. GENERAL INFORMATION

MX’er 50

1

1
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GENERAL INFORMATION
__________________________________________________________________________________

SERIAL NUMBER -----------------------------------------------------SPECIFICATIONS -----------------------------------------------------SERVICE PRECAUTIONS--------------------------------------------TORQUE VALUES ----------------------------------------------------SPECIAL TOOLS ------------------------------------------------------LUBRICATION POINTS----------------------------------------------CABLE & HARNESS ROUTING ------------------------------------WIRING DIAGRAM ---------------------------------------------------TROUBLESHOOTING -------------------------------------------------

1-1

1- 2
1- 3
1- 4
1-12
1-13
1-13
1-16
1-20
1-22

1. GENERAL INFORMATION

MX’er 50

SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number

1-2

1. GENERAL INFORMATION

MX’er 50

SPECIFICATIONS

Carburetor

Ignition System

Spark plug

Spark plug gap
Battery Capacity
Clutch Type
Operation
Reduction
Gear

Damping
Device

1-3

Separate type
Plunger type
Full-flow filtration

Air cleaner type & No
Fuel capacity
Type
Main jet No.
Venturi dia.(mm)
Throttle type
Type
Ignition timing

Type

Reduction 1st
ratio
2nd
Final gear ratio
Front Caster angle
Axle Trail length
Tire pressure Front
(kg/cm_)
Rear
Turning
Left
angle
Right
Rear
Brake system
type
Front
Front
Suspension
type
Rear
Front
Shock
type
Rear
absorber
Frame type
Moving Device

Lubrication type
Oil pump type
Oil filter type

Power Drive System

Engine

2.5
Starting motor &
Starting system
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
7.2:1
Compression pressure
12.0
(kg/cm_)
Max. output (ps/rpm)
4.3/6000
Max. torque (kg m/rpm)
0.55/5500
Intake
Open Automatic controlled
Port (1mm) Close Automatic controlled
timin Exhaust Open
°–
g
(1mm) Close
°–
Valve clearance Intake
°–
(cold) (mm)
Exhaust
°–
Idle speed (rpm)
2000rpm
Min. turning radius (m)

Electrical

Ance

Fuel System

Name & Model No.
LA10AD
Motorcycle Name & Type
MX’er
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
140
Front wheel
73
Gross weight(kg) Rear wheel
77
Total
150
Front
wheel
20*7-8
Tires
Rear wheel
22*10-8
Ground clearance (mm)
130
Breaking distance
20.6 below
Perform
(m)(ANSI)

Sponge
8.1 liters
PB
80
f14
VALVE PISTON
CDI
22°/2000rpm
NGK
BR8HAS
0.6_ 0.7mm
12V4AH
CVT
Automatic centrifugal
Type
Chain drive
°–
°–
23.678
°–

°–
0.35
0.35
44°
44°
Disk brake
Drum brake
Swing
Swing arm
Swing
Swing arm
SP pipe

1. GENERAL INFORMATION

MX’er 50

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

n When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

n Use genuine parts and lubricants.

n When servicing the motorcycle, be sure to
use special tools for removal and
installation.

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

1-4

1. GENERAL INFORMATION
n Apply or add designated greases and
lubricants to the specified lubrication
points.

n After reassembly, check all parts for
proper tightening and operation.

n When two persons work together, pay
attention to the mutual working safety.

n Disconnect the battery negative (-) terminal
before operation.
n When using a spanner or other tools, make
sure not to damage the motorcycle surface.

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

1-5

MX’er 50

1. GENERAL INFORMATION
n If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.

MX’er 50

Confirm
Capacity

n After operation, terminal caps shall be
installed securely.

n When taking out the connector, the lock on
the connector shall be released before
operation.

n Hold the connector body when connecting
or disconnecting it.
n Do not pull the connector wire.

