Kymco Yager 200I User Manual
Do not remove this Owner’s Manual from the vehicle. Read this manual carefully
before operating the vehicle as it contains important safety information.
Read this manual carefull y.
WARNING
CAUTION
WARNING
This Owner’s Manual contains important information on safety, operation and maintenance of your KYMCO Yager scooter.
Anyone who operates your scooter should carefully read and understand the contents of this manual before riding the scooter.
For your safety, understand and follow all of the warnings contained in this Owner’s Manual and the labels applied to your
scooter. This Owner’s Manual should be considered a permanent part of the vehicle. Keep it with your scooter at all times.
ON-ROAD USE ONLY This scooter has been designed to be used on the road.
Particularly important information is called out in this manual by the following icons and notations:
The SAFETY ALERT symbol with the exclamation point in the triangle means ATTENTION!
BE ALERT! YOUR SAFETY CAN BE AFFECTED.
Failure to follow instructions associated with a WARNING symbol could result in severe injury or
death to the rider, a passenger, a bystander, or a person inspecting or repairing the scooter.
A CAUTION symbol indicates that special precautions must be taken to avoid damaging
the scooter.
NO NO
NO
NO NO
TETE
TE
TETE
The NOTE symbol indicates key information about a procedure, or clarifies an operation.
California Proposition 65
This product contains or emits chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
TABLE OF CONTENTS
Manual Icon Legend ....................................................(inside of front-cover)
CA Prop 65 Warning.................................................... (inside of front-cover)
Table of Contents.......................................................................................... 1
SECTION 1 - SAFETY................................................................. 2 - 6
Foreword ....................................................................................................... 2
Scooter Safety ......................................................................................... 3 - 4
Load Limits & Guidelines ............................................................................. 5
Accessories & Modifications ........................................................................ 6
SECTION 2 - CONTROLS & FEATURES ............................... 7 - 28
Locations of Parts & Controls ................................................................. 7 - 8
VIN & ESN .................................................................................................... 9
Keys............................................................................................................. 10
Ignition Switch............................................................................................. 10
Instruments .......................................................................................... 11 - 16
Multifunction Display ............................................................................12 - 17
Trip-meter.............................................................................................12 - 13
Oil Service Indicator ............................................................................13 - 14
Fuel Level Gauge ....................................................................................... 14
Clock.....................................................................................................15 - 16
Right-hand Handlebar Switch .................................................................... 18
Engine-stop Switch..................................................................................... 18
Electric Start Button....................................................................................18
Left-hand Handlebar Switch ................................................................18 - 19
Headlight Dimmer Switch........................................................................... 18
Turn Signal Switch......................................................................................19
Horn Button ................................................................................................. 19
Brakes ......................................................................................................... 20
Fuel Filler Cap......................................................................................20 - 21
Seat ............................................................................................................. 22
Under-seat Storage Compartment ............................................................ 23
Helmet Posts ............................................................................................... 24
Passenger Pegs ......................................................................................... 25
Main Stand .................................................................................................. 26
Side stand ................................................................................................... 26
Headlight Aim Adjuster ............................................................................... 27
Diagnostic Tool Connector ......................................................................... 28
SECTION 3 - OPERATION ..................................................... 29 - 37
Break-in Recommendations ....................................................................... 29
Tire Break-in ................................................................................................ 30
Troubleshooting .......................................................................................... 30
Pre-ride Inspection ..................................................................................... 31
Starting the Engine ..............................................................................32 - 33
Ignition Cutoff .............................................................................................. 34
Riding Your Scooter.............................................................................34 - 36
Parking Your Scooter.................................................................................. 37
SECTION 4 - MAINTENANCE............................................... 38 - 67
Importance of Maintenance ....................................................................... 38
Maintenance Schedule........................................................................ 39 - 41
