KYMCO Maxxer User Manual
Front and rear brakes
The front and rear brakes are operated by
squeezing the front brake lever.
(1)
(1) Front brake lever
Brake pedal (MAXXER 90)
The both front and rear brakes are operated at
the same time by depressing the brake pedal.
(1)
(1) Rear brake pedal
31
WARNING
POTENTIAL HAZARD
Improper use of the parking brake.
WHAT CAN HAPPEN
The ATV could start moving unexpectedly
if the parking brake is not applied before
starting the engine. This could cause loss
of control or a collision.
The brake could overheat if you ride the
ATV without releasing the parking brake.
You could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
HOW TO AVOID THE HAZARD
Always set the parking brake before
starting the engine.
Always be sure you have released the
parking brake before you begin to ride.
Fuel tank cap
After refueling, be sure to tighten the fuel tank
cap.
TO refuel refer to page 42~43.
(1)
(1) Fuel tank cap
34
RES
OFF
ON
Fuel valve
The fuel valve supplies fuel from the fuel tank to
the carburetor.
The fuel valve has three positions.
OFF:
With the lever and " " mark in this
position fuel will not flow. Always turn the
lever to this position when the engine is
not running.
ON :
With the lever in this position,
fuel flows to the carburetor. Normal riding
is done with the lever in this position.
RES:
This indicates reserve. If you run out of
fuel while riding, turn the lever
to this position. THEN FILL THE FUEL
TANK AT THE FIRST OPPORTUNITY.
After refueling, return the fuel valve lever
to the "ON" position.
" " mark
" " mark
(2)
(1)
(1) Fuel lever (2) " " mark
NOTE:
After refueling, do not operate the ATV with the
fuel valve in the RES position. If you run out of
fuel, there will be no reserve supply.
35
Locking steering
Turn the steering handlebar left to full and turn
the key clockwise, the steering handlebar is
locked.
The key can be taken out.
Turn the key counterclockwise, the steering
handlebar is released automatically.
The key can be taken out.
(MAXXER 90)
LockingLocking
UnlockingUnlocking
WARNING
POTENTIAL HAZARD
Improper use of the locking steering.
WHAT CAN HAPPEN
The ATV could cause loss of control or
overturn.
HOW TO AVOID THE HAZARD
Always be sure you have released the
locking steering handlebar before you
begin to ride.
Never lock the steering handlebar, when
the engine is starting.
36
Starter (choke) ( 90)
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction (A) to turn on the starter
(choke).
Move in direction (B) to turn off the starter
(choke).
Refer to "starting a cold engine" for proper
operation. (See page 50.)
(A)(A)
(1)(1)
(1) Fully open (2) Half open
(3) Closed (A) Starter (choke)
MAXXER
(3)(3)
(2)(2)
(B)(B)
(B)
CAUTION:
‧Extended use of the choke may impair piston
and cylinder wall lubrication and shorten the
life of the engine.
‧Pushing the choke knob too hard to the OFF
position may dislodge the choke cable boot. If
this happens, water and dirt may enter the
choke cable and cause corrosion. If the choke
is hard to actuate, or feels like it is sticking,
Check the cable boot
37
Seat
To remove the seat, pull upward the seat lock
lever and pull up the seat the rear.
(1)
(1)
(1) Seat lock lever
To install the seat, align the tabs on the seat with
the grommets on the frame and press the seat
down until it locks.
NOTE:
Make sure that the seat is securely fitted.
38
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM
Brake
Fuel
Engine oil and
Transmission oil
Drive chain
Throttle
Wheels and tires
Fittings and fasteners
Switches
Lights
ROUTINE
‧Check operation, condition,
free play (drum brake) and
brake fluid level (disk brake).
‧Adjust (drum brake) if necessary.
‧Fill with DOT 4 brake fluid (disk brake)
if necessary.
‧Check fuel level.
‧Fill with fuel if necessary.
‧Check oil level.
‧Fill with oil if necessary.
‧Check chain slack and condition.
‧Adjust if necessary.
‧Check for proper throttle cable operation.
‧Check tire pressure, wear and damage.
‧Check all fitting and fasteners.
‧Check for proper function.
‧Check for proper operation.
PAGE
41～42, 110～117
42～43
44~45, 95～101
46, 118～120
46
47～49, 122
46
46
46
40
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibillty of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and
maintenance procedures and schedules
described in the Owner's Manual.
Front and rear brakes
1.
Drum brake
Check for correct free play in the brake levers.
If the free play is incorrect, adjust it. (See
pages 110~117.)
Check operation of the levers. They should
move smoothly and there should be a firm
feeling when the brake is applied. If not, have
the machine inspected by a KYMCO dealer.
Disk brake
2.
Make sure there is no brake fluid leakage.