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

1-6

1. GENERAL INFORMATION
n The connector shall be inserted
completely.
n If the double connector has a lock, lock
it at the correct position.
n Check if there is any loose wire.

n Before connecting a terminal, check for
damaged terminal cover or loose negative
terminal.

n Check the double connector cover for
proper coverage and installation.

n Insert the terminal completely.
n Check the terminal cover for proper
coverage.
n Do not make the terminal cover opening
face up.

n 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.

1-7

MX’er 50

Snapping!

1. GENERAL INFORMATION

MX’er 50

n After clamping, check each wire to make
sure it is secure.

n Do not squeeze wires against the weld or
its clamp.

n After clamping, check each harness to make
sure that it is not interfering with any
moving or sliding parts.

n When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.

No Contact !

n Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
n Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.

1-8

1. GENERAL INFORMATION

MX’er 50

n Route harnesses so they are neither
pulled tight nor have excessive slack.
Do not pull too
tight!

n Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.

n When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed 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 tape
or replace it.

n When installing other parts, do not press or
squeeze the wires.

1-9

Do not press or
squeeze the wire.

1. GENERAL INFORMATION

MX’er 50

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

n 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.

n When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.

Do you understand
the instrument? Is
the instrument set
correctly?

n Be careful not to drop any parts.

n When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.

Remove Rust !

1-10

1. GENERAL INFORMATION
n Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.

Engine Oil

: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)

Engine Oil

Grease

: Apply grease for lubrication.

Special

: Use special tool.

°Ø


: Caution

: Warning

1-11

MX’er 50

1. GENERAL INFORMATION

MX’er 50

TORQUE VALUES
STANDARD TORQUE VALUES
Item
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
14mm bolt, nut

Torque (kgf-m)
0.45_ 0.6
0.8_ 1.2
1.8_ 2.5
3.0_ 4.0
5.0_ 6.0
6.0_ 8.0

Item
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut

Torque (kgf-m)
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
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 bolt
Spark plug

Q‘ty Thread dia.(mm) Torque (kgf-m)
4
BF7X115
1.5_ 1.7
1
39
5.0_ 6.0
1
12
3.5_ 4.0
1
NH10
3.5_ 4.0
1
10
3.5_ 4.0
1
8
1.0_ 1.5
2
NC6mm
1.0_ 1.4
2
BF8X35
3.0_ 3.6
1.1_ 1.7

Remarks

Q‘ty Thread dia.(mm) Torque (kgf-m)

Remarks

FRAME
Item
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_
4.0_
6.0_
6.0_
3.5_
3.5_
3.5_
6.0_
6.0_
11.0_
3.5_
3.5_
4.0_

8.0
5.0
8.0
8.0
4.5
4.5
4.5
8.0
8.0
13.0
4.5
4.5
5.0

1-12

1. SPECIFICATIONS

MX’er 50

SPECIAL TOOLS
Tool Name
Flywheel puller
Oil seal and bearing install
Universal holder
Clutch spring compressor
Bearing puller
Crankshaft install
Crankshaft & crankcase install
Crankcase puller
Crankshaft Bearing puller
Nut wrench
Float level gauge

Tool No.
E001
E014
E017
E034
E037
E016
E024
E026
E030
F010

Remarks Ref. Page

LUBRICATION POINTS
ENGINE
Lubrication Points
Crankcase sliding & movable parts
Cylinder movable parts
Transmission gear (final gear)
Kick starter spindle bushing
Drive pulley movable parts
Starter pinion movable parts

1-13

Lubricant
JASO-FC or API-TC
JASO-FC or API-TC
Gear oil: SAE90#
Grease
Grease
Grease

1. GENERAL INFORMATION

MX’er 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 avoid
abnormal noise and rise the durability of the motorcycle.
Rear Brake Cable

Front Brake Cable
Throttle Cable

Front Arm Bush

Steering Column Upper

Front Arm Bush
Front Brake
camshaft/Oil
Seal/O-ring
Front Brake
camshaft/Oil
Seal/O-ring

Front Wheel
Oil Seal
Steering Column Lower

Steering knuckle/Thrust
Cover/Bush/Collar

Front Wheel
Oil Seal

Steering knuckle/Thrust
Cover/Bush/Collar

1-14

1. SPECIFICATIONS

Swing arm Thrust
Cover

Rear Brake Cam/ Axle
Hub Collar/Oil
Seal/Bearing

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

1-15

MX’er 50

Driven Sprocket

1. GENERAL INFORMATION

MX’er 50

CABLE & HARNESS ROUTING
Rear Brake Cable
Throttle Cable

Front Brake Cable
Handlebar Switch Lead
A.C.G Wire
Starter Motor Wire
Auto Bystarter
Wire

Left Front Brake Cable
Right Front Brake Cable

1-16

1. SPECIFICATIONS

MX’er 50

Fuel Filter
Fuel Tube
Throttle Cable

Ignition Coil Wire
Oil Meter Wire

Left Front Brake Cable

Right Front Brake Cable
Rear Brake Cable

1-17

1. GENERAL INFORMATION

MX’er 50

Ignition Coil
Wire Harness

Rectifier/Regulator
Resistor

Oil Tube
Right Front Brake Cable

1-18

1. SPECIFICATIONS

MX’er 50

Main Switch

Rear Brake Cable
Breather Hose

Oil Meter Wire

Battery

Negative Cable

Positive Cable

Starter Relay
CDI Unit

1-19

Fuse

1. GENERAL INFORMATION

MX’er 50

WIRING DIAGRAM (ON ROAD)

1-20

1. SPECIFICATIONS
WIRING DIAGRAM (OFF ROAD)

1-21

MX’er 50

1. GENERAL INFORMATION

MX’er 50

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment

Probable Cause

Symptom

Check if fuel reaches
carburetor by
loosening drain screw.
Fuel reaches
carburetor

Fuel does not
reach carburetor

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground.
Spark jumps

Weak or no spark

Test cylinder
compression.

Å
Ç
É

Empty fuel tank
Clogged float valve
Clogged charcoal
canister
Ñ
Clogged fuel filter
Ö
Faulty auto fuel valve

Å
Ç
É
Ñ
Ö

Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Broken or shorted
ignition coil
Ü
Broken or shorted
exciter coil
áFaulty ignition switch
Å

Burned or worn
cylinder piston
Ç
Faulty reed valve
É
Blown cylinder head
gasket
Ñ
Leaking crankcase
Ö
Faulty crankcase oil
seal

Normal
compression

Low or no
compression

Engine does not
fire

Engine fires but
does not start

Dry spark plug

Wet spark plug

Å
Ç

Not clogged

Clogged

Å

Start engine by following normal starting
procedure.

Å

Incorrectly adjusted idle
speed
Ç
Air leaking through
intake pipe
É
Incorrect ignition
timing

Remove spark plug and
inspect again.

Wait for 30 minutes
and then remove the
carbu-retor auto choke
circuit hose and blow
the hose with mouth.

Flooded carburetor
Throttle valve
excessively open

Faulty auto bystarter

1-22

1. SPECIFICATIONS

MX’er 50

ENGINE STOPS IMMEDIATELY AFTER IT STARTS
Inspection/Adjustment

Symptom

Probable Cause

Check if fuel reaches
carburetor by
loosening drain screw.
Fuel reaches
carburetor

Fuel does not
reach carburetor

Å
Ç
É

Plug fouled or
discolored

Å
Ç

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground.
Plug not fouled or
discolored
Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground.
Good spark

Weak or intermittent spark

Test cylinder
compression (using a
compression gauge).

Empty fuel tank
Clogged float valve
Clogged charcoal
canister
Ñ
Clogged fuel filter
Ö
Faulty auto fuel valve

plug

Fouled spark plug
Incorrect heat range

Å
Ç
É
Ñ
Ö

Fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted high
tension wire
Ü
Faulty ignition switch
Å

Normal
compression

Abnormal
compression

Worn cylinder and
piston rings
Ç
Blown cylinder head
gasket
É
Flaws in cylinder head
Ñ
Faulty reed valve
Ö
Seized piston

Check carburetor for
clogging.
Not Clogged

Clogged

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

Å

Clogged carburetor jets

Check ignition timing.
Å

Faulty CDI unit or A.C.
generator
Ç
A.C.G. flywheel not
aligned

Check carburetor air
screw adjustment.

1-23

Å

Mixture too rich (turn
screw out)
Ç
Mixture too lean (turn
screw in)

1. GENERAL INFORMATION

Inspection/Adjustment

MX’er 50

Symptom

Probable Cause

Check carburetor
gasket for air leaks.
Å
No air leak

Air leaks

Not clogged

Clogged

Å
Ç
É

Broken cable
Dirty auto bystarter
Faulty auto bystarter

Clogged

Not Clogged

Å

Faulty auto bystarter

Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.

Connect auto bystarter
wire to battery. Wait
for 5 minutes, then
connect a hose to fuel
enriching circuit and
then blow the hose
with mouth.

Carburetor not securely
tightened
Ç
Faulty intake manifold
gasket
É
Deformed or broken
carburetor O-ring

1-24

1. SPECIFICATIONS

MX’er 50

ENGINE LACKS POWER
Inspection/Adjustment

Symptom

Probable Cause

Start engine and
accelerate lightly for
observation.
Engine speed
increases

Engine speed does
not increase
sufficiently

Å
Ç
É

Clogged air cleaner
Clogged fuel filter
Clogged exhaust
muffler
Ñ
Faulty auto bystarter
Ö
Faulty charcoal canister

Check ignition timing
(using a timing light).
Correct timing

Incorrect timing

Å
Ç

Faulty CDI unit
Faulty A.C. generator

Test cylinder
compression (using a
compression gauge)
Normal
compression

Abnormal
compression

Å

Worn cylinder and
piston rings
Ç
Blown cylinder head
gasket
É
Faulty reed valve

Check carburetor for
clogging
Not Clogged

Å

Clogged carburetor jets

Plug fouled or
discolored

Å
Ç

Fouled spark plug
Incorrect heat range

Engine overheats

Å
Ç
É

Clogged

Remove spark plug
and
inspect
Plug not fouled or
discolored

plug

Check if engine
overheats
Engine does not
overheats

Mixture too lean
Poor quality fuel
Excessive carbon buildup in combustion chamber
Ñ
Ignition timing too
early

Rapidly accelerate or
run at high speed
Å
Engine does not
knock

1-25

Engine knocks

Excessive carbon buildup in combustion chamber
Ç
Poor quality fuel
É
Clutch slipping
Ñ
Mixture too lean

1. GENERAL INFORMATION

MX’er 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing.

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

Å
Ç

Faulty CDI unit
Faulty A.C. generator

Check carburetor air
screw adjustment.
Å

Mixture too rich (turn
screw out)
Ç
Mixture too lean (turn
screw in)

Check carburetor
gasket for air leaks.
Å
No air leak

Air leaks

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground.

Carburetor not securely
tightened
Ç
Faulty intake manifold
gasket
É
Deformed carburetor
O-ring

Å
Good spark

Weak or intermittent spark

Not clogged

Clogged

Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.

Connect auto bystarter
wire to battery. Wait
for 5 minutes, then
connect a hose to fuel
enriching circuit and
then blow the hose
with mouth.

Ç
É
Ñ
Ö

Faulty or fouled spark

Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted high
tension wire
Ü
Faulty ignition switch

Å
Ç

Clogged

plug

wire

Broken auto bystarter
Faulty auto bystarter

Not clogged

1-26

1. SPECIFICATIONS

MX’er 50

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing.

Correct timing

Incorrect timing

Å
Faulty CDI unit
Ç Loose A.C.G. stator
É
Faulty A.C. generator

Check auto fuel valve
for fuel supply.
Fuel flows freely

Fuel flow
restricted

Å
Ç

Empty fuel tank
Clogged fuel tube or
filter
É
Clogged charcoal
canister

Check carburetor jets
for clogging.
Not clogged

Clogged

Å

Not clogged

Clogged

Å

Clean and unclog

Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.

Connect auto bystarter
wire to battery. Wait
for 5 minutes, then
connect a hose to fuel
enriching circuit and
then blow the hose
with mouth.

1-27

Ç

Clogged

Not clogged

Å

wire

Broken auto bystarter
Faulty auto bystarter

Faulty auto bystarter

1. GENERAL INFORMATION

MX’er 50

CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom

Engine starts but
motor-cycle does not
move

Probable Cause
Å
Ç
É
Ñ
Ö
Ü
á

Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel
rotates when engine
idles)

Å
Ç

splines

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

Broken shoe spring
Clutch outer and clutch weight

stuck
ÉSeized pivot

Engine lacks power at
start of a grade (poor
slope performance)

Å
Ç
É
Ñ
Ö

Worn or slipping drive belt
Worn weight rollers
Seized drive pulley bearings
Weak driven face spring
Worn or seized driven pulley
bearings

Engine lacks power at
high speed

Å
Ç
É

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

There is abnormal
noise
or smell while running

Å
Ç
É
Ñ

Oil or grease fouled drive belt
Worn drive belt
Weak driven face spring
Worn or seized driven pulley
bearings

1-28

1. SPECIFICATIONS

MX’er 50

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
Symptom

Probable Cause
(Front and rear tire pressures are normal)

Steering is heavy

Å
Ç

Steering stem nut too tight
Broken steering steel balls

Front or rear wheel is
wobbling

Å
Ç
É

Excessive wheel bearing play
Bent rim
Loose axle nut

Steering handlebar pulls
to one side

Å
Ç

Misaligned front and rear wheels
Bent front fork

POOR SUSPENSION PERFORMANCE
Symptom

Probable Cause
(Front and rear tire pressures are normal)

1-29

Suspension is too soft

Å
Ç
É

Weak shock spring
Excessive load
Shock damper oil leaking

Suspension is too hard

Å
Ç

Bent fork tube or shock rod
Fork slider and tube binding

Suspension is noisy

Å
Ç

Fork tube and spring binding
Fork slider and tube binding

1. GENERAL INFORMATION

MX’er 50

POOR BRAKE PERFORMANCE

Symptom

Probable Cause
(Adjust brake according to standards)

Index mark on brake
panel aligns with wear
indicator arrow

Worn brake linings
Worn brake cam contacting area

Å
Ç
É

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

on
brake shoes
É
Worn brake cam
Ñ
Worn brake drum

Brake squeaks

Brake performance is
poor

Å
Ç

Expanding
Brake

Hydraulic
Brake

Å
Ç

Sluggish or elongated brake cables
Brake shoes improperly contact
brake drum
É
Water and mud in brake system
Ñ
Oil or grease on brake linings
Å
Ç
É
Ñ
Ö

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

1-30

1. SPECIFICATIONS

MX’er 50

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

Symptom

Probable Cause

Check battery circuit
by operating turn
signals.
Signals operate
properly
Connect indicator
light bulb to battery
for bulb inspection.

Signals dim, remain
on or don‘t
operate

Å
Ç
É
Ñ

Burned out fuse
Weak or dead battery
Faulty ignition switch
Loose or disconnected
connector
Ö Broken wire harness

Bulb lights

Bulb does not light

Good

Faulty

Å
Ç
É

Good

Faulty

Å
Ç

ÅBurned out bulb

Check connectors for
proper operation.

Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on

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)
Inspection/Adjustment

Symptom

Probable Cause

Check connectors for
proper connection.

1-31

Loose or disconnected

Good

Faulty

connector
Ç Broken wire harness
É Incorrectly connected
wire

Good

Faulty

Å
Ç

Faulty float
Broken or shorted wire
in meter

Å
Ç

Damaged oil tank
Foreign matters in oil
tank

Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on

Å

1. GENERAL INFORMATION

MX’er 50

FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Inspection/Adjustment

Symptom

Probable Cause

Check battery circuit
by operating turn
signals.
Remove fuel unit and
check operation of
pointer by moving
float up and down.
Check operation of
pointer by opening
and shorting fuel unit
terminal on wire
harness side.

Signals operate
properly

Signals dim, remain
on or don‘t
operate

Å
Ç
É
Ñ

Burned out fuse
Weak or dead battery
Faulty ignition switch
Loose or disconnected
connector
Ö Broken wire harness

Pointer does not
move

Pointer moves

Å

Pointer does not
move

Pointer moves

Å

Faulty float

Broken or shorted fuel
unit wire

Check connectors for
proper connection.
Faulty

Good

Å
Ç

Loose or disconnected

connector

Incorrectly connected
connector
Å Broken or shorted wire
in fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON)
Inspection/Adjustment

Symptom

Probable Cause

Check battery circuit
by operating turn
signals and horn.

Remove fuel unit and
check operation of
pointer by moving
float up and down.

Signals operate
properly

Pointer moves
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer.

Pointer moves in
accordance with
float

Signals dim, remain
on or don‘t
operate

Pointer does not
move

Pointer does not
move in accordance with float

Å
Ç
É
Ñ

Burned out fuse
Weak or dead battery
Faulty ignition switch
Loose or disconnected
connector
Ö Broken wire harness
Å

Poor contact in fuel
unit

Å

Insufficient damping oil
in fuel gauge

Check connectors for
proper connection.
Good

Faulty

Å

Loose or disconnected
connector
Å Broken or shorted wire
in fuel gauge

1-32

1. SPECIFICATIONS

MX’er 50

STARTER MOTOR
1. Starter motor won‘t turn
Symptom

Inspection/Adjustment

Probable Cause

Check operation of
stop switch by
applying brake.
Check battery
circuit by operating
turn signals.
Check operation of
starter relay by
depressing starter
button.

Stoplight comes
on

Stoplight does not
come on

Signals operate
properly

Signals dim, remain
on or don‘t
operate

Å
Ç
É
Ñ

Burned out fuse
Weak or dead battery
Faulty stop switch
Loose or disconnected
connector
Ö
Broken or shorted
ignition switch wire
Å

Faulty or weak battery

Relay operates
properly

Relay does not
operate

Å

Starter motor
turns

Starter does not
turn

Å

Faulty starter motor

Å

Faulty wire harness

Connect starter
motor directly to
battery.

Poor starter button
connection
Ç
Faulty starter relay
É
Loose or disconnected
connector

2. Starter motor turns slowly or idles
Symptom

Inspection/Adjustment

Probable Cause

Check battery
circuit by operating
turn signals.
Connect starter
motor directly to
battery.

Signals operate
properly

Signals dim, remain
on or don‘t
operate

Starter motor
turns slowly

Starter motor
turns normally

Å

Turns easily

Hard to turn

Å
Å

Å

Weak or dead battery

Loose or disconnected
connector
Ç
Faulty starter relay

Rotate crankshaft.

3. Starter motor does not stop turning

Seized cylinder
Broken or shorted
starter motor cable
Ç
Faulty starter pinion

Symptom

Inspection/Adjustment

Probable Cause

Turn ignition switch
OFF.
Not stopped

Stopped

Å
Å

1-33

Faulty starter pinion
Starter relay shorted or
stuck
closed


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