Kymco Mxer 50R User Manual

OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

MXER 50R/90R

ON-ROAD

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:

KXR 90:

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.

The minimum recommended age for this ATV model is 6. Children under

age 6 should never operate this vehicle.

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

age 12 should never operate this vehicle.

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.

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.

Indicates a strong possibility that serious injury or death may

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:

WARNING

Indicates a strong possibility that serious injury or death may 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 WARNINGAND

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

SAFETY INFORMATION.............................4

DESCRIPTION AND MACHINE

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

Key identification number.. ........................9

Frame and engineserial number...............10

Model code............................................10

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

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

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

Indicator lamps ........... ...........................17

Instrument ....... .......... ...........................18

Handlebar switches................................23

Horn button................................. ........23

Turnsignal switch ................................23

Headlight switches ..............................24

Engine stop switch...............................25

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

Kick starter.............. ..............................27

Remote engine stopswitch.. ....................28

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

Speedlimiter..........................................30

Front and rearbrake................................31

Brake pedal (MXER 90R)........................31

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

Parking brake (MXER 90R)......................33

Fuel tank cap.. .......................................34

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

Locking steering ( 90R)

Starter (choke) (MXER 90R)....................37

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

Flag pole bracket.................................... 39

Storage compartment . ...........................39

MXER

MXER .................36

(Cont'd)

Page Page

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

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

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

Engine (MXER 90R) and

transmission oil ....................................44

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

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

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

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

Lights...................................................46

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

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

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

Tire wear limit .......................................49

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

Starting a cold engine ( 90R).........50

Starting engine (MXER 50R)...................53

Engine break-in.....................................54

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

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

Accessories ..........................................58

MXER ....................45

MXER

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

GETTINGTOKNOWYOUR ATV.. ...... ......60

RIDE WITH CARE AND

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

Age Recommendation (MXER 50R)..........62

Age Recommendation (MXER 90R)..........63

Never carry passenger on the carrier........64

Apparel..... ...........................................65

Do not operate after consuming alcohol or

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

Pre-operation checks..............................67

Loading and accessories.........................69

Loading and OperationalGuidelines.........69

Accessories...................... ....................70

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

During operation ...................................72

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

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

Remote engine stop switch for new

Riders..................................................76

GOOD

(Cont'd)

Page Page

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

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

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

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

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

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

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

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

PERIODIC MAINTENANCE AND

ADJUSTMENT.........................................89

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

PERIODIC MAINTENANCE/

LUBRICATION ( 50R)....................91

PERIODIC MAINTENANCE/

LUBRICATION (MXER 90R)....................93

Engine oil (MXER 90R)...........................95

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

Spark plug inspection............................102

Air filter cleaning..................................103

Valve clearance adjustment

(MXER 90R)........................................107

Idle speed adjustment.. ........................108

Throttle lever adjustment .....................109

MXER

Front and rear brake shoes (drum brake)

inspection...........................................110

Front brake lever free play adjustment....111

Rear brake lever free play adjustment

(Drum brake)........................................113

Brake pedal adjustment (MXER 90R)....115

Brake fluid inspection (Disk brake)........118

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

Drive chain slack adjustment.................120

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

Cable inspection and lubrication...........122

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

Knuckle shaft and rear fork shaft

lubrication...............................123

Draining the V-belt compartment

(MXER 90R)........................................123

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

Wheel installation.................................124

Battery .............................................125

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

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

Troubleshooting ...............................131

Troubleshooting chart........................132

(Cont'd)

Page

CLEANING AND STORAGE.....................133

A. Cleaning .........................................133

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

SPECIFICATIONS (MXER 50R)...............137

SPECIFICATIONS (MXER 90R)...............141

NOISE REGULATION.............................145

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

INDEX...................................................147

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

WARNING INFORMATION

Your ATV comes with a hang tag and several labels containing important safety information. Anyone who rides the vehicle should read and understand this information before riding.

Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride.

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

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER operate :

Without proper training or instruction.



At speeds too fast for your skills



the conditions. Do not operate the vehicle after consuming ALCOHOL OR DRUGS.

ALWAYS :

Use proper riding techniques to avoid



vehicle overturns on hills and rough terrain and in turns.

For your safety, wear gear to include



helmet gloves and foot protection.

Gasoline is flammable shut off engine,



avoid sparks and open flame when refueling.

READ OWNER'S MANUAL, FOLLOW

ALL INSTRUCTIONS AND WARNINGS.

NEVER USE WITH ALCOHOL OR DRUGS

( 50R)MXER ( 90R)MXER

WARNING

UNDER

Operating thisATV if you are under the age of 6 increases your chance of severe injury or death.

NEVER

under age 6.

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE : Set with tires cold

Recommended :

FRONT : 22~28 kpa, (0.22~0.28 kgf/cm ), 3.2~4.0 psi REAR :

Never set tire pressure over the recommended.



operate thisATV if you are

WARNING



22~28 kpa, (0.22~0.28 kgf/cm ), 3.2~4.0 psi

WARNING

UNDER

Operating thisATV if you are under the age of 12 increases your chance of severe injury or death.

NEVER

under age 12.

operate thisATV if you are

SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from

other vehicles including motorcycles and cars.A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:



Read this manual and all labels carefully and follow the operating procedures described.



Never operate an ATV without proper training or instruction.

Beginners should receive training from a certified instructor.



Always follow the age recommendation:

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

- A child under 12 years old should never operate an ATV with engine size greater than 90cc.



Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You



should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.



Never consume alcohol or drugs before or while operating this ATV.



Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.



Never attempt wheel, jump, or other stunt.



Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.



Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.



Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating theATV.



Never operate on excessively rough, slippery or loose terrain.



Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.



Never operate the ATV on hills.



Always follow proper procedures for climbing slopes as described in this manual. Check the terrain carefully before you start up any slope. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a slope at high speed.

Always follow proper procedures for going down slopes and for braking on slopes as described in

this manual. Check the terrain carefully before you start down any slope. Shift your weight backward. Never go down a slope at high speed.Avoid going down slope at an angle that would cause the vehicle to lean sharply to one side. Go straight down the slope where possible.

Never attempt to turn the ATV around on any slope until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep slope if possible.



Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.



Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.



Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.



Always use the size and type tires specified in this manual.Always maintain proper tire pressure as described in this manual.



Never modify an ATV through improper installation or use of accessories.



Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

WARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel right after the engine has been

running and is still very hot. Do not spill gasoline on the engine or exhaust

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

vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

When transporting the machine in another vehicle, be sure it is kept upright and that the fuel cock is in the "OFF" position.

Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

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

If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN Exhaust fumes are poisonous and may

cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD Always operate your machine in an area

with adequate ventilation.

DESCRIPTION AND MACHINE IDENTIFICATION

Identification number records

Record the keys identification number, frame serial number, engine serial number and model code information for assistance when order replacement parts.

IGNITION SWITCH KEY NO.

STEERING LOCK KEY NO.

FRAME NO.

Keys identification number

The keys identification number is stamped on the hang tag as shown in the following illustration.

(1)

(2)

ENGINE NO.

MODEL CODE

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

identification number

Frame and engine serial number

The frame serial number is stamped on the front of the frame.

The engine serial number is stamped on the left crankcase.

