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Owners Manual

1. sssssssss 46 Flag pole bracket ssseeeesee 39 FOR ON ROAD USE ONLY A Frame and engine serial number 10 Front and rear brake shoes drum brake inspection ssse 110 Front and rear brakes 31 41 Front brake lever free play adjustment 111 le ne 42 Fuse replacement sssssssssusss 127 Fuel tank cap cereo ert e 34 Fuel valve sssssssssesss 35 G GETTING TO KNOW YOUR ATV 60 H Handlebar switches ssssesssusse 23 Headlight switch sessssssesesssssss 24 Headlight beam adjustment 130 High beam indicator lamp 17 Horn DUON iesnas 23 l Identification number records 9 Idle speed adjustment sssssse 108 Ignition SWE 2 oui ince tee mittet rete 16 IMPORTANT NOTICES sssee A Indicator lamps sssesssssm 17 Instr ments etre ete RI Ree RE ROXEE E HEER 18 K Key identification number 9 Kick starte esinaine 27 Knuckle shaft and rear fork Shaft lubrication ccceceeeeee ee eee 123 L Bl E T AN 46 Loading and accessories sss 69 Loading and Operational Guidelines 69 LOCATION OF THE WARNING AND SPECIFICATION LABELS ss 1 Locking steering M
2. Drive chain Check and adjust slack alignment clean lube Spark plug Check condition Adjust gap and clean Replace if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary 93 C OO X a INITIAL m lt T X ITEM ROUTINE Check valve clearance Valves Adjust if necessary O O Check leakage Exhaust system Retighten if necessary e Replace gasket if necessary Check balance damage runout Replace if necessary Check bearing assembly for looseness damage Replace if damaged Check operation Replace if damaged Check toe in e Adjust if necessary lt ORN 3 6 6 months months months Wheels Wheel bearings Steering system Knuckle shafts Steering shaft Lubricate every 6 months Check all chassis fittings and fasteners Correct if necessary OUO XXE BOE X Fittings and Fasteners 1iltis recommended that these items be serviced by a KYMCO dealer Lithium soap base grease 94 Engine oil MAXXER 90 1 Engine oil level measurement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Remove right side cover 1 Right side cover D Remove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in NOTE Wait a few minute
3. KYMCO MAXXER 50 90 on roav Issued 30 11 2004 IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner s Manual contains important information on safety operation and maintenance Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle AGE RECOMMENDATION KXR 50 The minimum recommended age for this ATV model is 6 Children under age 6 should never operate this vehicle KXR 90 The minimum recommended age for this ATV model is 12 Children under age 12 should never operate this vehicle RIDER TRAINING Anyone who operates this vehicle should get proper instruction FOR ON ROAD USE ONLY This machine is designed and manufactured for ON ROAD use only It is illegal and unsafe to operate this machine on any hills and rough orloose terrain This machine complies with all applicable ON ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine A SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle For your safety and the safety of others pay special attention to all warnings preceded by this alert symbol Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH Indicates a strong possibility that serious injury or death may result if instructions are
4. See page 56 32 Parking brake MAXXER 90 To set the parking brake squeeze the front brake lever and lock it with the lock pin Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the front brake lever until the lock pin releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position See page 56 1 Lock pin 33 A WARNING Fuel tank cap After refueling be sure to tighten the fuel tank POTENTIAL HAZARD cap Improper use of the parking brake TO refuel refer to page 42 43 WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the parking brake before you begin to ride 1 Fuel tank cap 34 Fuel valve The fuel valve supplies fuel from the fuel tank to the carburetor The fuel valve has three positions OFF With the lever and A mark in this position fuel will not flow Always turn the lever to this position when the engine is ON notrunning With the lever
5. Remember excessive noise bothers everyone and creates a bad image for ATV During operation l A WARNING Always keep your feet on the footboards during operation Otherwise your feet may contact the POTENTIAL HAZARD rear wheels Removing hands from handlebars or feet from footboards 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 a footpeg your foot or leg may come into contact with the rear 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 footpegs of your ATV during operation 72 Avoid wheelies and jumping You may lose control of the machine or overturn Z WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 73 Exhaust system The exhaust on the machine is very hot during and following operation To prevent burns avoid touching the exhaust system Park the machine in a place where pedestrians or children are not likely to touch it A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE
6. in position the starter choke should be returned to position to warm up the engine If the engine is started with the starter choke in position keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position before riding CAUTION See the engine break in section prior to operating engine for the first time To start the engine without the electric starter 1 Follow steps 1 through 5 2 With the throttle closed operate the kick starter with a rapid continuous motion CAUTION Do notallow the kick starter to snap back freely against the pedal stop as engine case damage could result Raise the kick starter pedal after the kick starter lever is returned to the stop 3 Follow steps 7 through 8 52 Starting a warm engine MAXXER 90 To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The throttle should be opened slightly Warming up MAXXER 90 To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke turned off CAUTION Do notoperate the throttle open and close rapidly as the ATV will move forward suddenly causing possible loss of control D
7. not followed 130 Troubleshooting Although KYMCO machines receive a rigid inspection before shipment from the factory trouble may occur during operation Any systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it toa KYMCO dealer The skilled technicians at a KYMCO dealership have the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills 131 A WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces Troubleshooting chart Water or dirt Clean filter element mixed in fuel and fuel tank Supply fuel Turn the fuel Turn the fuel valve to valve to RES Turn the fuel h f ih valve to ore nose from the fuel valve Engine turns Clean fuel valve 2 Battery m Check fluid recharge check connections over slowly Engine turns over quickly Battery good Wipe clean with dry cloth Check if there is f i uel in the
8. Be sure to drive slowly until the V belt becomes dry If slipping is noticed aska Knuckle shaft and rear fork shaft lubrication KYMCO dealer to inspect Lubricate the pivot points using a grease gun Recommended lubricant Lithium soap based grease 1 Drain bolt Wheel removal 1 Elevate the wheel by placing a suitable stand under the frame Wheel nut torque 2 Remove the nuts from the wheel Front 40 Nm 4 0 m kg 30 ft Ib 3 Remove the wheel assembly Rear 40 Nm 4 0 m kg 30 ft Ib 1 Safe nut Wheel installation When installing the wheel reverse the removal procedure Pay attention to the following 124 Battery A WARNING Your ATV battery is located in a compartment under the seat The battery is sealed so it is not necessary POTENTIAL HAZARD Allowing open flames or sparks near the to check the electrolyte level or add distilled water If battery the battery seems weak see your authorized KYMCO dealer for information on recharging or WHAT CAN HAPPEN replacement If you replace the battery choose one Gases may explode and possibly cause that is sealed and equivalent to the original Be sure injury to read and follow all safety precautions indicated on HOW TO AVOID THE HAZARD the battery Do not allow open flames or sparks near the battery CAUTION Do not attempt to remove the caps from the battery cells as this may damage the battery Although the battery is sealed it ve
9. HAZARD Do not touch the hot exhaust system Do not park the machine in a place where others might be likely to touch it 74 Select a flat area to become familiar with your ATV Make sure that this area is free of POTENTIAL HAZARD obstacles and other riders You should practice Starting or running the engine in a closed control of the throttle brakes shifting before arga trying more difficult terrain WHAT CAN HAPPEN Always avoid riding on rough surfaces the ATV Exhaust fumes are poisonous and may is designed for on road use only and handling cause loss of consciousness and death maneuvers are more difficult to perform on level within a short time surfaces HOW TO AVOID THE HAZARD Always operate your machine in an area Set the parking brake and follow the instruction with adequate ventilation on page 50 54 to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components Practice with the remote engine stop switch and throttle limiter adjusted as delivered until you are confident in braking and making turns 75 Remote engine stop switch for new riders The ATV has a remote engine stop switch page 28 This allows the supervisor to follow close behind and stop the engine by pulling a tethered core Practice using it when the beginner first sta
10. Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element 1 Air filter element 5 Squeeze the excess solvent out of the filter 4 Wash the element gently but thoroughly in and let it dry solvent CAUTION Do not twist the filter element when squeezing it 104 6 Inspectthe element If damaged replace it To clean the air cleaner MAXXER 50 7 Apply quality foam air filter oil to the element 1 Remove the air filter case cover If foam air filter oil is not available motor oil may be used NOTE The element should be wet but not dripping 8 Reinstall the element to the air filter case 9 Reinstall the element assembly and parts removed for access 1 Air filter case cover 105 2 Remove the air filter element and separate it A WARNING from the box POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element 1 Air filter element 4 Squeeze the excess solvent out of the filter 3 Wash the element gently but thoroughly in and let it dry solvent CAUTION Do not twist the filter element when squeezing it 106 5 Inspect the element If damaged replace it Valve clearance a