Check operation of the levers. They should
move smoothly and there should be a firm
feeling when the brake is applied. If not, have
the machine inspected by a KYMCO dealer.
Brake operation
3.
Test the brakes at slow speed after starting
out to make sure they are working properly. If
the brakes do not provide proper braking
performance, inspect the brakes for wear.
(See page 110.)
41
WARNING
POTENTIAL HAZARD
Riding with improperly operating brakes.
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of
every ride. Do not ride the ATV if you find
any problem with the brakes. If a problem
cannot be corrected by the adjustment
procedures provided in this manual, have
the ATV inspected by a KYMCO dealer.
Fuel
Fill the fuel tank when necessary and make sure
there is sufficient gasoline in the tank.
Check for leaks.
Fuel level should be below the filler neck.
(1)
(1) Filler neck
Recommended fuel:
UNLEADED FUEL
Fuel tank capacity:
Total: 5.5L(1.16 lmp gal, 1.4 US gal)
Reserve: 1.5L(0.32 lmp gal, 0.38 US gal)
42
Your KYMCO engine has been designed to use
regular unleaded gasoline with a pump octane
number of 86 or higher, or research octane
number of 91 or higher. If knocking or pinging
occurs, use a different brand of gasoline or
premium unleaded fuel. Unleaded fuel will give
you longer spark plug life and reduced
maintenance cost.
Use unleaded fuel only because it produces
fewer engine and spark plug deposits and
extends the life of the exhaust system. Never
use stale or contaminated gasoline or an
oil/gasoline mixture.
Avoid getting dirt, dust or water in the fuel tank.
WARNING
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and
severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not
to spill fuel, especially on the engine or
exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely.
Do not refuel right after the engine has
been running and is still very hot.
43
Engine ( 90)and transmission oil
MAXXER
Make sure the engine and transmission oil at the
specified level. Add oil as necessary. (See page
95~101.)
Check for leaks.
1 0
0
30
0
50
0
70
0
90
0
0
110 F
SAE 5W
SAE 10W－30
CAUTION:
Be sure to use motor oils that do not
contain anti-friction modifiers. Passenger
car motor oils (often labeled "Energy
Conserving") contain anti-friction
additives which will cause starter clutch
slippage, resulting in reduced component
life and poor engine performance.
SAE 10W－40
SAE 20W－40
SAE 20W－50
-1 0
0
0
0
10
0
20
0
30
0
0
40 C
Recommended engine/transmission oil
classification: API Service SE, SF, SG type or
higher
Oil quantity:
Engine oil:
Periodic oil change:
0.7 L (0.62 lmp qt, 0.74 US qt)
Total amount:
0.8 L (0.70 lmp qt, 0.84 US qt)
Transmission oil:
Periodic oil change:
0.11 L (0.10 lmp qt, 0.12 US qt)
Total amount:
0.12 L (0.11 lmp qt, 0.13 US qt)
44
Engine oil ( 50)
Oil level
When the low oil level indicator lights, it means
the oil level in the oil tank is low; stop the engine
and fill the oil tank as soon as possible.
MAXXER
(1)
CAUTION:
．If the low oil level indicator comes on while
riding, stop riding and shut the engine off. Fill
the oil tank to the upper level mark with the
recommended oil. Continuing to ride with a
low oil level may lead to engine failure that
could result in an accident.
．if the engine has been run after the low oil
level indicator has come on, the scooter must
be taken to an authorized KYMCO dealer for
inspection and bleeding of the oil system.
Failure to do this will result in serious engine
damage.
To fill, lift seat (see page 38), remove the cap
from the oil tank, and fill with the recommended
oil up to the upper level mark.
NOTE:
When filling, do not let dirt or other foreign
materials enter the tank.
(2)
(3)
(1) Cap (2) Upper level mark (3) Fill duct
Oil recommendation :
Use KYMCO 2-STROKE OIL OR ITS
EQUIVALENT
CAUTION:
The use of improper oils may cause excessive
and/or premature carbon build-up in the engine
and exhaust system, resulting in loss lf power
and possible engine damage. Genuine KYMCO
2-Stroke Oil has been specifically designed
and tested in KYMCO ATV and is a proper oil.
45
Chain
Check the general condition of the chain and
check the chain slack before every ride.
Lubricate and adjust the chain as necessary.
(See pages 118~120 for details.)
Lights
Check the position light and taillight/stop light to
make sure they are in working condition. Repair
as necessary for proper operation.
Throttle lever
Check to see that the throttle lever operates
correctly. It must open smoothly and spring back
to idle position when released. Repair as
necessary for proper operation.
Fittings and fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Take the machine to
a KYMCO dealer or refer to the Service Manual
for correct tightening torque.
Switches
Check the operation of the
switch, engine stop switch, remote engine stop
switch and any other switches.
