KYMCO maxxer50/99 on-road 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 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)

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)

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)

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

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

( 50)MAXXER ( 90)MAXXER

WARNING

UNDER

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

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

+ 26 hidden pages