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.
A
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.
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.
C
CONTENTS
Page Page
LOCATION OF THE WARNING AND
SPECIFICATION L ABELS.. ....... ....... ....... ....1
SAFETY I NFORMATION.............................4
DESCRIPTION AND MACHINE
IDENTIFICATION....... ................... .............9
Key iden tificat ion numbe r.. ........................9
Frame and engine serial number...............10
Model code ....... ....... ....... ....... ....... ....... ..10
Parts location...................................... 11
CONTROL FUNCTIO NS........... ................16
Igniti on switch....................................... .16
Ind icator la mps ..... ...... ...........................17
Ins trument .... ... ..... ..... ...........................18
Handlebar switche s...... ....... ....... ....... .....23
Horn button.... ............................. ........23
Turn sign al switch ........ ....... ....... ....... ...23
Headlight switches ....... ....... ....... ....... ..24
Engine stop switch. ....... ....... ....... ....... ..25
Stater button .. . ....................................26
Kick starter.............. ...... ....... ....... ....... ...27
Remote engine stop switch.. ....................28
Throttle le ver... ....... ....... ....... ....... ....... ..29
Speed limiter.... ....... ....... ....... ....... ....... ..30
Front and rear bra ke..... ....... ....... ....... .....31
Brake pedal (MAXXER 90). ....... ....... ....... 31
Parking brake ( 50)....................32
Parking brake (MAXXER 90)... ....... ....... ..33
Fuel tank cap .. .......................................34
Fuel valve . .................................... ....... 35
Lock ing steering ( 90)
S tarter (choke) ( MAXXER 90).................37
Seat.. ....... ....... ....... ....... ....... ....... ....... ...38
Fla g pol e bra cket... ....... ....... ....... ....... ..... 39
Storag e com partmen t . ...........................39
MAXXER
MAXXER ..... ....... ..36
(Cont'd)
D
Page Page
PRE-OPERATION CHECKS......................40
Front and rear brakes ....... ....... ....... ....... .41
Fuel .... ....... ....... ....... ....... ....... ....... ....... 42
Engine (MAXXER 90) and
transmission oil ....................................44
Engine oil ( 50).......
Chain ...................................................46
Throt tle lever..... ....... ....... ......................46
Fitt ings and fasteners... ..........................46
Lights ...................................................46
Switches .......................... ........ ....... .....46
Tires ............................. .. ....... ....... ....... 47
How to meas ure tire pressure ..... ....... .....48
Tire wear limit .......................................49
OPERATION. .... .... .... .... .... .... .... .... .... .... ...5 0
St arting a cold engine ( 90)........50
Starting eng ine (MAXXER 50).... ....... .....53
Engine brea k-in... ....... ....... ....... ....... ......5 4
Parking .. ..... ....... ....... ....... ....... ....... ......5 6
Parking on a slope ....... ....... ....... ....... .....57
Access ories .. ....... ....... ....... ....... ....... .....58
MAXXER ..... ....... ......4 5
MAXXER
Riding Your ATV....... ....... ....... ....... ....... .....59
GETT ING TO KNOW YOUR ATV.. ..... . ......60
RIDE WI TH CARE AND
JUDGEMENT......... ....... ......................... 61
Age Recom mendation (MAXXER 50)... .....62
Age Recom mendation (MAXXER 90)... .....63
Never carry passenger on th e ca rrier... .....64
Ap parel.. ... ..... ....... ....... ....... ....... ....... ...65
Do not operate after consuming alcohol or
drugs. .... .... .... ................................. .... ..66
Pre-op eration checks.. ....... ....... ....... ....... 67
Lo ading and accessories.........................69
Loading and Operational Guidelines.........69
Access ories......... ....... ...... ........ ....... .....70
No Mod ificati ons.... ....... ....... ....... ....... ....71
During operation ... ....... ....... ....... ....... ....72
Exhaust system....................................74
RIDING................................................75
Remote engine stop switch for new
Ride rs..... ....... ....... ....... ....... ....... ....... ...76
GOOD
(Cont'd)
E
Page Page
Speed limiter for ne w rid ers.....................77
BRAKING..................................... ....... ..78
TURNING YOUR ATV .............................79
CLIMBING UP SLOPE. ....... ....... ....... .....80
RIDING DOWN SLOPE .........................86
PARKING.......... ............... ............... ......87
WHAT TO DO IF....................................8 8
WHAT TO DO.... ....... ....... ....... ....... ....... 88
PERIODIC MAINTENANCE AND
AD JUSTM ENT.... ..... .............. ..... ......... ....8 9
Tool ki t...................................................89
PERIO DIC MAINTENANCE/
LUBRICATION ( 50)... ....... ....... .91
PERIODIC MAINTENANCE/
LUBRICATION (MAXXER 90)..................93
Engine oil (MAXXER 90 )..........................95
Transmi ssion o il..... ....... ....... ....... ...........99
Spark plug inspection............................102
Air filter clea ning... ....... ....... ....... ....... ...103
Valve clearance adju stment
(MAXXER 90).... .................................107
Idle spee d adjust ment.. ........ ....... .........108
Thro ttle lever adjustment .... ....... ....... ...109
MAXXER
Front and rear brake shoes (drum brake)
in spect ion.. ..... ..... ..... ..... ..... ..... ..... ..... .110
Front brake leve r free play adjustment....111
Rear brake lever free play adjustment
(Drum brake) ....... ....... ....... ....... ....... .....113
Br ake pedal ad justmen t (MAXXER 90 )..115
Brake fl uid inspec tion (Disk br ake)... .....118
Drive chain slack ch eck.... ....... ....... ....... 120
Drive chain slack adjustm ent.... ....... ......1 20
Driv e chain clea ning and Lubricatio n...... 122
Cable in spectio n and lubri cation. ....... ...122
Brake lever lubrication..........................123
Knuckle shaft and rear fork shaft
l u b r ic a t i o n. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . .1 2 3
Draining the V-belt compartment
(MAXXER 90)......................................123
Wheel removal .....................................124
Wheel installation.................................124
Ba ttery . ..... ..... .............. ..... ..... ..........125
Fuse replacement................................127
Headlight beam adjustment...................130
Trouble shooting .. . ....... ....... . ....... . .....13 1
Troub l eshoot ing char t..... ...... ...... ...... .132
(Cont'd)
F
Page
CLEANING AND STORA GE..... ....... ....... ..133
A. Cle aning .........................................133
B. Storage ...........................................135
SPECIFICATIONS (MAXXER 50)... ....... ....137
SPECIFICATIONS (MAXXER 90).............141
NOISE REGULATION. ....... ....... ....... ....... 145
MAINTENANCE RECORD.......................146
IN DEX. .... .... .... ................................. .... .147
G
WARNING INFORMATION
Your ATV c omes with a hang tag and several
labels containing important safety informatio n.
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 th em to
ride.
The labels should be considered as permane nt
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.
ALWAYS U SE AN
APPROVED HELMET AND
PROTECTIVE GEAR
NEVER operat e :
‧With out p roper trainin g or in struction.
‧At speeds too fa st fo r your skills
the condi tio ns.
Do not oper ate t he ve hicle after
consumi ng ALCOHOL OR DRUGS.
ALWAYS :
‧Use proper rid ing t echniques to av oid
vehicle o ver tur ns on hills and rou gh
terrain and in t urns.
‧For your safet y, wear ge ar to i nclude
helmet gl ove s and f oot protectio n.
‧Gasoline is fl amm able shut off eng ine ,
avoid spa rks a nd op en flame when ref uel ing.
READ OWNER'S M ANU AL, FOLLOW
ALL IN STRUCTIONS AND WARNINGS.
NEVER USE WITH
ALCOHOL OR DR UG S
or
2
( 50)MAXXER ( 90)MAXXER
WARNING
UNDER
6
Oper ating thi s ATV if y ou a re unde r th e
age of 6 i ncrease s your chan ce of
seve re injury o r death.
NEVE R operate t his ATV if y ou are
unde r age 6.
WARNING
IMPR OPER TIRE P RESSURE O R OVERLOA DING CAN
CAUS E LOSS OF CON TROL.
LOSS O F CO NTROL CAN R ES ULT IN SEVER E IN JURY
OR DEATH.
OPER ATI NG T IRE PRE SS URE : Set w it h tires c ol d‧
Reco mmended :
FRON T : 22 ~2 8 kpa, (0 .2 2~0.2 8 kg f/cm ) , 3. 2~4.0 p si
REAR :
‧Neve r set tire pr essure ov er the reco mmended .
22~2 8 kpa, (0.2 2~0.28 kg f/cm ), 3. 2~4.0 psi
2
2
Oper ating thi s ATV if y ou a re unde r th e
age of 1 2 increas es your cha nce of
seve re injury o r death.
NEVE R operate t his ATV if y ou are
unde r age 12.
WARNING
UNDER
12
3
SAFETY INFORMATION
AN ATV IS NOT A TOY AND C AN BE HAZAR DOUS TO OPERATE. An ATV handles different ly from
other vehicles including motorcycles a nd cars. A collisio n can occur q uickly, even during rout ine
maneuvers, if you fail to take proper pre-cautions.
SEVERE INJURY OR DEATH can result if you do not follow these in structi ons:
‧Read this manual and all labels carefully an d follow th e operati ng procedures described.
‧Never operate an ATV without pr oper trai ning or ins tructio n.
Beginners should receive training from a certifie d instruc tor.
‧Always follow the age recommendation:
- A chil d under 6 years old should never operate an ATV with en gine size greater than 70cc.
- A chil d under 12 years old should never operate an ATV w ith engin e size greater than 90cc.
‧Never allow a child under age 16 to operate an ATV wi thout adult supervision, and never allow
continued use of an ATV by a ch ild if he or sh e does not ha ve the abil ities to operate it safely.
‧Never operate an ATV without we aring an ap proved mo torcycle helmet that fits properly. You
should also wear eye protection (goggles o r face shie ld), glov es, boots , long-sleeved shirt or
jacket, and long pants.
4
‧Never consume alcohol or drugs before or whi le operat ing this ATV.
‧Never operate at speeds too fast for your skills or the con ditions . Always go at a s peed that i s
proper for the terrain, visibility and operating co ndition s, and your e xperience.
‧Never attempt wheel, jump, or other stunt.
‧Always inspect your ATV each time you use it t o make sure i t is in safe op erating condition. Always
follow the inspection and maintenance pr ocedure s and sched ules described in this manual.
‧Always keep both hands on the handlebars and b oth feet on t he footbo ards of the ATV during
operation.
‧Always go slowly and be extra careful when ope rating on u nfamili ar terrain. Always be alert to
changing terrain conditions when opera ting the ATV.
‧Never operate on excessively rough, slip pery or loo se terrai n.
‧Always follow proper procedures for turning as desc ribed in th is manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at ex cessive s peed.
‧Never operate the ATV on hi lls.
‧Always follow proper procedures for clim bing slop es as descr ibed in this manual. Check the
terrain carefully before you start up any slope. Shif t your weig ht forwar d. Never op en the throttle
suddenly. Never go ove r the top of a sl ope at high s peed.
5
‧Always follow proper procedures for goin g down slop es and for br aking on slopes as described in
this manual. Check the terrain carefully before you s tart down a ny slope. S hift your w eight
backward. Never go down a slope at high speed. Avoid going down slope at an angle that wo uld
cause the vehicle to lean sharply to one side. Go straigh t down the sl ope where p ossible.
‧Never attempt to turn the ATV around o n any slope u ntil you ha ve 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 ar ea. Never a ttempt to o perate over large
obstacles, such as large rocks or fallen trees. Always f ollow pro per proce dures when operating
over obstacles as described in this manual .
‧Always be careful when skidding or sliding . Learn to sa fely cont rol skidding or sliding by
practicing at low speeds and on level, smoot h terrain . On extrem ely slipp ery surfaces, such as
ice, go slowly and be very cautious in order to reduce the ch ance of ski dding or sl iding out of
control.
‧Never operate an ATV in fast flowing water o r in water de eper than t hat recommended in this
manual. Remember that wet brakes may have reduced sto pping abi lity. Test your br akes afte r
leaving water. If necessary, app ly them sev eral time s to let friction dry out the linings.
‧Always use the size and type tires specified in this manu al. Always m aintain p roper tire pressure
as described in this manual.
‧Never modify an ATV throu gh improp er instal lation or use of accessories.
‧Never exceed the stated load capacity for an ATV. Ca rgo shoul d be proper ly distributed and
securely attached. Reduce speed and foll ow instru ctions in t his 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 eng ine when re fueling .
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 r efuelin g.
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 injuri es.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhal e
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 clothin g,
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 wh en
order replacement parts.
Keys identification number
The keys identification number is stamped on
the hang tag as shown in the following
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
9
MAXXER
(2)
(1)
(1) Headlight switch
Headlight switch
Turn the sw itch to the " " p osition t o switch on
the low beam.
Turn the sw itch to the " " p osition t o switch on
the high beam.
Turn the sw itch to the " " p osition t o switch off
the headlight.
NOTE:
The headlight can be turned on only when the
engine is running.
24
(1) Engine stop switch " "/" "
(1)
Engin e stop switch
When the switch is in the RUN ( ) position, the
engine will operate. When the switch is in OFF
( ) posit ion, the engine will not operate.
This switch is intended primarily as a safety or
emergency control, and it should normall y
remain in the RUN ( ) position.
NOTE:
If you st op your ATV by turning the engi ne stop
switch OFF ( ), be sure to turn the ignition
switch OFF to prevent battery discharge.
25
(1)
Stater button
To starter the engine, apply brake and press the
starter button, with the ignition switch ON (‧)
and the engine stop switch at RUN ( )
CAUTION:
See starting instructions prior to starting
engine (see page 50 for details).
(1) Start button
NOTE:
If the st arter switch is pushed with the ignition
switch " " and the engine stop switch " ", the
starter motor will be activated but the engine
will not start. To start the engine, b e sure to
position the engine stop switch at " ".
26
．
Throttle lever
It is operated by the thumb. Pressing the lever
opens the throttle. When pressure is released,
spring tension automatically closes the throttl e.
Regulate the speed of the machine by varying
the throttle position.
(1)
(1) Throttle lever
WARNING
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The thr ottle could be hard to operate,
making it difficult to speed up or slow down
when you need to. Th is could ca use an
accident.
HOW TO AVOID THE HAZARD
Check the operation of the throttle lever
before you start the engine. If it does not
work smoothly, check for the cause.
Correct the problem before riding the ATV.
Consult a KYMCO dealer if you can't find or
solve the problem yourself.
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