Kymco MXU 400 User Manual

MXU 375 / 400

OWNER'S MANUAL

Do not remove this Owner’s Manual from this ATV according to the guidelines and agreement with the U.S. Consumer Product Safety Commission.

Read this manual carefully. It contains impotant safety information.

KWANG YANG MOTOR CO.,LTD.

Your ATV can be hazardous to operate.

A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

For your safety, understand and follow all the warnings contained in this Owner's Manual and the labels on your ATV.

Keep this Owner's Manual with your ATV at all times.

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED.

WARNING

NOTE

Failure to follow WARNING instructions could result in severe injury or death to the operator, a passenger, a bystander, or a person inspecting or repairing the ATV.

A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.

A NOTE provides key information to make procedures easier or more clear.

California Proposition 65

WARNING

This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Introduction

FOREWORD

Congratulations and thank you purchase a KYMCO All-Terrain Vehicle(ATV). Built with American engineering and manufacturing know-how, it is designed to provide superior ride, comfort, and utility.

Protect Your Sport

‧Know all local, state/provincial riding

laws,

‧Respect your ATV,

‧Respect the environment, and you

will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.

This Owner’s Manual is furnished to enssure that the operator is aware of safe operating procedures. It also includes information about the general care and maintenance of your ATV. Carefully read the following pages. If you have any questions regarding this ATV, contact an authorized KYMCO ATV dealer

for assistance.

Remember, only authorized KYMCO ATV dealers have the knowledge and facilities to provide you with the best service possible.

All information in this manual is based on the latest product data and specifications available at the time of printing. KYMCO Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations without notice.

KYMCO and the ATV Safety Institute recommend that all ATV operators ride the appropriate-sized ATV according to age.

Age (Years)

6-11

12-15

16 and Older

Engine Size (cc)

Up to 70

Up to 90

Over 90

Speed Limitations (MPH)

10 - Governed 15 - Maximum

15 - Governed 30 - Maximum

According to Local

Regulations

Table of Contents

INTRODUCTION ----------------------------1 HANGTAGS & WARNING INFORMATION ---------------------------7 WARNING LABELS --------------------- 8-9 LOCATION OF PARTS AND CONTROLS------------------------------ 10 WARNINGS----------------------------- 11-21 PREVENTION--------------------------22-27

Safe Riding Clothing and Gear--------- 22 Condition of the ATV ---------------------- 24 First Aid and Survival --------------------- 27

ACTIVE RIDING -----------------------28-42

Basic Operating Maneuvers ------------ 28 How to Handle the ATV (Active Riding Techniques) -------- 31 Tips-------------------------------------------- 40

SOUND JUDGMENT-----------------43-50

Environment--------------------------------- 44 Those Around You ------------------------- 46 Equipment -----------------------------------47 Personal Choices-------------------------- 47 Load Capacity Ratings Chart ----------- 48 Speedrack -----------------------------------48

SUPERVISION -------------------------51-52

Taking Responsibility --------------------- 51

PREFACE -----------------------------------53 PARTS AND ACCESSORIES---------- 53 SPECIFICATIONS ------------------------ 54 GENERAL INFORMATION---------55-65

ATV Identification Numbers ------------- 55 Ignition Switch Key ------------------------ 55 Control Locations and Function-------- 55 Primer - Cold Start------------------------- 60 Gas/Vent Hoses---------------------------- 60 Carburetor Float Bowl Drain ------------ 61 Oil Level Stick------------------------------- 61 Seat Latch ---------------------------------- 61 Safety Flag Bracket ----------------------- 62 Rack Loading (Front and Rear) -------- 62 Trailering and Towing --------------------- 62

Transporting ATV -------------------------- 63 Gasoline-Oil-Lubricant ------------------- 63 Break-In Procedure ----------------------- 64

GENERAL MAINTENANCE--------66-80

Maintenance Schedule------------------- 67 Oil Cooler ------------------------------------68 Shock Absorbers--------------------------- 68 General Lubrication ----------------------- 68 Hydraulic Hand Brake -------------------- 70 Auxiliary Brake ----------------------------- 71 Protective Rubber Boots----------------- 72 Battery ---------------------------------------- 73 Spark Plug ----------------------------------- 74 Engine Idle RPM Adjustment ----------- 75 Throttle Cable Adjustment--------------- 75 Air Filter -------------------------------------- 76 Air Filter Housing Drain ------------------ 76 Draining V-Belt Cover--------------------- 77 Tires------------------------------------------- 77 Wheel Removal ---------------------------- 78 Muffler/Spark Arrester -------------------- 78 Light Bulb Replacement ----------------- 78 Checking/Adjusting Headlight Aim ---- 79 Fuses ----------------------------------------- 80 Electrical Output Terminals-------------- 80 Storage Compartment/Tools ------------ 80

PREPARATION FOR STORAGE-------------------------------- 81 PREPARATION AFTER STORAGE - 82 MAINTENANCE RECORD ------------- 83 U.S. EPA EMISSION CONTROL STATEMENT/WARRANTY COVERAGE (U.S.)--------------------- 84 INDEX ---------------------------------------- 85 IDENTIFICATION NUMBERS

RECORD INSIDE BACK COVER

DIVISION 1 - SAFETY

DIVISION II OPERATION/MAINTENANCE

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

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

Never operate on excessively rough, slippery, or loose terrain. Always follow proper procedures for

turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Do

not turn at excessive speed. Always have the ATV checked by an authorized KYMCO ATV dealer if it

has been involved in an accident. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before

attempting larger hills.

Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any

hill at high speed.

Always follow proper procedures for

going down hills and for braking on hills

as described in this manual. Check the

terrain carefully before you start down

any hill. Shift your weight backward.

Never go down a hill at high speed.

Avoid going down a hill at an angle

which would cause the ATV to lean

sharply to one side. Go straight down

the hill where possible.

Always follow proper procedures for

crossing the side of a hill as described

in this manual. Avoid hills with slippery

or loose surfaces. Shift your weight to

the uphill side of the ATV. Never

attempt to turn the ATV around on any

hill until you have mastered the turning

techniques described in this manual on

level ground. Avoid crossing the side of

a steep hill if possible.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Always use proper procedures if you stall or roll backward when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to either side if pointed straight uphill. Turn the ATV around and mount following the procedure described in this manual.

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 of skidding or sliding. On 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 the footrests. Remember that wet brakes may have reduced stopping capability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

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

Never improperly install or improperly use accessories on this ATV.

Never install a twist grip throttle on this ATV.

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

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 or pulling a trailer and allow greater dis-

tance for braking.

No one under the age of 16 should operate this ATV. Some operators at the age of 16 may not be able to operate an ATV safely. Parents should supervise the use of the ATV at all times. Parents should permit continued use only if they determine that the operator has the ability to operate the ATV safely.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

ATV SAFETY ALERT

You should be aware that 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 or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills and over obstacles, if you fail to take proper precautions.

TO AVOID DEATH OR SEVERE PERSONAL

INJURY:

Always read the owner's manual

carefully and follow the operating procedures described. Pay special attention to the warnings contained in the manual and on all labels.

Never operate an ATV without

proper instruction. Take a training course. Beginners should complete

a training course.

Always follow these age recom-

mendations:

A child under 12 years old should never operate an ATV with an

engine size 70cc or greater.

A child under 16 years old should never operate an ATV with an

engine size greater than 90 cc.

A child under 16 years old should never operate an ATV without adult supervision. Children need to be observed carefully because not all children have the strength, size, skills, or judgment to operate an

ATV safely.

Never carry a passenger on an ATV.

Carrying a passenger may upset the balance of the ATV and may cause it to go out of control.

Always avoid paved surfaces.

ATV's are not designed to be used on paved surfaces and may seriously affect handling and control.

Never operate an ATV on a public

road, even a dirt or gravel one, because you may not be able to avoid colliding with other vehicles. Also, operating an ATV on a public road may be against the law.

Never operate an ATV without an

approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket.

Never consume alcohol or drugs

before or while operating an ATV.

Never operate an ATV at excessive

speeds. Go at a speed which is proper for the terrain, visibility conditions, and your experience.

Never attempt to do wheelies,

jumps, or other stunts.

Always be careful when operating

an ATV, especially when approach ing hills, turns, and obstacles and when operating on unfamiliar or

rough terrain.

Never lend an ATV to anyone who

has not taken a training course or has not been driving an ATV for at least a year.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

1. DECAL OF EPA (For US)

2. CERTIFICATE LABEL OF SVIA (For US)

LOCATION (For US)

HANGTAG OF EPA (For US)

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Hangtags & Warning Information

A KYMCO ATV comes with hangtags and several labels containing important safety information. Anyone who rides the ATV should read and understand this information before riding.

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

For U.S.

WARNING

2255-741AFor France 2256-475For Europe

Indicates a potential hazard that could result in a serious injury or death.

Warning Labels

1 1 1

3 3

222

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warning Labels

5 5

6 66

7 7 7

888

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Location of Parts and Controls

1.Battery

2.Headlights

3.Hand Brake Lever

4.Power Distribution Module

5.Electrical Access Panel

6.Seat Latch

7.Storage Compartment

KC0044A

8.Horn Button

9.Auxiliary Brake Pedal

10.Brake Lever Lock

11.Key Switch

12.Shift Lever

13.Throttle Limiter

14.Throttle Lever

15.DC Power Outlet

16.Taillight/Brakelight

KC0047A

17.Headlight HI/LO Switch

18.Engine Starter Button

19.Engine Stop Switch

20.2WD/4WD Selector Switch

21.Gas Tank Valve

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

KC0041A

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the certified training course offered. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner's Manual.

WARNING

POTENTIAL HAZARD

Allowing anyone under age 16 to operate this ATV.

WHAT CAN HAPPEN

Use of an ATV by children can lead to severe injury or death of the child. Children under the age of 16 may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.

HOW TO AVOID THE HAZARD

A child under 16 should never operate this ATV.

WARNING

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WARNINGS

WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this ATV.

Could cause an accident, resulting in injury or death to you and/or your passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The long seat is to allow the operator to shift positions as needed during operation. It is not for carrying passengers.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV on paved surfaces.

WHAT CAN HAPPEN

The ATV's tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control.

HOW TO AVOID THE HAZARD

Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots, and streets.

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads, or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any public street, road, or highway, even a dirt or gravel one. In many states it is illegal to operate an ATV on public streets, roads, or highways.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye protection, and protective clothing.

WHAT CAN HAPPEN

Operating without an approved 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 protective clothing increases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly. You should also wear:Eye protection (goggles or face shield) Gloves Boots Long sleeved shirt or jacket Long pants

WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV after or while consuming alcohol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD

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

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV at excessive speeds.

WHAT CAN HAPPEN

Increases your chances or losing control of the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD

Always ride at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident including a rollover.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or jumps. Don’t try to show off.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating. Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

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

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Removing hands from handlebars or feet from footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from a footrest, your foot or leg may come into contact with the wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARD

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

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating the ATV

on unfamiliar terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or holes without enough time to react. Could result in the ATV overturning or going out of control.

HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

WARNINGS

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating on rough, slippery, or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or ATV control, which could result in an accident including a rollover.

HOW TO AVOID THE HAZARD

Do not operate on rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

ATV could go out of control, causing a collision or rollover.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on steep hills.

WHAT CAN HAPPEN

The ATV can overturn more easily on steep hills than on level surfaces or small hills.

HOW TO AVOID THE HAZARD

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

POTENTIAL HAZARD

Climbing hills improperly.

WARNING

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25

WARNINGS

WARNING

Maximum

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for going down hills as described in this Owner's Manual. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possible.

WARNING

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this Owner’s Manual. Practice first on level ground. Be very

careful when turning on any hill. Avoid crossing the side of a steep hill, if possible.

When crossing the side of a hill:

Always follow proper procedures as described in this Owner's Manual. Avoid hills with slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards, or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in the ATV overturning.

HOW TO AVOID THE HAZARD

Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Engage the brake lever lock after you are stopped. If you begin rolling backwards: Keep weight uphill. Apply the brakes while rolling backwards. When fully stopped, engage the brake lever lock. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and mount following the procedure described in this Owner's Manual.

WARNINGS

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision. Could cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in this Owner's Manual.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Learn to safely control skidding or sliding by practicing at slow 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.

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never operate the ATV in fast flowing water or in water deeper than the footrests. Remember that wet brakes may have reduced stopping capability. Test your brakes after leaving water. If necessary, apply them several times to dry out the pads.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or person behind you, resulting in serious injury.

HOW TO AVOID THE HAZARD

Before you engage reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Warnings

WARNING

POTENTIAL HAZARD

Operating the ATV with improper tires or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on the ATV, or operation of the ATV with improper or uneven tire pressure, may cause loss of control increasing your risk of accident.