Repair as necessary for proper operation.
46
taillight/stop light
Tires
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or
operation of this ATV with improper or
uneven tire pressure, may cause loss of
control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
1.The tires listed below have been
approved by Kwang Yang Motor Co., Ltd.
for this model. Other tire combinations
are not recommended.
2.The tires should be set to the
recommended pressure:
‧Recommended tire pressure
Front: 25 kpa (0.25 kgf/cm , 3.6 psi)
Rear: 25 kpa (0.25 kgf/cm , 3.6 psi)
2
2
‧Check and adjust tire pressures when the
tires are cold.
‧Tire pressures must be equal on both
sides.
3.Tire pressure below the minimum
specified could cause the tire to dislodge
from the rim under severe riding
conditions.
The following are minimums:
Front: 22 kpa (0.22 kgf/cm , 3.2 psi)
Rear: 22 kpa (0.22 kgf/cm , 3.2 psi)
2
2
Front
Rear
MAXXER 5 0
16*8-7
16*8-7
Size
MAXXER 9 0
18*7-8
18*9-8
Type
TUBELESS
TUBELESS
47
4.Never set tire pressure over the
recommended
Front: 28 kpa (0.28 kgf/cm , 40 psi)
Rear: 28 kpa (0.28 kgf/cm , 40 psi)
2
2
Higher pressures may cause the tire to
burst. Inflate the tires very slowly and
carefully. Fast inflation could cause the
tire to burst.
How to measure tire pressure
Use the low-pressure tire gauge.
NOTE:
The low-pressure tire gauge is included as
standard equipment. Make two
measurements of the tire pressure and use
the second reading. Dust or dirt in the gauge
could cause the first reading to be incorrect.
Set pressure tires cold.
Set tire pressures to the following
Front
Rear
Recommended
pressure
25 kpa
(0.25 kgf/cm ,
3.6 psi)
25 kpa
(0.25 kgf/cm ,
3.6 psi)
2
(0.22 kgf/cm ,
2
(0.22 kgf/cm ,
Minimum
22 kpa
3.2 psi)
22 kpa
3.2 psi)
(1) Low-pressure tire gauge
2
(0.28 kgf/cm ,
2
(0.28 kgf/cm ,
Maximum
28 kpa
4.0 psi)
28 kpa
4.0 psi)
2
2
48
Tire wear limit
When the tire groove decreases to 3 mm (0.12
in) due to wear, replace the tire.
A. 3mm (0.12 in)
49
OPERATION
Starting a cold engine ( 90 )MAXXER
WARNINGWARNING
POTENTIAL HAZARD
Operating ATV without being familiar with
all controls.
WHAT CAN HAPPEN
Loss of control, which could cause an
accident or injury.
HOW TO AVOID THE HAZARD
Read the Owner's Manual carefully. If there
is a control or function you do not
understand, ask your KYMCO dealer.
POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always make
sure all control cables work smoothly
before you begin riding.
1. Select a level surface and lock the parking
brake (see page 32 or 33) before starting the
engine.
2. Turn the fuel lock to "ON".
3. Turn the main switch to "．" and the engine
stop switch to " ".
4. Make sure the tethered road lead
into the
50
remote engine stop switch.
is installed
5. Use the starter (choke) in reference to the
figure:
Position :Cold engine start-ambient
temperature below 5C (40F).
Position :Cold engine start-ambient
temperature at 0C (30F)~30C(90F)
and warming up position.
Position :Cold engine start-ambient
temperature above 25C(80F) and
warm engine start position.
1. Fully open
3. Closed
2. Half open
a. Starter (choke)
6.With the throttle closed, push the starter
button. Release the starter button as soon as
the engine starts.
NOTE:
Do not use the electric starter for more than 5
seconds at a time. Release the starter button
for approximately 10 seconds before pressing
it again.
7. If the engine is started with the starter
(choke) in position , the starter (choke)
should be returned to position to warm up
the engine. If the engine is started with the
starter (choke) in position , keep the starter
(choke) in this position to warm up the
engine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to
position before riding.
CAUTION:
See the "engine break-in section prior to
operating engine for the first time.
51
To start the engine without the electric starter.
1. Follow steps 1 through 5.
2. With the throttle closed, operate the kick
starter with a rapid, continuous motion.
Starting a warm engine (MAXXER 90)
To start a warm engine, refer to the "Starting a
cold engine" section. The starter (choke) should
not be used. The throttle should be opened
slightly.
CAUTION:
．Do not allow the kick starter to snap back
freely against the pedal stop as engine case
damage could result.
．Raise the kick starter pedal after the kick
starter lever is returned to the stop.
3. Follow steps 7 through 8.
Warming up (MAXXER 90)
To get maximum engine life, always warm up the
engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, check if it responds to the
throttle normally with the starter (choke) turned
off.
CAUTION:
．Do not operate the throttle (open and close
rapidly) as the ATV will move forward
suddenly, causing possible loss of control.
．Do not leave the ATV unattended while the
engine is warming up
52
Starting engine ( 50)MAXXER
WARNING
POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always make
sure all control cables work smoothly
before you begin riding.
1. Select a level surface and lock the parking
brake ( ) before starting the
engine.
2. Turn the fuel lock to "ON".
3. Turn the main switch to "．" and the engine
stop switch to " ".
4. Make sure the tethered road lead
into the
see page 32 or 33
is installed
remote engine stop switch.
5.With the throttle closed, push the starter
button. Release the starter button as soon as
the engine starts.
NOTE:
Do not use the electric starter for more than 5
seconds at a time. Release the starter button
for approximately 10 seconds before pressing
it again.
6. Be sure to keep the throttle closed and the
parking brake locked while starting and
warming up the engine.
7. Allow the engine warm up before riding.
CAUTION:
．Do not operate the throttle (open and close
rapidly) as the ATV will move forward
suddenly, causing possible loss of control.
．Do not leave the ATV unattended while the
engine is warming up
53
To start the engine without the electric starter.
1. Follow steps 1 through 4.
2. With the throttle closed, operate the kick
starter with a rapid, continuous motion.
CAUTION:
．Do not allow the kick starter to snap back
freely against the pedal stop as engine case
damage could result.
．Raise the kick starter pedal after the kick
starter lever is returned to the stop.
3. Follow steps 6 through 7.
If you cannot restart a warm engine:
1. Follow steps 1 through 4.
2. Open the throttle slightly (1/8－1/4) while
starting the engine . If the throttle limiter Is
adjusted as delivered, open the throttle fully.
Engine break-in
There is never a more important period in the life
of your machine than the period between zero
and 20 hours.
For this reason, we ask that you carefully read
the following material. Because the engine is
brand new, you must not put an excessive load
on it for the first 20 hours, the various parts in
the engine wear and polish themselves to the
correct operating clearances.
During this period, prolonged full throttle
operation or any condition which might result in
excessive engine heating must be avoided.
However, momentary (2~3 seconds maximum)
full throttle operation under load does not harm
the engine.
Each full throttle acceleration sequence should
be followed with a substantial rest period for the
engine by cruising at lower r/min so the engine
can rid itself of the temporary build up of heat.
If any abnormality is noticed during this period,
consult a KYMCO dealer.
54
1. 0~10 hours:
Avoid continuous operation above half
throttle. Allow a cooling off period of five to ten
minutes after every hour of operation. Vary
the speed of the machine from time to time.
Do not operate it at full throttle position.
2. 10~20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely through the gears but
do not use full throttle at any time.
3. After break-in
Avoid prolonged full throttle operation. Vary
speeds occasionally.
55
Parking ( 50)
When parking, stop the engine. Turn the fuel
lock to "OFF" and apply the parking brake.
MAXXER
Parking ( 90)
When parking, stop the engine. Turn the fuel
lock to "OFF" and apply the parking brake.
MAXXER
Make sure the lock plate into the locked
position.
To set the parking brake, see page 32.
(1)
(1)Locked position
Make sure the lock pin into the locked position.
To set the parking brake, see page 33.
(1)
(1)Locked position
56
Parking on a slope
WARNING
POTENTIAL HAZARD
Parking on a slope or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, increasing
the chance of an accident.
HOW TO AVOID THE HAZARD
Avoid parking on slope or other inclines. If
you must park on an incline, place the
machine transversely across the incline,
apply the parking brake, and block the front
and rear wheels with rocks or other objects.
Do not park the ATV at all on slope that are
so steep you could not walk up them easily.
1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the brake applied, apply the parking
brake.
57
Accessories
Accessories can affect the handling and control
of your ATV. Keep the following in mind when
considering an accessory or operating an ATV
which has accessories.
‧Choose only accessories designed for your
ATV. Your KYMCO dealer has a variety of
genuine KYMCO accessories. Other
accessories may also be available on the
market. However, it is not possible for KYMCO
to test all non-KYMCO accessories, nor have
any control over the quality or suitability of
them. Choose a genuine KYMCO accessory,
or one that is equivalent in design and quality.
‧Accessories should be rigidly and securely
mounted. An accessory which can shift
position or come off while you are riding could
affect your ability to control the ATV.
‧Do not mount an accessory where it could
interfere with your ability your to control the
ATV. Examples include (but are not limited to)
a heavy or bulky object attached to the
handlebars which could make steering
difficult, an accessory that limits your ability to
move around on the seat, or one that limits
your view.
‧Use extra caution when riding an ATV with
accessories. The ATV may handle differently
58
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