Tool Kit.........................................................................................................42
Crankcase Breather Drain .......................................................................... 42
Engine Oil Recommendation ..................................................................... 43
Engine Oil Level Inspection ................................................................43 - 44
Engine Oil Change ...............................................................................44 - 46
Engine Oil Screen Cleaning................................................................46 - 47
Engine Oil Filter Change .....................................................................48 - 49
Transmission Fluid Change ....................................................................... 50
Air Filter Maintenance .........................................................................50 - 51
Throttle Operation ....................................................................................... 51
Throttle Free-play Adjustment .................................................................... 52
Spark Plug ................................................................................................... 52
Coolant Level Inspection............................................................................ 53
Coolant Replacement................................................................................. 54
Suspension Adjustment (spring preload) .................................................. 55
Side Stand Inspection ................................................................................ 55
Brake Fluid Inspection................................................................................ 56
Brake Pad Inspection ..........................................................................56 - 57
Battery ..................................................................................................57 - 59
Fuses ........................................................................................................... 59
Tires......................................................................................................60 - 62
Chassis Inspection ..................................................................................... 62
Cleaning Your Scooter......................................................................... 63 - 64
Storage................................................................................................. 65 - 66
Maintenance Record .................................................................................. 67
Specifications.............................................................................................. 68
Emission Information & EPA Warranty ...............................................69 - 70
KYMCO Limited Scooter Warranty ............................................................ 71
Index............................................................................................................72
Identification Numbers Record .................................. (inside of back-cover)
1
SECTION 1 FOREWORD & SAFETY INTRODUCTION
Thank you for purchasing this KYMCO Yager 200i scooter, and welcome to the KYMCO riding family.
Please read this Owner's Manual carefully before riding so that you will be thoroughly familiar with
the proper operation of your scooter’s controls, its features, its capabilities, and its limitations.
To ensure a long, trouble-free life for your scooter, provide it with the proper care and maintenance as
described in this manual.
For replacement parts and accessories, you should always use genuine KYMCO products, as they
have been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.
Keep this Owner's Manual aboard your scooter at all times, so that you can refer to it whenever you
need information. This manual should be considered a permanent part of the scooter and should
remain with the scooter when it is sold.
All information, illustrations, photographs and specifications contained in this manual are based on
the latest product information available at the time of publication. Due to improvements or other
changes, there may be information in this manual that differs slightly from your vehicle. KYMCO
reserves the right to make product and publication changes at any time, without notice, and without
incurring any obligation.
2
SCOOTER SAFETY
IMPORTANT SAFETY INFORMATION
Your scooter can provide you many years of service and pleasure if you take responsibility for your own safety and understand the challenges that you can meet on the road. There is
much that you can do to protect yourself when you ride. You
will find many helpful recommendations throughout this
manual. Here are some very important safety tips:
Wear a helmet
Scooter safety equipment starts with a quality helmet. One of
the most serious injuries you can suffer in a crash is a head
injury. Always wear a properly approved helmet. You should
also wear suitable eye protection.
Make yourself easy to see
To make yourself more visible, wear bright, reflective clothing,
position yourself so other drivers can see you, signal before
turning or changing lanes, and use your horn when it will help
others notice you.
Know your limits
Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you to avoid
accidents. Always ride with both hands on the handlebars.
Keep your scooter in safe condition
For safe riding, it is important to inspect your scooter before
every ride and perform all recommended maintenance. Never
exceed load limits, and only use accessories that have been
approved by KYMCO for this scooter.
Inspect your scooter before riding
Remember to perform an entire safety inspection to ensure
your and your passenger's safety before each ride.
Be extra cautious on bad weather days
Riding on bad weather days, especially wet ones, requires extra caution. Braking distances can double on a rainy day. Stay
off of painted surfaces, manhole covers and greasy appearing
areas on the pavement, as they can be especially slippery. Use
extreme caution at railway crossings and on metal gratings and
bridges. Whenever you are in doubt about the road conditions,
slow down.
Modification
Modification of your scooter or removal of original equipment
may render the vehicle unsafe or illegal. Obey all applicable
equipment regulations in your area.
3
SCOOTER SAFETY
PROTECTIVE APPAREL
For your safety, always wear an approved motorcycle or scooter
helmet, eye protection, boots, gloves, long pants, and a longsleeved shirt or jacket whenever you ride your scooter.
Helmets and protection
Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. Your
helmet should fit your head comfortably and securely. Always
wear a face shield or goggles to protect your eyes and to aid
your vision.
Additional riding gear
In addition to a helmet and eye protection, you should also
use:
• Sturdy boots with nonslip soles to help protect your
feet and ankles
• Leather gloves to keep your hands warm and help prevent blisters, cuts, burns and bruises
• A motorcycle or scooter riding suit or jacket that has
been designed for comfort as well as protection.
Brightly colored and reflective clothing can help make
you more noticeable in traffic. Be sure to avoid loose
clothing that can get caught on any part of your scooter.
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1 Wear gloves
2 Clothes should fit properly (not too tight or loose)
3 Always wear a helmet. You should also wear
eye protection
4 Wear bright or reflective clothing.
5 Footwear should be the proper size, have low
heels, and offer ankle protection
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Not wearing a helmet increases your chance of serious
injury or death in a crash.
4
Be sure both you and your passenger always wear
properly fitting, approved motorcycle helmets. You
should also wear eye protection and other protective apparel when you ride.
LOAD LIMITS & LOADING GUIDELINES
These general guidelines may help you decide how to add
accessories to your scooter and how to load it properly.
Load limits
These specifications are the load limits for your Yager scooter.
Overloading the scooter will affect its stability and handling.
Be sure to stay within the limits listed below:
Maximum weight capacity
(includes the weight of the rider, passenger, cargo and
accessories): ...............................................358 lbs (163 kg)
Maximum cargo weight:.................................40 lbs (18 kg)
Under-seat compartment
Rear carrier (rack)
Helmet hook
Overloading or improper loading will affect vehicle handling, stability and braking, and can lead to an accident.
Never exceed the stated load capacity of your scooter.
Cargo should be properly distributed and securely at-
tached. Reduce speed when carrying cargo and allow more
room for braking.
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7 weight limit:....................11 lbs (5 kg)
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8 8
8 weight limit: ..............................6 lbs (3 kg)
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6 6
6 weight limit: .....22 lbs (10 kg)
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Loading guidelines
Improperly loading your scooter will affect its stability and handling. You should ride at reduced speeds when you are carrying a passenger or cargo. Follow these guidelines whenever
you carry a passenger or cargo:
• Check that both tires are properly inflated
• To prevent loose items from creating a hazard, make
sure all cargo is securely tied down before you ride
• Place cargo weight as close to the center of the scooter
as possible
• Balance cargo weight evenly on both sides of the
scooter
5
ACCESSORIES & MODIFICATION
There is a large variety of accessories available to KYMCO
scooter owners. KYMCO cannot have direct control over the
quality or suitability of any accessories you may wish to purchase. The addition of unsuitable accessories to your scooter
can lead to unsafe operating conditions. It is not possible for
KYMCO to test each available accessory on the market, or
combinations of all such available accessories; however, your
KYMCO dealer can assist you in the selection and installation
of quality accessories.
Use extreme caution when selecting and installing accessories for your scooter.
No modifications
KYMCO strongly advises you against removing any original
equipment from, or modifying your scooter in any way, that
would change its design or operation.
Improper accessories or modifications can make your
scooter unsafe and can lead to an accident.
Never modify your scooter through the improper installation or use of accessories. All parts and accessories
added to this vehicle should be genuine KYMCO or
equivalent components designed for use on this scooter
and should be installed and used according to the accessory manufacturer’s instructions. If you have any
questions, consult an authorized KYMCO dealer.
6
SECTION 2 CONTROLS & FEATURES
Location of par ts & contr ols
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ANAN
AN
ANAN
AMAM
AM
AMAM
ALAL
AL
ALAL
AKAK
AK
AKAK
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9
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ATAT
AT
ATAT
1 Left shock absorber spring
preload adjuster
2 Turn signal switch, headlight
dimmer switch, horn button
3 Left mirror
4 Instruments
NOTE: Your scooter may differ slightly in appearance from the images in this manual.
5 Right mirror
6 Engine stop switch, starter button
7 Right shock absorber spring
preload adjuster
8 Rear brake lever
9 Front brake lever
AT Throttle grip
AK Front brake fluid reservoir
AL Ignition switch
AM Fuel filler cap
AN Rear brake fluid reservoir
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CONTROLS & FEATURES
Location of par ts & contr ols
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2
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ATAT
AT
ATAT
AKAK
AK
AKAK
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1 Coolant filler cap
2 Helmet holder
3 Under-seat storage compart-
ment
4 Battery, fuse box, spare fuse
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NOTE: Your scooter may differ slightly in appearance from the images in this manual.
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5 Air cleaner
6 Left passenger footpeg
7 Center stand
8 Side stand
9 Coolant level window
AMAM
AM
AMAM
ALAL
AL
ALAL
AT Seat
AK Helmet hook
AL Right passenger footpeg
AM Oil filler cap/Dipstick
CONTROLS & FEATURES
Vehicle Identification Number (VIN)
To read your scooter ’s VIN, release the cover on the inner
cowl with a flat head screw driver AN.
ANAN
AN
ANAN
Engine Serial Number (ESN)
Your scooter’s ESN AO is stamped in the left engine case.
AOAO
AO
AOAO
NOTE: Write your scooter’s VIN and ESN in the boxes provided on the inside, rear cover of this Owner's Manual.
9
CONTROLS & FEATURES
Keys
Your Yager scooter is supplied with two identical ignition switch
keys 1. The ignition key operates the ignition switch and the
steering lock, and is used to open the seat to gain access to
the underseat storage compartment.
NOTE: The keys have a unique code
stamped on the tab supplied with
the keys. For security reasons,
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Therefore, since this code is known only to you and is required
to obtain replacement keys, it is important that you record it in
the box provided on the inside, rear cover of this manual.
Ignition switch & Steering lock
Use the ignition key to operate the ignition switch, the steering
lock and open the fuel filler cap:
Position: All electrical circuits are off. The engine will not start
or run. The key can be removed from the ignition switch.
Position: The ignition circuit is "ON" and engine can now be
started. The key cannot be removed from the ignition switch in
this position.
Position: To lock the steering, turn the handlebar all the way
to the left, push in and turn the key to the " " position and re-
move the key . All electrical circuits are off and the key can be
removed.
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this code is not stamped on the
scooter or recorded in the
vehicle's basic documentation.
After locking the ignition switch, turn the handlebar gently to confirm that the steering is locked.
Position: To open the fuel filler cap, turn the key to the
“ “ position. Before starting the engine, return the key to the
“ “ position.
Do not turn the ignition switch to the lock position when
riding, as this could cause the steering to lock and result in you losing control of your scooter. Do not park
your scooter in a position that will interfere with vehicle
or pedestrian traffic.
CONTROLS & FEATURES
Instrument & indicator s
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1 Adjust button
2 Mode button
3 Multifunction display
4 CELP indicator
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5 Tachometer
6 Left turn signal indicator
7 Right turn signal indicator
8 High beam indicator
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ATAT
AT
ATAT
AKAK
AK
AKAK
9 Oil service indicator
AT Met-In (seat open) indicator
AK Overheat indicator
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CONTROLS & FEATURES
Multifunction display
The liquid crystal display (LCD) on the dash digitally indicates
speed, mileage ridden, fuel level and time.
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1 Digital clock
2 Speedometer
3 Fuel level gauge
4 Odometer/Trip meter/ Oil service meter
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Multifunction display - Initial display
When the ignition switch is turned “ON”, the multifunction display will temporarily show all of its functions so you know the
LCD is functioning properly .
Multifunction display - Speedometer
The speedometer displays the scooter ’s road speed in milesper-hour (mph) or in kilometers-per-hour (Km/h).
To toggle between the speed display types, press and hold the
MODE button for two seconds to select mph or Km/h.
Multifunction display Odometer, Tripmeter & Oil ser vice meter
Odometer: Displays the scooter ’s accumulated, total mileage
Tripmeter: Displays the scooter ’s mileage between reset in-
tervals (as reset by the rider)
Oil service meter: Displays the miles for engine oil service
frequency
CONTROLS & FEATURES
The toggle between the odometer , tripmeter and oil service
meter display types, press and hold the MODE button for two
seconds to select mph or Km/h.
To reset the tripmeter:
1. Press and hold the ADJUST button for more than two seconds to select the TRIP mode.
2. Press and hold both the MODE button and the ADJUST
button at the same time until the tripmeter rests to “zero”.
To select the odometer, tripmeter or oil service meter display ,
press and hold the ADJUST button for two seconds to select
odometer, tripmeter or oil service meter display.
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CONTROLS & FEATURES
To reset the oil service meter and the oil service indicator
light:
1. Press and hold the ADJUST button for more than two seconds to select the oil service meter .
2. Press and hold both the MODE button and the ADJUST
button at the same time until the oil service meter resets.
Multifunction display - Fuel gauge
The fuel gauge indicates the approximate fuel supply available in a graduated display . The normal operating fuel range
are the “N” segments between the “F” segment and the “E”
segment. When the “E” segment and the fuel indicator “ “
icon flashes, the fuel level is low and you should refill the fuel
tank as soon as possible.
NOTE: “E” symbolizes “EMPTY” and “F” symbolizes
“FULL”.
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1 “E” Segment
2 “N” segments
3 “F” segment
4 Fuel indicator icon
CONTROLS & FEATURES
Multifunction display - Digital clock
The clock indicates the time in hours and minutes when the
ignition is “ON”. The clock display also indicates AM or PM.
To adjust the clock’s time manually, follow this procedure:
1. Tune the ignition switch “ON”
2. Press and hold the ADJUST button for more than two seconds to select the ODO mode
4. To set the hour display , press the ADJUST button until it
displays the correct “hour” time
NOTE: The digital clock can be only be adjusted in the
ODO mode. Do not select the tripmeter or oil service meter
mode if you want to adjust the time on the clock.
3. Press and hold both the MODE button and the ADJUST
button at the same time for more than two seconds. T he
“hour” digits will begin flashing, indicating the clock time can
be adjusted
5. To change the minute display, press the MODE button until
the “minute” digits begin flashing
6. To set the minute display , press the ADJUST button until it
displays the correct “minute” time
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CONTROLS & FEATURES
7. To end the clock adjustment, press both the MODE and
ADJUST buttons at the same time. The display will stop
flashing automatically. The adjustment will be cancelled if
any button is not pressed within approximately ten seconds.
Instruments - CELP (Check engine indicator)
The CELP indicator 1 will illuminate if a fault is detected in
the scooter ’s engine, fuel or electrical systems. If the CELP
indicator lights or flashes, reduce your riding speed and take
your scooter to your KYMCO dealer for service as soon as
possible.
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NOTE: To check if the CELP indicator is functioning properly, place the engine stop switch in the “
retract the side stand; and without starting the engine,
turn the ignition switch to the “ON” position. The CELP
indicator will light for two seconds and then turn off. This
indicates the CELP indicator is functioning normally.
The CELP indicator will illuminate if the engine speed
is too high, indicating the ignition system’s over-rev protection feature is being engaged.
The CELP indicator will turn off when the engine speed
returns to acceptable levels. Reduce the scooter’s engine speed to avoid damaging the engine.
Instruments - Tachometer
The analog tachometer indicates engine revolutions per minute
(RPM).
NOTE: When the ignition switch is turned “ON” the tachometer needle will sweep from zero to the maximum
range, and then return to zero to calibrate the meter and
confirm its functionality.
“ position;
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CONTROLS & FEATURES
Instruments - Tur nsignal indicators
The left turn signal indicator “ “ flashes when the left turn
signal is operated.
The right turn signal indicator “
“ flashes when the right turn
signal is operated.
Instruments - High beam indicator
The high beam indicator “ “ is illuminated when the high
beam is selected (using the switch on the left handlebar).
Instruments - Oil ser vice indicator
The oil service indicator “ “ will illuminate during riding when
the engine oil service interval has been reached and the oil
should be serviced.
NOTE: When the ignition switch is turned “ON” the oil
service indicator will illuminate. The indicator should turn
off once the engine is running. If it does not turn off, take
your scooter to your KYMCO dealer for service.
To reset the oil service indicator, see the procedure on
pages 13 and 14 of this manual.
Instruments - Overheating indicator
The overheating indicator “ “ will illuminate during riding if
the coolant temperature exceeds the normal range. If the over-
heating indicator illuminates, stop the engine and check the
coolant reserve tank’s fluid level (see page 53).
NOTE: When the ignition switch is turned “ON” the overheating indicator will light for two seconds and then turn
off. This indicates the indicator is functioning normally.
The overheating indicator will illuminate if the engine
coolant temperature is too high. Do not operate the engine unless the indicator goes out once the engine is
running.
Operating the scooter with the overheating indicator illuminated could result in damage to the engine. Consult your KYMCO dealer for service if the overheating
indicator does not turn off during operation.
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CONTROLS & FEATURES
Right handlebar switch
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Engine stop switch
The engine stop switch turns off the ignition, stopping the engine. The scooter’s lights and horn will still function.
1 1
1 " & ":
1 1
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2 2
2 "
2 2
":
Electric starter button
Press the electric starter button to activate the starter motor .
NOTE: The starter motor will not engage unless the ignition
switch is “ON”, the side stand is fully up, and one of the
brake levers is squeezed at the same time the starter button
is pressed.
To prevent damage to the starter motor, do not operate
the starter motor for more than five seconds at a time. If
the scooter fails to start immediately, check the fuel level
and the battery condition, and allow the starter motor to
cool before attempting to start the engine again.
Left handlebar switch
Dimmer switch -UP
" "switch position turns the headlight high beam on and
the high beam indicator light on the dash is activated.
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Dimmer switch -DOWN
"
" switch position turns the headlight low beam on.
Passing light lever - PULL IN
Pull in on the lever to rapidly flick the headlight high beam
on and off to signal other vehicles that you wish to pass.
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CONTROLS & FEATURES
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Turn signal switch:
Use the turn signal indicator to signal to other traf fic your
intention to turn or change lanes. The turn signal light on
the dash will flash to alert the rider that the switch is engaged.
" " for turning to the "left".
" " for turning to the "right".
To cancel the turn signal, press in on the signal switch
Horn button
Press the horn button to sound the horn.
NOTE: The horn will only sound when the ignition is “ON”.
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6 " ":
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CONTROLS & FEATURES
Brakes
Apply the rear brake by squeezing the left brake lever gently
towards the grip. The brake light will illuminate when the lever
is squeezed.
Apply the front brake by squeezing the right brake lever gently. The brake light will illuminate when the lever is squeezed.
Fuel filler cap
To open the fuel filler cap:
1. Insert the ignition key into the ignition switch and turn it right
to the “ “ position (the key cannot be removed). T hen
rotate the key clockwise to the “
filler cap 1.
“ position to open the
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CONTROLS & FEATURES
Do not overfill the tank. There should be no fuel in the
filler neck
rative emission canister, resulting in poor driveability.
To close and lock the fuel filler cap:
1. Push the fuel filler cap 3 down in place until you feel the
cap’s latch engage with the filler neck.
Fuel recommendation
Use unleaded gasoline with a research octane number of 91
or higher. Unleaded gasoline will extend spark plug life.
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2. Excess fuel can contaminate the evapo-
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Do not use fuel that contains Ethanol or Methanol. This
type of fuel can corrode metal parts in your scooter’s
fuel system, and can also damage plastic and rubber
parts. Repairs to damage caused by improper fuel will
not be covered under your scooter’s limited warranty.
Gasoline is highly flammable and explosive. You can be
burned or seriously injured while handling fuel.
* Stop the engine and keep heat, sparks, and flame away.
* Refuel only out doors.
* Clean up fuel spills immediately.
NOTE: After refueling, turn
the ignition key from the
“ “ position to the “ “
position to restart the engine.
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