(1)

(1) Frame serial number (1) Engine serial number (MXER 50R)

(2) Engine serial number (MXER 90R)

(2)

Parts location

(01)(03)(04)(05)(06)(07) (02)

(01) Left front turn signal light (02) Rear brake lever (03) Left back mirror (04) Headlight (05) Right back mirror (06) Front brake lever (07) Right front turn signal light (08) Front wheel (09) Position light

(08)(09)(08)

(02) (01)(03)

(01) Throttle lever (02)

Remote engine stop switch (03) Instrument (04) Left rear turn signal light (05)

Rear wheel (06) Right

rear turn signal light

(04)

(05)

(06)

(02) (01)(03)(04)

(01) Flag pole bracket (02) Right footboard (03) Indicator lamps (04) Parking brake ( 90R) (05) Parking brake ( 50R) (06) Fuel fill cap (07) Left footboard (08)

Taillight/Stop light

MXER MXER

(05) (07) (08)

(06)

(02) (01)

(04)(03) (05)

(01) Storage compartment, containing

Owner's manual Air pressure gauge

Tool kit (02) Handlebar switches (03) Fuel vavle (04) Kick starter (05) Exhaust pipe

(02)(03) (01)

(04) (06)(05)

(01) Speed limiter (02) Ignition switch (03) Seat (04) Seat lock lever (05) Brake pedal (06) Steering handlebar lock ( 90R)MXER

NOTE:

The machine you have purchased may differ slightly from those shown in the figures of this manual.

CONTROL FUNCTIONS

Ignition switch

Functions of the respective switch positions are as follows:

OFF: All electrical circuits are switched off. The key

can be removed in this position.

ON ( :

)

The position and taillight can be turned on.

With the engine stop switch at run ( ), the engine can be started.

The key can not be removed.

OFF

(1)

(2)

(1) Ignition switch (2) Key

Indicator lamps

Right/Left turn signal indicator lamps

FUNCTION: Flashes when the right turn signal

Operates. Flashes when the left turn signal Operates.

High beam indicator lamp

The high beam indicator lamp will light when the headlight switch to select high beam ( )and the ignition switch is ON (

Low oil level indicator " " (MXER 50R)

The low level indicator lights when the 2-stroke engine oil level is low.

).

CAUTION:

If the low oil level indicator comes on while riding, stop riding and shut the engine off. Fill the oil tank to the upper level mark with the recommended oil (see page 45). Continuing to ride with a low oil level may lead to engine failure that could result in an accident.

(1)

(2) (3)

(1) Right/Left turn signal indicator lamps (2) High beam indicator lamp (3) Low oil level indicator lamp

Instruments Display description

AUTO

M O D E

TM DST ODO

km h

mile h

T. / S T O P

TM DST

ODO

AUTO

km hkm h

mile hmile h

1. Display

2. MODE button

3. ST./STOP button

1. TM start symbol

Bar-graph speed symbol

Mode symbol

Auto (automatic start/stop) mode symbol

Distance scale symbol

Data display (TM, DST, ODO, CLOCK)

MODE

1. Button function MODE Button: Each press of button converts

．

the screen to display will be changed to other functions. (CLOCK TM

ST./STOP Button: When this button was

．

→

→→ →DST ODO CLOCK)

pressed, measurement of the trip distance and elapsed time is simultaneously started or stopped. While the unit is operating, the TM symbol flashes.

MODE+ST./STOP Button: When the mode

．

button and ST./STOP button are pressed simultaneously

,DST,

TM are cleared.

AUTO

MODE

km h mile h

TM DST ODO

km h

ST./STOP

km h

MODE

km h

ST./STOP

km h

MODE

km h

ST./STOP

km h

MODE

km h

ST./STOP

km h

MODE

MODE MODE

km h

DST

MODE

ST./STOP

TM and DST are cleared

km h

MODE

ST/STOP

km h

ODO

MODE

ST./STOP

km h

ST./STOP

AUTO

km h

MODE

2. Function Speed: Current speed is displayed

．

continuously when the motor in motion. TM: Elpased time is measures from the

．

starting point of a trip.

DST: Trip distance is measures traveled

．

since the time of the last reset.

．ODO: Total distance: Mileage is continuously

measured accumulated and displayed until the battery wears down.

km/h

DST

km/h

ODO

．CLOCK: The 24HR clock always displayed

the current time on the screen.

+ 132 hidden pages

Kymco Mxer 50R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual