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.
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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.
WARNING
CAUTION
Indicates a strong possibility that serious injury or death may result if instructions are not followed.
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.
B
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.
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CONTENTS
Page |
Page |
LOCATION OF THE WARNING AND |
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SPECIFICATION LABELS........................... |
1 |
SAFETY INFORMATION............................. |
4 |
DESCRIPTION AND MACHINE |
|
IDENTIFICATION....................................... |
9 |
Key identification number.. ........................9 |
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Frame and engine serial number............... |
10 |
Model code............................................ |
10 |
Parts location...................................... |
11 |
CONTROL FUNCTIONS........... ................ |
16 |
Ignition switch....................................... . |
16 |
Indicator lamps ........... ........................... |
17 |
Instrument ....... .......... ........................... |
18 |
Handlebar switches................................ |
23 |
Horn button................................. ........ |
23 |
Turn signal switch ................................ |
23 |
Headlight switches .............................. |
24 |
Engine stop switch............................... |
25 |
Stater button.. . ....................................26 |
|
Kick starter.............. .............................. |
27 |
Remote engine stop switch.. ....................28 |
|
Throttle lever... .....................................29 |
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Speed limiter.... ..................................... |
30 |
Front and rear brake............................... |
31 |
Brake pedal (MAXXER 90)...................... |
31 |
Parking brake (MAXXER 50).................... |
32 |
Parking brake (MAXXER 90)................... |
33 |
Fuel tank cap .. ....................................... |
34 |
Fuel valve . ........................................... |
35 |
Locking steering (MAXXER 90).............. |
36 |
Starter (choke) (MAXXER 90)................. |
37 |
Seat...................................................... |
38 |
Flag pole bracket.................................... |
39 |
Storage compartment . ........................... |
39 |
(Cont'd)
D
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Page |
PRE-OPERATION CHECKS...................... |
40 |
Front and rear brakes............................. |
41 |
Fuel ..................................................... |
42 |
Engine (MAXXER 90) and |
|
transmission oil .................................... |
44 |
Engine oil (MAXXER 50)......................... |
45 |
Chain ................................................... |
46 |
Throttle lever......................................... |
46 |
Fittings and fasteners............................. |
46 |
Lights ................................................... |
46 |
Switches .......................... .................... |
46 |
Tires ............................. ....................... |
47 |
How to measure tire pressure ................. |
48 |
Tire wear limit ....................................... |
49 |
OPERATION............................................ |
50 |
Starting a cold engine (MAXXER 90)........ |
50 |
Starting engine (MAXXER 50)................ |
53 |
Engine break-in..................................... |
54 |
Parking .. .............................................. |
56 |
Parking on a slope ................................. |
57 |
Accessories .......................................... |
58 |
|
Page |
Riding Your ATV........................................ |
59 |
GETTING TO KNOW YOUR ATV.. ...... ......60 |
|
RIDE WITH CARE AND GOOD |
|
JUDGEMENT......................................... |
61 |
Age Recommendation (MAXXER 50)........ |
62 |
Age Recommendation (MAXXER 90)........ |
63 |
Never carry passenger on the carrier........ |
64 |
Apparel..... ........................................... |
65 |
Do not operate after consuming alcohol or |
|
drugs.................................................... |
66 |
Pre-operation checks.............................. |
67 |
Loading and accessories......................... |
69 |
Loading and Operational Guidelines......... |
69 |
Accessories...................... .................... |
70 |
No Modifications.................................... |
71 |
During operation ................................... |
72 |
Exhaust system.................................... |
74 |
RIDING................................................ |
75 |
Remote engine stop switch for new |
|
Riders.................................................. |
76 |
(Cont'd)
E
|
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 MAINTENANCE AND |
|
ADJUSTMENT......................................... |
89 |
Tool kit................................................... |
89 |
PERIODIC MAINTENANCE/ |
|
LUBRICATION (MAXXER 50).................. |
91 |
PERIODIC MAINTENANCE/ |
|
LUBRICATION (MAXXER 90).................. |
93 |
Engine oil (MAXXER 90 ).......................... |
95 |
Transmission oil..................................... |
99 |
Spark plug inspection............................ |
102 |
Air filter cleaning.................................. |
103 |
Valve clearance adjustment |
|
(MAXXER 90)..................................... |
107 |
Idle speed adjustment.. ........................108 |
|
Throttle lever adjustment ..................... |
109 |
Page |
|
Front and rear brake shoes (drum brake) |
|
inspection........................................... |
110 |
Front brake lever free play adjustment.... |
111 |
Rear brake lever free play adjustment |
|
(Drum brake)........................................ |
113 |
Brake pedal adjustment (MAXXER 90).. |
115 |
Brake fluid inspection (Disk brake)........ |
118 |
Drive chain slack check......................... |
120 |
Drive chain slack adjustment................. |
120 |
Drive chain cleaning and Lubrication...... |
122 |
Cable inspection and lubrication........... |
122 |
Brake lever lubrication.......................... |
123 |
Knuckle shaft and rear fork shaft |
|
l u b r i c a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 2 3 |
Draining the V-belt compartment |
|
(MAXXER 90)...................................... |
123 |
Wheel removal..................................... |
124 |
Wheel installation................................. |
124 |
Battery ............................................. |
125 |
Fuse replacement................................ |
127 |
Headlight beam adjustment................... |
130 |
Troubleshooting ............................... |
131 |
Troubleshooting chart........................ |
132 |
(Cont'd)
F
|
Page |
CLEANING AND STORAGE..................... |
133 |
A. Cleaning ......................................... |
133 |
B. Storage ........................................... |
135 |
SPECIFICATIONS (MAXXER 50).............. |
137 |
SPECIFICATIONS (MAXXER 90)............. |
141 |
NOISE REGULATION............................. |
145 |
MAINTENANCE RECORD....................... |
146 |
INDEX................................................... |
147 |
G
WARNING INFORMATION
Your ATV comes with a hang tag and several labels containing important safety information. Anyone who rides the vehicle should read and understand this information before riding.
Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride.
The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
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NEVER USE WITH |
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ALWAYS USE AN |
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APPROVED HELMET AND |
ALCOHOL OR DRUGS |
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PROTECTIVE GEAR |
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NEVER operate :
Without proper training or instruction.At speeds too fast for your skills or
the conditions.
Do not operate the vehicle after consuming ALCOHOL OR DRUGS.
ALWAYS :
Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns.
For your safety, wear gear to include helmet gloves and foot protection.
Gasoline is flammable shut off engine,
avoid sparks and open flame when refueling.
READ OWNER'S MANUAL, FOLLOW ALL INSTRUCTIONS AND WARNINGS.
2
(MAXXER 50)
WARNING
UNDER
6
Operating this ATV if you are under the age of 6 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 6.
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN
CAUSE LOSS OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE INJURY
OR DEATH.
OPERATING TIRE PRESSURE : Set with tires cold
Recommended :
FRONT : 22~28 kpa, (0.22~0.28 kgf/cm2 ), 3.2~4.0 psi REAR : 22~28 kpa, (0.22~0.28 kgf/cm2 ), 3.2~4.0 psi
Never set tire pressure over the recommended.
(MAXXER 90)
WARNING
Operating this ATV if you are under the age of 12 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 12.
3
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or instruction. Beginners should receive training from a certified instructor.
Always follow the age recommendation:
-A child under 6 years old should never operate an ATV with engine size greater than 70cc.
-A child under 12 years old should never operate an ATV with engine size greater than 90cc.
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
4
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.
Never attempt wheel, jump, or other stunt.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain.
Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate the ATV on hills.
Always follow proper procedures for climbing slopes as described in this manual. Check the terrain carefully before you start up any slope. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a slope at high speed.
5
Always follow proper procedures for going down slopes and for braking on slopes as described in this manual. 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 slope at an angle that would cause the vehicle to lean sharply to one side. Go straight down the slope where possible.
Never attempt to turn the ATV around on any slope until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep slope if possible.
Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.
Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.
6
WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
Do not spill gasoline on the engine or exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.
When transporting the machine in another vehicle, be sure it is kept upright and that the fuel cock is in the "OFF" position.
Otherwise, fuel may leak out of the carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause injuries.
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, see your doctor immediately.
If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.
7
DESCRIPTION AND MACHINE IDENTIFICATION
Identification number records
Record the keys identification number, frame serial number, engine serial number and model code information for assistance when order replacement parts.
IGNITION SWITCH KEY NO.
STEERING LOCK KEY NO.
FRAME NO.
ENGINE NO.
MODEL CODE
Keys identification number
The keys identification number is stamped on the hang tag as shown in the following illustration.
(1)
(2)
(1)Ignition switch key identification number
(2)Steering lock key (MAXXER 90) identification number
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