HOW TO AVOID THE HAZARD

Always use the size and type tires specified in this Owner's Manual for this ATV. Always maintain proper tire pressure as described in this Owner's Manual.

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV may cause changes in handling which, in some situations, could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or improper use of accessories. All parts and accessories added to this ATV should be genuine KYMCO ATV components designed for use on the ATV and should be installed and used according to instructions. Never install a twist grip throttle. If you have questions, consult an authorized KYMCO ATV dealer.

WARNINGS

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for the ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in this Owner's Manual for carrying cargo or pulling a trailer.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Prevention

Overview

When using an ATV, prevention is the name of the game. "Had you only known" something could go wrong, you would have prevented it. If you don't notice your conditions and surroundings before riding your ATV, you give up control over the situation. Using ATV prevention techniques helps you forecast potential hazards before they injure you or damage your ATV.

Following the safety instructions and warnings in this manual will help you "P.A.S.S." the safety test. P.A.S.S. sta n ds fo r "P reventi o n ," "Active Ri ding," "Sou nd Judgment ," and "Supervision." Remembering P.A.S.S. and what it stands for will help you have a safe, predictable ride every time you go out on your ATV.

Safe Riding Clothing and Gear

Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. You'll find it important to dress correctly for ATV riding in order to prevent scraped skin and serous head injuries. It's easy and could save you time in the long run not having to contend with an injury. Of course, it also makes sense to remember the seasons. Wear a hat under your helmet and a snowmobile suit in the winter and lighter, protective clothing in the summer. Following is the minimum protection you need to wear during every ride.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

ATV-0004

Gloves

Your hands are targets for flying objects and branches. Along with providing skin protection, gloves will shield your hands from harsh weather. Wear gloves that are weather resistant and have a gripping suface to keep them from sliding off the handlebars. Off-road style gloves with knuckle pads are the best for comfort and protection

Boots/Ankle Protection

Wear a boot that covers the largest possible area of your leg (preferably up to your knee) and can handle significant impact. Choosing boots with low heels and a good tread will help prevent your feet from slipping off the footrests in wet or rugged conditions or getting hurt if they get hit by rocks, dirt, or branches.

Prevention

Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head

Injury.

These helmets should provide full-face Protection.

If you drop or damage your helmet, get a new one immediately. Your helmet may not protect your head from injury if it has cracks, fissures, or other damage to its outside or core padding.

Remember, your helmet won't do you any good if the chin strap isn't fastened.

Eye Protection

Wear eye protection, such as goggles, to completely surround your eyes to prevent getting dirt or other items in your eyes. Do not depend on sunglasses for proper eye protection. Sunglasses are not recommended; they don't prevent objects from flying in

through the sides.

Long Pants and Long Sleeved Shirt

The goal is to protect your body from branches, long grass, airborne objects, or anything else that could scrape your skin. The more thick and durable the material, the better protection it'll provide. Riding pants with kneepads, a jersey, and shoulder pads provide the best

protection.

PREVENTION

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Prevention

Condition of the ATV

The second step in Prevention is checking the condition of your ATV. Chances are good that you'll be using your ATV in some rough terrain, and there's no way you want your brakes to go out when riding downhill. You need to check the following parts on your ATV

before every ride.

1. Brakes

2. Throttle

3. Tires and Wheels

4. Fluids

5. Lights

6. Electrical

7. Controls and Cables

8. Chassis and Suspension

9. Miscellaneous Items

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Prevention

One easy way to remember what parts you need to check is by using the acronym “T-CLOC.” It stands for:

TIRES AND WHEELS

CONTROLS AND CABLES

LIGHTS AND ELECTRIC

TIRES AND WHEELS

Correct tire pressure is crucial. Consult the Specifications section of this Owner's Manual for tire pressure guidelines. Incorrect tire pressure can cause poor handling, instability, and a loss of ATV control.

Check:

1. Tire pressure

2. Tire surface (tread and sidewalls)

While checking the tire pressure, inspect the tread and sidewalls of the tires for cracks, cuts, or other damage that could indicate they need to be

replaced.

CONTROLS AND CABLES

With the engine running and brake applied, check all transmission positions: forward, neutral, and reverse.

Check:

1. Forward

2. Neutral

3. Reverse

A. Brakes

Squeeze the hand brake lever. If it feels soft or "squishy," it could be low on fluid or have a leak─refer to the General Maintenance section of this Owner's Manual for instructions. Don't use the ATV until the brakes are operating normally.

L O

OIL AND FUEL CHASSIS

Test the brake lever lock and see if it locks the hand brake lever into position; then disengage it to release the brake. Be sure that the auxiliary brake near the footrest is working; your brakes could fail during a ride if they're not maintained.

Check:

1. Hand brake lever

2. Auxiliary brake pedal

3. Brake lever lock

B. Throttle

The throttle should have a free, smooth range of motion. If it seems to “stick” at any point, refer to the General Maintenance section of this Owner's Manual for instructions. Driving your ATV with a sticking throttle can turn your leisurely ride into an unwelcome accident. Don't drive your ATV if the throt-

tle sticks.

Check:

1. Free, smooth range of motion

PREVENTION

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Prevention

LIGHTS AND ELECTRIC

Turn the hi-beam and lo-beam on and off to make sure they work. At the same time, check that the taillight and brakelight work. Also, check the status/ warning indicators (reverse, neutral, and hi-lo beam) on the handlebars when you start the ATV. Don't drive the ATV unless all systems are working. Check the ignition switch and engine stop switch.

Check:

1. Hi-beam

2. Lo-beam

3. Taillight/brakelight

4. Status/warning indicators

Check:

1. Ignition switch

2. Stop switch

OIL AND FUEL

Start with a full tank of gas before every ride, and while you're at it, top off the oil. Don't forget to check for fluid leaks around the ATV. Watch the overheat indicator to ensure the engine coolant level is adequate.

CHASSIS

Grass and leaves can gum-up your suspension and shocks. Clear and clean the suspension arms, shock springs, and fenders. Check smoothness by turning the handlebar full-left and fullright. Check that there is no binding, restrictions, free-play, or looseness in

steering components.

Check:

1. Suspension arms

2. Shock springs

3. Fenders

4. Steering

Miscellaneous Items

Inspect your air filter. Look for debris or damage that may indicate you need to replace it. A clogged filter can stop an engine. Check your battery terminals for corrosion. Also, be sure to tighten any loose parts, nuts, or bolts.

Check:

1. Air filter

2. Battery

3. Tighten parts, nuts, and bolts

Check:

1. Gas

2. Oil

3. Fluid leaks

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Prevention

First Aid and Survival

You need to prepare for the unexpected. Emergencies and accidents are traumatic enough, but they're even worse when you're not prepared for them. At the minimum during every ATV ride, you should have the follow-

ing items on board:

‧Tools ‧Water ‧Identification ‧First Aid Kit

For rides that are longer in duration and distance, the following additional items

are recommended:

‧Cellular Phone ‧Maps/GPS ‧Emergency Kit with Flashlight and First Aid Kit

Tools

Routine maintenance will generally eliminate the need for emergency repairs. Riding on rough terrain could cause loosening of nuts, bolts, and fasteners. Especially on long rides, carrying the right tools can prevent an inconvenience from becoming a crisis.

Carry these items on your ATV:

1. Bulbs

2. Duct tape

3. Rope

4. Spark plugs

5. Spare parts

6. Tool Kit

Water

Water is so important that you need to carry it regardless of the duration of your ride. Heat exhaustion and heat stroke can creep up suddenly and can take you out of commission. If you become dehydrated, you could find yourself physically unable to safely operate your ATV.

Identification

If something does happen to you, the emergency personnel will want to know who you are and whom to contact. It's possible you may be in no condition to give them that information. Put your I.D. in your pocket before you ride. Without it, you're anonymous.

Cellular Phone

It may be necessary to make an urgent phone call.

Maps/GPS (Global Positioning System)

Maps may be unnecessary when you're familiar with the area. But when you're riding on unfamiliar trails, it's good to know where you are, what's coming

up, and how to get back.

Emergency Kit with Flashlight and First Aid Kit

You'll need several items in your Emergency Kit including a flashlight. The matches will come in handy if you need to start a fire to stay warm. Flares are appropriate for signaling help. A first aid kit is very important if an injury of some type should happen. A good First Aid Kit should include bandages, antiseptic spray, gauze, tape, etc.

Carry these items:

1. Flashlight

2. Matches

3. Flares

4. First Aid Kit

5. Money

PREVENTION

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

Overview

“ Active Riding” is the second part of “P.A.S.S.” It involves an understanding of

h o w y o u r b o d y we i g h t , b a l a n c e , gravity, and physical forces affect the ha ndling of th e ATV. For exampl e, when you drive a car quickly into a sharp turn, your body is pulled to the outside of the vehi cle by cent rifugal force. Although a car is relatively stable, enough centrifugal force can cause an ATV to overturn . Constan tly shifting your weight is one major difference between driving a car and riding an AT V. K n ow i n g h o w t o s h if t y o u r weight is necessary to avoid rolling or

flipping the ATV.

Basic Operating Maneuvers

Active riding and basic maneuvers are the foundation of your ATV ride. Without basic skills, it's impossible to move to this level ─ active riding. These are

your basic maneuvers: ‧Mounting the ATV ‧Starting the Engine ‧Starting a Cold Engine

‧Braking/Stopping ‧Shifting ‧Parking ‧Dismounting the ATV

Mounting the ATV

To get seated:

1.From the left side, grab the left-side handlebar, apply the brake, and put

your left foot on the footrest.

2.Grab the right-side handlebar.

3.Swing your leg over the seat and set your right foot down on the

right-side footrest.

4.Get seated in a comfortable posi-

tion.

5.Always keep your feet planted on

the footrests.

Starting the Engine

Always start with the ATV on a flat, level surface. Carbon monoxide poisoning can kill you, so keep your ATV outside while it's running. Follow these steps to start it up:

1. Climb up onto the ATV and sit down.

2. Engage the brake lever lock.

3. Shift into neutral.

4. Turn on the ignition.

5. Move the emergency stop switch to

RUN.

6. Press the starter button.

7. Let the engine warm up.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

Another way to remember the starting procedure is by using the acronym BONE-C. It stands for:

B O N E C

BRAKES

LOCKED

IGNITION SWITCH ON

NEUTRAL TRANSMISSION

ENGINE SWITCH

AUTOMATIC CHOKE

Starting A Cold Engine

NOTE: It is very important not to touch or compress the throttle lever during the starting proce-

dures.

Turn off all electrical accessories (hand warmer, lights, etc.); then rotate the ignition switch key to the first position (ON) leaving the headlights OFF. Note that the N is indicated on the LCD.

NOTE: Pump the primer three times when the temperature is at

0 C (32 F) or colder. To access the primer, the seat and right-side heat shield must be removed.

735-887C

Press the starter button for eight

2. seconds maximum.

CAUTION

Allow 30 seconds between starting attempts for the starter motor to cool. Continuous starter motor operation can result in overheating

the starter motor.

If the engine does not start, press the starter button again for eight

seconds.

NOTE: At this point if the engine does not start, pump the primer three more times; then press the starter button again.

Allow the engine to warm up for approximately 2-3 minutes or until the ATV will accelerate without

hesitating.

ACTIVE RIDING

WARNING

738-436A

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

Braking/Stopping

Always allow plenty of room and time to stop safely. Sometimes quick stops are inevitable, so always be prepared. Whether you're stopping slowly or

stopping quickly, do this:

Squeeze the brake lever on the left handlebar to apply both the front

and rear brakes.

If your wheels lock, release them for a second; then apply them

again.

Never ride the brake. Even main-

3. taining minimal pressure on the brake lever will cause the brake pads to drag on the disc and may

overheat the brake fluid.

WARNING

Excessive repetitive use of the hydraulic brake for high speed stops will cause overheating of the brake fluid and premature brake pad wear which will result in an unexpected loss of brakes.

WARNING

Use only KYMCO approved brake fluid. Never substitute or mix different types or grades of brake fluid. Brake loss can result. Check brake fluid level and pad wear before each use. Brake loss can result in severe injury or even death.

Shifting

The KYMCO ATV with an automatic transmission has a dual-range transmission with reverse. To shift the ATV, follow these steps:

Low

High

Neutral

Reverse

CF130B

To engage the high range from neu-

tral, move the shift lever forward.

To engage the low range from high range, move the shift lever outward

and forward.

NOTE: The high range is for normal riding with light loads. The low range is for carrying heavy loads or trailer towing. Compared to HIGH range, the LOW range position provides slower speed and greater torque to the wheels.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

CAUTION

Always shift into low range when operating on wet or uneven terrain, when towing or pushing heavy loads, and when using a plow. Failure to follow this caution may result in premature V-belt failure or in damage to related drive system components.

To engage reverse gear from neutral, move the shift lever outward and rearward into the R position.

CAUTION

Always come to a complete stop before attempting to shift from one range to the other or into reverse. Always shift on level ground, or engage the brake lever lock before shifting into another range or into reverse.

WARNING

Do not start the engine or operate this ATV with the clutch shield removed. Severe injury could result.

Parking

Parking involves following the previous rules for braking; then:

After the ATV stops, shift into neutral.

Stop the engine using the engine stop switch.

Turn off the ignition.

If you have to park on a hill, shift

the ATV into low gear; otherwise,

try to park only on level surfaces.

Engage the brake lever lock.

Dismounting the ATV

After you've followed the procedure

for parking, it's time to dismount:

1.Double check that the brake lever lock is engaged.

2.Swing your right leg over to the left

side of the seat.

3.Step to the ground on the left side of the ATV.

How to Handle the ATV (Active Riding

Techniques)

Active riding involves moving your body. You must learn to lean and shift your weight into your turns to maintain

Control. Your safety depends on using safe

riding techniques.

Safe riding techniques include: ‧Starting ‧Leaning, Weight Shift, and Balance ‧Wide Turns

‧Sharp Turns ‧Quick Turns ‧K-Turns ‧Riding Uphill ‧Riding Downhill ‧Sidehilling/Traversing ‧Swerving ‧Crossing Obstacles

ACTIVE RIDING

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

Starting

Once the engine's warm, the ATV is ready to go.

ATV-0012

1.Keep your feet on the footrests and both hands on the handlebar.

2.Hold the brake lever, and release the brake lever lock.

3.Shift into first gear.

4.Release the brake slowly and apply the throttle.

ATV-0013

ATV-0024

Leaning, Weight Shift, and Balance

When you turn, the trick is to move forward and slide over to the side of the seat that's on the inside of the turn. Support your body weight on the outside footrest. At the same time, lean your body to the inside of the turn. Pay attention to the handling if you feel the tires coming off the ground, reduce speed, shift more of your body weight to the side that's lifting, and make the

turn wider if possible.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

ATV-0025

Active Riding

Wide Turns

About 20% of ATV accidents happen during turns. If you don't understand turning techniques, it's easy for the ATV to get away from you by losing traction, plowing, or tipping. Use this

method for wide turns:

ATV-0046

Sharp Turns

After mastering wide turns, practice the advanced skill of sharp turns.

ATV-0038

ATV-0039

ATV-0045

ATV-0044

1.Ease off the throttle as you approach the turn to slow down.

2.Use the principles of leaning, weight shifting, and balancing ─ shift your body weight to the inside of the turn.

3.Gradually increase your speed as you come out of the turn.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

ATV-0040

1.Ease off the throttle as you approach

the turn to slow down.

2.Use the principles of leaning, weight shifting, and balancing─shift your body weight to the inside of the turn.

3.You might have to lean into the turn

more than you do in a wide turn.

4.If shifting your weight and balance aren't enough to keep the ATV tires on

the ground, straighten out the handle bars as much you can.

5.Gradually increase your speed as you

come out of the turn.

ACTIVE RIDING

Active Riding

Quick Turns

Quick turns are the most difficult turns and should only be done after you are

experienced with your ATV.

1. Ease off the throttle as y ou appr oach the tur n to slow down.

2.Turn the handle bars, shift your weight, an d balance at the same ti me as you e nter th e turn (use th e principle s of lean ing, weight shifting, and bal ancing ─ shift your bod y weight to the inside o f the turn).

ATV-0021

ATV-0022

ATV-0023

3. Follow this with slight acce leration.

4. For multi ple turns, repeat t his movement as needed.

5.To make your turn quicker, tr y raising yourself off th e seat a few inches as yo u shift your weight .

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

K-Turns

Use K-turns if you accidentally stall while riding uphill; you need to take action before the ATV rolls backward

down the hill.

ATV-0020

ATV-0034

ATV-0037

1.Stop where you are, apply the brakes, and shift to neutral.

2.Shut off the engine.

3.Keep your body weight shifted forward.

4.Get off the ATV on the uphill side.

5.If you're to the left of the ATV, turn the handlebar all the way left.

6.Partially release the brake, but lightly hold the brake lever.

7.Let the ATV roll to your right side until it faces slightly downhill.

WARNING

8.Reapply the brakes.

9.Get back on the ATV from the uphill si-

de, and keep your weight shifted uphill when you sit down.

10.Start the engine and follow the method for riding downhill.

ATV-0035

ATV-0036

Indicates a potential hazard that could result in a serious injury or death.

ACTIVE RIDING

Active Riding

Riding Uphill

Roughly 20% of accidents happen while riding on hills and as a result of

the ATV rolling or flipping. So, obviously, use extreme caution and follow this methed for riding uphill.

Shift down and accelerate before you start climbing; then maintain a

steady pace.

Lean as far forward as possible. For steeper hills, come off your seat to stand and lean forward.

If you lose sp eed, quickly shif t to a lower gear. At the same time, release t he throttle (so you r front

tires don't lift),OR

If that doesn't work and you still have for ward motion and the terrain permits, do a U-turn, go bac k down, and try climbing again, O R

ATV-0019

ATV-0032

ATV-0033

If you have lost all forward motion,

follow the K-turn procedure.

NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25

Maximum

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

Riding Downhill

Success in riding downhill depends on

how well you know your brakes─take

it easy on them, or you could flip over.

ATV-0018

ATV-0030

ATV-0017

ATV-0028

ATV-0031

1.Shift your body weight as far back on the seat as possible.

2.Keep it in a low gear; stay out of ne utral.

3.Lightly apply the brake and ease up on the throttle.

Sidehilling/Traversing

Sidehilling is considered an advanced skill; it's really tricky and unpredictable. So, whether your skills are advanced or not, try to avoid this kind of riding. If you're in a situation where you absolutely have to sidehill, follow

this method:

WARNING

Indicates a potential hazard that could result in a serious injury or death.

ATV-0029

1. Keep your speed low and consistent.

2. Shift all your body weight to the uphill side of the seat; also, support your weight on the uphill footrest.

3. Steer like you're driving into the hill.

4. If the ATV feels like it's tipping, turn the handlebar downhill. If that's not possible because of the terrain or other conditions or if it just doesn't work, stop and get off. Dismount the ATV on the uphill side.

ACTIVE RIDING

Active Riding

Swerving

Swerving is usually an emergency

reaction to avoid an obstacle but is sim-

ilar to quick turns. The difference is

that quick turns involve slight acceleration in the turn; don't accelerate if you swerve.

ATV-0043

1.Ease off the throttle as you approach the obstacle.

2.Turn the handlebar. At the same time, shift your weight and balance as you swerve. Use the principles of leaning, weight shifting, and balancing─ shift your body weight to the inside of the turn.

3.Keep your hand off the brake until the emergency is over and you're back in control.

WARNING

ATV-0042

ATV-0041

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

Crossing Obstacles

Crossing obstacles is risky; avoid it if

possible. Riding over logs, rocks, and

ruts means combining all the active

riding skills into one big motion. Your

ATV will respond differently for differ-

ent obstacles (logs, ruts, etc.), but these

are general guidelines for overcoming

two-track (both tires contacting the

obstacle at the same time) obstacles:

ATV-0016

1.Keep your speed way down; less than 5 mph.

2.Approach the obstacle head-on.

3.Come up off the seat.

4.Keep your weight on the footrests.

5.Apply a little throttle when the front tires make contact with the obstacle.

6.Lean forward and release the throttle when the front tires clear the obstacle.

7.Keep your body loose to absorb any shock.

8.If the ATV starts tipping, shift your weight to keep it in balance.

To clear a single-track (only one tire contacts) obstacle, follow the same rules except:

1.Use the ATV's momentum to clear the obstacle.

WARNING

2.Don't pull up on the handlebar.

3.Don't apply the throttle.

ATV-0026

ATV-0027

Indicates a potential hazard that could result in a serious injury or death.

ACTIVE RIDING

Active Riding

Tips

Driving an ATV and a car have some simi-

arities; however, there are a few situations

that require special attention:

‧Reversing

‧Skidding or Sliding

‧Parking on a Hill

‧Stalling on a Hill

‧Crossing Water

‧Crossing Roads

‧Driving in Cold Weather

‧Stopping the ATV

‧Stopping the Engine

Reversing

It's tough to see things behind you.

1.Go slowly. It's hard to see behind you.

2.Keep your handlebar straight.

3.Backing down hills is a bad idea; do a U-turn or K-turn instead to turn around.

Skidding or Sliding

If you lose control after hitting sand, ice,

mud, or water:

1.Turn your handlebar into the direction

of the slide.

2.Keep your hand off the brakes until you're out of the skid.

3.Shift your weight forward.

Sometimes your ATV may not respond

and goes straight ahead instead of letting

you turn. Here's how to handle it:

1.Slow down.

2.Move forward on the seat.

3.Lean to inside of turn.

4.Turn handlebar.

Parking on a Hill

This shouldn't be necessary, but if it is:

1.Keep it in gear.

2.Engage the brake lever lock.

3.Find something to block the rear tires.

Stalling on a Hill

If you use the right method for riding uphill, this shouldn't happen. But if you have a problem, do this:

1.If the ATV hasn't started rolling backw ards yet, follow the procedure for the K-Turn, OR

2.If the ATV is already rolling backward, lean as far forward as possible standi ng up on the footrests.

3.Nice and easy, apply the hand brake lever.

4.When you come to a stop, follow the procedure for the K-turn.

5.If the ATV continues to roll backward, dismount immediately on the uphill side.

Crossing Water

Your ATV can only handle water up to its footrests. Any more than that and you risk engine damage and/or personal injury. Stay away from fast moving rivers. ATV tires can be buoyant, so if the water is too deep, you might find the ATV suddenly afloat.

CAUTION

Riding through water deeper than the footrests may lead to severe engine damage due to water ingestion.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

NOTE: Engine damage caused by water ingestion or immersion will not be covered by KYMCO warranty.

1.Physically check the depth and current of the water, especially if you can't see the bottom. You're also checking for boulders, logs, or any other hidden obstacles.

2.Keep your speed slow.

3.Make sure you have a way out on the other side of the water.

4.If you get stuck in the sludge or mud, try rocking the ATV from side to side.

5.Once you've cleared the water, briefly apply the brakes to make sure they work.

Crossing Roads

Crossing roads on your ATV is also a bad idea, so avoid it. If you can't:

1.Stop completely on the shoulder of the road.

2.Check both directions for traffic.

3.Crossing near a blind corner or inters ection is dangerous; don't do it.

4.Drive straight across to the opposite shoulder.

5.Take into account that your ATV could stall while crossing; give yourself enough time to get off the road.

6.You have to assume that oncoming cars don't see you, and if they do, they won't be able to predict your actions.

7.It's illegal to cross public roads in some places. Know your local laws.

Driving In Cold Weather

NOTE: Check that all control levers move freely. Make sure that the footrest, shift lever, and mechanical brake pedal are free of ice and snow.

WARNING

For your personal safety, it is very important to wear the type and amount of coldweather clothing according to the coldest anticipated temperatures.

1.With the transmission in neutral, move the ATV forward and backward to check that the wheels roll freely. If the ATV will not roll, the tires may be frozen to the ground or the brake pads may be frozen to the discs.

2.If the tires are frozen to the ground, pour warm water around them to melt the ice.

CAUTION

Before riding, manually move the ATV forward and backward to make certain that all wheels roll freely.

3.If the brakes are frozen, take the ATV to a warmer area to thaw out the brakes.

WARNING

Do not attempt to free frozen brakes by pouring warm water on the brake pads and housings.

NOTE: After the brakes thaw, dry them by applying them several times while riding slowly.

ACTIVE RIDING

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Active Riding

NOTE: After riding through water, mud, snow, or slush, it is important to dry both brake systems before parking the ATV.

Learn how the ATV responds to steering and braking on the type of terrain to be encountered on the ride.

WARNING

Go slowly and be extra careful when riding on snow-covered or ice-covered terrain. Always be alert to changing terrain conditions when operating the ATV.

Practice driving in an open snow-

4. covered or ice-covered area at slow speeds before driving on snow-covered or ice-covered trails.

Stopping The ATV

To stop the ATV, first release the throttle lever. Next, apply the brake.

Stopping The Engine

To stop the engine, turn the ignition switch key to the OFF position or set the emergency stop switch to the OFF position.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Sound Judgment

Overview

You are not invincible. Knowing that the first "S" in " P.A.S.S" stands for “Sound Judgme nt" me ans you nee d to use yours. Do you consider yo urself to be pretty conservative, or a re yo u a heavy risktaker? Before continuing wi th this section on soun d judgment, check y our Risk Factor by doing this short survey:

1.Do you drive over the speed lim it? 1 2 3 Never Some times Often

2.Are you more daring around yo ur friends th an you are when alone ? 1 2 3 Never Some times Often

3.Do you drive your car when the gas gauge is on empty? 1 2 3 Never Some times Often

4.Do you feel that no matter what you do, you wo n't get hurt? 1 2 3 Never Some times Often

5.Do you drink or use drugs befor e you drive yo ur car? 1 2 3 Never Some times Often

6.Do you drive your car even if it ha s a major problem with the brakes , tires, or en gine? 1 2 3 Never Some times Often

7.Do you thrive on the adrenali ne rush you get from speeding and dangerous situations? 1 2 3 Never Some times Often

8.Do you hurt yourself becaus e you do things th at are out of your abil ity range? 1 2 3 Never Some times Often

9.Do you tailgate other drive rs when you think th ey're driving too s low? 1 2 3 Never Some times Often

10.Do you ignore weather repo rts bef ore you do out side activities l ike swimming , camping, fishin g, or boating? 1 2 3 Never Some times Often

Add the totals from lines 1-10. Y OUR

RISK FACTOR IS:

10-15: You ' r e pretty conservativ e .

Chances are good that the consi stently safe choices you make will help you avoid hurting yourself and the peo ple

around you.

16-20 : You're straddling the fence. Depen ding on your mood or wh om you're with, the choices you ma ke may

help you or hurt you.

21-30: You're taking your chan ces. Time to reconsider a lot of the judgments you ma ke. You'r e destined to put yourself in dan gerous si tuations and potentially hurt yourse lf and the

peopl e around you.

SOUND JUDGMENT

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Sound Judgment

Environment

The environment you operate an ATV in is often harsh and sometimes dangerous if you don't take proper precautions.

Weather

You need to consider the weather. It is dangerous to ride your ATV when the weather is bad or potentially bad. Keep abreast with weather forecasts.

Terrain

Always pay close attention to the terrain you're on, even if it is familiar to you. You can't assume that the landscape you're used to doesn't change. Changes to landscape can happen at nearly any time. Fences can be constructed and excavations dug in a short period of time. Weather, climate, and development take their toll.

The thing about terrain is that sometimes you don't know it's changed until you get there. Whether it's familiar or not, check out your surroundings before and during your ride.

Night Riding

Don't do it! It's a lot more difficult to see what's coming.

Paved Surfaces

Don't do it! The ATV isn't designed for pavement. Its handling becomes more difficult on paved surfaces.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Sound Judgment

Trail Riding

Use sound judgment when trail riding; that means riding on a trail that fits your ability level. If the trail is pretty rugged, standing up on your footrests will make it easier for you to endure the rough terrain.

Make yourself visible by using headlights and taillights, and pull completely off the trail if you need to stop.

Trail Signs

Outsloped trails (trails that slant to allow rain to run off) make trail riding a bit more challenging. Accepting that challenge means keeping your weight shifted into the slope. Denying the challenge means sliding off the trail.

It also helps to know which trails you can ride and who else might be on those same trails. These are signs currently used in some areas to designate trail types and

restrictions.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

ATV-0068

SOUND JUDGMENT

Sound Judgment

Those Around You

People do all kinds of things that you can't predict or control.

Riding Companions

Leave a lot of space between you and other riders, especially in dusty and dirty conditions, because it'll be difficult to see the riders in front of you

stopping.

Riding with companions on several ATV's is not the same as riding one ATV with a passenger. Passengers are prohibited; it's unsafe. The extra weight on the seat makes the ATV difficult to control. About 50% of all ATV accidents involve passengers.

Other Vehicles

Hikers

With the renewed interest in hiking, camping, and other outdoor activities, people can show up in remote areas where you would never expect them. For their sake, keep your eyes open.

Animals and Nature

Respect the outdoors that you love. Don't use your ATV to chase animals or birds. Drive around young trees rather than over them. Keep clear of streams and ditches with standing

water.

Tread Lightly and leave it as you

found it.

Depending on where you're riding, you might encounter other ATV's, bikes, or motor vehicles on publ ic lands. Respect the presence of cars if you're crossing roads or riding in public areas and make yourself be seen. If you can't see other vehicles coming, that means

you're invisible, too.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Sound Judgment

Equipment

The last thing you expected was that your ATV would break down in the middle of the field... it's usually so reliable that sometimes you forget the ATV has its limits.

ATV Maintenance

You have to maintain your ATV. The General Maintenance section of this Owner's Manual tells you about taking care of your ATV. If, at any time, abno r m a l no i ses, vibrations, or improper functioning of any component of this ATV is detected, DO NOT OPERATE THE ATV. Take the ATV to an authorized KYMCO ATV dealer for inspection and adjustment or repair.

Cargo Limitations

One reason why passengers are prohibited on ATV's is because their presence throws off the weight and balance of the ATV. Cargo can do the same if it weighs too much. Limit the ATV to the load capacity ratings identified in the following chart for the particular model being operated. So if you're weighing in at over 200 lb (91kg) when you ride, leave some of that extra cargo at home. The combined weight limit, including you, your rack cargo, and your trailer, is a specified amount, so consult the ATV Load Capacity Ratings Chart and monitor it carefully.

Extra weight on the ATV will also throw you off balance if it's not distributed evenly, side-to-side and front-torear. If you have 160 lb (73 kg) on the rear rack only and you're heading up an incline, shifting your own weight forward isn't going to do enough to compensate for that cargo sitting over the back tires.

Cargo has such a huge affect on ATV handling that you need to pay a lot of attention to your speed. Even on really level areas, you should keep it under 10 mph (16kph) if you've got a trailer attached. Avoid uneven terrain. Also, consider that your braking distance is going to increase with the more weight

you carry.

Think about these when dealing with cargo:

1. Rack weight limit

2. Trailer weight limit

3. Weight distribution

4. ATV speed

Personal Choices

A safe, enjoyable ride is dependent on many personal choices. An ATV, like all motorized vehicles, can be dangerous to operate if you choose to ignore safety precautions, take unnecessary chances, or ride beyond your abilty or your machine's capabilty. Don't allow the thrill of freedom or adventure to affect your ability to make good, safe choices.

SOUND JUDGMENT

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Sound Judgment

Load Capacity Ratings Chart

KYMCO ATV Load Capacity Ratings

Max Load Capacity

Front Rack (max)

Rear Rack (max)

Tongue Weight

Tongue and Rear Cargo Weight (max)

Towing Capacity

Max Load Capacity - Total weight of rider, tongue weight, and cargo on front

and rear racks. Tongue Weight - Weight on trailer

Tongue. Tongue and Accessory Weight - Must

be included as part of the front and rear rack weights.

Speedrack:

When installing Speedrack accessories, make sure to read and carefully follow the instructions provided in each kit.

SpecificationsItem

(Lb)

485

150

200

1050

Tongue and Rear Cargo Weight Total weight on trailer tongue and rear rack capacity.

Towing Capacity - Total weight of trailer and all cargo in the trailer.

NOTE: Use extra caution when operating an ATV with additional loads such as accessories and/or cargo. Handling of the ATV may be adversely affected. Reduce speed when adding additional loads.

(Kg)

220

477

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling, which could lead to an accident.

HOW TO AVOID THE HAZARD

WARNING

Indicates a potential hazard that could result in a serious injury or death.

Sound Judgment

Alcohol and Drug Consumption

Alcohol is related to 30% of all hospital admissions due to ATV accidents in the U.S. This isn't an issue of morality. It's extremely dangerous to drink alcoholic beverages and ride... it's also very foolish. When the alcohol starts kicking in and you're tearing along on your ATV, those odds can catch up to you.

Substances to avoid when riding:

1. Alcohol

2. Over-the-counter or prescription drugs

3. Illegal/mood altering drugs

THE EFFECTS OF ALCOHOL*

The Number of Drinks that Impair Mental and Physical Abilities

Be aware of prescription and over-thecounter medications. Drowsiness and impaired judgment can be caused by a wide variety of medications. The same is true of allergy, cold, flu, and headache medications. Your physical size and weight can't protect you... just one antihistamine tablet can affect your judgment.

If your sense of adventure persuades you to do illegal drugs when you're riding your ATV, this is a reality check. Something to think about there can be legal consequences that will take away all that freedom you love. Don't use alcohol or drugs before or during your ATV ride.

1-2 DRINKS

3-4 DRINKS

5+ DRINKS

WARNING

Mental processes such as restraint, awareness, concentration, and judgment affected; reaction time slowed; inability

to perform complicated tasks.

Depth perception, glare recovery, eye movement, and focus

affected; decreased judgment and control.

Coordination deteriorates, loss of critical judgment, and

impaired memory and comprehension.

*According to the ATV Safety Institute.

Indicates a potential hazard that could result in a serious injury or death.

SOUND JUDGMENT

Sound Judgment

Your Physical Condition

Being physically exhausted is like being drunk. Try to do something that's detail-oriented when you're really tired, and you'll feel totally uncoordinated.

Dont ride:

1. When you’re tired.

Reckless Riding

If you are involved in an ATV accident when you're speeding, you have a 25% chance of landing yourself in the hospital. The faster you go, the more likely you are to destroy your head and internal organs, and skip the wheelies, jumps, stunts, and any other showboat-

ing.

Laws and Regulations

Any police officer will tell you that ignorance of the law is no defense. Your best defense is to check out your local, state, or provincial ATV laws before riding. It'll also make sure that you can continue to ride in your favorite areas. The quickest way to have a land area closed is by riding over the

regulations.

Group Behavior

People always do crazier and riskier things in a group than they would consider doing by themselves. When you're ATV riding with others and things start to get out of hand, decide whether you're willing to be injured or

see your friends injured.

SIPDE

By themselves, none of these safe behaviors and sound judgments will go very far. But when you put them all together... When you're paying attention to how you feel, when you're monitoring the movements of your ATV, and when you're constantly evaluating your environment, then you're practicing SIPDE. SIPDE is an acro-

nym that stands for:

S I P D E

SCAN/

IDENTIFY

HAZARDS

WARNING

PREDICT WHAT

WILL HAPPEN

Indicates a potential hazard that could result in a serious injury or death.

DECIDE WHAT

TO DO

EXECUTE THE

DECISION

Supervision

Overview

You're responsible for supervising those who ride your ATV. Your wisdom is valuable... it'll bring them all back safely─ your friends, your family, your relatives, and your ATV. It's crucial that you consider yourself a supervisor for all riders of your ATV. Whether you accept responsibility or not, the truth is that you are responsible for others

riding your ATV.

Taking Responsibility

You're to the last letter in “ PASS” “ Supervision.” You've just gon e

through the manua l, and you'v e seen what's invo lved. That puts yo u in a good position to be confiden t about what you know. So now it's time to use your knowledge an d supervise others

who ride your ATV.

Inexperienced/ Untrained Riders

Experienced/Trained Riders

If anyone is going to borrow your ATV, you are responsible for their supervision. Before they ride, have them take the training course, have them watch the safety video, and have them read the Owner's Manual. You train them. It doesn't matter how you do it, as long as you do it.

ATV's are all a little different from the handling to the stability to the controls. So regardless of how much experience your family members have with ATV's, they don't have experience with your ATV. Let experienced riders get familiar with your ATV─ show them the basics before they take off. You don't want it on your conscience that someone got hurt because you didn't tell them how to use your ATV.

You can't let people ride your ATV who don't know what they're doing. Unless they've had over a year of experience with ATV riding or taken an ATV training course, it's your responsibility to keep them off your ATV. It can be dangerous (especially for underaged children) all the more reason

for you to be firm.

WARNING

Indicates a potential hazard that could result in a serious injury or death.

SUPERVISION

Supervision

Remember that regardless of experience, you should never let anyone under the age of 16 operate your

ATV.

Age (Years) Engine Size (cc) Speed Limitations (MPH)

6-11

12-15

16 and Older

Up to 70

Up to 90

Over 90

KYMCO and the ATV Safety Institute recommend that all ATV operators ride the appropriate-sized ATV according to age.

10 - Governed 15 - Maximum

15 - Governed 30 - Maximum

According to Local Regulations

WARNING

Indicates a potential hazard that could result in a serious injury or death.

DIVISION II - PREFACE

(Operation/Maintenance)

T h is KY M C O AT V O w n e r ' s Ma n ual should be co nsidered a perman ent part of the ATV and must remain with the ATV at the time of resale. If the ATV changes owners-hip more than o n c e , co n t a c t K Y M C O U S A I n c . , Service Department, f or proper registration in f o r m a t i o n . D i v i s i o n II of th is Owner 's Manua l wa s prepared b y t h e S e r v i ce D e p ar tm e n t o f KY M C O In c . Yo u ha v e cho s e n a qua l i ty KYM C O AT V desi g n ed and man u fac t u re d t o giv e d epe n dab l e service. Be sure, as the owner/ operator of an KYMCO ATV, to becom e thoroughly familiar with its basic operation, maintenance and storag e procedures . Read and unde rstand the entire Owner's Manual before operating the ATV to ensure safe and proper use of your new KYMCO ATV. Always operate the ATV within yo ur level of sk ill and current terrain condition s.

Division II of this manual covers operatorrelated maintenance, operating instructions, and storage instructions. If major repair or service is ever required, contact an authorized KYMCO ATV deal e r for profess i o n a l se r v i ce. At the time of publication, all information and illustrations in Division II were technically correct. Some illustrations used in Division II are used for clarity purposes only and are not designed to depict actual conditions. Because KYMCO Inc. Constantly refines and improves its products, no retroactive obligation is incurred.

PARTS AND ACCESSORIES

When in need of replacement parts, oil, or accessories for your KYMCO ATV, be sure to use only GENUINE KYMCO PARTS, OIL, AND ACCESSORIES. Only genuine KYMCO parts, oil, and accessories are engineered to meet the standards and requirements of your KYMCO ATV. For a complete list of accessories, refer to the current KYMCO ATV Accessory Catalog.

To aid in service and maintenance procedures on this ATV, a Service Manual and an Illustrated Parts Manual are available through your local KYMCO ATV

dealer.

SPECIFICATIONS*

ENGINE AND DRIVE

Type

Bore x Stroke Displacement Ignition Type

Spark Plug Type Spark Plug Gap Brake Type Carburetor Type

CHASSIS

Length (Overall)

Height (Overall) Width (Overall) Suspension Travel

Wheelbase Tire Size (Front) Tire Size (Rear)

Tire Inflation Pressure

MISCELLANY

Dry Weight (Approx)

Gas Tank Capacity (Rated) Differential Capacity Rear Drive Capacity Engine Oil Capacity Engine Oil Changed Capacity 2.2 L (2.3 U.S. qt) Engine Oil Changed Capacity 2.4 L (2.5 U.S. qt) With Oil Filter Changed Gasoline (Recommended) Engine Oil (Recommended) Differential/Rear Drive

Lubricant Taillight/Brakelight

Headlight Starting System

* Specifications subject to change without notice.

Four-Cycle/Oil Cooled 81 mm x 71.2 mm (3.19 x 2.80 in.) 366 cc (22.33 cu in.)

CDI NGK CR8E

0.7 - 0.8 mm (0.028 - 0.032 in.) Hydraulic w/Brake Lever Lock and Auxiliary Brake

Keihin CVK34

210.8 cm (83.0 in.) ─ U.S.

212.3 cm (83.6 in.) ─ Europe

110.2 cm (43.4 in.)

119.2 cm (46.9 in.)

19.0 cm (7.5 in.)

121.7 cm (47.9 in.)

24 x 8-12 24 x 10-12

0.28 kg/cm (4.0 psi)

275 kg (605 lb) ─ U.S. 276 cm (607.2 lb) ─ Europe 15 L (3.75 U.S. Gal.) 270 ml (9.1 fl oz) 250 ml (8.5 fl oz)

2.8 L (3.0 U.S. qt)

87 Octane Regular Unleaded

SAE 5W-30

SAE Approved 80W-90 Hypoid

12V/5W/21W 12V/35W (4)

Electric

GENERAL INFORMATION

ATV IDENTIFICATION NUMBERS

The KYMCO ATV has two identification um bers: Vehi cle Ident ification Number (VIN) and Engine Serial

Number (ESN).

The VIN is located on the lower-front crossmember.

VIN

KC0055A

The ESN is located on the rear of the engine crankcase and is visible from

the side.

These numbers are required by the dealer to complete warranty claims properly. No warranty will be allowed by KYMCO if the VIN or ESN is removed or mutilated in any way. Always provide the ATV name, Vehicle Identification Number, and Engine Serial Number when contacting an authorized KYMCO ATV dealer for parts, service, accessories, or warranty. If a complete engine must be replaced, ask the dealer to notify KYMCO for cor-

rect registration information.

IGNITION SWITCH KEY

Two keys come with the ATV. Keep the spare key in a safe place. An identifying number is stamped on each key. Use this number when ordering a

replacement key.

Y O

Y OK

ATV-0055

CONTROL LOCATIONS AND FUNCTIONS

Ignition Switch

The ignition switch has three positions.

ATV-0056

OFF position - All electrical circuits except the accessory plug are off. The engine will not start. The key can be

removed in this position.

NOTE: The accessory plug is powered by the battery at all times.

ON position - The ignition circuit is

complete and the engine can run. The key cannot be removed in this position. LIGHTS position - The ignition circuit is complete and the headlights and taillight are on. The key cannot be

removed in this position.

GENERAL INFORMATION

CAUTION

Leaving the ignition switch in the LIGHTS position for a long period of time when the engine is not running may cause the battery to discharge. Always leave the ignition switch in the OFF position when engine is not running.

Gas Tank Valve

The gas tank valve is incorporated in the gas tank. There are three positions:

ON, RES, and OFF.

1.To engage the high range from neu tral, move the shift lever forward.

2.To engage the low range from high range, move the shift lever outward and forward.

In the OFF position, the valve will not allow gasoline to flow to the carburetor. In the ON position (the normal operating position), gasoline will flow from the tank to the carburetor. In this position, 2.46 L (0.65 U.S. gal.) will remain in the tank as a reserve quantity. Moving the valve to the reserve (RES) position will allow the operator to use the remaining gasoline in the tank. When turning the valve to any of the three positions, be sure the indicator is pointed directly at the position desired.

WARNING

Never leave the valve in the ON or RES position when the engine is

not running.

Shifting

Low

High

Neutral

CAUTION

3.To engage reverse gear from neu tral, move the shift lever outward and rearward into the R position.

CAUTION

reverse.

2WD/4WD Selector

Switch

2WD/4WD Selector Switch

Reverse

CF130B

This ATV has a dual-range automatic transmission with reverse. To shift the

ATV, follow these steps:

CF246A

The 2WD/4WD selector switch allows the operator to operate the ATV in either two-wheel drive (rear wheels) or four-wheel drive (all wheels). For normal riding on flat, dry, hard surfaces, two-wheel drive should be sufficient. In situations of aggressive trail conditions, four-wheel drive would be the

desired choice.

To either engage or disengage the front wheels, move the switch to the 4WD

position or to the 2WD position.

CAUTION

Do not attempt to either engage or disengage the front differential while the ATV is moving.

Hand Brake Lever/ Brake Lever Lock

738-420B

The hand brake is considered to be the normal operating (main) brake. It should be applied whenever a braking

situation is needed.

Apply the brake by compressing the brake lever toward the handlebar.

To engage and release the brake lever lock, use the following procedure.

1.Squeeze the hand brake lever two or three times and release it.

2.Depress and hold the brake lever lock.

3.While holding in on the brake lever lock, squeeze the brake lever.

NOTE: It will click as it engages and the brake lever will not return

to its released position.

Release the brake lever lock by squeezing the brake lever. It will return to its released position.

Check to make sure the brake lever lock engages properly and that the brake (when engaged) locks the

wheels.

1.Pump the brake lever 2 or 3 times.

2.Engage the brake lever lock.

3.Attempt to push the ATV.

NOTE: The brake lever lock must lock the wheels. If it doesn’t, take the ATV to an authorized KYMCO ATV dealer for service.

CAUTION

Always check to be sure that the brake lever lock has been disengaged before operating the ATV. An accident could result if the brake lever lock is left engaged while the ATV is operated. The brake may relax if left engaged for a long period of time. This could cause an accident; therefore, do not leave the ATV on a hill depending on the brake lever lock. Always block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a sidehill position.

Headlight HI/LO Switch

Starter Button

Headlight HI/LO Switch

Turn Signal Switch

CF245A

Emergency Stop Switch

GENERAL INFORMATION

Use the headlight HI/LO switch to select the high or low headlight beam when the ignition switch is in the LIGHTS position. When the switch is in the HI position, the high beam will illuminate. When the switch is in the LO position, the low beam will illumi-

nate.

Throttle Lever

Emergency Stop Switch

OFF position - The ignition circuit is off. The engine cannot be started or will not run. If the emergency stop switch is used to stop engine without turning off ignition switch, the battery

may discharge.

RUN position - The ignition circuit is on. The engine can start and run.

Starter Button

Pushing in on this button activates the starter motor. Before starting the engine, make sure the ignition switch is in the ON position, the transmission is in neutral, and the brake lever lock is

engaged.

NOTE: This ATV has safety interlock switches which prevent the starter motor from activating when the transmission is not in neutral.

Turn Signal Switch

Move to (L) to signal a left turn, (R) to signal a right turn. Press to turn signal off.

CAUTION

The turn signal light will not be released automatically. Be sure to reset it after using, otherwise it may affect the traffic safety.

CF246A

Control engine RPM with the position of the throttle lever. Operate this lever with the thumb. Pushing it forward increases engine RPM and allowing it to retract decreases engine RPM.

Throttle Limiter Screw

Jam Nut

Throttle lever travel may be limited by adjusting the throttle limiter screw. The throttle limiter should be adjusted according to the operator's skill and experience. To adjust the throttle limiter, use the following procedure.

1.Loosen the jam nut. Turn the throttle limiter screw

2. clockwise to decrease engine RPM maximum or counterclockwise to increase engine RPM maximum.

3.Tighten the jam nut securely.

NOTE: The ATV is equipped with a CDI unit that retards ignition timing when maximu m RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.

Limit Screw

ATV-0053

Auxiliary Brake Pedal

CF117

Pressing the auxiliary brake pedal downward will apply the brake to the

rear wheels.

Speedometer/LCD

KC0001A

Adjust/Set Button - In conjunction with the Mode Button (2), sets the clock and resets the trip meter to zero. Also used to toggle between

MPH and km/h.

NOTE: Both the Adjust/Set Button (1) and the Mode Button (2) must be depressed and held for three seconds to activate the gauge function. Approximately ten seconds after releasing the buttons, the display will return to normal operating mode.

Mode Button - Used to toggle

2. between Clock, Hour Meter, Odometer, and Trip Meter in the display (5) on the LCD. In conjunction with the Adjust/Set Button (1), sets the clock or resets the trip

meter to zero.

3.Gear Position Indicator - Indicates which gear position is selected. ‧R (reverse)/N (neutral)/L (low range)/H (high range).

NOTE: An E will be displayed if the transmission is not engaged in a selected gear.

4.Spe e d ome t e r- Indic a tes the approximate vehicle speed in miles per hour (MPH) or kilometers per hour (km/h).

5.Clock/Hour Meter/Odometer/Trip Meter - Displays time, total engine hours, total miles/kilometers trav eled, or trip miles/kilometers trav eled. To set the clock, use steps A C. To reset the trip meter, proceed to step D.

To set the clock, press and hold

the Mode Button (2) until CLOCK is displayed.

KC0008

Press and hold the Adjust/Set Button (1) and Mode Button (2) until the hour display starts to flash (approximately three seconds); then release the buttons and press the Mode Button

(2) to set the hour.

GENERAL INFORMATION

KC0006A

NOTE: The hour display will read from 1 to 24 and may be cycled rapidly by holding the Mode Button (2) down for three seconds.

After the c o r r ect hour is attained, momentarily press the Adjust/Set Button (1) to toggle the clock to the minute display (minutes flashing); then press the Mode Button (2) to set the minutes. After approximately ten seconds, the minute display will stop flashing and the gauge will return to normal operation.

To reset the trip meter, press

and hold the Mode Button (2) until TRIP is displayed in the display; then press and hold the Ad just /Set Bu tton (1) a nd Mode Button (2) until the trip meter reads 0.

KC0011

PRIMER - COLD START

KC0007A

NOTE: Clock memory power is supplied through the 15-amp accessory fuse and verified during gauge power-up”and reset. In the event of clock memory power failure (blown fuse, etc.), the gauge will“ power-up,” reset, and shut down repeatedly until clock memory power is restored. Always check the 15-amp accessory fuse if this gauge condition is noted.

CF123A

The primer is located on the carburetor. Depress and release the lever several times prior to attempting to start a cold engine.

GAS/VENT HOSES

Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the carburetor/throttle body vent hose. Make certain that the vent hose is securely connected to the carburetor/throttle body and hose holder and the opposite end is always open.

CARBURETOR FLOAT BOWL DRAIN

AF925

Periodically, the float bowl should be drained to remove condensation. To drain the float bowl, use the following procedure.

1.Direct the hose from the float bowl

drain into a container.

WARNING

Do not drain float bowl contents directly onto the engine. Gasoline is highly flammable and could ignite. Use a hose.

2.Loosen the drain screw and allow the gasoline and condensation to flow out.

3.Tighten the drain screw securely and remove the hose.

WARNING

It is very important that the drain screw be tightened securely. If it is not tightened securely, gasoline could drip onto the engine.

Oil Level Stick

KC0051A

There is an oil level stick for checking the engine oil level. To check the oil level, use the following procedure.

NOTE: The ATV should be on level ground when checking the engine oil level.

Unstall the oil level stick and wipe

1. it with a clean cloth. Install the oil level stick and thread

2. it into the engine case.

Remove the oil level stick; the

3. engine oil level should be above the

“ L” mark but not higher than the “F”mark.

CAUTION

Do not overfill the engine with oil. Always make sure the oil level is above the “L”mark but not higher than the“F” mark.

SEAT LATCH

GENERAL INFORMATION

OIL LEVEL STICK

ATV-0100AA

AL676A

To remove the seat, lift up on the latch release (located at the rear of the seat); then raise the rear of the seat and slide it rearward.

To lock the seat into position, slide

2. the front of the seat into the seat retainers and push down firmly on the rear of seat. The seat should automatically lock into position.

WARNING

Make sure the seat is secure before mounting the ATV. Severe personal injury may result if the seat is not properly secured.

SAFETY FLAG BRACKET

A bracket is provided for mounting a flag at the rear of the ATV.

RACK LOADING (Front and Rear)

The front rack and rear rack are designed to carry specified load capacities. Always refer to the ATV Load Capacity Ratings Chart for proper capacities.

WARNING

Make sure the loads on the front and rear racks will not interfere with the ATV controls or obstruct the view of the operator. Also, make sure the loads are evenly distributed, properly secured, and will not shift while operating the ATV.

TRAILERING AND

TOWING

WARNING

Never use the racks as a towing or trailering point.

KYMCO ATV's are equipped with a frame-mounted receiver for a standard

5.1 cm (2 in.) receiver hitch. The standard receiver hitch must be purchased separately.

738-424A

When loading a trailer properly, two items are critical: Gross Trailer Weight (the weight of the trailer plus cargo) and Trailer Tongue Weight.

WARNING

Make sure that the load in the trailer is properly secured and will not shift while moving. Also, do not overload the trailer.

WARNING

Never exceed any of the ATV weight restrictions.

Trailer Tongue Weight is the downward force exerted on the hitch by the trailer coupler when the trailer is fully loaded and the coupler is at its normal towing height. Refer to the Load Capacity Ratings Chart for tongue weight information.

Always maintain a slow speed when trailering and towing and avoid sudden accelerations, quick maneuvers, and sudden stops. Braking distance will be affected when towing a trailer. When towing a trailer, always maintain slow speed and allow more stopping distance than when not towing a trailer.

WARNING

Riding an ATV without extra caution when towing a trailer will be hazardous. Trailer towing can affect the handling and braking of the ATV. Tow only at low speeds and never exceed 10 mph. Avoid sudden accelerations and stopping of the ATV. Do not make quick maneuvers. Avoid uneven surfaces and do not tow on hills. Never carry passengers in a trailer unless the trailer is designed for such use and has a rigid tow bar. Allow more stopping distance than when not towing a trailer.

TRANSPORTING ATV

When transporting the ATV, KYMCO recommends that the ATV be in its normal operating position (on all four wheels) and the following procedure be used.

Engage the brake lever lock and

1. place the transmission in gear.

Secure the ATV with load rated hold-down straps.

NO TE : Su i ta bl e ho l d - do w n straps are available from your KYMCO ATV dealer. Ordinary r o p e i s n o t re co mm e n d e d because it can stretch under load.

CAUTION

If using additional hold-down straps in any other areas, care must be taken not to damage the ATV.

GASOLINE-OILLUBRICANT

Recommended Gasoline

The recommended gasoline to use in this ATV is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or MTBE are acceptable gas-

olines.

When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

Recommended Engine/ Transmission Oil

The recommended oil to use in this ATV is an oil which is rated SE, SF, or SG under API service classification. These oils meet all of the lubrication requirements of the KYMCO ATV engine. The recommended engine oil viscosity is SAE 5W-30. Ambient temperature should determine the correct weight of oil. See the viscosity chart or an authorized KYMCO ATV dealer for details.

GENERAL INFORMATION

CAUTION

When transporting the ATV, make sure the brake lever lock is engaged, the transmission is in first gear, and the ATV is properly secured.

OILCHARTC

CAUTION

Any oil used in place of the recommended oil could cause serious engine damage.

Recommended Front Differential/Rear Drive

Lubricant

The recommended lubricant (front differential and rear drive when applicable) is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the KYMCO ATV.

CAUTION

Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.

Filling Gas Tank

WARNING

Always fill the gas tank in a wellventilated area. Never add gasoline to the ATV gas tank near any open flames or with the engine running or hot. DO NOT SMOKE while filling the gas tank.

Since gasoline expands as its temperature increases, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area.

ATV0049D

Allow the engine to cool before filling the gas tank. Care must be taken not to overfill the tank. If overfilled, gas may leak onto the engine creating a fire haz-

ard.

WARNING

Do not over-flow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank.

WARNING

Do not overfill the gas tank.

Tihten the gas tank cap securely after filling the tank.

BREAK-IN PROCEDURE

New ATV's and renewed ATV eng ines requi re a“break-in” period. The fir st month is most critical to the l ife of this ATV. Pro per operation during this break -in period will help assure maxi mum life and perform ance from the ATV.

During the fir st 10 hours o f o peration , always use l ess t han throttl e. Varying the engine R PM du ring the b rea k-in period al lows the compon ents to “load” (a idin g the engine /tra nsmissi on comp o ne n t m a ti n g p r oc e s s ) a n d t h e n “ un l o a d” ( a l lowing compone n t s t o cool). Al though it is essen tia l to place some stres s on the engine com ponents during break -in, care should b e tak en not t o ov erload th e en gine t oo often. Do not pull a trailer during the bre ak-in

period.

When the engine starts , a llo w i t t o warm up properly. Id le the en gin e s everal minutes u n til th e en g i n e ha s reached normal operating temperatu re. Do not idle the eng ine for excessively

long peri ods of time.

CAUTION

WARNING

Do not attempt sudden stops or put yourself into a situation where a sudden stop will be required until the brake pads are properly burnished.

After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners. At the discretion and expense of the owner/operator, the ATV may be taken to an authorized KYMCO ATV dealer for this initial service.

GENERAL INFORMATION

BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRAKING EFFECTIVENESS.

Braking distance will be extended until brake pads are properly bur-

nished.

TO PROPERLY BURNISH THE BRAKES, USE FOLLOWING PRO-

CEDURE:

Choose an area sufficiently

‧

large to safely accelerate ATV to 30 mph and to brake to a stop.

Accelerate to 30 mph; then com-

‧

press brake lever to decelerate to 0-5 mph.

‧ Repeat procedure 5 times.

GENERAL MAINTENANCE

NOTE: Proper maintenance of the ATV is important for optimum performance. Follow the Maintenance Schedule and all ensuing maintenance instructions/information.

If, at any time, abnormal noises, vibrations, or improper function of any component of this ATV is detected, DO NOT OPERATE THE ATV. Take the

ATV to an authorized KYMCO ATV dealer for inspection and adjustment or repair.

If the owner/operator does not feel qualified to perform any of these maintenance procedures or checks, take the ATV to an authorized KYMCO ATV dealer for professional service.

NOTE: The following instruction and information refer to specific items in the maintenance and care of the ATV.

MAINTENANCE SCHEDULE

Item Page

Initial 100

miles after

break-in

Initial 100

miles after 1

month

Initial 300

miles after 3

months

Initial 500

miles or 6

months

Battery 73 I I *Engine nuts and bolts - I I *Valve clearance - I I

74 I I ISpark plug

74 Replace every 4000 miles or 18 months Oil cooler 68 I I I Idle RPM 75 I I Throttle cable 75 I Inspect every time before riding

60 I Inspect every time before ridingGas / vent hoses

60 Replace every 2 years Engine / transmission oil and filter

68 R R

Air filter 76 I I

69 I IGear lubricant (Front differential-rear drive)

69 Replace every 4 years V-Belt 77 I I Muffler / spark arrester 78 C Tires / air pressure 77 I Inspect every time before riding *Brake components 70/71 I Inspect every time before riding Brake fluid 70 I *Replace every 2 years Brake hoses 71 I *Replace every 4 years *Steering - I Inspect every time before riding *Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)

- I Inspect every time before riding

*Chassis nuts and bolts - I T Frame / welds / racks - I I Electrical connections - I I Headlight / taillight-brakelight 79 I Inspect every time before riding Air filter housing drain 76 I Inspect every time before riding I=Inspect and clean, adjust, lubricate, replace as necessary * = Dealer maintenance T=Tighten R = Replace C = Clean

GENERAL MAINTENANCE

OIL COOLER

KC0083

NOTE: Dirt and debris must be cleaned from the cooling fins regularily to ensure proper engine oil change.

CAUTION

Continued operation of the ATV with high engine temperature may result in engine damage or premature wear.

NOTE: High engine RPM, low vehicle speed, or heavy load can raise engine temperature. Decreasing engine RPM, reducing load, and selecting an appropriate transmission gear can lower the temperature.

SHOCK ABSORBERS

Each shock absorber should be visibly checked weekly for excessive fluid leakage (some seal leakage may be observed but it does not indicate the shock is in need of replacement), cracks or breaks in the lower case, or a bent shock rod. If any one of these conditions is detected, replacement is necessary.

NOTE: When the ATV is operated in extremely cold weather (-23 C/-10 F or colder), a small amount of leakage may be present.

Unless the leakage is excessive, replacement is not necessary. The shock absorber has a spring force adjustment sleeve with five adjustment positions to allow the spring to be adjusted for different riding and loading conditions. If the spring action is too soft or too stiff, adjust it according to the chart.

CD453

NOTE: Use a spanner wrench to adjust the sleeve to the desired position.

Position

1 2 3 4 5

Spring Force

Stronger

Setting

Soft

Stiff

Load

Light

Heavy

GENERAL LUBRICATION

Cables

None of the cables require lubrication; however, it is advisable to lubricate the ends of the cables periodically with a good cable lubricant.

Engine/Transmission Oil and Filter

NOTE: Refer to the recommended oil viscosity chart (on page 64) in this manual for the proper engine oil.

Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain easily and completely.

1.Park the ATV on level ground. Remove the oil level stick. Be care-

2. ful not to allow contaminates to enter the opening.

Oil Level Stick

KC0051A

Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.

Apply oil to the new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely.

Install the oil filter drain plug and tighten securely.

Install the engine drain plug and

8. tighten it securely. Pour the recommended oil in the filler hole. Install filler plug.

Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes.

10.

Turn the engine off and wait approximately one minute. Recheck the oil level.

Inspect the area around the drain

11. plug and oil filter for leaks.

Front Differential And Rear Drive Gear Lubricant (Inspecting/

Changing)

Inspect and change the gear lubricant in each according to the Maintenance Schedule. When changing the lubricant, use approved SAE 80W-90 hypoid oil and use the following procedure.

733-441A

Remove the oil filter plug from the filter mounting boss (located on the front-right side of the transmission case) and allow the filter to drain

completely.

Using the oil filter wrench and a ratchet handle (or a socket or boxend wrench), remove the old oil filter and dispose of properly. Do not re-use oil filter.

NOTE: Clean up any excess oil after removing the filter.

1.Place the ATV on level ground.

2.Remove each oil filler plug.

3.Drain the oil into a drain pan by removing in turn the drain plug from each.

CF107B

GENERAL MAINTENANCE

CF106C

4.After all the oil has been drained, install the drain plugs and tighten securely.

CAUTION

Inspect the oil for any signs of metal filings or water. If found, take the ATV to an authorized KYMCO ATV dealer for servicing.

5.Pour recommended oil into each fille hole.

NOTE: If the gear case has a level plug, fill to the threads of the level plug. If the gear case has only a fill plug, fill to within 1 in. of the threads of the fill plug.

6.Install the filler plugs and level plugs.

HYDRAULIC HAND BRAKE

738-420B

WARNING

Be sure to inspect the hydraulic brake system before each use. Always maintain brakes according to the Maintenance Schedule

Brake Fluid

Check the brake fluid level in the brake fluid reservoir. If the level in the reservoir is not visible in the sight glass, add DOT 4 brake fluid.

Sight Glass

CF113A

738-420A

CF116A

NOTE: If the sight glass appears dark, there is a sufficient amount of fluid in the reservoir.

CAUTION

Be careful not to spill any fluid when filling the brake fluid reservoir. Wipe away spilled fluid immediately.

Brake Lever Lock

Check to make sure the brake lever lock engages properly and that the brake (when engaged) locks the wheels.

1.Pump the brake lever 2 or 3 times.

2.Engage the brake lever lock.

3.Attempt to push the ATV.

If thickness of either brake pad is less than 1.0 mm (0.039 in.), take the ATV to an authorized KYMCO ATV dealer to have brake pads replaced.

Install the wheel and tighten to 40 ft-lb.

AUXILIARY BRAKE

PR376B

NOTE: The brake lever lock must lock the wheels. If it doesn't, take the ATV to an authorized KYMCO ATV dealer for service.

Brake Hoses

Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, take the ATV to an authorized KYMCO ATV dealer to have the brake hoses replaced.

Brake Pads

The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows:

1.Remove a front wheel.

2.Measure the thickness of each brake pad.

The auxiliary brake must be main-

tained to be fully functional.

WARNING

Be sure to inspect the auxiliary brake system before each use. Always maintain brakes according to the Maintenance Schedule.

Check the brake fluid level in the reservoir. The fluid level must be maintained between the MAX and MIN level marks. If the level in the reservoir is low, add DOT 4 brake fluid.

CD474A

NOTE: The brake fluid reservoir is located under the seat.

GENERAL MAINTENANCE

Press the auxiliary brake pedal sev-

2. eral times to check for firmness.

If the pedal is not firm, the system must be bled.

NOTE: Take the ATV to an authorized KYMCO ATV dealer for this service.

PROTECTIVE RUBBER BOOTS

The protective boots should be inspected periodically according to the

Maintenance Schedule.

Ball Joint Boots (Upper and Lower/

Right and Left)

CC791

Tie Rod Boots (Inner and Outer/Right and Left)

CC792

Secure the ATV on a support stand

to elevate the front wheels. Remove both front wheels.

Inspect the four tie rod boots for

cracks, tears, or perforations.

Check the tie rod end free-play by

grasping the tie rod near the end and attempting to move it up and down.

If boot damage is present or tie rod end free-play seems excessive, contact an authorized KYMCO ATV dealer for service.

Secure the ATV on a support stand to elevate the front wheels.

Remove both front wheels.

Inspect the four ball joint boots for cracks, tears, or perforations.

Check the ball joint for free-play by grasping the steering knuckle and turning it from side to side and up and down.

If boot damage is present or ball joint free-play seems excessive, contact an authorized KYMCO ATV dealer for service.

Drive Axle Boots

CC793

CF125A

Inspect all drive axle boots for cracks, tears, or perforations.

If boot damage is present, contact an aut h orized KY M CO ATV dealer for service.

BATTERY

The battery is located under the seat. After being in service, batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life. The following procedures are recommended for cleaning and maintaining lead-acid batteries. Always read and follow instructions provided with battery chargers and battery products.

NOTE: Battery maintenance can be performed by the ATV owner if qualified to do so. If the owner does not feel qualified, take the ATV to an authorized KYMCO ATV dealer for this service. This service is at the discretion and expense of the ATV owner.

WARNING

Anytime service is performed on a battery, the following must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear safety glasses. Protect skin and clothing when handing a battery. When servicing battery in enclosed space, keep the area well-ventilated. Make sure ba t tery v enting is not obstructed.

Remove the battery hold-down;

1. then disconnect the battery cables (negative cable first).

Disconnect the vent hose.

Remove the battery from the battery compartment; then thoroughly wash the battery and battery compartment with soap and water.

NOTE: If battery posts, cable ends, or the battery case has a build-up of white/green powder residue, apply water and baking soda to neutralize acid; then flush off with warm soapy water.

Using a wire brush, clean the bat-

4. tery posts and cable ends removing all corrosive buildup. Replace damaged cables or cable ends.

Add clean distilled water to bring fluid level to the UPPER level line.

WARNING

Battery acid is harmful if it contacts eyes ,skin, or clothing. Care must be taken whenever handling a battery.

CAUTION

Never use electrolyte (sulfuric acid) to“top off”the battery. Use only distilled water or severe battery damage may occur.

Using a multimeter, test the battery

6. voltage. The meter must read at least 12.5 DC Volts for a fully charged battery.

NOTE: At this point, if the meter reads as specified, the battery may be returned to service (see step

10).

If the meter reads less than speci-

fied voltage, charge the battery using the following guidelines.

GENERAL MAINTENANCE

When using an automatic bat-

Battery

Voltage (DC)

Charge

State

Charge Time

Required

(at 1.5-2.0

Amps)

12.5 or more 100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

tery charger, always follow the charger manufacturer's instructions.

When using a constant-current

battery charger, use the following Battery Charging Chart.

CAUTION

Never exceed the standard charging rate.

WARNING

An overheated battery could explode causing severe injury or death. Always monitor charging times and charge rates carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

Battery Charging Chart

(Constant-Current Charger)

After charging the battery for the specified time, remove the battery charger and allow the battery to sit for 1-2 hours.

Connect the multimeter and test the battery voltage. The meter should read at least 12.5 DC Volts. If the voltage is as specified, the battery is ready for service.

NOTE: If voltage in step 9 is below specifications, charge the battery an additional 1-5 hours; then retest. Recheck electrolyte level and the battery is ready for service.

Place the battery in the battery

10. compartment; then coat the battery posts and cable ends with a light coat of multi-purpose grease.

CAUTION

Before installing the battery, make sure the ignition switch is in the OFF position.

11.

Connect the battery cables (positive cable first); then install the battery hold-down.

NOTE: If the battery voltage is

11.5 DC Volts or less, some chargers may“cut off＂and fail to charge. If this occurs, connect a fully charged booster battery in parallel (positive to positive and negative to negative) for a short period of time with the charger connected. After 10-15 minutes, disconnect the booster battery leaving the charger connected and the charger should continue to charge. If the charger“cuts off,＂ replace the battery.

CAUTION

Connecting cables in reverse (positive to negative and negative to positive) can cause serious damage to the electrical system.

SPARK PLUG

The ATV comes equipped with a specified spark plug. See the specifications chart for the correct spark plug. A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the engine may need to

be serviced or the carburetor may need to be adjusted. Consult an authorized KYMCO ATV dealer if the plug insulator is not a light brown color.

To help prevent cold weather fouling, make sure to thoroughly warm up the engine before operating. To maintain a hot, strong spark, keep the plug free of carbon.

Before removing the spark plug, be sure to clean the area around the spark plug. If you do not, dirt could enter engine when removing or installing the spark plug.

Adjust the gap to 0.7-0.8 mm (0.028-

0.032 in.) for proper ignition. Use a wire-type feeler gauge to check the gap.

0.7-0.8 mm

(0.028-0.032 in.)

ATV-0052

When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8

-1/4 turn once the washer contacts the cylinder head.

ENGINE IDLE RPM ADJUSTMENT

Turn the idle adjustment screw in

2. or out until the engine idles at 1250-1350 RPM.

AF920

WARNING

Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM.

THROTTLE CABLE ADJUSTMENT

To adjust the throttle cable free-play:

Loosen the jam nut from the throttle cable adjuster.

Slide the rubber boot away and turn the adjuster until the throttle lever has the proper free-play of 3-6 mm (1/8-1/4 in.).

GENERAL MAINTENANCE

To properly adjust the idle, a tachometer is necessary. If one is not available, take the ATV to an authorized KYMCO ATV dealer.

To adjust idle RPM:

NOTE: Th e idle ad justment screw is located on the right-hand side of the carburetor.

Start the engine and warm it up to normal operating temperature.

ATV-0047

Tighten the knurled nut against the

throttle cable adjuster securely; then slide the rubber boot over the adjuster.

AIR FILTER

The air filter inside the air filter housing must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently. Use the following procedure to remove the filter and inspect and/or clean it.

Rotate the three latches to release

1. the filter housing cover; then loosen the inlet boot clamp.

KC0056A

Put the element in a plastic bag;

6. then pour in air filter oil and work the oil into the element.

Squeeze the element to remove excess oil.

CAUTION

A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

Clean any dirt or debris from inside

8. the air cleaner. Be sure no dirt enters the carburetor.

Install the air filter and cover.

10.

Connect the inlet boot and tighten the clamp securely.

Remove the filter housing cover and air filter element.

Fill a wash pan larger than the ele-

3. ment with a non-flammable solvent; then dip the element in the solvent and wash it.

Squeeze the element by pressing it between the palms of both hands to remove excess solvent. Do not twist or ring the element or it will develop cracks.

Dry the element.

KC0056B

AIR FILTER HOUSING DRAIN

Inspect the “duck bill” drain in front of the main housing for debris and for proper sealing.

KC0056C

DRAINING V-BELT COVER

KC0049A

NOTE: If the ATV has been driven through water, the V-belt cover must be drained of any water.

Place the ATV on a level surface.

Remove the drain bolt from the cover and allow the water to drain out.

Shift the range lever to the neutral position; then start the engine.

Increase and decrease engine RPM

several times to“ blow out” any water; then stop the engine.

Install the drain bolt and tighten securely.

NOTE: The V-belt and pulleys should be inspected every 500 miles and the belt replaced (if necessary).

TIRES

WARNING

Always use the size and type of tires as specified. Refer to the appropriate specifications chart for proper tire inflation pressure, and always maintain proper tire inflation pressure.

Tire Tread Condition

The use of worn-out tires on an ATV is very dangerous. A tire is considered to be worn out when the depth of the tread is less than 3 mm (1/8 in.). Be sure to replace the tires before reaching this minimum specification.

0732-649

WARNING

The use of worn-out tires can be dangerous and can increase the risk of an accident.

Tire Replacement

The ATV has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If either the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these areas when replacing tires.

It is very important to use the proper tools when repairing or replacing tires to prevent damage to the tire bead or wheel rims. If proper tools and related items are not available, have this maintenance performed by an authorized KYMCO ATV dealer or a qualified tire repair station

CAUTION

When breaking the tire bead loose from the wheel, be extremely careful not to damage the inner wheel surface or the tire bead.

GENERAL MAINTENANCE

WARNING

Use only KYMCO approved tires when replacing tires. Failure to do so could result in unstable ATV operation.

Tubeless Tire Repair

Should a leak or flat tire occur due to a puncture, the tire may be repaired using a plug-type repair. If the damage is from a cut or if the puncture cannot be repaired using a plug, the tire must be replaced. When operating the ATV in areas where transportation or service facilities are not readily available, it is strongly recommended to carry a plugtype repair kit and a tire pump along.

WHEEL REMOVAL

Park the ATV on level ground and

1. engage the brake lever lock.

Loosen the lug nuts on the wheel to

2. be removed. Elevate the ATV by placing a jack

3. under the axle.

Remove the lug nuts.

Remove the wheel. Install the wheel and install the lug

6. nuts.

Tighten the nuts in a crisscross pattern to 40 ft-lb.

Remove the jack.

MUFFLER/SPARK ARRESTER

The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Maintenance Schedule, clean the spark arrester using the following procedure.

WARNING

Wait until the muffler cools to avoid burns.

Remove the cap screws securing

1. the spark arrester assembly to the muffler; then remove the spark arrester.

KC0098

Using a suitable brush, clean the

2. carbon deposits from the screen taking care not to damage the screen.

NOTE: If the screen or gasket is damaged in any way, it must be replaced.

Install the spark arrester assembly

3. and secure with the cap screws. Tighten securely.

LIGHT BULB REPLACEMENT

The wattage rating of each bulb is shown in the chart. When replacing a burned bulb, always use the same wattage rating.

Headlight

Taillight/Brakelight

12V/35W (4)

12V/5W/21W

CAUTION

Use only specified bulbs indicated in the chart as replacement bulbs.

Headlight

NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.

To replace the headlight bulb, use the following procedure.

Remove the wiring harness connec-

1. tor from the back of the headlight.

Grasp the bulb housing, turn it counterclockwise, and remove the bulb. Install the new bulb into the hous-

3. ing and rotate it completely clockwise. Install the wiring harness connec-

4. tor.

CAUTION

When replacing the headlight bulb, be careful not to touch the glass portion of the bulb. Grasp the new bulb with a clean cloth.

Taillight/Brakelight

To replace the taillight/brakelight bulb, use the following procedure.

Rotate the socket counterclock-

1. wise and remove it from the housing.

To remove the bulb from the socket, push in and rotate counterclockwise. To install the bulb, push in and turn

3. clockwise. Insert the socket into the housing

4. and rotate it clockwise.

CHECKING/ADJUSTING HEADLIGHT AIM

The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.

Position the ATV on a level floor so the headlights are approximately

6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).

ATV-0070

NOTE: There should be an average operating load on the ATV when adjusting the headlight aim.

Measure the distance from the floor to the mid-point of each headlight.

Using the measurements obtained

3. in step 2, make horizontal marks on the aiming surface.

Make vertical marks which inter-

4. sect the horizontal marks on the aiming surface directly in front of the headlights.

Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM.

Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface.

GENERAL MAINTENANCE

Adjust each headlight until correct aim is obtained by turning the adjuster clockwise to lower or counterclockwise to raise the beam.

KC0108A

FUSES

The fuses are located in a power distribution module in front of the steering post under the electrical access panel. If there is any type of electrical system failure, always check the fuses first.

NOTE: To remove the fuse, compress the locking tabs on either side of the fuse cover and lift out.

ELECTRICAL OUTPUT TERMINALS

Two output terminals for electrical accessories are located on the front and rear wiring harnesses. The accessory plug is located on the front body panel.

CAUTION

Always use electrical accessories less than 180W.

STORAGE COMPARTMENT

Store an owner’s manual in the storage compartment under the seat.

0411-837

CAUTION

Always replace a blown fuse with a fuse of the same type and rating. If the new fuse blows after a short period of use, consult an authorized KYMCO ATV dealer immediately.

ATV-1097

PREPARATION FOR STORAGE

Drain the carburetor float bowl.

CAUTION

Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration.

KYMCO recommends the following procedure to prepare the ATV for storage. An authorized KYMCO ATV dealer should perform this service; however, the owner/operator may per-

form this service if desired.

Clean the seat cushion (cover and base) with a damp cloth and allow to dry.

Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake.

Either drain the gas tank or add a

3. fuel stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using KYMCO Engine Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds. Install the air filter and housing cover.

Plug the hole in the exhaust system with a clean cloth.

Apply light oil to the upper steering

6. post bushing and plungers of the shock absorbers.

Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications.

Disconnect the battery cables (negative cable first); then remove the battery, clean the battery posts and cables, and store in a clean, dry area.

Store the ATV indoors in a level position.

Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.

CAUTION

GENERAL MAINTENANCE

CAUTION

If the interior of the air filter housing is dirty, clean the area before starting the engine.

PREPARATION AFTER STORAGE

Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. KYMCO recommends the following procedure to prepare the ATV.

Clean the ATV thoroughly.

Clean the engine. Remove the cloth from the exhaust system.

Check all control wires and cables for signs of wear or fraying. Replace if necessary.

Change the engine/transmission oil and filter.

Charge the battery; then install. Connect the battery cables making sure to connect the positive cable first.

CAUTION

Before installing the battery, make sure the ignition switch is in the OFF position.

Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace if necessary.

Check the tire pressure. Inflate to recommended pressure as necessary.

Tighten all nuts, bolts, cap screws,

and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications.

Make sure the steering moves freely and does not bind.

10.

Check the spark plug. Clean or replace as necessary.

11.

Follow the recommendations found in the pre-start inspection.

MAINTENANCE RECORD

DATE MILEAGE

SERVICE PERFORMED/NOTES

U.S. EPA EMISSION CONTROL STATEMENT/

WARRANTY COVERAGE

(U.S. Only)

STATEMENT/WARRANTY

KYMCO warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified KYMCO ATV's are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. Please read the following information completely.

Your authorized KYMCO dealer will repair or replace any defective emission-related component at no cost to you during the warranty period. You may have non-warranty service performed by any repair establishment that uses equivalent components. The regulations provide significant civil penalties for tampering that causes your ATV to no longer meet U.S. EPA emission standards.

KYMCO further warrants that the engine and its emission-related components are free from defects in materials or workmanship that could cause the engine to fail to comply with applicable regulations during the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contact your local authorized KYMCO dealer.

WARRANTY PERIOD

The emission warranty period for this ATV begins on the same date as the standard warranty coverage and continues for 30 months or 3100 miles, whichever comes first.

COMPONENTS COVERED

The emissions warranty covers major emissions control components and emissionrelated components listed as follows:

Engine Management and Sensors

Barometric Pressure Sensor Camshaft Position Sensor Engine Control Unit (ECU)

Engine Coolant Temperature Sensor

Intake Air Temperature Sensor

Manifold Absolute Pressure Sensor Oxygen Sensor

Throttle Position Sensor Crankshaft Position Sensor

Ignition System

Connectors Ignition Coil Knock Sensor System Spark Plugs Capacitive Discharge Ignition (CDI) Module

Magneto Pick-Up

Fuel/Air System

Fuel Injectors Fuel Pressure Regulator Carburetor(s)

Turbocharger Assembly Air Bypass Valve Turbo Waste Gate Control Valve

Crankcase Ventilation System

ISC Valve

Miscellaneous Items Used in

Aforementioned Systems

Switches

Grommets

Clamps

Hoses

Ties

Gaskets

Wiring

OWNER'S RESPONSIBILITIES

The owner of any ATV warranted under this KYMCO Emission Control Statement is responsible for the proper maintenance and use of the ATV as stated in the Owner's Manual. Proper maintenance generally includes replacement and service, at the owner's choosing, such items as air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified in the Owner's Manual. It is the owner's responsibility to ensure that the ATV is used in a manner for which it was designed.

INDEX

Accessories---------------------------------------------------------------- 53 Active Riding -------------------------------------------------------------- 28 Air Filter --------------------------------------------------------------------- 76 Air Filter Housing Drain------------------------------------------------ 76 Alcohol (Effects)---------------------------------------------------------- 49 Battery ----------------------------------------------------------------------- 73 Boots (Protective)-------------------------------------------------------- 72 BONE-C---------------------------------------------------------------------- 29 Brake (Auxiliary)---------------------------------------------------------- 71 Brake Fluid ----------------------------------------------------------------- 70 Brake (Hand)--------------------------------------------------------------- 57 Brake (Hand - Hydraulic) ---------------------------------------------- 70 Brake Lever Lock ---------------------------------------------------- 57,71 Brake Pads ----------------------------------------------------------------- 71 Brake Pads (Burnishing) ---------------------------------------------- 65 Brake Pedal (Auxiliary)------------------------------------------------- 59 Braking/Stopping -------------------------------------------------------- 30 Break-In Procedure------------------------------------------------------ 64 Cables------------------------------------------------------------------------ 68 Carburetor Float Bowl Drain ----------------------------------------- 61 Choices (Personal) ------------------------------------------------------ 47 Clothing and Gear ------------------------------------------------------- 22 Cold Weather Driving --------------------------------------------------- 41 Condition of the ATV---------------------------------------------------- 24 Controls (Locations and Functions) ------------------------------ 55 Cooler (Oil) ----------------------------------------------------------------- 68 Crossing Obstacles ----------------------------------------------------- 39 Crossing Roads ---------------------------------------------------------- 41 Crossing Water ----------------------------------------------------------- 40 Dismounting the ATV --------------------------------------------------- 31 DIVISION II – PREFACE ------------------------------------------------ 53 Electrical Output Terminals ------------------------------------------ 80 Environment --------------------------------------------------------------- 44 Equipment ------------------------------------------------------------------ 47 Experienced/Trained Riders------------------------------------------ 51 First Aid --------------------------------------------------------------------- 27 Foreword----------------------------------------------------------------------1 Fuses------------------------------------------------------------------------- 80 Gasoline (Recommended) -------------------------------------------- 63 Gas Tank (Filling) -------------------------------------------------------- 64 Gas Tank Valve------------------------------------------------------------ 56 General Information ----------------------------------------------------- 55 Handling the ATV--------------------------------------------------------- 31 Hangtags----------------------------------------------------------------------7 Headlight Aim (Checking/Adjusting) ------------------------------ 79 Headlight HI/LO Switch ------------------------------------------------ 57 Hoses (Brake/Gas/Vent) ------------------------------------------- 61,71 Identification Numbers ------------------------------------------------- 55 Idle RPM Adjustment --------------------------------------------------- 75 Ignition Switch Key------------------------------------------------------ 55 Inexperienced/Untrained Riders ------------------------------------ 51 Introduction ------------------------------------------------------------------ 1 K-Turns ---------------------------------------------------------------------- 35 Leaning, Weight Shift, and Balance ------------------------------- 32 Light Bulb Replacement ----------------------------------------------- 78 Load Capacity Ratings Chart ---------------------------------------- 48 Lubricant (Inspecting/Changing) ----------------------------------- 69 Lubricant (Recommended Front Differenti al/Rear Drive) ------------------------------------- 64 Lubrication (General) --------------------------------------------------- 68 Maintenance (General) ------------------------------------------------- 66 Maintenance Record ---------------------------------------------------- 83 Maintenance Schedule ------------------------------------------------- 67 Mounting the ATV-------------------------------------------------------- 28 Muffler/Spark Arrester-------------------------------------------------- 78 Oil and Filter --------------------------------------------------------------- 68 Oil Level Stick ------------------------------------------------------------- 61

Oil (Recommended - Engine/Transmission)-------------------- 63 Operating Maneuvers (Basic)---------------------------------------- 28 Operation/Maintenance ------------------------------------------------ 53 Parking----------------------------------------------------------------------- 31 Parts -------------------------------------------------------------------------- 53 Parts and Controls (Locations) ------------------------------------- 10 Prevention ------------------------------------------------------------------ 22 Primer - Cold Start ------------------------------------------------------- 60 Protect Your Sport---------------------------------------------------------1 Quick Turns ---------------------------------------------------------------- 34 Rack Loading (Front and Re ar) ------------------------------------- 62 Responsibility ------------------------------------------------------------- 51 Reversing ------------------------------------------------------------------- 40 Riding Downhill----------------------------------------------------------- 37 Riding Uphill --------------------------------------------------------------- 36 Safety Alert-------------------------------------------------------------------5 Safety Flag Bracket------------------------------------------------------ 62 Seat Latch ------------------------------------------------------------------ 61 Selector Switch (2WD/4WD)------------------------------------------ 56 Sharp Turns---------------------------------------------------------------- 33 Shifting ------------------------------------------------------------------ 30,56 Shock Absorbers--------------------------------------------------------- 68 Sidehilling/Traversing -------------------------------------------------- 37 SIPDE------------------------------------------------------------------------- 50 Skidding or Sliding ------------------------------------------------------ 40 Sound Judgment --------------------------------------------------------- 43 Spark Plug------------------------------------------------------------------ 74 Specifications ------------------------------------------------------------- 54 Speedometer/LCD ------------------------------------------------------- 59 Speedrack ------------------------------------------------------------------ 48 Starter Button ------------------------------------------------------------- 58 Starting ---------------------------------------------------------------------- 32 Starting a Cold Engine ------------------------------------------------- 29 Starting the Engine ------------------------------------------------------ 28 Stopping the ATV--------------------------------------------------------- 42 Stopping the Engine ---------------------------------------------------- 42 Stop Switch (Emergency) --------------------------------------------- 58 Storage Compartment -------------------------------------------------- 80 Storage (Preparation After) ------------------------------------------- 82 Storage (Preparation For) --------------------------------------------- 81 Supervision ---------------------------------------------------------------- 51 Survival---------------------------------------------------------------------- 27 Swerving -------------------------------------------------------------------- 38 T-CLOC ---------------------------------------------------------------------- 25 Those Around You------------------------------------------------------- 46 Throttle Cable Adjustment -------------------------------------------- 75 Throttle Lever ------------------------------------------------------------- 58 Throttle Limiter Screw-------------------------------------------------- 58 Tips---------------------------------------------------------------------------- 40 Tire Inflation Pressure-------------------------------------------------- 54 Tire Replacement -------------------------------------------------------- 77 Tires -------------------------------------------------------------------------- 77 Tire Tread Condition ---------------------------------------------------- 77 Tire Repair (Tubeless) -------------------------------------------------- 78 Tools-------------------------------------------------------------------------- 80 Towing ----------------------------------------------------------------------- 62 Trailering-------------------------------------------------------------------- 62 Transporting AT V -------------------------------------------------------- 63 Turn signal switch ------------------------------------------------------- 58 V-Belt Cover (Draining) ------------------------------------------------ 77 Warning Information ------------------------------------------------------7 Warning Labels -------------------------------------------------------------8 Warnings-------------------------------------------------------------------- 11 Warranty Coverage (U.S. only) -------------------------------------- 84 Warranty (Limited) ------------------------------------------------------- 85 Wheel Removal ----------------------------------------------------------- 79 Wide Turns ----------------------------------------------------------------- 33

8385

Identification Numbers Record

WARNING

Indicates a potential hazard that could result in serious injury or death.

MC O

1. KEY IDENTIFICATION NUMBER:

The key identification number is stamped on the key as shown in the illustration. Record this number in the space provided for reference if you ever need a new key.

2. VEHICLE IDENTIFICATION NUMBER:

3. ENGINE SERIAL NUMBER:

Record the Vehicle Identification Number and Engine Serial Number in the spaces provided to assist you in ordering parts from your authorized KYMCO ATV dealer or for reference in case the ATV is stolen.

For U.S.

KWANG YANG MOTOR CO.,LTD.

NO.35 Wan Hsing Street, San Min District, Kaohsiung, Taiwan, Republic of China

Telephone : 886-7-3822526 FAX : 886-7-3950021

The portio ns of this manual are u sed under license from Arctic C at Inc.

Issued: 2008.03

T100-LA70AD

Kymco MXU 400 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual