. GENERAL INFORMATION MX’er 50 1 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION _________________________________
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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.
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.
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.
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. 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.
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.
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.
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.
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.
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.
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.
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.
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1. GENERAL INFORMATION MX’er 50 CABLE & HARNESS ROUTING Rear Brake Cable Throttle Cable Front Brake Cable Handlebar Switch Lead A.C.
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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.
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.
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.
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.
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.
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.
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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.
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.
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.
