Kymco Maxxer 90 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.
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 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)
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)
E
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)
F
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
G
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
or
2
( 50)MAXXER ( 90)MAXXER
WARNING
UNDER
6
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
2
2
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
12
3
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.
4
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.
5
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.
6
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.
7
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
9
MAXXER
(2)
(1)
(1) Headlig ht switch
Headlight switch
Turn the sw itch to the " " position to switch on the low beam.
Turn the sw itch to the " " position to switch on the high beam .
Turn the sw itch to the " " position to swit ch off the headlig ht.
NOTE:
The headlig ht can be turned on only when th e engine is run ning.
24
(1) Engine stop switch " "/" "
(1)
Engine stop switch
When the switch is in the RU N ( ) position, the engine will o perate. When the switch is i n OFF
( ) position, the engine will not operate .
This switch is intende d primarily as a sa fety or emergency c ontrol, and it should norm ally remain in the R UN ( ) position.
NOTE:
If you stop your ATV by turning the engine sto p switch OFF ( ), be sure to tur n the ignition switch OFF to prevent ba ttery dischar ge.
25
(1)
Stater button
To starter the engine, apply brake and press the starter button, with t he ignition swi tch ON () and the engin e stop switch at RUN ( )
CAUTION:
See starting instruc tions prior to starting engine (see page 50 for de tails).
(1) Start button
NOTE:
If the starter switch is p ushed with the ig nition switch " " and the engin e stop switch " ", the starter motor will be ac tivated but the e ngine will not start. To start the engi ne, be sure to position the engine stop switch at " ".
26
Throttle lever
It is operated by the thum b. Pressing the l ever opens the throttle. Wh en pressure is re leased, spring tens ion automatically clos es the throttle . Regulate the speed of the machine by vary ing the throttle positio n.
(1)
(1) Throttle lever
WARNING
POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPP EN The throttle could be hard to opera te,
making it difficult to speed up or sl ow down when you need to. This could cause an accident.
HOW TO AVOID THE HAZARD Check the operation of t he thrott le lever
before you start the eng ine. If it do es not work smoothly, check f or the cause.
Correct the problem be fore ridi ng the ATV. Consult a KYMCO dealer i f you can't f ind or
solve the problem yourself.
29
Front and rear brakes
The front and rear brakes are operated by squeezing t he front brake lever.
(1)
(1) Front brake lever
Brake pedal (MAXXER 90)
The both front and rear br akes are operat ed at the same time by depressing the brake pedal.
(1)
(1) Rear brake pedal
31
WARNING
POTENTIAL HAZARD Improper use of the parking brake .
WHAT CAN HAPP EN The ATV could start moving unexpect edly
if the pa rking brake is not applied b efore starting the engine. This could c ause loss of control or a collision.
The brake could overhe at if you rid e the ATV without releasin g the parking brake.
You could lose braking performance which could cause an accident. You could also wear out the brakes prem aturely.
HOW TO AVOID THE HAZARD Always set the parking b rake before
starting the engine. Always be sure you have re leased the
parking brake before y ou begin to r ide.
Fuel tank cap
After refueling, be su re to tighten the fuel tank cap.
TO refuel re fer to page 42~43.
(1)
(1) Fuel tank cap
34
RES
OFF
ON
Fuel valve
The fuel valve supplies fuel from the fue l tank to the carbure tor.
The fuel valve has three positions.
OFF:
With the lever and " " mark in t his position fuel will not flow. Always turn th e lever to this position when the engine is not running .
ON :
With the lever in this position, fuel flows to the carbur etor. Normal rid ing is done with the lever in this position.
RES:
This indica tes reserve. If you run out of fuel while ri ding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FI RST OPPORTU NITY. After refueling, ret urn the fuel valv e lever to the "ON" position.
" " mark
" " mark
(2)
(1)
(1) Fuel lever (2) " " mark
NOTE:
After refueling, do no t operate the ATV wi th the fuel valve in the RES position. If you run ou t of fuel, there will be no reserve supply.
35
Locking steering
Turn the st eering handle bar left to full an d turn the key clockwise, the steering handl ebar is locked.
The key can be taken out. Turn the ke y countercloc kwise, the stee ring
handlebar i s released automatically. The key can be taken out.
(MAXXER 90)
LockingLocking
UnlockingUnlocking
WARNING
POTENTIAL HAZARD Improper use of the locking steer ing.
WHAT CAN HAPP EN The ATV could cause loss of control or
overturn.
HOW TO AVOID THE HAZARD Always be sure you have re leased the
locking steering handlebar be fore you begin to ride.
Never lock the steerin g handlebar, when the engine is starting.
36
Starter (ch oke) ( 90)
Starting a cold engine requires a richer air-fuel mixture. A separate starter circu it supplies thi s mixture.
Move in direc tion (A) to turn on the starte r (choke).
Move in direc tion (B) to turn off the starter (choke).
Refer to "starting a col d engine" for pro per 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 us e of the choke may impair piston and cylinde r wall lubrication and shorten the life of the engine. Pushing the c hoke knob too hard to the OFF position may dislodge the choke cable boot. If this happen s, water and dirt may enter th e choke cable a nd cause corros ion. If the choke is hard to actuate, or fee ls like it is sticking, Check the cable boot
37
Seat
To remove the sea t, pull upward the seat lock lever and pul l up the seat the rear.
(1)
(1)
(1) Seat lock lever
To install the se at, align the tabs on the seat w ith the grommets on the fram e and press the sea t down until it locks.
NOTE:
Make sure tha t the seat is securely fitte d.
38
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, 118120
46
4749, 122
46
46 46
40
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before ope rating. Failure to properly ma intain th e ATV.
WHAT CAN HAPP EN Increases the possib illty of an a ccident or
equipment damage.
HOW TO AVOID THE HAZARD Always inspect your ATV ea ch time you use
it to make sure the ATV is in safe operatin g condition.
Always follow the inspection an d maintenance proced ures and schedules described in the Owner's Manual .
Front and rear brakes
1.
Drum brake Check for correct free play in the brake le vers.
If the free play is incorrect, adjust it. ( See pages 110~117.)
Check opera tion of the levers. They should move smooth ly and there should be a firm feeling whe n the brake is applied. If not , have the machine i nspected by a KYMCO dealer.
Disk brake
2. Make sure the re is no brake fluid leakage.
Check opera tion of the levers. They should move smooth ly and there should be a firm feeling whe n the brake is applied. If not , have the machine i nspected by a KYMCO dealer.
Brake opera tion
3. Test the brakes a t slow speed after startin g
out to make sur e they are working properly. If the brakes do n ot provide proper braking performan ce, inspect the brakes for w ear. (See page 110 .)
41
WARNING
POTENTIAL HAZARD Riding with improperly operat ing brakes.
WHAT CAN HAPP EN You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD Always check the brake s at the start of
every ride. Do not ride th e ATV if you find any problem with the brakes. If a pro blem cannot be corrected by t he adjustment procedures provide d in this man ual, have
the ATV inspected by a KYMCO d ealer.
Fuel
Fill the fuel tank when ne cessary and mak e sure there is sufficient gasoline in the ta nk.
Check for lea ks. Fuel level sh ould be below the filler neck.
(1)
(1) Filler neck
Recommend ed fuel: UNLEADED FUEL Fuel tank capacity: Total: 5 .5L(1.16 lmp gal, 1.4 US gal ) Reserve: 1.5L(0.32 l mp gal, 0.38 US gal )
42
Your KYMCO engine has been designed to use regular unl eaded gasolin e with a pump octane number of 86 or h igher, or research octane number of 91 or h igher. If knocking or pinging occurs, use a d ifferent bra nd of gasoline or premium unl eaded fuel. Unleaded fuel will give you longer sp ark plug life and reduced maintenan ce cost.
Use unleade d fuel only becau se it produces fewer engin e and spark plug de posits and extends the life of the ex haust system. N ever use stale or contaminated gasoline or a n oil/gasol ine mixture.
Avoid gett ing dirt, dust or water in the f uel tank.
WARNING
POTENTIAL HAZARD Improper care when ref ueling.
WHAT CAN HAPP EN Fuel can spill, which can cause a fir e and
severe injury. Fuel expands when it heats up. If the f uel
tank is overfilled, fuel could sp ill out due t o heat from the engine.
HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be car eful not
to spill fuel, especially on the engine or exhaust pipe. Wipe up any spi lled fuel immediately. Be sure the fuel tank cap is closed securely.
Do not refuel right afte r the engin e has been running and is still very hot.
43
Engine ( 90)and transmi ssion oil
MAXXER
Make sure the e ngine and transmission oil at the specified l evel. Add oil as nec essary. (See pa ge 95~101.)
Check for lea ks.
1 0
0
30
0
50
0
70
0
90
0
0
110 F
SAE 5W
SAE 10W30
CAUTION:
Be sure to use motor oils th at do not contain anti-frict ion modif iers. Passenger car motor oils (often la beled "Energy Conserving") conta in anti-f riction additives which will cause star ter clutch slippage, resulting in reduce d compone nt life and poor engine performanc e.
SAE 10W40
SAE 20W40
SAE 20W50
-1 0
0
0
0
10
0
20
0
30
0
0
40 C
Recommend ed engine/transmission oil classific ation: API Service SE, SF, SG typ e or higher
Oil quantity: Engine oil: Periodic oil change:
0.7 L (0.62 l mp qt, 0.74 US qt)
Total am ount:
0.8 L (0.70 l mp qt, 0.84 US qt)
Transmission oil:
Periodic oil change:
0.11 L (0.1 0 lmp qt, 0.12 US qt) Total am ount:
0.12 L (0.11 lmp qt, 0.13 US qt)
44
Engine oil ( 50)
Oil level When the low oil level indicator lights , it means
the oil level i n the oil tank is low; stop the en gine and fill the oil tank as soo n as possible.
MAXXER
(1)
CAUTION:
If the low oil level indicator comes on whi le
riding, stop riding and shut the engine off. Fill the oil tank to the upper le vel mark with the recommend ed oil. Continuing to ride with a low oil level m ay lead to engine failure that could resul t in an accident.
if the engine h as been run after the low oil
level indic ator has come on, the scoote r must be taken to an authorized KYMCO dealer fo r inspectio n and bleeding of the oil system. Failure to do this will result in serious e ngine damage.
To fill, lift seat (see page 3 8), remove the ca p from the oil tank, and fil l with the recomm ended oil up to the upper level mark.
NOTE:
When filling, do not let d irt or other fore ign materials e nter the ta nk.
(2)
(3)
(1) Cap (2) Upper level mark (3) Fill duct
Oil recomme ndation : Use KYMCO 2-S TROKE OIL OR ITS
EQUIVALEN T
CAUTION:
The use of improper oils may cause excess ive and/or prem ature carbon build-up in the engine and exhaust s ystem, resulting in loss l f power and possibl e engine damage . Genuine KYMCO 2-Stroke Oil has been specifically designed and tested in KYMCO ATV and is a prop er oil.
45
Chain
Check the gen eral condition of the chain and check the cha in slack before every ride.
Lubricate a nd adjust the chain as necessary. (See pages 118~120 for detai ls.)
Light s
Check the pos ition light and tailligh t/stop light to make sure the y are in working co ndition. Repair as necessar y for proper oper ation.
Throttle lever
Check to see that the thro ttle lever oper ates correctly. It must open smoothly and spring back to idle position when released. Repair as necessary f or proper opera tion.
Fittings and fastene rs
Always chec k the tightness of chassis f ittings and fasteners before a ride. Take the machine to a KYMCO deale r or refer to t he Service Manu al for correct tighteni ng torque.
Switches
Check the ope ration of the switch, engine stop switch, remote en gine stop switch and an y other switches.
Repair as nec essary for prop er operation.
46
taillight/stop lig ht
Tires
WARNING
POTENTIAL HAZARD Operating this ATV with improper ti res, or
with improper or uneven tire pres sure.
WHAT CAN HAPP EN Use of improper tires on t his ATV, or
operation of this ATV with improper o r uneven tire pressure , may cause loss of control, increasin g your risk o f accident.
HOW TO AVOID THE HAZARD
1.The tires listed bel ow have bee n approved by Kwang Yang M otor Co., Ltd. for this model. Other tire combin ations are not recommended.
2.The tires should be set to the recommended pressu re:
Recommended tire pre ssure
Front: 25 kpa (0.25 kgf/ cm , 3.6 psi)
Rear: 25 kpa (0 .25 kgf/c m , 3.6 psi)
2
2
Check and adjust tire pressures when the
tires are cold.
Tire press ures must be equal on both
sides.
3.Tire pre ssure below the minimum specified could cause the tire to d islodge from the rim under sever e riding conditions.
The following are minimums:
Front: 22 kpa (0.22 kgf/ cm , 3.2 psi)
Rear: 22 kpa (0 .22 kgf/c m , 3.2 psi)
2
2
Front
Rear
MAXXER 50
16*8-7
16*8-7
Size
MAXXER 90
18*7-8
18*9-8
Type
TUBELESS
TUBELESS
47
4.Never set tire press ure over the recommended
Front: 28 kpa (0.28 kgf/ cm , 40 psi)
Rear: 28 kpa (0 .28 kgf/c m , 40 psi)
2
2
Higher pressures may c ause the tire to burst. Inflate the tir es very slowly and carefully. Fast inflation could cause the tire to burst.
How to measure tire pres sure
Use the low-p ressure tire gauge.
NOTE:
The low-pre ssure tire gauge is included as standard eq uipment. Make two measureme nts of the tire pressure and use the second re ading. Dust or dirt in the gau ge could cause t he first reading to be incor rect.
Set pressur e tires cold. Set tire pres sures 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)
2
(0.22 kgf/cm ,
2
(0.22 kgf/cm ,
Minimum
22 kpa
3.2 psi)
22 kpa
3.2 psi)
(1) Low-pressure tire gauge
2
(0.28 kgf/cm ,
2
(0.28 kgf/cm ,
Maximum
28 kpa
4.0 psi)
28 kpa
4.0 psi)
2
2
48
Tire wear limit
When the tire groove decreases to 3 mm (0.1 2 in) due to wear, r eplace the tire.
A. 3mm (0.12 in)
49
OPERATION
Starting a cold engine ( 90 )MAXXER
WARNINGWARNING
POTENTIAL HAZARD Operating ATV without being familiar with
all controls.
WHAT CAN HAPP EN Loss of control, which could cause an
accident or injury.
HOW TO AVOID THE HAZARD Read the Owner's Manua l carefully. If there
is a control or function you do not understand, ask your K YMCO dealer.
POTENTIAL HAZARD Freezing control cables in cold w eather.
WHAT CAN HAPP EN 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, alway s make
sure all control cables work smoo thly before you begin riding.
1. Select a level surface and lock the park ing brake (see pa ge 32 or 33) before s tarting the engine.
2. Turn the fuel lock to "ON" .
3. Turn the main s witch to "" and the engine stop switch to " ".
4. Make sure the tethere d road lead into the
50
remote engi ne stop switch.
is installe d
5. Use the starter (chok e) in reference t o the figure:
Position :Cold engine start-ambie nt
temperature below 5C (40F).
Position :Cold engine start-ambie nt
temperature at 0C (30F)~30C(90F) and warming u p position.
Position :Cold engine start-ambie nt
temperature above 25C(80F) and warm engine s tart position.
1. Fully open
3. Closed
2. Half open a. Starter (choke)
6.With the throttle cl osed, push the starter button. Release the st arter button as soon as the engine starts.
NOTE:
Do not use the electric st arter for more than 5 seconds at a ti me. Release the starter bu tton for approxi mately 10 seconds before pressing it again.
7. If the engine is starte d with the starter
(choke) in po sition , the starter (chok e) should be ret urned to position to warm up the engine. If the engine is started with t he starter (choke) in position , keep the st arter (choke) in th is position to warm up the engine.
8. Continue warming up the engine until i t idles smoothly an d return the starter (chok e) to position before riding.
CAUTION:
See the "engine break- in section prior to operating engine for the first ti me.
51
To start the engi ne without the electric st arter.
1. Follow steps 1 through 5.
2. With the throttle clo sed, operate the kick starter with a rapid, co ntinuous moti on.
Starting a warm engine ( MAXXER 90)
To start a warm eng ine, refer to the "Startin g a cold engine " section. The s tarter (choke) should not be used. The throttle should be opened slightly.
CAUTION:
Do not allow the kick star ter to snap back
freely agai nst the pedal stop as engine case damage coul d result.
Raise the kic k starter p edal after the ki ck
starter lever is retur ned to the stop.
3. Follow steps 7 through 8.
Warming u p (MAXXER 90)
To get maximum en gine life, always warm up the engine befo re starting off. Never accelerate
hard with a col d engine! To see whether or not the engine is w arm, check if it responds to t he throttle normally with the starter (c hoke) turned off.
CAUTION:
Do not operate the throt tle (open and clo se
rapidly) as t he ATV will move for ward suddenly, causing possib le loss of contro l.
Do not leave the ATV unattended while the
engine is war ming up
52
Starting engine ( 50)MAXXER
WARNING
POTENTIAL HAZARD Freezing control cables in cold w eather.
WHAT CAN HAPP EN 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, alway s make
sure all control cables work smoo thly before you begin riding.
1. Select a level surface and lock the park ing brake ( ) before starting the engine.
2. Turn the fuel lock to "ON" .
3. Turn the main s witch to "" and the engine stop switch to " ".
4. Make sure the tethere d road lead into the
see page 32 or 33
is installe d
remote engi ne stop switch.
5.With the throttle cl osed, push the starter button. Release the st arter button as soon as the engine starts.
NOTE:
Do not use the electric st arter for more than 5 seconds at a ti me. Release the starter bu tton for approxi mately 10 seconds before pressing it again.
6. Be sure to keep the throt tle closed and th e
parking bra ke locked while s tarting and warming up th e engine.
7. Allow the eng ine warm up before riding.
CAUTION:
Do not operate the throt tle (open and clo se
rapidly) as t he ATV will move for ward suddenly, causing possib le loss of contro l.
Do not leave the ATV unattended while the
engine is war ming up
53
To start the engi ne without the electric st arter.
1. Follow steps 1 through 4.
2. With the throttle clo sed, operate the kick starter with a rapid, co ntinuous moti on.
CAUTION:
Do not allow the kick star ter to snap back
freely agai nst the pedal stop as engine case damage coul d result.
Raise the kic k starter p edal after the ki ck
starter lever is retur ned to the stop.
3. Follow steps 6 through 7.
If you cannot restart a wa rm engine:
1. Follow steps 1 through 4.
2. Open the throttle sli ghtly (1/81/4) while starting the engine . If t he throttle lim iter Is adjusted as d elivered, open the throt tle fully.
Engine break-in
There is neve r a more important period in t he life of your machine than the p eriod between z ero and 20 hours.
For this reason, we ask th at you carefull y read the following material. Because the e ngine is brand new, you m ust not put an excessive load on it for the first 20 hours , the various par ts in the engine we ar and polish themselves to the correct ope rating clearances.
During this p eriod, prolonged full th rottle operation o r any condition which might result in excessive e ngine heating m ust be avoided. However, mom entary (2~3 seconds maximum) full throttle operat ion under load do es not harm the engine.
Each full throttle acc eleration seq uence should be followed w ith a substantial rest per iod for the engine by cru ising at lower r/min so the en gine can rid itsel f of the temp orary build up of h eat.
If any abnormality is noticed during th is period, consult a KYM CO dealer.
54
1. 0~10 hours : Avoid cont inuous operat ion 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 th rottle positi on.
2. 10~20 hour s: Avoid prol onged operati on above 3/4 thro ttle.
Rev the machi ne freely through the gear s but do not use full throttle a t any time.
3. After break-in Avoid prol onged full thro ttle operation. Vary
speeds occa sionally.
55
Parking ( 50)
When parkin g, stop the e ngine. Turn the fu el lock to "OFF" and apply th e parking brake .
MAXXER
Parking ( 90)
When parkin g, stop the e ngine. Turn the fu el lock to "OFF" and apply th e parking brake .
MAXXER
Make sure the l ock plate into the locked position.
To set the parkin g brake, see page 3 2.
(1)
(1)Locked position
Make sure the l ock pin into the locked position.
To set the parkin g brake, see page 3 3.
(1)
(1)Locked position
56
Parking on a slope
WARNING
POTENTIAL HAZARD Parking on a slope or other incline .
WHAT CAN HAPP EN The ATV could roll out of control, increasing
the chance of an acciden t.
HOW TO AVOID THE HAZARD Avoid par king on slope or other inclines. If
you must park on an incline, place th e machine transverse ly across the incline, apply the parking brak e, and bloc k the front and rear wheels with rocks or other o bjects.
Do not park the ATV at all on slope that are so steep you could not walk up them eas ily.
1. Bring the machine to a stop by applying th e brakes.
2. Stop the engine.
3. With the brake applied, apply the park ing brake.
57
Accessories
Accessori es can affect th e handling and co ntrol of your ATV. Keep the foll owing in mind whe n consideri ng an accessory o r operating an ATV which has acc essories.
Choose only a ccessories de signed for your
ATV. Your KYMCO deal er has a variety of genuine KYM CO accessorie s. Other accessori es may also be avai lable on the market. However, it is not possible for KY MCO to test all non-KYMCO ac cessories, no r have any control over the quality or suitabi lity of them. Choose a genuine KYMCO accessory, or one that is equivalent in design and quality.
Accessori es should be rigi dly and securel y
mounted. An ac cessory which c an shift position or come off while yo u are riding coul d affect you r ability to control the ATV.
Do not mount an accessory where it could
interfere with your ability your to con trol the ATV. Examples in clude (but are not limited t o) a heavy or bulk y object attached to the handlebar s which could mak e steering difficul t, an accessory that limits your ability to move around o n the seat, or one that limits your view.
Use extra cau tion when riding an ATV with
accessori es. The ATV may han dle differently
58
WARNING
Indic ates a potentia l hazard that could result
in serious injury or death.
GETTING TO KNOW YOUR ATV
This ATV is for re creation and utility use . This section, riding your ATV, provides ge neral ATV riding inst ructions for recreatio nal riding. The skills and te chniques desc ribed in this section, however, are a ppropriate for all types of riding. Riding your ATV requires spec ial skills acqu ired through pra ctice over a period of time. Take the time to learn the basic te chniques well b efore attempting more difficult maneuvers.
Riding your n ew ATV can be a very enj oyable activity, providing you wi th hours of pleasure. But it is essential to fam iliarize your self with the operation o f the ATV to achieve the sk ill necessary t o enjoy riding safely. Before you begin to ride , be sure you have read this Owner's manual.
Manual comp letely and unde rstand the operation o f the controls. Pay partic ular attention to the safet y information on pages 4~8. Please a lso read all caution and warning labels on you r ATV.
60
RIDE WITH CARE AND GOOD JUDGEMENT
Get training if you are inexperie nced.
Beginners a nd inexperien ced riders shou ld get proper inst ruction on how to operate th is ATV.
WARNING
POTENTIAL HAZARD Operating this ATV without proper
instruction.
HOW TO AVOID THE HAZARD Become familiar with t his ATV at slow
speeds first, even if yo u are an experienced operator.
Do not attempt to operat e at maximum performance until yo u are totally familiar with the machine's handling and performance charac teristics.
WHAT CAN HAPP EN The risk of an accident is greatly in creased
if the op erator does not know how to operate the ATV properly i n different situations and on different typ es of terrain.
Riding your machine requires sk ills acquired through practice ove r a period of t ime.
Take the time to learn the basic techniques w ell before attempting mo re difficult maneuvers.
61
Age Recommendation ( MAXXER 50)
The minimum recommended age for this ATV model is 6. For safety, never let childre n under 6 years old ope rate this vehicle. Child ren under 16 should be su pervised by an ad ult.
WARNING
POTENTIAL HAZARD Failure to follow the age recomme ndations for this ATV. Failure to supervise c hildren u nder 16 on ATV models intended fo r their use.
HOW TO AVOID THE HAZARD A child und er 6 should n ever operate this ATV. Never allow a child under 16 to opera te an ATV without adult supe rvision a nd never allow continued use of t e ATV by a child If he or she does not have the abilities t o operate it safely.
WHAT CAN HAPP EN If children use ATVs that ar e not recommended for thei r 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 skil ls, abili ties, or judgm ent needed to operate the ATV sa fely and may be involved in a serious acci dent.
UNDER
6
62
Age Recommendation ( MAXXER 90)
The minimum recommended age for this ATV model is 12. Fo r safety, never let childr en under 12 years old op erate this vehicle. Chil dren under 16 shou ld be supervise d by an adult.
WARNING
POTENTIAL HAZARD Failure to follow the age recomme ndations for this ATV. Failure to supervise c hildren u nder 16 on ATV models intended fo r their use.
HOW TO AVOID THE HAZARD A child und er 12 shoul d never operate t his ATV. Never allow a child under 16 to opera te an ATV without adult supe rvision a nd never allow continued use of t e ATV by a child If he or she does not have the abilities t o operate it safely.
WHAT CAN HAPP EN If children use ATVs that ar e not recommended for thei r 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 skil ls, abili ties, or judgm ent needed to operate the ATV sa fely and may be involved in a serious acci dent.
UNDER
12
63
Apparel
WARNING
POTENTIAL HAZARD
Operating this ATV without wearin g an approved motorcycl e helmet, eye protection and prote ctive 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 protectiv e clothing increases your chanc es of severe injury in the event of an accident .
HOW TO AVOID THE HAZARD
Always wear an approve d motorcycle helmet that fits properly.
You should also wear:
eye protection(goggles or fac e shield)
glove s
boots
long- sleeved shirt or jacket
Long pa nts
65
Do not operate after con suming alcohol or drugs.
Operator's performance capability is reduced by the influence of alcohol or drugs.
WARNING
POTENTIAL HAZARD Operating this ATV after c onsumin g
alcohol or drugs.
WHAT CAN HAPP EN Could seriously affe ct your jud gment. Could cause you to react m ore slowl y. Could affect your bala nce and per ception. Could result in an accident.
HOW TO AVOID THE HAZARD Never consume alcoho l or drugs be fore or
while d riving this ATV.
66
Pre-operation chec ks
Always perf orm the pre-operation checks listed on page 40 befo re riding for safety and pro per care of the mac hine.
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before ope rating. Failure to properly ma intain th e ATV.
WHAT CAN HAPP EN Increases the possib ility of an a ccident or
equipment damage.
WARNING
POTENTIAL HAZARD Operating this ATV with improper ti res, or
with improper or uneven tire pres sure.
WHAT CAN HAPP EN Use of improper tires on t his ATV, or
operation of this ATV with improper o r uneven tire pressure , may cause loss of control, increasin g your risk o f an accident.
HOW TO AVOID THE HAZARD Always inspect tour ATV ea ch time you u se
it to make sure the ATV is in safe operatin g condition.
Always follow the inspection an d maintenance proced ures and schedules described in the Owner's Manual .
HOW TO AVOID THE HAZARD Always use the size and ty pe tires specified
in the Ow ner's Manual for this vehi cle on pages47~48.
Always maintain prop er tire pressure as described in the Owner's Manual o n page47.
67
Do not operate at speeds t oo fast your skills or the conditions.
WARNING
POTENTIAL HAZARD Operating this ATV at spee ds too fast f or
your skills or the conditions.
WHAT CAN HAPP EN Increases your chanc es of losing control of
the ATV, which c an result in an accident.
HOW TO AVOID THE HAZARD Always go at a speed that is proper for t he
terrain, visibility and opera ting conditions, and your experience.
Speed limit er For riders inexperienced with this mo del, this
model is equi pped with a speed l imiter in the throttle lever housing. The speed limiter limits the power and top speed of the machine.
Turning the screw in decre ases top speed, a nd turning it out increases top speed.
(2)
(1)
1. Adjuster
68
2. Locknut
Loading and accessories
Use extra cau tion when riding the machine with additiona l loads, such as accessories or cargo.
The machine 's handling may b e adversely affected . Reduce your speed when adding additiona l loads.
Loading and Operational Guidelines
Carrying ca rgo will affec t how your ATV handl es and greatly reduce its ability in accel erating, braking and m aking turns and o ther maneuvers.
Be sure to obse rve the weight limits and fo llow these guide lines:
1. Do not tow another vehi cle.
2. Make sure al l cargo is secured before riding.
3. Allow extra r oom for sta rting, stoppi ng and turning whe never you carry cargo or pull a trailer.
4. Avoid ridi ng on steep slope s when carrying cargo or pill ing a trailer.
5. Never cross a slope when toeing a traile r.
69
WARNING
POTENTIAL HAZARD Overloading this ATV or carrying or t owing
cargo improperly.
WHAT CAN HAPP EN Could cause changes in vehicle ha ndling,
stability and brakin g which cou ld lead to an accident.
HOW TO AVOID THE HAZARD Never excee d the stated load capacity f or
this ATV. Cargo should be properly distri buted and
securely attached. Reduce speed when carr ying cargo or
pulli ng a trailer. Al low greater distance for braking.
Always follow the instruction s in your Owner's Manual for car rying car go or pulli ng a trailer.
Accessories
Genuine KYM CO accessories have been specifica lly designed for and teste d on this vehicle. Be cause KYMCO cannot test al l other accessori es, you are perso nally responsible for properly se lecting, installing, a nd using non­KYMCO acces sories. Always follow the loading instructions above, plus the follow ing:
1. Carefully inspect the accessory to m ake sure it does not block any lights, reduce grou nd clearance , or limit suspension trav el, steering travel, or other contr ols.
2. Make sure the accessory does not inter fere with your ability to shi ft body positio n on the seat or operate hand and foot controls.
3. Do not add electrical equipment that w ill exceed the vehicle's electrical system capacity. A blown fuse cou ld cause a loss of lights or engine power.
70
Modifications
WARNING
POTENTIAL HAZARD Operating this ATV with improper
modifications.
WHAT CAN HAPP EN Improper installat ion of acce ssories or
modification of this vehicle ma y cause changes in handling which in some situations could lead to an accid ent.
HOW TO AVOID THE HAZARD Never modify this ATV thro ugh impro per
installation or use of accessories. All parts and accessories adde d to this vehicle should be genuine KYMCO or equiva lent components designed for use on th is ATV and should be installed and used ac cording to instruction. If you have quest ion, consult an authorized ATV dealer.
No Modifications
Modifying this ATV or removing original equipment m ay render the vehicle unsafe or illegal. Sp ark arresters and mufflers ar e required in m ost areas. Don't modify yo ur exhaust sys tem or emission control system component s. Remember, excessive noise bothers eve ryone and creates a bad image for ATV.
71
RIDING
Select a flat area to become familiar wit h your ATV. Make sure that this area is free of obstacles a nd other riders. You should practice control of the throttl e, brakes, shif ting before trying more d ifficult ter rain.
Always avoi d riding on rough s urfaces: the ATV is designed f or on-road use on ly, and handlin g maneuvers a re more diffic ult to perform on l evel surfaces.
Set the parki ng brake and follow the instruction on page 50~54 t o start the engine. Once it ha s warmed up you a re ready to begin r iding your ATV. Remember that the engine and exhaust pipe will be ho t when riding and a fterwards; do not allow ski n or clothing to come in conta ct with these compo nents.
WARNING
POTENTIAL HAZARD Starting or running the engine in a closed
area.
WHAT CAN HAPP EN Exhaust fumes are pois onous and m ay
cause loss of consciousness and d eath within a short time.
HOW TO AVOID THE HAZARD Always operate your ma chine in an a rea
with adequate ventilation.
Practice wi th the remote engine stop sw itch and throttle limiter adj usted as delive red until you are confide nt in braking and making turns.
75
Speed limiter for new ri ders
Your ATV has an a djustable throttle lim iter. The screw and l ocknut in the lower thrott le
housing can b e adjusted to limit thrott le lever movement.
To adjust the thr ottle limiter:
1. Loosen the lock nut.
2. Turn the throttle limi ter screw clock wise to reduce thro ttle lever movement or countercl ockwise to increase throttle lever movement.
3. Hole the screw in place and tighten the lo ck nut.
1. Adjuster
77
(2)
(1)
2. Locknut
BRAKING
Practice starting and stopping at slo w speeds. Gradually w ork up to faster starts and st ops.
1. Steer straight ahea d. Close the thro ttle completel y, remove your th umb from the throttle lever.
2. Gently apply the brakes: pull both han d levers.
Gradually i ncrease the lever or/and pedal pressure as y ou feel the brakes slowing y our speed. The p ressure used de pends on your speed and the c ondition of the terrain yo u are riding. Sli ck , slippery or muddy ground requires gentler bra king.
Pulling one o r both brake leve rs or/and depressin g brake pedal too h ard may cause the front and/or rear whee ls to skid or slide o ut of control. If this happens, release all p ressure on the lever(s ) immediately. Steer str aight ahead to regain cont rol. Then gent ly reapply the brakes.
Independe nt use of only the front or rear b rakes reduces stopping performance. Ext reme braking may cause the wheels to lock, reducing co ntrol of the ATV
When possib le, reduce speed or brake before entering a turn. Closing the throttle o r braking in mid-turn ma y cause wheel slippage which will reduce cont rol of your ATV.
78
CLIMBING UP SLOPE
Use proper ri ding techniques to avoid vehicle overturns o n slopes. Be sure that you can maneuver yo ur ATV well on flat gr ound before attempting any incline and then pract ice riding first on gentle slopes. Try more difficult climbs only after you have developed your skil l. In all cases avoid i nclines with sl ippery or loose surfaces, or obstacles that might cau se you to lose contro l.
WARNING
POTENTIAL HAZARD Operating on excessi vely steep slopes.
WHAT CAN HAPP EN The vehicle can overtu rn more easily on
extremely s teep slop es than on level surfaces or small slop es.
HOW TO AVOID THE HAZARD Never operate the ATV on slo pes too steep
for the ATV or for your abilities. Practice on smaller sl opes before
attempting large slo pes.
It is important when cli mbing a slope to ma ke sure that tour weight is transferred fo rward on the ATV. This can be a ccomplished b y leaning forward, steeper inclines and stand ing on the footboards and leaning forward over the handlebar s.
80
If your ATV has stall ed or stopped and y ou believe you c an continue up the slope, restart carefully to make sure you do not lift the fr ont wheels whic h could cause you t o lose control. If you are unabl e to continue up the slope, dismount th e ATV on up slope side . Physically turn the ATV aro und and then desc end the slope.
WARNING
POTENTIAL HAZARD Stalling, rolling backwards o r imprope rly
dismounting while climbing a slope.
WHAT CAN HAPP EN Could result in ATV overturning.
If you start to roll backw ards, DO NOT use t he rear brake to s top. The ATV could easily ti p over backwards . Instead, dismount the ATV immediate ly on the up of slope side.
HOW TO AVOID THE HAZARD Maintain steady spee d when clim bing a
slope.
If you lose all forward speed: Keep weight up slope. Apply the brakes. Lock parking brake, af ter you are stopped.
If you begin rolling backwards: Keep weight up slope. Never apply the rear bra ke while rolling
backwards.
83
RIDING DOWN SLOPE
When riding y our ATV down s lope, shift your weight as far to the rear an d up slope side of th e ATV as possib le. Move back on th e seat and sit with your arm s straight. Improper bra king may cause a loss of t raction.
Use caution w hile descendi ng a slope with loose or slippery surfaces. Braking abili ty and traction may be advers ely affected b y these surfaces.
Improper br aking may also ca use a loss of traction. Whenever possible, ride y our ATV straight down slope. Avoid s harp angles whi ch could allow t he ATV to tip or roll over. Carefully choose your p ath and ride no faster than yo u will be able to reac t to obstacles which may appear.
WARNING
POTENTIAL HAZARD Going d own a slope i mproperly.
WHAT CAN HAPP EN Could cause loss of control or caus e the
ATV to overtu rn.
HOW TO AVOID THE HAZARD Always follow proper procedur es for going
down sl opes as described in this Owner's Manual. Note: a specia l techniq ue is required when brakin g as you go dow n a slope.
Always check the terra in carefully before you start down any slope.
Shift your weight backward. Never go down a slope at high speed. Avoid goi ng down a slo pe at an angl e that
would c ause the vehicle to lean sha rply to one side. Go straight down the slope where possible.
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WHAT TO DO IF
This section is designed to be a referenc e guide only. Be sure t o read each secti on on riding technique s completely.
WHAT TO DO.. ..
If your ATV doesn't turn when you want it to: Bring the ATV to a s top and practice the turni ng
maneuvers a gain. Be sure you a re putting your weight on the footboar d to the outside of t he turn. Position your weight over the fro nt wheels for better control. (S ee pages 79.)
If your ATV can't mak e it up a slope you are trying to climb:
Turn the ATV around if you stil l have forward speed. If not, stop, dis mount on the up slo pe side of the ATV an d physically tu rn the ATV around. If the ATV starts to slip backward s 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 .)
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PERIODIC MAINTENANCE AND ADJUSTMENT
Periodic in spection, adjustment and lubricatio n will keep you r machine in the safest and mo st efficien t condition pos sible. Safety is an obligatio n of the machine owner. The most important points of ma chine inspect ion, adjustmen t and lubrication are explained on the following p ages.
WARNING
POTENTIAL HAZARD Servicing an engine while it is running.
WHAT CAN HAPP EN Moving parts can catch c lothing o r parts of
the body, causing injury. Electrical compone nts can cause shocks or
can start fires.
Have KYMCO de aler perform service if yo u are not familiar with machine ser vice.
Tool kit
A tool kit is prov ide with your ATV. You are recommen ded to put the tool kit in the
vinyl bag and a lways carry them on the seat reverse sid e.
(1)
(2)
HOW TO AVOID THE HAZARD Turn off the engine when performing
maintenance unless o therwis e specified.
(1) Tool kit (2) Rubber band
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The tools in the kit are sufficient to per form routine mai ntenance and simple repairs. Any extensive w ork requiring additional tools should be performe d by your authorized KYMCO dealer.
WARNING
POTENTIAL HAZARD Operating this ATV with improper
modifications.
The tool kit includes th e following ite ms: (1)
Air pressur e gauge
(2)
Spark plug wr ench
(3)
Standard/Phillips screwdriver
(4)
Screwdriv er handle
(5)
10/12 mm wren ch
(6)
Tool bag
(7) Rubber ba nd
(1) (2) (3) (4) (5) (6) (7)
WHAT CAN HAPP EN Improper installat ion of acce ssories or
modification of this vehicle ma y cause changes in handling which in some situation could lead to an accide nt.
HOW TO AVOID THE HAZARD Never modify this ATV thro ugh impro per
installation or use of accessories. All parts and accessories adde d to this vehicle should be genuine KYMCO or equiva lent components designed for use on th is ATV and should be installed and used according to instruc tions. If y ou have questions, consult an authori zed KYMCO dealer.
90
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
1
month3months6months
Every 20~40 hours
(More often in wet or dusty areas.)
months
EVERY
6
1
year
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