Kymco Maxxer 50 User Manual

IMPORTANT NOTICES

READ THIS MANUAL CAREFULLY

Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle.

AGE RECOMMENDATION KXR 50: The minimum recommended age for this ATV model is 6. Children under

age 6 should never operate this vehicle.

KXR 90: The minimum recommended age for this ATV model is 12. Children under

age 12 should never operate this vehicle.

RIDER TRAINING

Anyone who operates this vehicle should get proper instruction.

FOR ON-ROAD USE ONLY

This machine is designed and manufactured for ON-ROAD use only. It is illegal and unsafe to operate this machine on any hills and rough or loose terrain.

This machine complies with all applicable ON-ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this machine.

SPECIAL MESSAGES

KYMCO provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol . Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.

Indicates a strong possibility that serious injury or death may

WARNING

result if instructions are not followed.

CAUTION Indicates a possibility that equipment or property damage could result if instructions are not followed.

Note: Gives helpful information

The Owner's Manual should be considered a permanent part of your ATV. It should remain with the vehicle at all times and stay with the ATV if it is sold.

PREFACE

Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service.

For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.

This manual will provide you with a good basic understanding of the features and operation of this machine. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your machine. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your machine, please consult a KYMCO dealer.

We wish you many years of safe and enjoyable riding.

While reading this manual, remember:

Indicates a strong possibility that serious injury or death may

WARNING

result if instructions are not followed.

All information in this publication is based on the latest product information available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD reserves the right to make changes at any time without notice and without incurring any obligation.

CONTENTS

Page Page

LOCATION OF THE WARNING AN D

SPECIFICATION LABELS...........................1

SAFETY INFORM ATION.............................4

DESCRIPTION AND MACHINE

IDENTIFICATION........... .... ....................... .9

Key iden tification number.. ........................9

Frame and engine seri al number...............10

Mod el co de............................................10

Parts location.... ....... ....... ....... ....... ...... 11

CONTROL FUNCTIONS........... ..... ....... ....16

Ignition switch....................................... .16

Ind icator lamps ........... ...........................17

Ins trument ....... .......... ...........................18

Han dlebar switches................................23

Hor n but ton................................. ........23

Turn signal switch ................................23

Hea dlight switc hes ..............................24

Eng ine stop swit ch...............................25

Stater button.. . ....................................26

Kick sta rter.... ....... ... ..............................27

Remote eng ine stop switch.. ....................28

Throttle lever... .....................................29

Speed limi ter.... .....................................30

Front and rear brake.. ....... ....... ....... ....... .31

Brake pedal (MAX XER 90)..... ....... ....... ...31

Parking brake ( 50)....................32

Parking brake (M AXXER 90) ....... ....... .....33

Fuel tank cap .. .......................................3 4

Fuel valve . ... ....... ....... ....... ....... ....... ..... 35

Lock ing steering ( 90)

Starte r (choke) (MAXXER 90)... ....... ....... 37

Seat.. ....... ....... ....... ....... ....... ....... ....... ...38

Fla g pol e bra cket.................................... 39

Storage com partment . ...... ....... ....... ....... 39

MAXXER

MAXXER ..... ....... ..36

(Cont'd)

Page Page

PRE-OPERATION CHECKS......................40

Front and rear brakes.... ....... ....... ....... ....41

Fuel .... ....... ....... ....... ....... ....... ....... ....... 42

Engine (MAXXER 90) and

transmiss ion oil ....................................44

Engine oil ( 50).......

Chain ...................................................46

Throttle lever.........................................46

Fittings and fasteners.............................46

Ligh ts ...................................................46

Switches ... ....... ....... ....... .. ....................46

Tires ....... ....... ....... ....... . .......................47

How to measure tire pressure .................48

Tire wea r limit .......................................49

OPERATION. .... .... .... ...............................50

Starting a cold engi ne ( 90)........50

Starting e ngine (M AXXER 50 )................53

Eng ine br eak-in.....................................54

Parking .. ..............................................56

Parking on a slope .................................57

Accessorie s ...... ....... ....... ....... ....... ....... .58

MAXXER ..... ....... ......4 5

MAXXER

Riding Your ATV........................................59

GETTING TO KNOW YOUR ATV.. ..... . ......60

RIDE WITH CARE AND

JUDGEMENT.. ........... ........... ........... ......61

Age Recommen dation (MAXXER 50)........62

Age Recommen dation (MAXXER 90)........63

Never ca rry passenger on the carrier........64

Ap parel..... ... ....... ....... ....... ....... ....... .....65

Do not operate after con suming alcoho l or

drugs. ............. .... ............. ............. .... ....66

Pre-operation chec ks..............................67

Loading and accessor ies.... ....... ....... ....... 69

Loading and Opera tional Guidel ines.........69

Accessorie s...... ....... ....... .. ..... ....... ....... .70

No Modifications. ....... ....... ....... ....... ....... 71

Dur ing operation . ..................................72

Exhaust system....................................74

RIDING.... ....... ....... ....... ....... ....... ....... ..75

Remote engine stop switch for new

Ride rs..................................................76

GOOD

(Cont'd)

Page Page

Speed limiter for new riders.....................77

BRAKING.. ........... ........... ........... ........... 78

TURNING YOUR ATV .............................79

CLIMBING UP SLOPE...........................80

RIDING DOWN SLOPE .........................86

PARKING.............. .... ....................... .... .87

WHAT TO DO IF........ ....... ....... ....... ....... 88

WHAT TO DO.... ....... ....... ....... ....... ....... 88

PERIODIC MAINTENAN CE AND

AD JUSTM ENT.... ..... ..... ..... .............. ..... ...89

Tool kit...................................................89

PERIODIC MAINTENAN CE/

LU BRICATION ( 50). ....... ....... ...91

PERIODIC MAINTENAN CE/

LU BRICATION (MAXXER 90)..................93

Engine oil (MAXXER 90 )..........................95

Transmission oil.....................................99

Spark plug ins pection............................102

Air filter cleaning ....... ....... ....... ....... ......1 03

Valve clear ance adjustme nt

(MAXXER 90).....................................107

Idle speed adjustment.. ..... ....... ....... .....10 8

Throttle lev er adjustm ent ...... ....... ....... .109

MAXXER

Front and rear brake shoes (drum brake)

in spect ion.. ................ ..... ..... ..... ..... ..... 110

Front brake lever free play adjustment.... 111

Rear brake le ver free play adjustment

(D rum brak e)........................................113

Br ake peda l adjustment (MAXXER 90)..115

Brake fluid inspection (Disk brak e)........118

Drive chain slack check.........................120

Drive chain sl ack adju stment.................120

Drive chain cleaning and Lubrication......122

Cable inspection and lubrica tion...........122

Brake lever lubrication... ....... ....... ....... ..123

Knuckle sha ft and rear fork shaft

l ub ri c a t io n . . . . .. . . . . .. .. . . . . .. .. . . . .. .. . . 1 23

Draining th e V-belt compartment

(MAXXER 90)......................................123

Wheel removal.....................................124

Wheel insta llation.................................124

Ba ttery ............. ..... ..... .............. ..... ...12 5

Fuse replacement................................127

Headlight beam adjustment...................130

Trouble s hooting ... ........ ........ . ....... . ...131

Troubl eshoot ing chart ...... ...... ...... ...... 132

(Cont'd)

Page

CLEANING AND STORAGE.. ....... ....... .....13 3

A. Cle aning .........................................133

B. Storage ...... ....... ....... ....... ....... ....... ..135

SPECIFICATIONS (MAXXE R 50) ....... ....... 137

SPECIFICATIONS (MA XXER 90).............141

NOISE REGU LATION.............................145

MAINTENANCE RECORD.......................146

IN DEX. ............. .... ............. ............. .... ...147

WARNING INFORMATION

Your ATV come s with a hang tag and several labels containing important safet y information . Anyone who ri des the vehicle s hould read and understan d this information befor e riding.

Parents of young riders should make sure their youngster s read and understand the ha ng tag and label inf ormation before allowing them to ride.

The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes har d to read, contact your KYMC O dealer for replacements

WARNING

Improper ATV use can resul t in SEVERE INJURY or DEATH.

ALWAYS U SE AN APPROVED HEL ME T AND PROTECTIVE GEAR

NEVER operate :

‧With out p roper training or in str uct ion. ‧At speeds too fa st fo r you r skills

the conditio ns. Do not operate t he ve hic le after consuming ALCOHOL OR DRUGS. ALWAYS : ‧Use proper rid ing t echniques to avoid vehicle over tur ns on hills and rough terrain and in t urn s. ‧For your safet y, wear gear to i ncl ude helmet glove s and f oot protection. ‧Gasoline is fl amm able shut off engine , avoid sparks a nd op en flame when refuel ing .

READ OWNER'S M ANU AL, F OLLOW

ALL IN STRUCTIONS AND WAR NINGS.

NEVER USE WITH ALCOHOL OR DR UG S

( 50)MAXXER ( 90)MAXXER

WARNING

UNDER

Oper ating thi s ATV if y ou are un de r the age of 6 i ncrea se s your ch an ce of seve re inju ry o r death .

NEVE R opera te t his ATV if you ar e unde r age 6.

WARNING

IMPR OPER TIRE P RESSU RE O R OVERL OADING CA N

CAUS E LOSS OF CON TROL.

LOSS O F CONTROL CAN R ESULT IN SEVER E INJURY

OR DEATH.

OPER ATI NG T IRE PRE SSURE : S et w ith tir es c old‧

Reco mmend ed :

FRON T : 22 ~2 8 kpa, (0 .22~0 .2 8 kgf/c m ) , 3.2~4 .0 psi

REAR :

‧Neve r set tire pr essur e over the re comme nd ed.

22~2 8 kpa, (0 .2 2~0.2 8 kg f/cm ) , 3.2~4.0 p si

Oper ating thi s ATV if y ou are un de r the age of 1 2 incre as es your c ha nce of seve re inju ry o r death .

NEVE R opera te t his ATV if you ar e unde r age 12.

WARNING

UNDER

SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN BE HAZAR DOUS TO OPERATE. An ATV handles differ ently fro m

other vehicles including motorcycles and cars. A collision can oc cur quickly, ev en during routi ne maneuvers , if you fail to take proper pre -cautions.

SEVERE INJU RY OR DEATH can result if you do not f ollow these ins tructions:

‧Read this manual and all labels careful ly and follow the o perating proc edures descri bed.

‧Never opera te an ATV with out proper training or ins truction.

Beginners should receive training from a certified i nstructor.

‧Always foll ow the age recommendation:

- A child und er 6 years old should never operate an ATV with engine size greater than 70cc.

- A child und er 12 years old sho uld never opera te an ATV with engine size greater than 90 cc.

‧Never allow a c hild under age 16 t o operate an ATV wit hout adult supervision, and never allow

continued u se of an ATV by a child if he or she does not have the abili ties to operate i t safely.

‧Never opera te an ATV with out wearing an approved motorcycle helm et that fits prop erly. You

should also w ear eye protection (goggles or face shield), gloves, boo ts, long-slee ved shirt or jacket, and long pants.

‧Never consu me alcohol or dru gs before or while operating this ATV.

‧Never opera te at speeds too fast for your s kills or the cond itions. Always go at a speed th at is

proper for the terrain, visibility an d operating con ditions, and yo ur experience .

‧Never attempt wheel, jump, or other stu nt.

‧Always insp ect your ATV each ti me you use it to make s ure it is in safe operating co ndition. Alway s

follow the inspection and maintenan ce procedures a nd schedules de scribed in this m anual.

‧Always keep b oth hands on the handlebars and both feet on th e footboards of the ATV during

operation .

‧Always go slo wly and be extra ca reful when operating on unfamiliar terr ain. Always be ale rt to

changing te rrain conditions when operating the ATV.

‧Never opera te on excessive ly rough, slippery or loose terrain.

‧Always foll ow proper proce dures for turning as described in this manu al. Practice tu rning at low

speeds befo re attempting to turn at fas ter speeds. Do not turn at exc essive speed.

‧Never opera te the ATV on hills.

‧Always foll ow proper proce dures for climbing slopes as described in this manual. Che ck the

terrain car efully before you start up a ny slope. Shift your weight forward. Neve r open the thrott le suddenly. Never go over the to p of a slope at high speed.

‧Always foll ow proper proce dures for going down slopes and for braking on slopes as described in

this manual. Check the t errain carefu lly before you st art down any slope. Shift yo ur weight backward. N ever go down a slop e at high speed. Avoid going down sl ope at an angle tha t would cause the veh icle to lean sharply to one side. Go straight d own the slope whe re possible.

‧Never attempt to turn th e ATV around on any sl ope until you hav e mastered the tu rning technique

described i n this manual on level ground. Avo id crossing the s ide of a steep slope if possible.

‧Always chec k for obstacles before ope rating in a new are a. Never attemp t to operate over large

obstacles , such as large rocks or fallen trees. Always fo llow proper pro cedures when op erating over obstac les as describe d in this manual.

‧Always be car eful when skidd ing or sliding. Learn to saf ely control ski dding or slidin g by

practicin g at low speeds and on level, smooth terrain. O n extremely sli ppery surfaces, such as ice, go slowl y and be very cautious in order to reduce the cha nce of skidding o r sliding out of control.

‧Never opera te an ATV in fas t flowing water or in water de eper than that re commended in th is

manual. Rem ember that wet brakes may ha ve reduced stop ping ability. Test your bra kes after leaving wat er. If necessary, apply them several times t o let friction dr y out the linings.

‧Always use th e size and type tires specif ied in this manua l. Always maintain proper tire pressure

as describe d in this manual.

‧Never modify an ATV through imp roper installation or use of accessorie s.

‧Never excee d the stated load capacity f or an ATV. Cargo sh ould be properl y distributed a nd

securely at tached. Reduce speed and follow instruc tions in this man ual for carrying cargo. Allow greater dis tance for braking.

WARNING

POTENTIAL HAZARD

Improper ha ndling of gasoline.

WHAT CAN HAPP EN

Gasoline ca n catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn o ff the engine wh en refueling. Do not refuel right afte r the engine has be en

running and i s still very hot. Do not spill ga soline on the engine or exhaust

pipe/muffler when refue ling. Never refuel while smoking, or while in the

vicinity of sparks, open flames, or oth er sources of ig nition such as the pilot lig hts of water heaters and clothes dryers.

When transporting th e machine in anot her vehicle, be s ure it is kept upright and tha t the fuel cock is in the "OFF" po sition.

Otherwise, fuel may leak out of the carbu retor or fuel tank.

WHAT CAN HAPP EN

Gasoline is p oisonous and ca n cause injurie s.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, se e your doctor immediately.

If gasoline spills on your skin, wash wit h soap and water. If gasoline spills on your clot hing, change your c lothes.

DESCRIPTION AND MACHINE IDENTIFICATION

Identification number recor ds

Record the ke ys identification numb er, frame serial numb er, engine seria l number and model code in formation for assistan ce when order repla cement parts.

Keys identificatio n number

The keys iden tification number is sta mped on the hang tag as shown in the f ollowing illustration.

IGNITION SWITCH KEY NO.

STEERING LOCK KEY NO.

FRAME NO.

ENGINE NO.

MODEL CODE

(1)

(1) Ignition switch key identification number (2) Steering lock key ( 90)

identification number

MAXXER

(2)