11. a a a E a a SW PS C Mni ECL 146 Page A ACCESSOS ouenn ririri eee 58 70 AGE RECOMMENDATION A 62 63 Air filter cleaning ceceeeeeeeeeeeeeeeeee ee ees 103 Appatel ener rue meg ede stie pe na iaaa 65 B Battery i i asses cc senex eset dvd a aa R 125 Brake fluid inspection Disk brake 118 Brake lever lubrication ssuss 123 Brake pedal MAXXER 90 31 115 BRANKING eise o ee viv Nana 78 C Cable inspection and lubrication 122 CNN asain EE 46 CLEANING sssss eens eset eees 133 CLIMBING UP SLOP Eccone 80 CONTIENT Sit 5 bri oae tren e o aeai D CONTROL FUNCTIONS seessses 16 Page D DESCRIPTION AND MACHINE IDENTIFICATION sesesenmHHHHHH 9 Display descripti M eein 18 Do not operate at speeds too fast your skills or the conditions 68 Do not operate after consuming alcohol or BID pP ies 66 Draining the V belt compartment MAXXER 90 123 Drive chain cleaning and lubrication 122 Drive chain slack adjustment 120 Drive chain slack check sssse 120 During operatio eessen 72 E Engine broak ii esne 54 Engine oil MAXXER 50 45 Engine oil MAXXER 90 seseesnse 95 Engine MAXXER 90 and transmission oil 44 Engine stop Swithin escnt 25 Exhaust system secet 74 Cont d 147 Page F Fittings and fasteners
12. fuel tank There is fuel Check fuel flow Restart engine Remove the fuel Use electric starter 3 Ignition Ask a KYMCO dealer to inspect mH Spark weak Spark good Ignition system normal Ask a KYMCO dealer to inspect Adjust plug gap or replace plug Remove plug and check electrode Attach plug cap and ground to chassis Use electric starter 4 Compression Use electric starter JNo compression to see if there is Fidi sob all There is compression Compression normal 132 CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the machine A Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used B Make sure the spark plug and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprockets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bi
13. not followed CAUTION Indicates a possibility that equipment or property damage could result if instructions are not followed Note Gives helpful information The Owner s Manual should be considered a permanent part of your ATV It should remain with the vehicle at all times and stay with the ATV if it is sold PREFACE Congratulations on your purchase of the KYMCO ATV KYMCO take pride in a worldwide reputation for quality in research design production and service For replacement parts and accessories we recommend genuine KYMCO products They ve been specially designed for your vehicle and manufactured to meet KYMCO s demanding standards This manual will provide you with a good basic understanding of the features and operation of this machine This manual includes important safety information It provides information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a KYMCO dealer We wish you many years of safe and enjoyable riding While reading this manual remember Indicates a strong possibility that serious injury or death may A WARNING Mis result if instructions are not followed All information in this publication is based on the latest product information available at the time of approval for printing KWANG YANG MOTOR CO LTD res
14. recommended to put the tool kit in the important points of machine inspection vinyl bag and always carry them on the seat adjustment and lubrication are explained onthe reverse side following pages A WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD 1 Tool kit 2 Rubber band Turn off the engine when performing maintenance unless otherwise specified 89 The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer The tool kit includes the following items 1 Air pressure gauge Spark plug wrench Standard Phillips screwdriver Screwdriver handle 10 12 mm wrench Tool bag 7 Rubber band 2 3 2 3 4 5 6 1 4 90 A WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situation could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components de
15. training or instruction At speeds too fast for your skills or the conditions Do not operate the vehicle after consuming ALCOHOL OR DRUGS ALWAYS Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e For your safety wear gear to include helmet gloves and foot protection e Gasoline is flammable shut off engine avoid sparks and open flame when refueling READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 2 MAXXER 50 A WARNING Operating this ATV if you are under the age of 6 increases your chance of severe injury or death NEVER operate this ATV if you are under age 6 2 MAXXER 90 A WARNING A Operating this ATV if you are under the age of 12 increases your chance of severe injury or death NEVER operate this ATV if you are under age 12 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold Recommended FRONT 22 28 kpa 0 22 0 28 kgf cm 3 2 4 0 psi CAUTION REAR 22 28 kpa 0 22 0 28 kgf cm 3 2 4 0 psi as Never set tire pressure over the recommended SAFETY INFORMATION AN ATV IS NOTA TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision can occur quickly even during routine maneuvers if you fail to
16. use the rear brake to stop The ATV could easily tip over backwards Instead dismount the ATV immediately on the up of slope side Z WARNING 83 POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a slope WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a slope If you lose all forward speed Keep weight up slope Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight up slope Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply rear brake as well and then lock parking brake Dismount on up slope side or to a side if pointed straight up slope Turn the ATV around and remount following the procedure described in the Owner s Manual 84 If the slope is not too steep and you have good footing you may be able to walk the ATV back down the slope Make sure your intended path is clear in case you lose control of the ATV If you decide you can walk the ATV safely 1 Stand with your body facing downslope beside the vehicle so you can reach the front brake lever with your left hand Be sure your legs are clear of the wheels Check your footing Then slowly and carefully back the ATV down the slope using the front brake lever to control speed 5 If you lose control of the ATV for your safety get away fr
17. 0 8 in specified free play is obtained Specified free play 10 20 mm 0 4 0 8 in 1 Loosen the upper locknut and fully turn in the adjusting bolt 4 Tighten the lower locknut 111 5 While applying the front brake turn out the upper adjusting bolt until the upper and A WARNING lower cable lengths are equal The cable POTENTIAL HAZARD joint will become vertical Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by KYMCO dealer 1 Cable joint A Cable length 6 Tighten the upper locknut 112 Rear brake lever free play adjustment Drum brake Turn the adjusting nut on the brake hub in The rear brake lever free play should be direction Ato decrease play and in direction B to adjusted to 10 20 mm 0 4 0 8 in at the tip of increase play the brake lever If the free play is incorrect adjust as follows 1 Adjusting nut A Decrease play B Increase play A Free play 10 20 mm 0 4 0 8 in 113 NOTE Make sure the cut out on the adjusting nut Is seated on the brake arm pin after making final A WARNING POTENTIAL HAZARD Operating with impr
18. 10 A WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do notride the ATV if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the ATV inspected by a KYMCO dealer Fuel Fill the fuel tank when necessary and make sure there is sufficient gasoline in the tank Check for leaks Fuel level should be below the filler neck 1 Filler neck Recommended fuel UNLEADED FUEL Fuel tank capacity Total 5 5L 1 16 Imp gal 1 4 US gal Reserve 1 5L 0 32 Imp gal 0 38 US gal 42 Your KYMCO engine has been designed to use regular unleaded gasoline with a pump octane number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Use unleaded fuel only because it produces fewer engine and spark plug deposits and extends the life of the exhaust system Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank 43 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fi
19. 2V 4AH Tire Type Size Front Rear Tubeless 18X7 8 18X9 8 Bulb voltage wattage quantity Headlight Taillight 144 12V35 35W 12V5W NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while itis in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e Modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 145 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty The chart below is printed only asa reminder to you that the maintenance work is required It is not acceptable proof of maintenance work INTERVAL rss NAME AND BEEN IMonh Month a O O www LL www S mew 0 LLL mw PS Ee ELLE sw ECL
20. 74 US qt Total amount 0 8 L 0 70 Imp qt 0 84 US qt CAUTION Be sure no foreign material enters the crankcase Warm up the engine for several minutes at idle speed Check for oil leakage while warming up CAUTION If oil leakage is found stop the engine immediately and check for the cause 2 2 Engine oil replacement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil filler cap and drain plug to drain the oil 97 1 Dipstick oil filler cap CAUTION Be sure no foreign material enters the crankcase 1 Drain plug E Reinstall the drain plug and tighten the drain plug to specification F Fill the engine with oil and install the oil filler cap G Warm up the engine for several minutes at idle speed Check for oil leakage while warming up 98 Tightening torque Drain plug engine 30 Nm 3 0 m kg 21 6 ft Ib CAUTION Be sure no foreign material enters the crankcase Recommended oil see page 142 Oil quantity see page 142 Transmission oil 1 Transmission oil measurement A Place the machine on a level place B Remove the oil filler bolt and check the oil level It should be up to the brim of the hole If the level is low add oil to raise it to the proper level C Reinstall the oil filler bolt and tighten to specification ightening t
21. 90 141 Speed limiter Lssseusues 30 68 77 Starter button 20 riren teeter een ed 26 Startingengine cece eee ee tee es 50 53 STORAGE nece ete tede tds 135 Storage compartment eeren 39 SWITCHES yn iicet ne 46 Cont d T Throttle lever eese 29 46 Throttle lever adjustment 109 TIES e E 47 Tire wear limit eec 49 TO ki e ET 89 Transmission oil schorsen 99 Troubleshooting sesssesseesses 131 Troubleshooting chart sssssss 132 Turn signal switch sss 23 TURNING YOUR ATV esseH 79 V Valve clearance adjustment MAXXEIR 90 iex ene the PR 107 Ww Warning information ccceceeeeeeeeene eens 2 WHAT TO OO earainn AAR 88 WHAT TO DO Ferenca aoa 88 Wheel installation 124 Wheel removal sssss 124 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 By KWANG YANG Motor Co Ltd First Edition Nov 2004 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4121 LBD3 4 U01 ALWAYS USE AN NEVER USE APPROVED HELMET WITH DRUGS AND PROTECTIVE ORALCOHOL GEAR NEVER operate Without proper training or instruction At speeds too fast for your
22. A mark in this position fuel flows to the carburetor Normal riding 1 Fuel lever 2 A mark RES is done with the lever in this position This indicates reserve If you run out of NOTE fuel while riding turn the lever A mark After refueling do not operate the ATV with the to this position THEN FILL THE FUEL fuel valve in the RES position If you run out of TANK AT THE FIRST OPPORTUNITY fuel there will be no reserve supply After refueling return the fuel valve lever to the ON position 35 Locking steering MAXXER 90 Turn the steering handlebar left to full and turn the key clockwise the steering handlebar is locked The key can be taken out Turn the key counterclockwise the steering handlebar is released automatically The key can be taken out A H E 2 Unlocking Y win Z WARNING POTENTIAL HAZARD Improper use of the locking steering WHAT CAN HAPPEN The ATV could cause loss of control or overturn HOW TO AVOID THE HAZARD Always be sure you have released the locking steering handlebar before you begin to ride Never lock the steering handlebar when the engine is starting 36 Starter choke MAXXER 90 Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction A to turn on the starter choke Move in direction B to turn off the starter choke Refer to starting a cold engine for pr
23. AXXER 90 36 Low oil level indicator ssssssss 17 Cont d 148 Page M Model GOde tte cete 10 Modifications ssessssseeR 71 N Never carry passenger on the carrier 64 No Modifications eeeeennnnmme 71 0 OPERATION essesm ern 50 P PARKING 2 tete epp Aa 56 87 Parking brake MAXXER 50 sss 32 Parking brake MAXXER 90 sss 33 Parking on a slope ssseseens 57 Parts location eseessseem 11 PERIODIC MAINTENANCE LUBRICATION MAXXER 50 91 PERIODIC MAINTENANCE LUBRICATION MAXXER 90 93 PERIODIC MAINTENANCE AND ADJUSTMIEN T i ie ceto peril p avr xu reis 89 PREFACE 5 ee oet reta C PRE OPERATION CHECKS 40 67 R READ THIS MANUAL CAREFULLY A Rear brake lever free play adjustment Drum brake 113 Remote engine stop switch 28 76 RIDE WITH CARE GOOD JUDGEMENT 61 RIDER TRAINING ssmmHHHI A RIDING oneens a aeaa mee T5 RIDING DOWN SLOPE esee 86 Riding Your ATV se eeireersin sirere trenirani 59 Right Left turn signal indicator lamps 17 S SAFETY INFORMATION sese 4 SII a T 38 Spark plug inspection ssssus 102 SPECIAL MESSAGES sess B SPECIFICATIONS MAXXER 50 137 SPECIFICATIONS MAXXER
24. a 0 22 kgf cm 3 2 psi for this model Other tire combinations are not recommended EE MAXXER 50 MAXXER 90 16 8 7 18 7 8 TUBELESS Rear 22 kpa 0 22 kgf cm 3 2 psi ron eer weer wea _ rupcuess 47 4 Never settire pressure over the Set pressure tires cold recommended Set tire pressures to the following Front 28 kpa 0 28 kgf cm 40 psi E pressure Higher pressures may cause the tire to 25 kpa 22 kpa 28 kpa burst Inflate the tires very slowly and Front 0 25 kgflcm 0 22 kgficm 028 Karin carefully Fast inflation could cause the 3 6 psi 3 2 psi 4 0 psi tire to burst 25 kpa 22 kpa 28 kpa Rear 0 25 kgf cm 0 22 kgf cm 0 28 kgf cm 3 6 psi 3 2 psi 4 0 psi How to measure tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 Low pressure tire gauge 48 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire A 3mm 0 12 in 49 OPERATION Starting a cold engine MAXXER 90 A WARNING POTENTIAL HAZARD Freezing control cables in cold weather A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN You could be unable to control the ATV w
25. and protective clothing HOW TO AVOID THE HAZARD Always wear an approved motorcycle WHAT CAN HAPPEN helmet that fits properly You should also wear eye protection goggles or face shield gloves Operating without an Protective approved motorcycle fining helmet increases your chances of a severe M head injury or death in Helmet f boots long sleeved shirt or jacket the event of an Long pants accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident 65 Do not operate after consuming alcohol or VAN WARNING drugs Operator s performance capability is reduced by the influence of alcohol or drugs POTENTIAL HAZARD Operating this ATV after 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 66 Pre operation checks Always perform the pre operation checks listed on page 40 before riding for safety and proper care of the machine Z 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 tour ATV each
26. cing a fuse A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN 1 Fuse holder An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse 127 3 Slide the old fuse out of the clips and discard 1 Lift the seat See page 38 it 2 Open the fuse holders and lift out the fuse with the clips Nn pem 1 Fuse holder 2 Clip 128 CAUTION 4 Slide the clips onto the ends of the new fuse push them back into the fuse holder and close the fuse holder The spare fuse is on the battery cover Do not pry the clips open to get a fuse out you could bend them and cause poor contact with the new fuse Aloose fuse could cause damage to the electrical system 1 p c and even start a fire After replacing the fuse be sure return the fuse holder to its original location zu 2 1 Fuse holder 2 Clip 129 Headlight beam adjustment CAUTION It is advisable to have a KYMCO dealer make this adjustment Vertical adjustment Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting screw 1 Adjusting screw A WARNING Indicates a strong possibility that serious injury or death may result if instructions are
27. cted frequently to ensure there are no fluid leaks f the brake lever travel become excessive and the brake pads are not worn beyond the recommended limit page 110 There is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service 119 CAUTION To prevent damage to the brake system use only fluid from a sealed container Never allow contaminants dirt water etc to enter the brake fluid reservoir e Brake fluid can damage paint and plastic so handle the fluid with care When adding brake fluid be sure the reservoir is horizontal before removing the cover to prevent accidental spilling e Use only DOT 4 brake fluid from a sealed container Drive chain slack check Drive chain slack adjustment Inspect the drive chain while all tires are 1 Loosen the upper and lower axle holding touching the ground Check the slack at the position shown in the figure The normal vertical deflection is approximately 10 20 mm 0 4 0 8in If the deflection exceeds 20 mm 0 8 in adjust the chain slack 1 Hub stopper nut 2 Axle holding bolt x 4 A 10 20 mm 0 4 0 8 in 120 2 Turn the adjusting nut to decreaseorincrease 3 Retighten the upper and lower axle holding chain slack bolts Tightening torque Axle holding bolts upper 70 Nm 7 0 m kg 48 ft Ib 1 Adjust nut CAUTION Too little of chain slack will overload the engine and other impor
28. djustment MAXXER 90 6 Apply quality foam air filter oil to the element The correct valve clearance changes with use If foam air filter oil is not available motor oil resulting in improper fuel air supply or engine may be used noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional KYMCO service NOTE technician The element should be wet but not dripping 7 Reinstall the element to the air filter case 8 Reinstall the element assembly and parts removed for access 107 Idle speed adjustment NOTE A diagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and outto decrease engine speed 1 Throttle stop screw Specified idle speed MAXXER 50 2000 RPM MAXXER 90 1700 RPM 108 Throttle lever adjustment NOTE Adjust the engine idling speed before adjusting the throttle lever free play p l amp al To adjust throttle free play d 1 Slide the rubber sleeves back to exposethe throttle cable adjuster 2 Loosen the lock nut then turn the adjus
29. e vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes N WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation DESCRIPTION AND MACHINE IDENTIFICATION Identification number records Keys identification number Record the keys identification number frame The keys identification number is stamped on serial number engine serial number and the hang tag as shown in the following model code information for assistance when illustration order replacement parts IGNITION SWITCH KEY NO STEERING LOCK KEY NO FRAME NO ENGINE NO 1 Ignition switch key identification number 2 Steering
30. e aae 76 Cont d Page Speed limiter for new riders 77 BRAKING cerea ert tentent e aas 78 TURNING YOURATNV see 79 CLIMBING UP SLOPE eeeeee 80 RIDING DOWN SLOPE sess 86 xlsQdh tee 87 WHAT TO DO IF sesse 88 WHAT TO DO wis iie Rh 88 PERIODIC MAINTENANCE AND ADJUSTMENT cesesmIMHMm 89 TOOL KI ri oboe er cox trio eom Exs 89 PERIODIC MAINTENANCE LUBRICATION MAXXER 50 91 PERIODIC MAINTENANCE LUBRICATION MAXXER 90 93 Engine oil MAXXER 90 Jaeno 95 Transmission Ojlercirercrriiiriorororii taere 99 Spark plug inspection ssssse 102 Air filter cleaning 103 Valve clearance adjustment MAXXER 90 tad bns 107 Idle speed adjustment ss 108 Throttle lever adjustment 109 Page Front and rear brake shoes drum brake INSPEC CUON ss cue etr Rete Re eun 110 Front brake lever free play adjustment 111 Rear brake lever free play adjustment Drum brake hn ated 113 Brake pedal adjustment MAXXER 90 115 Brake fluid inspection Disk brake 118 Drive chain slack check ss 120 Drive chain slack adjustment 120 Drive chain cleaning and Lubrication 122 Cable inspection and lubrication 122 Brake lever lubrication ssss 123 Knuckle shaft and rear fork shaft lubrication eiecti 123 D
31. e speeds al outer footboard CLIMBING UP SLOPE Use proper riding techniques to avoid vehicle overturns on slopes Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes Try more difficult climbs only after you have developed your skill In all cases avoid inclines with slippery orloose surfaces or obstacles that might cause you to lose control N WARNING POTENTIAL HAZARD Operating on excessively steep slopes WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep slopes than on level surfaces or small slopes HOW TO AVOID THE HAZARD Never operate the ATV on slopes too steep for the ATV or for your abilities Practice on smaller slopes before attempting large slopes Itis important when climbing a slope to make sure that tour weight is transferred forward on the ATV This can be accomplished by leaning forward steeper inclines and standing on the footboards and leaning forward over the handlebars AN WARNING POTENTIAL HAZARD Climbing slopes 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 climbing slopes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopels with excessively slippery or loose surfaces Shift your weight forward Never o
32. ealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the proper type Standard spark plug MAXXER 50 NGK BR8HAS MAXXER 90 NGK C7HSA Before installing the spark plug measure the electrode gap with a feeler gauge and adjust to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in A Spark plug gap When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten to the specified torque Tightening torque Spark plug 12 5 Nm 1 25 m kg 9 1 ft Ib Air filter cleaning The air cleaner accumulates dust and must be cleaned periodically If the ATV is ridden in dusty areas the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner MAXXER 90 1 Remove the seat See page 38 2 Remove the air filter case cover 1 Air filter case cover 103 3 Remove the air filter element and separate it A WARNING from the box POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN
33. ed operate the kick starter with a rapid continuous motion CAUTION Do notallow the kick starter to snap back freely against the pedal stop as engine case damage could result Raise the kick starter pedal after the kick starter lever is returned to the stop 3 Follow steps 6 through 7 If you cannot restart a warm engine 1 Follow steps 1 through 4 2 Open the throttle slightly 1 8 1 4 while starting the engine If the throttle limiter Is adjusted as delivered open the throttle fully 54 Engine break in There is never a more important period in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on itforthe first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a KYMCO dealer 1 0 10 hours Avoid co
34. erves the right to make changes at any time without notice and without incurring any obligation CONTENTS Page LOCATION OF THE WARNING AND SPECIFICATION LABELS sess 1 SAFETY INFORMATION sess 4 DESCRIPTION AND MACHINE IDENTIFIGAT IQ N 2 rrr tet ntn ke 9 Key identification number ssssss 9 Frame and engine serial number 10 Model Code ccccceceeeceeeeeeeeeeeeeeees 10 Parts l cati eesi iiaa 11 CONTROL FUNCTIONS sss 16 Ignition SWITCH eect eee tenet teenies 16 indicator lamps acana aaa 17 INStrUMENL eenean annnak 18 Handlebar switches 2 c eeeeeeeee ees 23 Horn DUTON oce tte 23 Page Turn signal switch ssesseseeess 23 Headlight switches sssesssssss 24 Engine stop switch sseesesessss 25 Stater button sseessssssssseeee 26 Kick starter eee tense 27 Remote engine stop switch 28 Throttle lever cin 29 Speed limiter cc cceeeeeeeeee ee eeeeee ees 30 Front and rear brak osica 31 Brake pedal MAXXER 90 sss 31 Parking brake MAXXER 50 32 Parking brake MAXXER 90 33 Fueltank Cap sessssssss 34 Fuel valve cete eee ces 35 Locking steering MAXXER 90 36 Starter choke MAXXER 90 37 SII 38 Flag pole brack
35. et sssseessss 39 Storage compartment sssssssss 39 Cont d PRE OPERATION CHECKS 40 Riding Your ATV isssseesmII 59 Frontandrearbrakes sssssse 41 GETTINGTOKNOWYOURATV 60 UMOR UNE 42 RIDE WITH CARE AND GOOD Engine MAXXER 90 and JUDGEMENT iiid tectis diu aos 61 S N UD js Age Recommendation MAXXER 50 62 Chan yg Age Recommendation MAXXER 90 63 Throttle LEVER seio oir rer orb orn 46 Never carry passenger on the carrier 64 Fittings and fasteners 46 PD Dale lis araen A Lee 65 a e E E E 46 Do not operate after consuming alcohol or Switches cece ccc ceccccccceee RR 46 GNUGS 2c55 seat iiantieg ee REI Ried 66 TPES erminea aI Jus asatnduntaepiad aan 47 Pre operation checks sesssse 67 How to measure tire pressure 48 Loading and accessories 69 Aire wear mit cierres 49 Loading and Operational Guidelines 69 OPERATION 50 AGCCOSSOFLIGS eire tod a EE 70 Starting a cold engine MAXXER 90 50 DU GE ae EM Starting engine MAXXER 50 Dg p Roe se i eT gts ae Engine break in 54 Exhaust system 74 PARKING oe criterio dette par detedd 56 RIDING eee eer eee 75 Parking on a slope sssse 57 Remote engine stop switch for new Accessories 2 ccc ccc ccccccccccccccecuceeecucenunecs 58 RIETS eiecti pis tac te deba ee Rob
36. g 283 8 Ibs Air cooled 4 stroke OHC Single cylinder 89 9 cm 47X51 8 10 0 1 Electric starter and kick started Wet sump Model MAXXER 90 Engine oil transmission oil Type Recommended engine oil classification Recommended transmission Oil classification Quantity Engine oil Periodic oil change Total amount Transmission oil Periodic oil change Total amount 142 90 110F SAE 10W 30 SAE 10W 40 SAE 20W 40 SAE 20W 50 40 o 10 20 30 40 C API Service SE SF SG type or higher SEA 90 0 7 L 0 62 Imp qt 0 74 US qt 0 8 L 0 70 Imp qt 0 84 US qt 0 11 L 0 10 Imp qt 0 12 US qt 0 12 L 0 11 Imp qt 0 13 US qt MAXXER 90 Air filter for engine for V belt compartment Wet type element Dry type element Fuel Type Tank capacity Reserve amount UNLEADED FUEL 5 5L 1 16 Imp gal 1 40 US gal 1 5 L 0 32 Imp gal 0 38 US gal Carburetor Type PB Spark plug Type Gap NGK C7HSA 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automatic Brake Front brake type Operation Rear brake type Operation 143 Drum brake Right hand operation Disk brake Left hand operation MAXXER 90 Suspension Front Rear Shock absorber Front Rear Swing axle Swing arm Coil spring Oil damper Coil spring Oil damper Electrical Ignition system Generator system Battery type C D I C D I Magneto 1
37. ge O O Replace if damaged Check operation Replace if damaged O Wheel bearings St t eering system Check toe in Adjust if necessary O Knuckle shafts O O Steering shaft Lubricate every 6 months Check all chassis fittings and fasteners Fittings and Fasteners Correct if necessary 1iltis recommended that these items be serviced by a KYMCO dealer Lithium soap base grease 92 PERIODIC MAINTENANCE LUBRICATION MAXXER 90 ITEM ROUTINE INITIAL EVERY 3 months 6 6 months months Engine oil Replace Warm engine before draining O O Oil strainer Clean Replace if necessary O Transmission oil Check oil level oil leakage Replace every 12 months V belt Check operation Replace if damage or excessive wear year O O O O Air filter element for engine and V belt compartment Clean Replace if necessary More often i Every 20 40 hours n wet or dusty areas Brake Check operation and brake fluid cable Replace brake pads shoes if necessary oA Battery Check specific gravity Check breather hose for proper operation Correct if necessary Carburetor Check idle speed starter operation Adjust if necessary Cylinder head cover breather system Check breather hose for cracks or damage Replace if necessary
38. gh beam indicator lamp 3 Low oil level indicator lamp 17 Instruments Display description 00101 LILY M DS A ERE Le 1 Display 1 TM start symbol 2 MODE button 2 Bar graph speed symbol 3 ST STOP button 3 Mode symbol Cx e 4 Auto automatic start stop mode symbol Ys 5 Distance scale symbol Q mem C 6 Data display TM DST ODO CLOCK 18 1 Button function MODE Button Each press of button converts the screen to display will be changed to other functions CLOCK TM DST ODO CLOCK ST STOP Button When this button was pressed measurement of the trip distance and elapsed time is simultaneously started or stopped While the unit is operating the TM symbol flashes MODE ST STOP Button When the mode button and ST STOP button are pressed simultaneously DST TM are cleared TM and DST aie cleared 19 2 Function Speed Current speed is displayed Four E eem continuously when the motor in motion f TM Elpased time is measures from the fon N Ey 123456 starting point of a trip DST Trip distance is measures traveled since the time of the last reset ODO Total distance Mileage is continuously measured accumulated and displayed until the battery wears down o9 136 B 20 CLOCK The 24HR clock always displayed the current time on the screen 21 3 Default setting or resetting the unit When the MODE button and ST STOP but
39. hich could lead to an accident or collision WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your KYMCO dealer 1 Select a level surface and lock the parking brake see page 32 or 33 before starting the engine 2 Turn the fuel lock to ON 3 Turn the main switch to and the engine stop switch to Q 4 Make sure the tethered road lead is installed into the remote engine stop switch 50 5 Use the starter choke in reference to the figure Position Cold engine start ambient temperature below 5C 40F Position Q Cold engine start ambient temperature at 0C 30F 30C 90F and warming up position Position Cold engine start ambient temperature above 25C 80F and warm engine start position AMBIENT TEMP STARTEA CHOKE POSITION 1 Fully open 3 Closed 2 Half open a Starter choke 51 6 With the throttle closed push the starter button Release the starter button as soon as the engine starts NOTE Do not use the electric starter for more than 5 seconds at a time Release the starter button for approximately 10 seconds before pressing it again 7 Ifthe engine is started with the starter choke
40. hicle to lean sharply to one side Go straight down the slope where possible PARKING Always choose a level place to park After bringing your ATV to a stop hold the brakes Then set the parking brake and turn the ignition switch OFF If you re through riding for the day also turn the fuel valve OFF 87 WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding techniques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 79 If your ATV can t make it up a slope you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the up slope side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the up slope side See pages 80 85 PERIODIC MAINTENANCE AND Have KYMCO dealer perform service if you ADJUSTMENT are not familiar with machine service Periodic inspection adjustment and lubrication will keep your machine in the safest and most Tool kit efficient condition possible Safety is an A tool kit is provide with your ATV obligation of the machine owner The most You are
41. igh beam Turn the switch to the zoo position to switch off the headlight NOTE The headlight can be turned on only when the engine is running 1 Engine stop switch Q 63 25 Engine stop switch When the switch is in the RUN position the engine will operate When the switch is in OFF X position the engine will not operate This switch is intended primarily as a safety or emergency control and it should normally remain in the RUN position NOTE If you stop your ATV by turning the engine stop switch OFF 3 be sure to turn the ignition switch OFF to prevent battery discharge Stater button To starter the engine apply brake and press the starter button with the ignition switch ON and the engine stop switch at RUN Q CAUTION See starting instructions prior to starting engine see page 50 for details NOTE 1 Start button If the starter switch is pushed with the ignition switch and the engine stop switch gq the starter motor will be activated but the engine will not start To start the engine be sure to position the engine stop switch at Q 26 Kick starter The kick starter cranks the engine when the kick starter is operated CAUTION See starting instructions prior to starting engine see page 50 for details NOTE If the kick starter is operated with the ignition switch at and the engine stop switch Sq the eng
42. ine will not start To start the engine be sure to position the engine stop switch at Q 2f 1 Start kick lever Remote engine stop switch The ATV has a remote engine stop switch This allows the supervisor to follow close behind and stop the engine by pulling a tethered core Practice using it when your youngster first starts riding See page 76 NOTE Make sure the tethered road lead is installed into the remote engine stop switch When the tethered road lead is not installed the engine will not operate 28 1 Remote engine stop switch 2 Tethered cord lead Throttle lever Itis operated by the thumb Pressing the lever opens the throttle When pressure is released spring tension automatically closes the throttle Regulate the speed of the machine by varying the throttle position 1 Throttle lever 29 A WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult aKYMCO dealer if you can t find or solve the problem yourself Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed t
43. lls have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Dry the chain and lubricate it to prevent rust 133 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it Z WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings B STORAGE Before storing your ATV for an extended time be sure you thoroughly check the vehicle for needed repairs and have them corrected Otherwise the repairs may be forgotten by the time you remove the vehicle from storage In addition extended storage requires that you take the following steps
44. lock key MAXXER 90 MODEL CODE identification number Frame and engine serial number The frame serial number is stamped on the The engine serial number is stamped on the front of the frame left crankcase 1 Frame serial number 1 Engine serial number MAXXER 50 2 Engine ser al number MAXXER 90 10 Parts location 07 06 05 04 03 02 01 01 Left front turn signal light 02 Rear brake lever 03 Left back mirror 04 Headlight 05 Right back mirror 06 Front brake lever 07 Right front turn signal light 08 Front wheel 09 Position light 08 09 08 11 05 02 01 01 Throttle lever 02 Remote engine stop switch 03 Instrument 04 Left rear turn signal light 05 Rear wheel 06 Right rear turn signal light 04 05 05 06 12 04 03 02 01 Flag pole bracket Right footboard Indicator lamps Parking brake MAXXER 90 Parking brake MAXXER 50 HL 02 ei BAA ES is a cy os M oo RM Mo Fuel fill cap om m 07 Left footboard NIE ERU 08 Taillight Stop light i SE 05 06 07 08 13 02 01 01 Storage compartment containing Owner s manual Air pressure gauge Tool kit Handlebar switches Fuel vavle Kick starter Exhaust pipe 02 03 04 05 Net 03 04 05 14 03 02 01 01 Speed limiter 02 Ignition switch 03 Seat 04 Seat lock leve
45. ly responsible for properly selecting installing and using non KYMCO accessories Always follow the loading instructions above plus the following 1 Carefully inspect the accessory to make sure it does not block any lights reduce ground clearance or limit suspension travel steering travel or other controls 2 Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls 3 Do not add electrical equipment that will exceed the vehicle s electrical system capacity A blown fuse could cause a loss of lights or engine power Modifications A WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through 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 ATV and should be installed and used according to instruction If you have question consult an authorized ATV dealer No Modifications Modifying this ATV or removing original equipment may render the vehicle unsafe or illegal Spark arresters and mufflers are required in most areas Don t modify your exhaust system or emission control system components
46. nce until you are totally familiar with the machine s handling and performance characteristics Riding your machine requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Age Recommendation MAXXER 50 The minimum recommended age for this ATV model is 6 For safety never let children under 6 years old operate this vehicle Children under 16 should be supervised by an adult Z WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV Failure to supervise children under 16 on ATV models intended for their use WHAT CAN HAPPEN If children use ATVs that are not recommended for their age severe injury or death can result Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident 62 HOW TO AVOID THE HAZARD A child under 6 should never operate this ATV Never allow achild under 16 to operate an ATV without adult supervision and never allow continued use of te ATV by a child If he or she does not have the abilities to operate it safely Age Recommendation MAXXER 90 The minimum recommended age for this ATV model is 12 For safety never let children under 12 years old operate this vehicle Children under 16 should be supervised b
47. ng temperatures and direct sunlight and out of the reach of children slow charge the battery once a month Z WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery WHAT CAN HAPPEN Gases may explode and possibly cause injury HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery 5 Wash and dry the ATV and wax all painted surfaces 6 Inflate the tires to their recommended pressures 7 Place the ATV on blocks to raise all four tires off the ground SPECIFICATIONS MAXXER 50 MAXXER 50 Dimension Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance Basic weight With oil and full fuel tank Engine Type Cylinder arrangement Displacement Bore x stroke mm Compression ratio Starting system Lubrication system 137 1385 mm 54 5 in 820 mm 32 23 in 900 mm 35 46 in 620 mm 24 37 in 900 mm 35 46 in 75 mm 2 96 in 111 kg 244 2 Ibs Air cooled 2 stroke Single cylinder 49 4 cm 39X41 4 7 2 1 Electric starter and kick starter Separate type Model MAXXER 50 Engine oil transmission oil Type Engine oil classification 2 stroke engine oil Transmission Oil classification SAE 10W 30 SAE 10W 40 SAE 20W 40 SEA90 API Service SE SF SG type or Quantity higher Engine oil 2 stroke engine oil 1 0L 0 9 Imp qt 1 1 US qt over Transmission oil Peri
48. ntinuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of the machine from time to time Do not operate it at full throttle position 2 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally 55 Parking MAXXER 50 Parking MAXXER 90 When parking stop the engine Turn the fuel When parking stop the engine Turn the fuel lock to OFF and apply the parking brake lock to OFF and apply the parking brake Make sure the lock plate into the locked Make sure the lock pin into the locked position position To set the parking brake see page 33 To set the parking brake see page 32 1 Locked position 1 Locked position 56 Parking on a slope Z WARNING POTENTIAL HAZARD Parking on a slope or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on slope or other inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on slope that are So steep you could not walk up them easily 57 1 Bring the machine to a stop by ap
49. nts explosive gases and should be handled with appropriate care NOTE When the ATV is to be stored for an extended period remove the battery from the vehicle and charge it fully Then store it in a cool dry place If the battery is to be left on the vehicle disconnect the negative cable from the battery terminal Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling 125 Battery remove Battery installation 1 Make sure the ignition switch is OFF 1 Install in the reverse order of removal 2 Remove the seat page 38 2 Check all bolts and other fasteners are secure 3 Remove the battery cover by removing the mount 3 After installing the battery check to see if the bolts battery cables are routed correctly 4 Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead 5 Remove the battery 1 Battery 2 Positive terminal lead 3 Negative terminal lead 1 Battery cover 2 Mount bolt 126 Fuse replacement Fuse holder When frequent fuse failure occurs it usually The fuse holder is located in the storage box indicates a short circuit or an overload in the under the seat electrical system See your authorized KYMCO The specified fuses are 7A dealer for repair CAUTION To prevent accidental short circuiting turn off the ignition switch before checking or repla
50. o notleave the ATV unattended while the engine is warming up Starting engine MAXXER 50 A WARNING 5 With the throttle closed push the starter POTENTIAL HAZARD Freezing control cables in cold weather button Release the starter button as soon as the engine starts NOTE Do not use the electric starter for more than 5 seconds at a time Release the starter button for approximately 10 seconds before pressing it again WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 6 Be sure to keep the throttle closed and the parking brake locked while starting and warming up the engine 7 Allow the engine warm up before riding 1 Selecta level surface and lock the parking brake see page 32 or 33 before starting the CAUTION Do notoperate the throttle open and close engine 2 Turn the fuel lock to ON rapidly as the ATV will move forward 3 Turn the main switch to and the engine suddenly causing possible loss of control Do notleave the ATV unattended while the engine is warming up stop switch to Q 4 Make sure the tethered road lead is installed into the remote engine stop switch 53 To start the engine without the electric starter 1 Follow steps 1 through 4 2 With the throttle clos
51. o the maximum Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV A WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN Adiuster The throttle cable could be damaged 2 Locknut S D Improper throttle operation could result A MAXXER 50 yA X Meri lose control have an accident or 18mm 0 72in we 28 d o SI a HOW TO AVOID THE HAZARD MARKER 90 iS MV 27 MAXXER 50 Do not turn the speed adjuster 8mm 0 32in la AWA g out more than 18 mm 0 72 in iN oy LN MAXXER 90 Do notturn the speed adjuster A N out more than 8 mm 0 32 in AED a ERE Always make sure the throttle lever free wig oa f play is adjusted to 1 0 4 0 mm 0 04 0 16 rm in See page 109 Front and rear brakes Brake pedal MAXXER 90 The front and rear brakes are operated by The both front and rear brakes are operated at squeezing the front brake lever the same time by depressing the brake pedal 1 Rear brake pedal 1 Front brake lever 31 Parking brake MAXXER 50 To set the parking brake squeeze the rear brake lever and lock it with the lock plate Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the rear brake lever until the lock plate releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position
52. odic oil change 0 11 L 0 10 Imp qt 0 12 US qt Total amount 0 12 L 0 11 Imp qt 0 13 US qt 138 MAXXER 50 Air filter for engine Wet type element Fuel Type Tank capacity Reserve amount UNLEADED FUEL 5 5L 1 16 Imp gal 1 4 US gal 1 5L 0 32 Imp gal 0 38 US gal Carburetor Type PB Spark plug Type Gap NGK BR8 HAS 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automatic Brake Front brake type Operation Rear brake type Operation 139 Drum brake Right hand operation Drum brake Left hand operation MAXXER 50 Suspension Front Rear Shock absorber Front Rear Swing axle Swing arm Coil spring Oil damper Coil spring Oil damper Electrical Ignition system Generator system Battery type C D I C D I Magneto 12V 4AH Tire Type Size Front Rear Tubeless 16X8 7 16X8 7 Bulb voltage wattage quantity Headlight Taillight 140 12V35 35W 12V5W SPECIFICATIONS MAXXER 90 MAXXER 90 Dimension Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance Basic weight With oil and full fuel tank Engine Type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system 141 1435 mm 56 54 in 905 mm 35 65 in 925 mm 36 45 in 650 mm 25 61 in 970 mm 38 22 in 100 mm 3 94 in 129k
53. om the vehicle AON If the slope is too steep or too slippery or if you have any doubt whether you can safely walk the ATV back down the slope leave the vehicle where it is and get help If possible block the wheels so the vehicle won t roll backwards 85 RIDING DOWN SLOPE When riding your ATV down slope shift your weight as farto the rear and up slope side of the ATV as possible Move back on the seat and sit with your arms straight Improper braking may cause a loss of traction Use caution while descending a slope with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction Whenever possible ride your ATV straight down slope Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear Z WARNING 86 POTENTIAL HAZARD Going down a slope 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 slopes as described in this Owner s Manual Note a special technique is required when braking as you go downa slope Always check the terrain carefully before you start down any slope Shift your weight backward Never go down a slope at high speed Avoid going down aslope at an angle that would cause the ve
54. oper operation See page 50 1 Fully open 2 Half open 3 Closed A Starter choke CAUTION Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life of the engine Pushing the choke knob too hard to the OFF position may dislodge the choke cable boot If this happens water and dirt may enter the choke cable and cause corrosion If the choke is hard to actuate or feels like it is sticking Check the cable boot 37 Seat To install the seat align the tabs on the seat with To remove the seat pull upward the seat lock the grommets on the frame and press the seat lever and pull up the seatthe rear down until it locks 1 Seat lock lever 38 Flag pole bracket Storage compartment To mount a flag pole in the bracket The storage compartment is located under the seat To remove the seat see page 38 NOTE Flag poles are required in some riding areas Check local regulations before riding Be careful not to flood this area when washing your ATV or riding through water and never put any electric conduction material in the storage compartment 1 Flag pole bracket 39 PRE OPERATION CHECKS Before using this machine check the following points ITEM ROUTINE PAGE e Check operation condition free play drum brake and brake fluid level disk brake Brake Adjust drum brake if necessary Ata MG TY Fill with DOT 4 brake fluid di
55. oper procedures when operating over obstacles as described in this manual e Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry outthe linings Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo Allow greater distance for braking Z WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or while in th
56. operly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by KYMCO dealer 1 Arm pin 2 Adjusting nut 114 Brake pedal adjustment MAXXER 90 3 Turn the adjusting bolts until the front The brake pedal free play should be adjusted Lower brake cables is tensed to 5 10 mm 0 2 0 4 in atthe brake pedal 4 Apply the front brake lever and check front pivot If the free play is incorrect adjust as brake cam levers to make sure that the Follows brake does not drag after adjusting A 5710 mm 0 20 4 in 1 Adjusting bolts 1 R L front lower cables Adjust 2 Locknuts 2 Brake cam lever 1 Keep front brake lever free play at 10 20 mm 0 4 0 8 in 2 Loosen the locknuts R L front lower brake cables 115 5 While remove the cable joint case cover and applying the brake pedal make sure the left and right front lower cable lengths A and B are equal The cable joint will become vertical 6 Tighten the locknuts R L front lower brake 1 Bolts 1 Cable joint 2 Cable joint case A Left front lower cable cover length B Right front lower cable length 116 7 Loosen the locknut B
57. orque Oil filler bolt 15 Nm 1 5 m kg 11 ft lb 99 1 Oil filler bolt measurement hole MAXXER 90 2 Transmission oil replacement A Place the machine on a level place B Place a container under the engine C Remove the oil filler bolt and drain plug to drain the oil D Reinstall the drain plug and tighten to Specification ightening torque Drain plug 1 Drain plug MAXXER 50 15 Nm 1 5 m kg 11 ft Ib 1 Drain plug MAXXER 90 100 E Fill the engine with oil and install the oil filler bolt Recommended oil See page 138 or 142 Oil quantity Periodic oil change 0 11L 0 10Imp qt 0 12US qt Total amount 0 12L 0 11Imp qt 0 13US qt CAUTION Be sure no foreign material enters the crankcase ightening torque Oil filler bolt 15 Nm 1 5 m kg 11 ft lb F Start the engine and warm up for a few minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause 1 Oil filler bolt MAXXER 90 101 Spark plug inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the machine to a KYMCO d
58. pen smoothly and spring back to idle position when released Repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a KYMCO dealer or refer to the Service Manual for correct tightening torque 46 Lights Check the position light and taillight stop light to make sure they are in working condition Repair as necessary for proper operation Switches Check the operation of the taillight stop light switch engine stop switch remote engine stop switch and any other switches Repair as necessary for proper operation Tires 2 The tires should be set to the recommended pressure A WARNING Recommended tire pressure POTENTIAL HAZARD Front 25 kpa 0 25 kgf cm 3 6 psi Operating this ATV with improper tires or Rear 25 kpa 0 25 kgf cm 3 6 psi with improper or uneven tire pressure Check and adjust tire pressures when the tires are cold WHAT CAN HAPPEN Tire pressures must be equal on both Use of improper tires on this ATV or sides operation of this ATV with improper or uneven tire pressure may cause loss of 3 Tire pressure below the minimum control increasing your risk of accident specified could cause the tire to dislodge from the rim under severe riding HOW TO AVOID THE HAZARD conditions 1 The tires listed below have been The following are minimums approved by Kwang Yang Motor Co Ltd Front 22 kp
59. pen the throttle suddenly The ATV could flip over backwards Never go over the top of any slope at high speed 81 An obstacle or a sharp drop could be on the other side of the slope If you are climbing a slope and you find that you When crossing the side of a slope Always follow proper procedures as described in the Owner s Manual Avoid slopes with excessively slippery or loose surfaces Shift your weight to the up of slope side of the ATV have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the slope A WARNING POTENTIAL HAZARD Improperly crossing slopes orturning on slopes 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 slope until you have mastered the turning technique as described inthe Owner s Manual on level ground Be very careful when turning on any slope Avoid crossing the side of a steep slope if possible 82 If your ATV has stalled or stopped and you believe you can continue up the slope restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the slope dismount the ATV on up slope side Physically turn the ATV around and then descend the slope If you start to roll backwards DO NOT
60. plying the brakes 2 Stop the engine 3 With the brake applied apply the parking brake Accessories Accessories can affect the handling and control of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories Choose only accessories designed for your ATV Your KYMCO dealer has a variety of genuine KYMCO accessories Other accessories may also be available on the market However itis not possible for KYMCO to test all non KYMCO accessories nor have any control over the quality or suitability of them Choose a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV 58 Do not mount an accessory where it could interfere with your ability your to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with accessories The ATV may handle differently Your ATV iding R Z WARNING Indicates a potential hazard that could result in serious injury or death GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use This section riding
61. r 05 Brake pedal 06 Steering handlebar lock MAXXER 90 NOTE The machine you have purchased may differ slightly from those shown in the figures of this 04 05 06 manual 15 CONTROL FUNCTIONS Ignition switch Functions of the respective switch positions are as follows OFF All electrical circuits are switched off The key can be removed in this position ON The position and taillight can be turned on With the engine stop switch at run OQ the engine can be started The key can not be removed 16 1 Ignition switch 2 Key Indicator lamps Right Left turn signal indicator lamps FUNCTION Flashes when the right turn signal Operates Flashes when the left turn signal Operates High beam indicator lamp The high beam indicator lamp will light when the headlight switch to select high beam zp and the ignition switch is ON Low oil level indicator MAXXER 50 The low level indicator lights when the 2 stroke engine oil level is low CAUTION If the low oil level indicator comes on while riding stop riding and shutthe engine off Fill the oil tank to the upper level mark with the recommended oil see page 45 Continuing to ride with a low oil level may lead to engine failure that could result in an accident O za s AG zs E D ha n ij Rim 1 Right Left turn signal indicator lamps 2 Hi
62. raining the V belt compartment MAXXER 90 sse 123 Wheel removal sssssesessess 124 Wheel installation sssesusss 124 Battery ciem eii ki cueci Deae tian 125 Fuse replacement ssssss 127 Headlight beam adjustment 130 Troubleshooting seeese 131 Troubleshooting chart 132 Cont d CLEANING AND STORAGE ss 133 A Cleaning occa 133 B Storage iisnikie cie attics 135 SPECIFICATIONS MAXXER 50 137 SPECIFICATIONS MAXXER 90 141 NOISE REGULATION sse 145 MAINTENANCE RECORD ss 146 LOCATION OF THE WARNING AND SPECIFICATION LABELS Ji WARNING INFORMATION Your ATV comes with a hang tag and several labels containing important safety information Anyone who rides the vehicle should read and understand this information before riding Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride The labels should be considered as permanent parts of the vehicle If a label comes off or becomes hard to read contact your KYMCO dealer for replacements A WARNING Improper ATV use can result in SEVERE INJURY or DEATH E AN NEVER USE WITH ALCOHOL OR DRUGS ALWAYS US APPROVED HELMET AND PROTECTIVE GEAR NEVER operate Without proper
63. rake pedal cable 8 Turn the adjusting bolt until the specified free play is obtained Specified free play 5 10 mm 0 2 0 4 in 9 Tighten the locknut Brake pedal cable SCA iL uw 1 Locknut 2 Adjusting bolt 3 Brake pedal cable A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct e Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by KYMCO dealer 117 Brake fluid inspection Disk brake Check if the fluid level is below the lower level mark through the brake fluid reservoir underthe rear fender right side A WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes WHAT CAN HAPPEN May cause irritation HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed 1 Brake fluid reservoir A Upper level mark B Lower level mark 118 NOTE As the brake pads wear brake fluid level drops automatically compensating for wear There are no adjustments to perform but fluid level and pad wear must be inspected periodically The system must be inspe
64. re and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot Engine MAXXER 90 and transmission oil Make sure the engine and transmission oil at the specified level Add oil as necessary See page 95 101 Check for leaks 110 F 10 30 50 70 90 SAE 10W 40 10 0 10 20 30 Recommended engine transmission oil classification API Service SE SF SG type or higher CAUTION Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance Oil quantity Engine oil Periodic oil change 0 7 L 0 62 Imp qt 0 74 US qt Total amount 0 8 L 0 70 Imp qt 0 84 US qt Transmission oil Periodic oil change 0 11 L 0 10 Imp qt 0 12 US qt Total amount 0 12L 0 11 Imp qt 0 13 US qt Engine oil MAXXER 50 Oil level When the low oil level indicator lights it means the oil level in the oil tank is low s
65. rs and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating 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 low speeds before attempting to turn at faster speeds Do not turn at excessive speed e Never operate the ATV on hills Always follow proper procedures for climbing slopes as described in this manual Check the terrain carefully before you start up any slope Shift your weight forward Never open the throttle suddenly Never go over the top of a slope at high speed Always follow proper procedures for going down slopes and for braking on slopes as described in this manual Check the terrain carefully before you start down any slope Shift your weight backward Never go down a slope at high speed Avoid going down slope at an angle that would cause the vehicle to lean sharply to one side Go straight down the slope where possible Never attempt to turn the ATV around on any slope until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep slope if possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow pr
66. rts riding Pull the tether after the ATV is moving The ATV may continue to roll for some distance Watch the distance until the ATV stops Be aware that this distance must be included in the stopping space of the ATV and that this distance may increase with speed 76 1 Tethered cord Speed limiter for new riders Your ATV has an adjustable throttle limiter The screw and locknut in the lower throttle housing can be adjusted to limit throttle lever movement 7T To adjust the throttle limiter 1 Loosen the lock nut 2 Turn the throttle limiter screw clockwise to reduce throttle lever movement or counterclockwise to increase throttle lever movement 3 Hole the screw in place and tighten the lock nut 1 Adjuster 2 Locknut BRAKING Practice starting and stopping at slow speeds Gradually work up to faster starts and stops 1 Steer straight ahead Close the throttle completely remove your thumb from the throttle lever 2 Gently apply the brakes pull both hand levers Gradually increase the lever or and pedal pressure as you feel the brakes slowing your speed The pressure used depends on your speed and the condition of the terrain you are riding Slick slippery or muddy ground requires gentler braking 78 Pulling one or both brake levers or and depressing brake pedal too hard may cause the front and or rear wheels to skid or slide out of control If this happens release all pressure on the le
67. s until the oil level settles before checking 95 E Remove the dipstick and inspect the oil level F The oil level should be between the maximum and minimum marks If the level is low add oil to raise itto the proper level 3 Ll 1 Dipstick oil filler cap Maximum level mark 3 Minimum level mark 2 CAUTION Be sure no foreign material enters the crankcase 2 1 Engine oil replacement and oil filter cleaning A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil filler cap and oil filter cap to drain the oil CAUTION Be sure no foreign material enters the crankcase When removing the drain plug the compression spring oil strainer and O ring will fall out Take care not to lose these parts E Clean the oil strainer with solvent F Inspect the O ring and replace if damaged G Reinstall the O ring oil strainer compression spring and drain plug Tighten the drain plug to specification CAUTION Before reinstalling the drain plug be sure to install the O ring compression spring and oil strainer 1 Oil filter cap ightening torque Oil filter cap engine 14 7 Nm 1 5 m kg 10 6 ft Ib H Fill the engine with oil and install the oil filler cap Recommended oil see page 136 Oil quantity Engine oil Periodic oil change 0 7 L 0 62 Imp qt 0
68. se extra caution when riding the machine with additional loads such as accessories or cargo The machine s handling may be adversely affected Reduce your speed when adding additional loads 69 Loading and Operational Guidelines Carrying cargo will affect how your ATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers Be sure to observe the weight limits and follow these guidelines Do nottow another vehicle 2 Make sure all cargo is secured before riding 3 Allow extra room for starting stopping and turning whenever you carry cargo or pull a trailer 4 Avoid riding on steep slopes when carrying cargo or pilling a trailer 5 Never cross a slope when toeing a trailer POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling stability and braking which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this 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 your Owner s Manual for carrying cargo or pulling a trailer 70 Accessories Genuine KYMCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personal
69. signed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized KYMCO dealer PERIODIC MAINTENANCE LUBRICATION MAXXER 50 ITEM ROUTINE INITIAL EVERY 3 months 6 months 6 months Drive chain Check and adjust slack alignment clean lube O O O Fuel line Check fuel hose for cracks or damage Replace if necessary O O Transmission oil Check oil level oil leakage Replace every 12 months V belt Check operation Replace if damage or excessive wear year O O o O Air filter element Clean Replace if necessary More often i Every 20 40 hours n wet or dusty areas Brake Check operation and brake fluid cable Replace brake pads shoes if necessary O O Battery Check specific gravity if necessary Check breather hose for proper operation if necessary Correct if necessary Carburetor Check idle speed starter operation Adjust if necessary Wheels Check balance damage runout Replace if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Exhaust system Check leakage Retighten if necessary e Replace gasket if necessary 91 INITIAL EVERY 3 6 6 months months months ITEM ROUTINE Check bearing assembly for looseness dama
70. sk brake if necessary Check fuel level LEE Fill with fuel if necessary US Engine oil and Check oil level Fill with oil if necessary 44 45 95 101 Check chain slack and condition Swiches Chekforprperfunon 40 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibillty 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 the Owner s Manual 41 Front and rear brakes 1 Drum brake Check for correct free play in the brake levers If the free play is incorrect adjust it See pages 110 117 Check operation of the levers They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a KYMCO dealer 2 Disk brake Make sure there is no brake fluid leakage Check operation of the levers They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a KYMCO dealer 3 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear See page 1
71. skills or the conditions Do not operate the vehicle after consuming ALCOHOL OR DRUGS ALWAYS Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns For your safety wear gear to include helmet gloves and foot protection Gasoline is flammable shut off engine avoid sparks and open flame when refueling READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS
72. take proper pre cautions SEVERE INJURY OR DEATH can result if you do notfollow these instructions Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper training or instruction Beginners should receive training from a certified instructor Always follow the age recommendation Achild under 6 years old should never operate an ATV with engine size greater than 70cc Achild under 12 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by achild if he or she does not have the abilities to operate it safely Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Never attempt wheel jump or other stunt Always inspect your ATV each time you use it to make sure itis in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handleba
73. tant parts Keep the slack within the specified limit 121 Drive chain cleaning and lubrication The drive chain is equipped with rubber O rings between the chain plates Steam cleaning high pressure washes and certain solvents can damage these O rings Use only kerosene to clean the drive chain Wipe it dry and thoroughly lubricate it with SAE 30 50 motor oil Do not use any other lubricants on the drive chain They may contain solvents that could damage the O rings 1 O rings Cable inspection and lubrication A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a KYMCO dealer to replace them Recommended lubricant KYMCO chain and cable lube or SAE 10W40 motor oil 122 Brake lever lubrication Draining the V belt compartment Lubricate the pivoting parts of the brake levers MAXXER 90 If water leaks into V belt compartment such as Recommended lubricant when the machine is drive in water remove the Lithium soap based grease drain screw on the bottom of compartment and All purpose grease drain the water
74. ter v Pa to obtain the correct free play 1 4 mm or D 9 0 04 0 16 in 1 Rubber sleeve 2 Cable adjuster 3 Tighten the locknut and reinstall the sleeve 3 Locknut 4 Throttle lever A 1 4 mm 0 04 0 16 in S Other checks Check the throttle cable for kinks and signs of wear that could cause stretching or failure Lubricate the throttle cable with a commercially available lubricant to prevent premature wear and corrosion 109 Front and rear brake shoes drum brake Rear brake pads inspection Disk brake inspection A wear indicator is provided on each brake The When turn the adjusting nut fully to decrease indicators allows checking of brake pads wear brake lever free play and the free play and the Check the position of the indicator Ifthe free play exceeds the specification 1 2cm it indicator reaches the wear limit line ask a means the brake shoe is worn out Go to our KYMCO dealer to replace the pads designated distributors or service stations for brake shoe replacing 1 Wear indicator 2 Rear brake 110 Front brake lever free play adjustment The front brake lever free play should be adjusted to 10 20 mm 0 4 0 8 in at the tip of the brake lever If the free play is incorrect adjust as follows 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 2 Loosen the lower locknut 3 Turn the lower adjusting bolt until A Free play 10 20 mm 0 4
75. 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 the Owner s Manual 67 Z WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle on pages47 48 Always maintain proper tire pressure as described in the Owner s Manual on page47 Do not operate at speeds too fast your skills or the conditions A WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go ata speed that is proper for the terrain visibility and operating conditions and your experience 68 Speed limiter For riders inexperienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiter limits the power and top speed of the machine Turning the screw in decreases top speed and turning it out increases top speed 1 Adjuster 2 Locknut Loading and accessories U
76. to reduce the effects of deterioration from non use of the vehicle 1 Change the engine oil 2 Drain the fuel tank and carburetor Be sure to drain the fuel in a well ventilated area not in a garage 135 Z WARNING POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite HOW TO AVOID THE HAZARD Always refuel this ATV and handle fuelina well ventilated area with the engine off Do not smoke or allow flames or sparks in the area where fuel is handled Do not overfill the tank Be careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting he engine Z WARNING POTENTIAL HAZARD Prolonged contact of fuel with the skin Breathing fuel vapor WHAT CAN HAPPEN The fuel can cause skin irritation Fuel vapor could cause lung damage HOW TO AVOID THE HAZARD Avoid repeated or prolonged contact of fuel with the skin or breathing of fuel vapor KEEP OUT OF REACH OF CHILDREN 3 Remove the spark plug and pour one tablespoon 15 20 cc of clean 2 stroke engine oil into the cylinder Operate the starter for a few seconds to distribute the oil then reinstall the spark plug Make sure the engine stop switch is OFF X before pressing the starter 4 Remove the battery page 126 And store it in an area protected from freezi
77. ton are pressed simultaneously and press the ST STOP button The indicator on the display will change between km h amp mile h Press the MODE button and press the ST STOP button to setting wheel circumference the body to set wheel circumference is MAXXER 50 1400mm MAXXER 90 1570mm Press the MODE button and press the ST STOP button to setting clock When the MODE button and ST STOP button are pressed simultaneously and press the ST STOP button to setting auto symbol ODO Mode 22 Handlebar switches 1 Horn button 2 Turn signal switch Horn button When the ignition switch is in the position push the horn button and it will sound Turn signal switch Use the turn signal switch while turning to another direction or shifting to another lane The turn signal light will wink when the switch is operated 2 For turning to the left cy For turning to the right The instrument turn signal indicator light will also wink when the switch is operated Push the switch and it will release CAUTION The turn signal light will not release automatically Be sure to reset it after use otherwise it may affect the traffic safety The turn signal switch does not work when the ignition switch is OFF 1 Headlight switch 24 Headlight switch Turn the switch to the zD position to switch on the low beam Turn the switch to the p position to switch on the h
78. top the engine and fill the oil tank as soon as possible CAUTION If the low oil level indicator comes on while riding stop riding and shut the engine off Fill the oil tank to the upper level mark with the recommended oil Continuing to ride with a low oil level may lead to engine failure that could result in an accident if the engine has been run after the low oil level indicator has come on the scooter must be taken to an authorized KYMCO dealer for inspection and bleeding of the oil system Failure to do this will result in serious engine damage To fill lift seat see page 38 remove the cap from the oil tank and fill with the recommended oil up to the upper level mark NOTE hen filling do not let dirt or other foreign materials enter the tank 45 1 Cap Oil recommendation Use KYMCO 2 STROKE OIL ORITS EQUIVALENT 2 Upper level mark 3 Fill duct CAUTION The use of improper oils may cause excessive and or premature carbon build up in the engine and exhaust system resulting in loss If power and possible engine damage Genuine KYMCO 2 Stroke Oil has been specifically designed and tested in KYMCO ATV andis a proper oil Chain Check the general condition of the chain and check the chain slack before every ride Lubricate and adjust the chain as necessary See pages 118 120 for details Throttle lever Check to see that the throttle lever operates correctly It must o
79. ver s immediately Steer straight ahead to regain control Then gently reapply the brakes Independent use of only the front or rear brakes reduces stopping performance Extreme braking may cause the wheels to lock reducing control ofthe ATV When possible reduce speed or brake before entering a turn Closing the throttle or braking in mid turn may cause wheel slippage which will reduce control of your ATV TURNING YOUR ATV To achieve maximum traction while riding on road the two rear wheels are mounted solidly on one axle and turn together at the same POTENTIAL HAZARD speed Therefore unless the wheel on the Turning improperly inside of the turn is allowed to slip or lose some traction the ATV will resist turning When approaching a corner or turn close the WHAT CAN HAPPEN ee pes eee ui rid Dy applying ATV could go out of control causing a oth front and rear brakes at the same time iei As you do so put your weight on the footboard EEO EEN to the outside of the turn opposite your desired direction and lean your upper body into the HOW TO AVOID THE HAZARD turn After completing the turn open the throttle Always follow proper procedures for gradually to accelerate the ATV turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions a weight on the Do not turn at excessiv
80. y an adult Z WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV Failure to supervise children under 16 on ATV models intended for their use WHAT CAN HAPPEN If children use ATVs that are not recommended for their age severe injury or death can result Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD Achild under 12 should never operate this ATV Never allow achild under 16 to operate an ATV without adult supervision and never allow continued use of te ATV by a child If he or she does not have the abilities to operate it safely 63 Never carry passenger on the carrier Z WARNING POTENTIAL HAZARD Carrying a passenger on the carrier WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger on the carrier The carrier is to allow the operator to carry cargo It is not for carrying passengers 64 Apparel A WARNING Operating without protective clothing POTENTIAL HAZARD Increases your chances of severe Injury in the event of an accident Operating this ATV without wearing an approved motorcycle helmet eye protection
81. your ATV provides general ATV riding instructions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure Butitis essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s manual Manual completely and understand the operation of the controls Pay particular attention to the safety information on pages 4 8 Please also read all caution and warning labels on your ATV 60 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners and inexperienced riders should get proper instruction on how to operate this ATV A 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 ofterrain 61 HOW TO AVOID THE HAZARD Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum performa

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