KYMCO Maxxer User Manual

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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

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

RES

OFF

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

(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.

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.

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

Seat

To remove the seat, pull upward the seat lock lever and pull up the seat the rear.

(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.

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

47～49, 122

46 46

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

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.)

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)

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.

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

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

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)

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.

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.

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)

‧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)

Front

Rear

MAXXER 5 0

16*8-7

Size

MAXXER 9 0

18*7-8

18*9-8

Type

TUBELESS

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)

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)

(0.22 kgf/cm ,

Minimum

22 kpa

3.2 psi)

22 kpa

3.2 psi)

(1) Low-pressure tire gauge

(0.28 kgf/cm ,

Maximum

28 kpa

4.0 psi)

28 kpa

4.0 psi)

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)

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

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.

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

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

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.

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.

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

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.

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

WARNING

Indicates a potential hazard that could result in serious injury or death.

GETTING TO KNOW YOUR ATV

This ATV is for recreation and utility use. This section, riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.

Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owner's manual.

Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 4~8. Please also read all caution and warning labels on your ATV.

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.

Beginners and inexperienced riders should get proper instruction on how to operate this ATV.

WARNING

POTENTIAL HAZARD Operating this ATV without proper

instruction.

HOW TO AVOID THE HAZARD Become familiar with this ATV at slow

speeds first, even if you are an experienced operator.

Do not attempt to operate at maximum performance until you are totally familiar with the machine's handling and performance characteristics.

WHAT CAN HAPPEN The risk of an accident is greatly increased

if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

Riding your machine requires skills acquired through practice over a period of time.

Take the time to learn the basic techniques well before attempting more difficult maneuvers.

Age Recommendation (MAXXER 50)

The minimum recommended age for this ATV model is 6. For safety, never let children under 6 years old operate this vehicle. Children under 16 should be supervised by an adult.

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. Failure to supervise children under 16 on ATV models intended for their use.

HOW TO AVOID THE HAZARD A child under 6 should never operate this ATV. Never allow a child under 16 to operate an ATV without adult supervision and never allow continued use of t e ATV by a child If he or she does not have the abilities to operate it safely.

WHAT CAN HAPPEN If children use ATVs that are not recommended for their age, severe injury or death can result. Even though a child may be within the age group for which an ATV is recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.

UNDER

Age Recommendation (MAXXER 90)

The minimum recommended age for this ATV model is 12. For safety, never let children under 12 years old operate this vehicle. Children under 16 should be supervised by an adult.

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. Failure to supervise children under 16 on ATV models intended for their use.

HOW TO AVOID THE HAZARD A child under 12 should never operate this ATV. Never allow a child under 16 to operate an ATV without adult supervision and never allow continued use of t e ATV by a child If he or she does not have the abilities to operate it safely.

UNDER

Apparel

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.

WHAT CAN HAPPEN

Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident.

Operating without eye protection can result in an accident and

increases your chances of a severe injury in the event of an accident.

Operating without protective clothing increases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle helmet that fits properly.

You should also wear:

eye protection(goggles or face shield)

gloves

boots

long-sleeved shirt or jacket

Long pants

Do not operate after consuming alcohol or drugs.

Operator's performance capability is reduced by the influence of alcohol or drugs.

WARNING

POTENTIAL HAZARD Operating this ATV after consuming

alcohol or drugs.

WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or

while driving this ATV.

Pre-operation checks

Always perform the pre-operation checks listed on page 40 before riding for safety and proper care of the machine.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV.

WHAT CAN HAPPEN Increases the possibility of an accident or

equipment damage.

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 an accident.

HOW TO AVOID THE HAZARD Always inspect tour 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.

HOW TO AVOID THE HAZARD Always use the size and type tires specified

in the Owner's Manual for this vehicle on pages47~48.

Always maintain proper tire pressure as described in the Owner's Manual on page47.

Do not operate at speeds too fast your skills or the conditions.

WARNING

POTENTIAL HAZARD Operating this ATV at speeds too fast for

your skills or the conditions.

WHAT CAN HAPPEN Increases your chances of losing control of

the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD Always go at a speed that is proper for the

terrain, visibility and operating conditions, and your experience.

Speed limiter For riders inexperienced with this model, this

model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the machine.

Turning the screw in decreases top speed, and turning it out increases top speed.

(2)

(1)

1. Adjuster

2. Locknut

Loading and accessories

Use extra caution when riding the machine with additional loads, such as accessories or cargo.

The machine's handling may be adversely affected. Reduce your speed when adding additional loads.

Loading and Operational Guidelines

Carrying cargo will affect how your ATV handles and greatly reduce its ability in accelerating, braking and making turns and other maneuvers.

Be sure to observe the weight limits and follow these guidelines:

1. Do not tow another vehicle.

2. Make sure all cargo is secured before riding.

3. Allow extra room for starting, stopping and

turning whenever you carry cargo or pull a trailer.

4. Avoid riding on steep slopes when carrying

cargo or pilling a trailer.

5. Never cross a slope when toeing a trailer.

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing

cargo improperly.

WHAT CAN HAPPEN Could cause changes in vehicle handling,

stability and braking which could lead to an accident.

HOW TO AVOID THE HAZARD Never exceed the stated load capacity for

this ATV. Cargo should be properly distributed and

securely attached. Reduce speed when carrying cargo or

pulling a trailer. Allow greater distance for braking.

Always follow the instructions in your Owner's Manual for carrying cargo or pulling a trailer.

Accessories

Genuine KYMCO accessories have been specifically designed for and tested on this vehicle. Because KYMCO cannot test all other accessories, you are personally responsible for properly selecting, installing, and using nonKYMCO accessories. Always follow the loading instructions above, plus the following:

1. Carefully inspect the accessory to make sure

it does not block any lights, reduce ground clearance, or limit suspension travel, steering travel, or other controls.

2. Make sure the accessory does not interfere

with your ability to shift body position on the seat or operate hand and foot controls.

3. Do not add electrical equipment that will

exceed the vehicle's electrical system capacity. A blown fuse could cause a loss of lights or engine power.

Modifications

WARNING

POTENTIAL HAZARD Operating this ATV with improper

modifications.

WHAT CAN HAPPEN Improper installation of accessories or

modification of this vehicle may cause changes in handling which in some situations could lead to an accident.

HOW TO AVOID THE HAZARD Never modify this ATV through improper

installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction. If you have question, consult an authorized ATV dealer.

No Modifications

Modifying this ATV or removing original equipment may render the vehicle unsafe or illegal. Spark arresters and mufflers are required in most areas. Don't modify your exhaust system or emission control system components. Remember, excessive noise bothers everyone and creates a bad image for ATV.

RIDING

Select a flat area to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting before trying more difficult terrain.

Always avoid riding on rough surfaces: the ATV is designed for on-road use only, and handling maneuvers are more difficult to perform on level surfaces.

Set the parking brake and follow the instruction on page 50~54 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.

WARNING

POTENTIAL HAZARD Starting or running the engine in a closed

area.

WHAT CAN HAPPEN Exhaust fumes are poisonous and may

cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD Always operate your machine in an area

with adequate ventilation.

Practice with the remote engine stop switch and throttle limiter adjusted as delivered until you are confident in braking and making turns.

Speed limiter for new riders

Your ATV has an adjustable throttle limiter. The screw and locknut in the lower throttle

housing can be adjusted to limit throttle lever movement.

To adjust the throttle limiter:

1. Loosen the lock nut.

2. Turn the throttle limiter screw clockwise to reduce throttle lever movement or counterclockwise to increase throttle lever movement.

3. Hole the screw in place and tighten the lock nut.

1. Adjuster

(2)

(1)

2. Locknut

BRAKING

Practice starting and stopping at slow speeds. Gradually work up to faster starts and stops.

1. Steer straight ahead. Close the throttle completely, remove your thumb from the throttle lever.

2. Gently apply the brakes: pull both hand levers.

Gradually increase the lever or/and pedal pressure as you feel the brakes slowing your speed. The pressure used depends on your speed and the condition of the terrain you are riding. Slick , slippery or muddy ground requires gentler braking.

Pulling one or both brake levers or/and depressing brake pedal too hard may cause the front and/or rear wheels to skid or slide out of control. If this happens, release all pressure on the lever(s) immediately. Steer straight ahead to regain control. Then gently reapply the brakes.

Independent use of only the front or rear brakes reduces stopping performance. Extreme braking may cause the wheels to lock, reducing control of the ATV

When possible, reduce speed or brake before entering a turn. Closing the throttle or braking in mid-turn may cause wheel slippage which will reduce control of your ATV.

CLIMBING UP SLOPE

Use proper riding techniques to avoid vehicle overturns on slopes. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.

WARNING

POTENTIAL HAZARD Operating on excessively steep slopes.

WHAT CAN HAPPEN The vehicle can overturn more easily on

extremely steep slopes than on level surfaces or small slopes.

HOW TO AVOID THE HAZARD Never operate the ATV on slopes too steep

for the ATV or for your abilities. Practice on smaller slopes before

attempting large slopes.

It is important when climbing a slope to make sure that tour weight is transferred forward on the ATV. This can be accomplished by leaning forward, steeper inclines and standing on the footboards and leaning forward over the handlebars.

If your ATV has stalled or stopped and you believe you can continue up the slope, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the slope, dismount the ATV on up slope side. Physically turn the ATV around and then descend the slope.

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly

dismounting while climbing a slope.

WHAT CAN HAPPEN Could result in ATV overturning.

If you start to roll backwards, DO NOT use the rear brake to stop. The ATV could easily tip over backwards. Instead, dismount the ATV immediately on the up of slope side.

HOW TO AVOID THE HAZARD Maintain steady speed when climbing a

slope.

If you lose all forward speed: Keep weight up slope. Apply the brakes. Lock parking brake, after you are stopped.

If you begin rolling backwards: Keep weight up slope. Never apply the rear brake while rolling

backwards.

RIDING DOWN SLOPE

When riding your ATV down slope, shift your weight as far to the rear and up slope side of the ATV as possible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction.

Use caution while descending a slope with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces.

Improper braking may also cause a loss of traction. Whenever possible, ride your ATV straight down slope. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear.

WARNING

POTENTIAL HAZARD Going down a slope improperly.

WHAT CAN HAPPEN Could cause loss of control or cause the

ATV to overturn.

HOW TO AVOID THE HAZARD Always follow proper procedures for going

down slopes as described in this Owner's Manual. Note: a special technique is required when braking as you go down a slope.

Always check the terrain carefully before you start down any slope.

Shift your weight backward. Never go down a slope at high speed. Avoid going down a slope at an angle that

would cause the vehicle to lean sharply to one side. Go straight down the slope where possible.

WHAT TO DO IF

This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely.

WHAT TO DO....

If your ATV doesn't turn when you want it to: Bring the ATV to a stop and practice the turning

maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 79.)

If your ATV can't make it up a slope you are trying to climb:

Turn the ATV around if you still have forward speed. If not, stop, dismount on the up slope side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE - the ATV may tip over on top of you. Dismount the ATV on the up slope side. (See pages 80~85.)

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.

WARNING

POTENTIAL HAZARD Servicing an engine while it is running.

WHAT CAN HAPPEN Moving parts can catch clothing or parts of

the body, causing injury. Electrical components can cause shocks or

can start fires.

Have KYMCO dealer perform service if you are not familiar with machine service.

Tool kit

A tool kit is provide with your ATV. You are recommended to put the tool kit in the

vinyl bag and always carry them on the seat reverse side.

(1)

(2)

HOW TO AVOID THE HAZARD Turn off the engine when performing

maintenance unless otherwise specified.

(1) Tool kit (2) Rubber band

The tools in the kit are sufficient to perform routine maintenance and simple repairs. Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer.

WARNING

POTENTIAL HAZARD Operating this ATV with improper

modifications.

The tool kit includes the following items:

Air pressure gauge

(1)

Spark plug wrench

(2)

Standard/Phillips screwdriver

(3)

Screwdriver handle

(4)

10/12 mm wrench

(5)

Tool bag

(6) (7) Rubber band

(1) (2) (3) (4) (5) (6) (7)

WHAT CAN HAPPEN Improper installation of accessories or

modification of this vehicle may cause changes in handling which in some situation could lead to an accident.

HOW TO AVOID THE HAZARD Never modify this ATV through improper

installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized KYMCO dealer.

PERIODIC MAINTENANCE/LUBRICATION ( 50)MAXXER

ITEM

Drive chain

Fuel line*

Transmission oil

V-belt*

Air filter element

Brake*

Battery*

Carburetor*

Wheels*

Spark plug

Exhaust system*

‧Check and adjust slack/alignment/clean/lube.

‧Check fuel hose for cracks or damage. ‧Replace if necessary.

‧Check oil level/oil leakage. ‧Replace every 12 months.

‧Check operation. ‧Replace if damage or excessive wear.

‧Clean. ‧Replace if necessary.

‧Check operation and brake fluid/cable. ‧Replace brake pads/shoes if necessary. ‧Check specific gravity . ‧Check breather hose for proper operation .

‧ ‧Check idle speed/starter operation. ‧Adjust if necessary.

‧Check balance/damage/runout. ‧Replace if necessary. ‧Check condition. ‧Adjust gap and clean. ‧Replace if necessary.

‧Check leakage. ‧Retighten if necessary. ‧Replace gasket if necessary.

ROUTINE

if necessary

Correct if necessary.

if necessary

INITIAL

month3months6months

Every 20~40 hours

(More often in wet or dusty areas.)

months

EVERY

year

ITEM

Wheel bearings*

Steering system*

Knuckle shafts/ Steering shaft*

Fittings and Fasteners*

* : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

‧Check bearing assembly for looseness/damage. ‧Replace if damaged.

‧Check operation. ‧Replace if damaged.

‧

‧Lubricate every 6 months.

‧Check all chassis fittings and fasteners.

ROUTINE

Check toe-in. Adjust if necessary.

Correct if necessary.‧

INITIAL

month3months6months

EVERY

months

year

PERIODIC MAINTENANCE/LUBRICATION ( 90)MAXXER

ITEM

Engine oil

Oil strainer*

Transmission oil

V-belt*

Air filter element (for engine and V-belt compartment)

Brake*

Battery*

Carburetor*

Cylinder head cover breather system*

Drive chain

Spark plug

Fuel line*

‧Replace (Warm engine before draining).

‧Clean. ‧Replace if necessary.

‧Check oil level/oil leakage. ‧Replace every 12 months.

‧Check operation. ‧Replace if damage or excessive wear.

‧Clean. ‧Replace if necessary.

‧Check operation and brake fluid/cable. ‧Replace brake pads/shoes if necessary. ‧Check specific gravity. ‧Check breather hose for proper operation.

‧Check idle speed/starter operation. ‧Adjust if necessary.

‧Check breather hose for cracks or damage. ‧Replace if necessary.

‧Check and adjust slack/alignment/clean/lube.

‧Check condition. ‧Adjust gap and clean. ‧Replace if necessary. ‧Check fuel hose for cracks or damage. ‧Replace if necessary.

ROUTINE

Correct if necessary.‧

INITIAL

month3months6months

Every 20~40 hours

(More often in wet or dusty areas.)

months

EVERY

year

ITEM

Valves*

Exhaust system*

Wheels*

Wheel bearings*

Steering system*

Knuckle shafts/ Steering shaft*

Fittings and Fasteners*

* : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

‧Check valve clearance. ‧Adjust if necessary. ‧Check leakage. ‧Retighten if necessary. ‧Replace gasket if necessary. ‧Check balance/damage/runout. ‧Replace if necessary.

‧Check bearing assembly for looseness/damage. ‧Replace if damaged.

‧Check operation. ‧Replace if damaged.

‧

‧Lubricate every 6 months.

‧Check all chassis fittings and fasteners.

ROUTINE

Check toe-in. Adjust if necessary.

Correct if necessary.‧

INITIAL

month3months6months

EVERY

months

year

Engine oil ( 90)

1.Engine oil level measurement A. Place the machine on a level place. B. Warm up the engine for several minutes

and stop it.

C. Remove right side cover.

MAXXER

E. Remove the dipstick and inspect the oil level. F. The oil level should be between the maximum

and minimum marks. If the level is low, add oil to raise it to the proper level.

(1)

(2)

(1)

(1) Right side cover

D. Remove the dipstick and wipe it off with a

clean rag. Insert the dipstick in the filler hole without screwing it in.

NOTE:

Wait a few minutes until the oil level settles before checking.

(3)

(1) Dipstick/oil filler cap (3) Minimum level mark

(2) Maximum level mark

CAUTION:

Be sure no foreign material enters the crankcase.

2-1. Engine oil replacement and oil filter

cleaning A. Place the machine on a level place. B. Warm up the engine for several minutes

and stop it. C. Place a container under the engine. D. Remove the oil filler cap and oil filter cap to

drain the oil.

CAUTION:

．Be sure no foreign material enters the

crankcase.

．When removing the drain plug, the

compression spring, oil strainer and Oring will fall out. Take care not to lose these parts.

E. Clean the oil strainer with solvent. F. Inspect the O-ring and replace if damaged. G. Reinstall the O-ring, oil strainer, compression

spring and drain plug. Tighten the drain plug to specification.

(1)

(1) Oil filter cap

CAUTION:

Before reinstalling the drain plug, be sure to install the O-ring, compression spring and oil strainer.

Tightening torque: Oil filter cap (engine):

14.7 Nm (1.5 m-kg, 10.6 ft-lb)

H. Fill the engine with oil and install the oil filler

cap.

Recommended oil: see page 136. 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)

2-2. Engine oil replacement

A. Place the machine on a level place. B. Warm up the engine for several minutes

and stop it. C. Place a container under the engine. D. Remove the oil filler cap and drain plug to

drain the oil.

CAUTION:

Be sure no foreign material enters the crankcase.

I. Warm up the engine for several minutes at idle

speed. Check for oil leakage while warming up.

CAUTION:

If oil leakage is found, stop the engine immediately and check for the cause.

(1)

(1) Dipstick/oil filler cap

CAUTION:

Be sure no foreign material enters the crankcase.

(1)

Tightening torque: Drain plug (engine): 30 Nm (3.0 m-kg, 21.6 ft-lb)

CAUTION:

Be sure no foreign material enters the crankcase.

Recommended oil: see page 142.

(1) Drain plug

E. Reinstall the drain plug and tighten the

drain plug to specification.

F. Fill the engine with oil and install the oil

filler cap.

G. Warm up the engine for several minutes at

idle speed. Check for oil leakage while warming up.

Oil quantity:

see page 142.

Transmission oil

1. Transmission oil measurement A. Place the machine on a level place. B. Remove the oil filler bolt and check the oil

level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level.

C. Reinstall the oil filler bolt and tighten to

specification.

(1)

Tightening torque Oil filler bolt: 15 Nm (1.5 m-kg, 11 ft-lb)

(1) Oil filler bolt/measurement hole (MAXXER 50)

(1)

(1) Oil filler bolt/measurement hole ( 90)MAXXER

2. Transmission oil replacement A. Place the machine on a level place. B. Place a container under the engine. C. Remove the oil filler bolt and drain plug to drain the oil. D. Reinstall the drain plug and tighten to Specification.

Tightening torque Drain plug: 15 Nm (1.5 m-kg, 11 ft-lb)

(1)

1. Drain plug (MAXXER 50)

(1)

(1) Drain plug (MAXXER 90)

100

E. Fill the engine with oil and install the oil filler

bolt.

Recommended oil : See page 138 or 142 Oil quantity:

Periodic oil change:

0.11L (0.10Imp qt, 0.12US qt) Total amount:

0.12L (0.11Imp qt, 0.13US qt)

CAUTION:

Be sure no foreign material enters the crankcase.

Tightening torque Oil filler bolt: 15 Nm (1.5 m-kg, 11 ft-lb)

F. Start the engine and warm up for a few

minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause.

(1)

1. Oil filler bolt ( 50)MAXXER

(1)

(1) Oil filler bolt ( 90)MAXXER

101

Spark plug inspection

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.

For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself.

Instead, take the machine to a KYMCO dealer. You should periodically remove and inspect the

spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

If electrode erosion becomes excessive, you should replace the spark plug with one of the proper type.

Standard spark plug: 50: NGK BR8HASMAXXER MAXXER 90: NGK C7HSA

Before installing the spark plug, measure the electrode gap with a feeler gauge and adjust to specification.

Spark plug gap:

0.6~0.7 mm (0.024~0.028 in)

A. Spark plug gap

When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque.

Tightening torque: Spark plug:

12.5 Nm (1.25 m.kg, 9.1 ft.lb)

102

Air filter cleaning

The air cleaner accumulates dust and must be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule. If the ATV is submerged in water, the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine.

To clean the air cleaner (MAXXER 90):

1. Remove the seat. (See page 38.)

2. Remove the air filter case cover.

(1)

(1) Air filter case cover

103

3. Remove the air filter element, and separate it from the box.

(1)

(1) Air filter element

4. Wash the element gently but thoroughly in solvent.

WARNING

POTENTIAL HAZARD Using low flash point solvents or gasoline

to clean the air filter element.

WHAT CAN HAPPEN Low flash point solvents or gasoline can

catch fire or explode.

HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air

filter element.

5. Squeeze the excess solvent out of the filter and let it dry.

CAUTION:

Do not twist the filter element when squeezing it.

104

6. Inspect the element. If damaged, replace it.

7. Apply quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used.

NOTE:

The element should be wet but not dripping.

To clean the air cleaner (MAXXER 50):

1. Remove the air filter case cover.

8. Reinstall the element to the .

9. Reinstall the element assembly and parts removed for access.

air filter case

(1)

(1) Air filter case cover

105

2. Remove the air filter element, and separate it from the box.

(1)

(1) Air filter element

3. Wash the element gently but thoroughly in solvent.

WARNING

POTENTIAL HAZARD Using low flash point solvents or gasoline

to clean the air filter element.

WHAT CAN HAPPEN Low flash point solvents or gasoline can

catch fire or explode.

HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air

filter element.

4. Squeeze the excess solvent out of the filter and let it dry.

CAUTION:

Do not twist the filter element when squeezing it.

106

5. Inspect the element. If damaged, replace it.

6. Apply quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used.

NOTE:

The element should be wet but not dripping.

Valve clearance adjustment ( 90)

The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional KYMCO service technician.

MAXXER

7. Reinstall the element to the .

8. Reinstall the element assembly and parts removed for access.

air filter case

107

Idle speed adjustment

NOTE:

A diagnostic tachometer must be used for this procedure.

1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

2. Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in to increase engine speed, and out to decrease engine speed.

Specified idle speed: 50: 2000 RPMMAXXER MAXXER 90: 1700 RPM

(1)

1. Throttle stop screw

108

Throttle lever adjustment

(4)

NOTE:

Adjust the engine idling speed before adjusting the throttle lever free play.

(1)

To adjust throttle free play:

1. Slide the rubber sleeves back to expose the throttle cable adjuster.

2. Loosen the lock nut, then turn the adjuster to obtain the correct free play. (1~4 mm or

0.04~0.16 in)

3. Tighten the locknut and reinstall the sleeve.

Other checks: Check the throttle cable for kinks and signs of

wear that could cause stretching or failure. Lubricate the throttle cable with a commercially available lubricant to prevent premature wear and corrosion.

(3)

(2)

)

(1) Rubber sleeve (2) Cable a (3

) Locknut (4) Throttle lever

(A) 1~4 mm (0.04~0.16 in)

109

djuster

Front and rear brake shoes (drum brake) inspection

When turn the adjusting nut fully to decrease brake lever free play and the free play and the free play exceeds the specification (1~2cm), it means the brake shoe is worn out. Go to our designated distributors or service stations for brake shoe replacing.

Rear brake pads inspection (Disk brake)

A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. If the indicator reaches the wear limit line, ask a KYMCO dealer to replace the pads.

(1)

(2)

(1) Wear indicator (2) Rear brake

110

Front brake lever free play adjustment

The front brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the the brake lever. adjust as follows:

If the free play is incorrect,

tip of

(A)

(1)

(2)

(A) Free play 10~20 mm (0.4~0.8 in)

1. Loosen the upper locknut and fully turn in the adjusting bolt.

(1) Upper locknut (3) Lower locknut

2. Loosen the lower locknut.

3. Turn the lower adjusting bolt until specified free play is obtained.

Specified free play: 10~20 mm (0.4~0.8 in)

4. Tighten the lower locknut.

111

(3)

(2) Upper adjusting bolt (4) Lower adjusting bolt

(4)

5. While applying the front brake, turn out the

(1)

(A)

upper adjusting bolt until the upper and lower cable lengths are equal. The cable joint will become vertical.

(1) Cable joint ( A) Cable length

6. Tighten the upper locknut.

WARNING

POTENTIAL HAZARD Operating with improperly serviced or

adjusted brakes.

WHAT CAN HAPPEN You could lose braking ability, which could

lead to an accident.

HOW TO AVOID THE HAZARD After servicing: ‧Make sure the brakes operate smoothly

and that the free play is correct. ‧Make sure the brakes do not drag. Replacement of brake components requires

professional knowledge. These procedures should be performed by KYMCO dealer.

112

Rear brake lever free play adjustment (Drum brake)

The rear brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. If the free play is incorrect, adjust as follows:

(A)

Turn the adjusting nut on the brake hub in direction A to decrease play, and in direction B to increase play.

A. Free play 10~20 mm (0.4~0.8 in)

(1) Adjusting nut (A) Decrease play (B) Increase play

113

(B)

(A)

(1)

NOTE:

Make sure the cut-out on the adjusting nut Is seated on the brake arm pin after making final free play adjustment.

(1)

(1) Arm pin (2) Adjusting nut

(2)

WARNING

POTENTIAL HAZARD Operating with improperly serviced or

adjusted brakes.

WHAT CAN HAPPEN You could lose braking ability, which could

lead to an accident.

HOW TO AVOID THE HAZARD After servicing: ‧Make sure the brakes operate smoothly

and that the free play is correct. ‧Make sure the brakes do not drag. Replacement of brake components requires

professional knowledge. These procedures should be performed by KYMCO dealer.

114

Brake pedal adjustment (MAXXER 90)

The brake pedal free play should be adjusted to 5~10 mm (0.2~0.4 in) at the brake pedal pivot. If the free play is incorrect, adjust as Follows:

(A)

3. Turn the adjusting bolts until the front Lower brake cables is tensed.

4. Apply the front brake lever and check front brake cam levers to make sure that the

brake does not drag after adjusting.

(2)

(A) 5~10 mm (0.2~0.4 in)

Adjust:

1. Keep front brake lever free play at 10~20 mm (0.4~0.8 in).

2. Loosen the locknuts. (R/L front lower brake cables)

(1)

Adjusting bolts (1) R/L front lower cables

(1) (2) Locknuts

115

(2) Brake cam lever

(1)

(2)

5. While remove the cable joint case cover and

applying the brake pedal, make sure the left and right front lower cable lengths (A and B) are equal. The cable joint will become vertical.

6. Tighten the locknuts. (R/L front lower brake

7. Loosen the locknut. (Brake pedal cable)

8. Turn the adjusting bolt until the specified free play is obtained.

Specified free play: 5~10 mm (0.2~0.4 in)

(1)

(1) Bolts (2) Cable joint case cover

( )

(1)

(2)

(1) Cable joint (A) Left front lower cable length (B) Right front lower cable length

9. Tighten the locknut. (Brake pedal cable)

(3)

(1)

)

116

(2)

(1) Locknut (2) Adjusting bolt (3) Brake pedal cable

WARNING

POTENTIAL HAZARD Operating with improperly serviced or

adjusted brakes.

WHAT CAN HAPPEN You could lose braking ability, which could

lead to an accident.

HOW TO AVOID THE HAZARD After servicing: ‧Make sure the brakes operate smoothly

and that the free play is correct. ‧Make sure the brakes do not drag. Replacement of brake components requires

professional knowledge. These procedures should be performed by KYMCO dealer.

117

Brake fluid inspection (Disk brake)

LOWER

UPPER

Check if the fluid level is below the lower level mark through the brake fluid reservoir (under the rear fender right side).

WARNING

POTENTIAL HAZARD Brake fluid contacting the skink or eyes.

WHAT CAN HAPPEN May cause irritation.

HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin

or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes

were exposed.

(1)

(A)

(B)

(1) Brake fluid reservoir (A) Upper level mark (B) Lower level mark

118

NOTE:

‧As the brake pads wear, brake fluid level

drops, automatically compensating for wear. There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks.

‧If the brake lever travel become excessive

and the brake pads are not worn beyond the recommended limit (page 110), There is probably air in the brake system and it must be bled. See your authorized KYMCO dealer for this service.

CAUTION:

‧To prevent damage to the brake system, use

only fluid from a sealed container. Never allow contaminants (dirt, water, etc.) to enter the brake fluid reservoir.

‧Brake fluid can damage paint and plastic, so

handle the fluid with care. When adding brake fluid, be sure the reservoir is horizontal before removing the cover to prevent accidental spilling.

‧Use only DOT 4 brake fluid from a sealed

container.

119

Drive chain slack check

(A)

Inspect the drive chain while all tires are touching the ground. Check the slack at the position shown in the figure. The normal vertical deflection is approximately 10~20 mm (0.4~0.8in). If the deflection exceeds 20 mm (0.8 in), adjust the chain slack.

Drive chain slack adjustment

1.Loosen the upper and lower axle holding

(2)

A. 10~20 mm (0.4~0.8 in)

1. Hub stopper nut

120

2. Axle holding bolt x 4

2.Turn the adjusting nut, to decrease or increase chain slack.

(1)

3.Retighten the upper and lower axle holding bolts.

Tightening torque:

Axle holding bolts (upper): 70 Nm (7.0 m-kg, 48 ft-lb)

1. Adjust nut

CAUTION:

Too little of chain slack will overload the engine and other important parts. Keep the slack within the specified limit.

121

Drive chain cleaning and lubrication

The drive chain is equipped with rubber O-rings between the chain plates. Steam cleaning, highpressure washes, and certain solvents can damage these O-rings. Use only kerosene to clean the drive chain. Wipe it dry, and thoroughly lubricate it with SAE 30~50 motor oil. Do not use any other lubricants on the drive chain. They may contain solvents that could damage the O-rings.

1. O-rings

Cable inspection and lubrication

WARNING

POTENTIAL HAZARD Damaged control cables.

WHAT CAN HAPPEN Corrosion can result when the outer

covering of control cables becomes damaged.

Cables can also become frayed or kinked. Operation of controls could be restricted,

which could cause an accident or injury.

HOW TO AVOID THE HAZARD Inspect cables frequently. Replace

damaged cables.

Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a KYMCO dealer to replace them.

Recommended lubricant: KYMCO chain and cable lube or SAE 10W40 motor oil

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Brake lever lubrication

Lubricate the pivoting parts of the brake levers.

Recommended lubricant: Lithium-soap-based grease (All-purpose grease)

Knuckle shaft and rear fork shaft lubrication

Lubricate the pivot points using a grease gun.

Recommended lubricant: Lithium-soap-based grease

Draining the V-belt compartment

MAXXER

( 90)

If water leaks into V-belt compartment such as when the machine is drive in water, remove the drain screw on the bottom of compartment and drain the water. Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a KYMCO dealer to inspect.

(1)

(1) Drain bolt

123

Wheel removal

1. Elevate the wheel by placing a suitable stand under the frame.

2. Remove the nuts from the wheel.

3. Remove the wheel assembly.

(1)

(1) Safe nut

Wheel installation

When installing the wheel, reverse the removal procedure. Pay attention to the following.

Wheel nut torque: Front: 40 Nm (4.0 m-kg, 30 ft-lb) Rear: 40 Nm (4.0 m-kg, 30 ft-lb)

124

Battery

Your ATV battery is located in a compartment under the seat. The battery is sealed, so it is not necessary to check the electrolyte level or add distilled water. If the battery seems weak, see your authorized KYMCO dealer for information on recharging or replacement. If you replace the battery, choose one that is sealed and equivalent to the original. Be sure to read and follow all safety precautions indicated on the battery.

CAUTION:

‧Do not attempt to remove the caps from the

battery cells as this may damage the battery.

‧Although the battery is sealed, it vents explosive

gases and should be handled with appropriate care.

WARNING

POTENTIAL HAZARD Allowing open flames or sparks near the battery.

WHAT CAN HAPPEN Gases may explode and possibly cause injury.

HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery.

NOTE:

‧When the ATV is to be stored for an extended

period, remove the battery from the vehicle and charge it fully. Then store it in a cool, dry place. If the battery is to be left on the vehicle, disconnect the negative cable from the battery terminal.

‧Battery posts, terminals and related accessories

contain lead and lead compounds. Wash

hands after handling.

125

Battery remove

1. Make sure the ignition switch is OFF.

2. Remove the seat (page 38)

3. Remove the battery cover, by removing the mount bolts.

4. Disconnect the negative (-) terminal lead from the

battery first, then disconnect the positive (+) terminal lead.

5. Remove the battery.

(1)

Battery installation

1. Install in the reverse order of removal.

2. Check all bolts and other fasteners are secure.

3. After installing the battery, check to see if the battery cables are routed correctly.

(1)

(3)

(2)

(1) Battery cover (2) Mount bolt

(1) Battery (2) Positive (+) terminal lead (3) Negative (-) terminal lead

126

Fuse replacement

When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your authorized KYMCO dealer for repair.

Fuse holder: The fuse holder is located in the storage box under the seat. The specified fuses are: 7A

CAUTION:

To prevent accidental short-circuiting, turn off the ignition switch before checking or replacing a fuse.

WARNING

POTENTIAL HAZARD Using an improper fuse.

WHAT CAN HAPPEN An improper fuse can cause damage to the

electrical system which could lead to a fire.

HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper

fuse.

(1)

(1) Fuse holder

127

1. Lift the seat. (See page 38)

2. Open the fuse holders and lift out the fuse with the clips.

(1)

(2)

(1) Fuse holder (2) Clip

3. Slide the old fuse out of the clips and discard it.

128

4. Slide the clips onto the ends of the new fuse, push them back into the fuse holder, and close the fuse holder. The spare fuse is on the battery cover.

(1)

(2)

(1) Fuse holder (2) Clip

CAUTION:

．Do not pry the clips open to get a fuse out;

you could bend them and cause poor contact with the new fuse. A loose fuse could cause damage to the electrical system and even start a fire.

．After replacing the fuse, be sure return the

fuse holder to its original location

129

KYMCO Maxxer User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual