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11. fuel system

1. 11 10 yg pp ete eee E eee ere eee ee 11 11 OG rr 11 13 CELP FAILURE CODES LIST 11 15 TILT SWITCH lt 11 17 TROUBLESHOOTING 11 18 DIAGNOSTIC REPORT 11 19 DIAGNOSTIC OPERATION PROCEDURE 11 20 11 1 KYMCO 11 EFI SYSTEM MAXXER 450i FUEL PUMP FUEL LEVEL SENSOR The electric fuel pump and fuel level sensor are not serviceable components If either component fails it must be replaced as a set TESTING Whenever maintenance or inspection is made on the fuel system during which there may be fuel leakage there should be no welding smoking open flames etc in the area Prior to removing the electric fuel pump the following check should be performed to determine that removal is necessary 1 Turn the ignition switch ON and listen for CONNECTOR FUEL a momentary whirring sound of the o serma 112 pump building pressure If the sound is 5 1670a Ptat sooo rmm heard 10 seconds no electrical checks wam pr ii P il s
2. Fd n a n e 5 BR Or 1 ee NEU UDIENSMEEM NX o 2 F F ILLA 8 8 I p 4 N Ji St RN BR L EENE MEERA L an mali i ee I esee ae I ann T a i ie I lt HEE o i L VR Al SENSORPOWER D 1 i I WL BRIL 1 44 12V SWITCH POWER BL Bl CAN HIGH i n mmm LR 2 83 ENG CHECK I a Th 6 I ale 1 17 gt i i 4 nu mmm HAV MEMORY E gp I li I I BN ee IM 7 mc Bal WA BRIL I O 25 59 gt LLI LLI LGR H4 GEAR C J1 FUEL RELAY 2 if 3 ICNITION RELAY G B 1 121 SWITCHED POWER i STARTER SOLENOID EWL INJECTOR IG
3. Gauges Indicators R Packs 1 1 1 L L3 L L Electrical Connectors L Hydraulic amp Auxiliary Brake Fluid 2 Yrs Brake Hoses 1 4 Service Inspect more frequently when operating in adverse conditions Periodic Maintenance This section has been organized into sub sections which show common maintenance procedures for the KYMCO AT V NOTE KYMCO recommends the use of new gaskets lock nuts and seals and lubricating all internal components when servicing the engine transmission NOTE Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions NOTE Critical torque specifications are located in Section 1 SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section Description pm Valve Clearance Adjuster NOTE Special tools are available from the KYMCO Spare Parts Department Lubrication Points It is advisable to lubricate certain components period ically to ensure free movement Apply light oil to the components using the following list as reterence A Throttle Lever Pivot Cable Ends B Brake Lever Pivot Cable Ends C Auxiliary Brake Cable Ends D Shift Lever Cable End
4. Hri L Ch jd li E 2 a a CESS m m 5 FUELUNT W ERE j t im Aa B G il 1 JI LI 2 ad ILI 4 ln a PERG a EN i iii ID J L mm e a EE rZ ull ifi meinur E TAIL STOP LIGHT nn a LILI NENNEN N 12V 5 21W J L L ib D G BR B ON PT eee ee mm aaa n o wa d Soy n m anal i G P E i a es m um E F ih z O iJ il i YYY i HEAD LICHT 12V 35W 35W 12V 10W Ju 5 55 em 6 zg RH FR WINKER ihi jJ 5 gt lt YYY 5 m z 9 alel F 2 22 8 0 2 5 PULSER aN ACG HALL SENSOR HORN SW WINKER SW STARTER SW DIMMER SW ENGINE HAZARD SW Fuel pump PDM POWER DISTRIBUTION MODULE HORN SW 2WD 4WD SW HAZARD SW WINKER SW COMB SW GRAY orien 8 Fi awe 6 12V S 21W REVE
5. 28 38 Cylinder Head 6 mmy Cylinder 8 11 Cylinder Head mm 20 ef Cylinder Head Cover Cylinder Head 8 11 Crankshatt Balancer Drive Crankshaft 63 B6 Gear Driven Pulley Driveshaft 83 115 Ground Cable Engine 8 11 Output Shaft Flange Nut Output Shaft 74 101 Magneto Rotor Nut 107 146 Sprocket 11 15 Cover 8 41 i 1 Span Plug Engine 8 11 Valve Adjuster Jan Mut Valve Adjuster 7 9 5 Oil Fitting Engine 58 78 Pump 56 78 Movable Drive Face Nut Clutch shaft 83 115 DRIVE TRAIN COMPONENTS Engine Mounting Through Bolt 3B 52 Front Differential Frama Differential 3B 52 Inear Flange 20 Output Joint Input Shaft Housing Differential Housing 23 Housing 31 Cafferential Housing Drive Bavel Gear Shaft 705 98 Driven Bevel Gear Nut Driven Shat 99 1372 Hub Nut ShattiAxle max 200 270 Oil Drain Plug Front Differential 4Sin lb 5 Rear Dive Fill Plug Front Differentials 16 22 Drive Oil Drain Plug Engine 20 2f Wheel Hub 40 54 Hear Drive Gear Case Engine Output Flange Input Flange w Hlue Loctite 243 w Red Loctite 271 Treen Loctibe 609 Torque Conversions ft Ib N m ft lb M m ft lb f
6. 2 17 Checking Replacing 2 17 Adjust Inspect Periodic Maintenance Chart D Drain Replace T Tighten Initial Service Every 3 6 After Break In Every Month or Months or Months or As Needed First Mo or Day Every 100 Every 300 Every 500 1500 Misa 100 MI Miles Miles Miles Battery Fuses Filter Drain Tube fr 85 R Valve Tappet Clearance Engine Compression Spark Plug E 4000 no Muffler Spark Arrester C Rn Gas Vent Hoses R 2 Yrs Throttle Cable 1 Coolant Cooling System 2 Yrs Engine Transmission Oil Level 4 Enaine Tra nsmission ilter H H Oil Strainer Front Differential Rear Drive Lubricant 4 Yrs Pressure R Steering Components A _ Suspension joint boots drive R axle boots front and rear tie rods 9 and rear drive bellows Nuts Cap Screws Screws T Throttle Body EMS Sensor 1 4 Lights l a Switches 4 Shift Lever A L Handlebar Grips R Handlebars
7. meter shows voltage troubleshoot gear shift position switch connector or gear shift position switch the meter does not show battery voltage inspect the LIGHTS fuse ignition switch or the main wiring harness Troubleshooting Problem Spark absent or weak Condition 1 Ignition coil defective 2 Spark plug defective 3 Magneto defective 4 ECUunit defective 5 Pick up coil defective Problem Spark plug fouled with carbon Remedy 1 Replace ignition cail Replace plug Replace magneto Replace ECU unit Replace pick up coil 4 9 Condition 1 Gasoline incorrect 2 Air cleaner element dirty 3 Spark plug incorrect too cold 4 Valve seals cracked missing 5 Oil rings worn broken Remedy 1 Change to correct gasoline Clean element 3 Replace plug 4 Replace seals 5 Replace rings Problem Spark plug electrodes overheat or burn Condition E Spark plug incorrect too hot 2 Engine overheats 3 Spark plug loose Remedy 1 Replace plug 2 Service cooling system 3 plug Problem Magneto does not charge Condition 1 Lead wires connections shorted loose open 2 Magneto coils shorted grounded open 3 Regulator rectifier defective Condition 1 Lead wires shorted open loose at terminals Stator coils magneto grounded o
8. eren 3 29 Removing Right Side Components 3 29 Servicing Right Side Components Installing Right Side 3 33 Center Crankcase 3 36 Separating Crankcase 3 37 Disassembling Crankcase Servicing Center Crankcase Components 3 39 Assembling Crankcase Half 3 42 Joining Crankcase 3 44 Installing Engine Transmission 0 00 0 0 3 44 Removing Engine Transmission Many service procedures can be performed without removing the engine transmission from the frame Closely observe the note introducing cach sub section for this important information AT THIS POINT If the technician s objective is to service Top Side Components Left Side Components or Right Side Components the engine transmission does not have to be removed from the frame AT THIS POINT If the technician s objective is to service replace left side cover oil seals or the oil strainer from beneath the engine transmission the engineffransmission does not have to be removed from the frame secure the ATV on asupport standto elevate the wheels WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 1 Remove the front rack lett and right
9. BBR Ril nm wt lt 3 55 550 SB i ER kc OS lt 3 Ja 327 9925 E PN al G 25 p 5305 I Ss a I I 1 I I l L l ju BR B 1 i 1 JE 1 O p 2 FR POSITION i i 12V 5W I I SSS TAIL STOP LIGHT I m n m mM o Z Li 12V 5 21W Ji ee E L0 EEE M i LED SL ee m SS SSS ES r re H Hoe rcs d bee a SB SB n DE RB a um o oe 11 San I e seh Bl ee ee ee a i BR B BR B L Nj es SB mm pamm 2 Jd B 3 cee cer
10. PR237 4 Adjust the auxiliary brake if necessary C Install the new brake pads 5 Verify that the brakelight illuminates when the D Secure the caliper to the knuckle and or axle Sin lever is compressed or the brake pedal is epressed housing with the cap screws Tighten to 20 ft Ib Checking Heplacing V Belt REMOVING 1 Remove the seat and right side engine cover then remove the cap screw securing the auxiliary brake pedal to the frame Account for a flat washer 2 17 S MINE KC149A Slide the auxiliary brake pedal part way off the pivot stud but do not remove then remove the cap screws from the V belt housing and remove the cover Account for two alignment pins and a gas ket KC142A Remove the nut securing the movable drive face to the clutch shaft then remove the movable drive face assembly being careful not to let the roller fall out Account for a bushing KC127 2 18 nd y KC128 Thread a cap screw from the V belt cover into the driven pulley fixed face and push the movable face open allowing the V belt to drop down between the pulley faces approximately 3 4 in KC137 5 Pinching the V belt together in front of the driven pulley pull it forward and outward off the clutch shaft then remove it from the driven pulley KC136 6 Inspect the faces of the drive and driven pulleys for scoring pitting cracks or grooving then clean any dirt and debris
11. 19 are necessary Turn ignition switch moremo nw _ 2 Disconnect gasoline hose from wsso Pr sxi Pume FUEL throttle body then install a suitable W x Se pressure gauge NANA REMARKS Gasoline may be under pressure Place an absorbant towel under the connector to absorb gasoline spray when disconnecting 3 Turn the ignition switch to the ON position The fuel pressure should build until the pump shuts off Pressure should read 3 0 kg cm 43 psi 4 Ifthe pump is not running disconnect the fuel pump tank sensor connector 11 2 11 EFI SYSTEM 5 Connect a multimeter to the power supply leads with the orange red tester lead to the red wire and the black tester lead to the black wire then turn the ignition switch to the ON position The meter should read battery voltage If battery voltage 15 indicated and the fuel pump does not run replace the pump assembly If no battery voltage 1s indicated check the ECU and the vehicle tilt sensor REMOVING 1 Remove the rear rack and fenders then disconnect the power supply fuel pump connector 2 Remove the spring clamp then remove the fuel hose 3 Remove the screws securing the fuel pump to the gas tank then make a reference mark on the fuel pump and tank 4 Lift out the fuel pump assembly carefully tilting it forward to clear the voltage
12. 20 27 Hydraulic Caliper Knuckle Tire Inflation Pressure 0 4 2 5 68 psi CHASSIS COMPONENTS Footrest Frame 8 mm 20 27 Bumper Frame 10 mm 35 47 MISCELLANEOUS Dry ht 274 603 Ib A Arm Frame 35 47 Gas Tank Capacity Rated 151 37505 Knuckle Ball Joint 35 47 Differential Capacity 270 ml 9 1 fl oz s em a5 47 Rear Drive Capacity 250 8 5 fl oz Shock Absorber Upper A Arm 35 47 Knuckle A Arm 35 47 Engine Oil Capacity 0 Oi Capacity Engine Oil Changed Capacity 221 Engine Oil Changed Capacity with Oil Filter Changed 24L 25US at 7 A Arm Frame 35 47 Gasoline Recommended 87 Octane ore IX Regular Unleaded Engine Oil Recommended SAE 5W 30 Differential Rear Drive Lubricant SAE 80W 90 Hypoid Taillight Brakelight 12V 5WI21W Headlight 12V 35W SUSPENSION COMPONENTS Rear Shock Absorber Upper Frame 35 47 Shock Absorber Lower Lower A Arm 35 47 Specifications subject to change without notice ENGINE TRANSMISSION Torque Part Bolted To idb m Clutch Shoe ICrankshaft Clutch Cover Housing Assembly Laft Sida Cover Crankcase Half 6 mm Half Crankcase 8 mm Half 21 28 Cylinder Head Cap Screw
13. 3 Meter must show voltage If the meter shows no battery voltage troubleshoot the battery or the main wiring har ness RESISTANCE Always disconnect the battery when performing resistance tests to avoid damaging the multimeter ENOTE Perform this test on the switch harness using the following procedure 27 Turn the ignition switch to the ON position 2 Set the meter selector to the OHMS position 3 Connect either tester lead to pin then connect the other tester lead to pin A 4 The meter must show less than ohm Turn the ignition switch to the LIGHTS position The meter must show less than ohm 6 Leaving the tester lead on pin connect the other tester lead to pin 7 The meter must show less than ohm ENOTE the meter shows more than 1 ohm of resistance replace the switch Handlebar Control Switches The connectors are located on the night side of the ATV next to the To access connector the electrical cover must be removed ENOTE These tests should be made on the switch side of the connector Always disconnect the Battery when performing resistance tests to avoid damaging the multimeter RESISTANCE HI Beam Set the meter selector to the OHMS position 2 Connect one tester lead to the brown black wire then connect the other tester lead to the lavender WITE With the dimmer sw
14. Tooth Contact Shim Correction Decrease Shim Thickness Contacts at Root Increase Shim Thickness MNOTE To correct tooth contact steps 1 and 2 with NOTE of Correcting Backlash must be fol lowed and the above Tooth Contact Shim Correc tion chart must be consulted CAUTION After correcting tooth contact backlash must again be checked and corrected if necessary Continue the correcting backlash correcting tooth contact procedures until they are both within tolerance val ues CRANKSHAFT ASSEMBLY Measuring Connecting Rod Small End Inside Diameter 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and mea sure it with micrometer 3 40 CC290D 2 Maximum diameter must not exceed specifica tions Measuring Connecting Rod Small End Deflection 1 Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection must not exceed specifica tions Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acc
15. MD1118 01094 7 Remove the nut holding driven pulley assem bly then remove the driven pulley assembly 3 30 MD1068 8 Using an impact screwdriver remove the three Phillips head cap screws holding the air intake plate Remove the air intake plate MD1092 9 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the posi tions of the different lengthed cap screws for installing purposes 10 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 D Gear Shift Position Switch E Centrifugal Clutch Assembly F Oil Pump Drive Gear G Oil Pump Driven Gear BNOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove cap screw holding gear shift posi tion switch onto the right side crankcase half KC324A 12 Remove the gear shift position switch Account for a spacer MD1016 15 Remove the cam chain gt 3 e sd A Pr sd has par fee ei 2 s dh v iD c TE CEU a Et KC326A 13 Remove the one way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes MD1335 16 Remove the oil pump drive gear cap screw MD1286
16. 0 06 mm 0 0024 in Valve Guide Valve Stem max 0 35 mm 0 014 in Deflection wobble method Valve Guide Inside Diameter 5 000 5 015 mm 0 1060 0 1974 in intake 4 975 4 090 mm 0 1959 0 1965 in exhaust 4 955 4 970 mm 0 1951 0 1957 in max 0 05 mm 0 002 in intake 2 03 mm 0 08 in exhaust 2 28 mm 0 09 in intake 2 25 mm 0 089 in exhaust 2 55 mm 0 100 in Seat Angle intake exhaust 45 Valve Face Radial Runout max 0 03 mm 0 001 in min 42 8 mm 1 68 in outer 18 6 21 4 Valve Stem Outside Diameter Stem Runout Haad Thickness Face Seat Width min Valve Spring Free Length Valve Spring Tension 32 5 mm 1 28 in 41 47 Ib CAMSHAFT AND CYLINDER HEAD Cam Lobe Height min intake exhaust 13 46 mm 0 530 in Camshaft Journal Oil Clearance 0 081 mm 0 003 in Camshatt Journal Holder right amp center 22 01 22 04 mm Inside Diameter 0 8665 0 8677 in 17 51 17 54 mm D 6893 0 6905 in right amp center 21 959 21 980 mm 0 8645 0 8654 in 17 466 17 480 mm 0 6276 0 6882 in 0 03 mm 0 0012 in 12 000 12 018 mm 0 472 0 473 in 11 975 11 887 mm 0 4715 0 4719 in max 0 05 mm 0 002 in max 0 05 mm 0 002 in Camshaft Journal Outside Diameter Rungut Rocker Arm Inside Diameter Rocker Arm Shaft Outside Diameter C
17. 1 Measure the piston pin outside diameter at each end and in the center If measurement exceeds specifications the piston pin must be replaced 1070 2 Insert inside dial indicator into the piston pin bore Take two measurements to ensure accuracy The diameter must not exceed specifications Ifthe diameter exceeds specifications the piston must be replaced 1069 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back in six places CC397D 2 Measure the corresponding piston diameter at a point 15 mm 0 6 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in step 1 The difference clearance must be within specifica tions Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration BNOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation 2 Compression Ring End Gap Oil Ring Expander End Gap ATV 1085B 2 Install the compression rings 1 and 2 so the let ter s on the top surface of each ring faces the dome of the piston Rotate the rings until the ring end gaps are on directly opposite sides of the pis ton according to the illustrati
18. A WARNING Always wear safety glasses when using compressed air 2 Inspect the tie rods for damaged threads or wear 3 Inspect the rods for cracks or unusual bends 4 Inspect all welded areas for cracks or deteriora 5 Inspect the steering post and steenng post brackets for cracks bends or wear 6 Inspect the bearing halves beanng caps and bear ing housings for cracks or wear 7 Inspect the handlebar tube for cracks wear or unusual bends 8 Inspect the handlebar grips for damage or wear INSTALLING l Install the steering post into the frame and secure the lower end in the beanng with a flat washer and cap screw Tighten to 40 ft lb KC184B 2 Apply grease to the inner and outer housings of the upper steering post support then with the housing cap in place secure with the cap screws Tighten to 20 ft lb Outer Housing Housing Cap Inner Housing 1 3 Using red Loctite 271 the threads install the tic rod ends into the lower steering post arm and tighten to 30 ft lb then install new cotter pins 4 Place the handlebar and caps in place on the steer ing post and with the handlebar correctly posi tioned tighten the cap screws to 20 ft lb 5 Install the steering post cover then install the front body panel fender see Front Body Panel Fender in this section Handlebar Grip REMOVING Loosen but do not remove the cap screws in th
19. Crankshaft right end bearing Relief Valve Cylinder Wall Piston Wall Piston Ring A 111 gt First Clutch Shoe 4 LUBRICATION SYSTEM OIL FILTER OIL PUMP Whenever internal engine components wear excessively or break and whenever oil is contaminated the oil pump should be replaced The oil pump is not a serviceable component TESTING OIL PUMP PRESSURE The engine must be warmed up to the specified temperature for this test 1 Connect the tachometer to the engine 2 Connect the oil pressure test kit to the oil filter drain plug Some oil seepage may occur when installing the oil pressure gauge Wipe up oil residue with a cloth 3 Start the engine and run at 3000 RPM The oil pressure gauge must read as specified Standard 1 1 1 5 kg cm 16 21 psi Oil Temperature 60 C 140 F If the oil pressure is lower than specified check for low oil level defective oil pump If the oil pressure is higher than specified check for too heavy engine oil weight clogged oil passage clogged oil filter or improper installation of the oil filter KYMCO MAXXER 4501 SECTION 5 ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical Specifications Battery Accessory Receptacle Connector Brakelight Switch 2 Thermostatic 2
20. 1 Press bearings into bores by outer ring to hard con tact with seat 2 Install the lock collar and tighten to 125 ft lb then on final assembling stake the lock collar edge approximately 1 5 mm into the lower oil channel CC891 3 Note the following shim selections shims are nominally 1 5 mm thick 738 268C A Cover Side add value A on the gear case hous ing to value B on the gear case cover then add 1 5 mm This will give you the proper shim thickness B Gear Case Side install a 1 3 1 4 mm shim and tighten the bolts to 25 31 ft lb Verify backlash to be within a range of 0 28 0 38 mm 0 011 0 015 in and end play to be within a range of 0 10 0 20 mm 0 004 0 008 1n If not within specification range reselect shim until backlash specification range can be verified 4 Prior to final assembling apply molybdenum dis ulfide grease to all oil seal lips 5 Prior to final assembling prelubricate journal on pinion assembly with SAE 80W 90 hypoid gear lubricant prior to pressing assembly into gear case housing Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar F 883 2 Place pinion assembly in a bearing puller then install the bearing using a press 884 3 Install the pinion gear assembly into housing Using the 48 mm Internal Hex Socket secure the pinion gear assembly with the existing lock collar Tighten to 1
21. Lubricate the input shaft splines with High Perfor mance 2 Molybdenum Disulphide Grease MNOTE Any time drive splines are separated clean all splines with parts cleaning solvent and dry with compressed air then lubricate with rec ommended grease Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside KX221 6 6 222 4 Install the input shaft into housing then install the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot clamp F 0007 CD112 5 Using a new O ring lubricated with grease install the front drive actuator and secure with the cap screws 6 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to 23 ft lb BNOTE new gear case housing is being installed tighten the cap screws to 28 ft lb CD103 Disassembling Pinion Gear BNOTE This procedure can be performed on a rear gear case 1 Remove the cap screws securing the pinion hous ing Account for the coupler fork and spring KX209 2 Remove the cap screws securing the gear case cover Account for and make note of the ID tag location for assembling purposes KX173 3 Using a plastic mallet tap lightly to remove the differentia
22. Using a multimeter test the battery voltage The meter must read 12 5 or more DC Volts for a fully charged battery NOTE At this point if the meter reads as speci fied the battery may be returned to service see step 10 It the meter reads less than specified voltage charge the battery using the following guidelines 2 3 When using an automatic battery charger alwavs follow the charger manufacturer s instructions B When using a constant current battery charger use the following Battery Charging Chart exceed the standard charging rate overheated battery could explode causing severe injury or death Always monitor charging times and icharge rates carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery Charging Chart Constant Current Charger Battery Voltage Charge Time Required state DC at 1 5 2 0 Amps 12 0 12 2 5 11 hours 11 0 11 9 2536 4996 BNOTE If the battery voltage is 11 5 DC Volts or less some chargers may cut off and fail to charge If this occurs connect a fully charged booster battery in parallel positive to positive and negative to negative for a short period of time with the charger connected After 10 15 minutes discon nect the booster battery leaving the charger con nected and the charger should continue to charge If the charger cuts off replace
23. master cylinder CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid 3 Remove the brake hose from the caliper then remove the caliper and plug the brake fluid port 4 Compress the caliper holder against the caliper and remove the outer brake pad then remove the inner brake pad PR237 PR238 5 Remove the caliper holder from the caliper and account for the brake caliper O ring Do not remove the piston from the caliper PR239B 6 Plug the fluid port with a suitable plug to prevent contamination during cleaning PR240A CLEANING AND INSPECTING 1 Clean all caliper components except the brake pads with parts cleaning solvent 2 Inspect the brake pads for damage and excessive wear ENOTE For measuring brake pads see Section 2 ASSEIVIBLING INSTALLING 1 Install the caliper onto the caliper holder making sure the caliper 15 correctly oriented on the holder PR239C 2 Compress the caliper holder toward the caliper and install the inner brake pad then install the outer pad 3 Place the brake caliper assembly into position and PR238 PR239 secure with the cap screws Tighten the caliper to 20 ft Ib 4 Place a new crush washer on each side of the brake hose fitting and install it on the caliper Tighten to 20 ft Ib 5 Fill the reservoir then bleed the brake system see Section 2 6 I
24. regulator then guide the pump and float lever through the opening in the gas tank Take care not to damage the float or float arm or replacement of the entire assembly will be necessary 5 Using duct tape or other suitable means cover the fuel pump opening INSPECTING 1 Inspect the fuel screen and blow clean with low pressure compressed air 2 Move the float lever and check for free 11 3 movement The float assembly should return to the lower position without force If not replace the fuel pump assembly C KYMCO MAXXER 450i KYMCO 11 EFI SYSTEM 4501 3 Test fuel level sensor by connecting multimeter A to the fuel level sensor leads B then select OHMS The multimeter should show gt 100 ohms at full fuel position C and lt 2 ohms at empty fuel position D INSTALLATION 1 Mark the new fuel pump with a reference mark in the same location as the removed pump then place the new gasket on the pump 2 Remove the material covering the fuel pump opening then carefully guide the fuel pump into position taking care not to damage the float or float lever 3 Rotate the fuel pump until the match marks align then install the mounting screws and tighten securely using a fixed pattern It is important to install fuel pump with correct orientation to ensure adequate float lever clearance 4 Connect the wires fuel hose and spring clamp
25. the shock absorber assembly must be replaced INSTALLING 1 Place bushings and sleeves where appropriate into shock eyelet then install shock with cap screws and nuts Tighten all nuts to 35 ft lb CAUTION Do not tighten the nuts beyond the 35 ft lb specifica tion or the shock eyelet or mount WILL be damaged 2 Remove the ATV from the support stand 7 2 Front A Arms REMOVING 1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels A WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Remove the cotter pin from the nut Discard the cotter pin 3 Remove the nut securing the hub 4 Remove the brake caliper Account for two cap screws KC187A 5 Remove the hub assembly 6 Remove the cap screws securing the ball joints to the knuckle CAUTION Support the knuckle when removing the cap screws or damage to the threads will occur KC313A 7 Tap the ball joints out of the knuckle then free the knuckle from the axle and swing out of the way KC297 8 Remove the lower shock absorber eyelet from the upper A arm 9 Remove the cap screws securing the A arms to the frame 10 Remove the circlip from the ball joint then remove the ball joint from the A arm CLEANING AND INSPECTING BNOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean a
26. 11 11 EFI SYSTEM MAXXER 450i INSPECTION V R 1 SENSOR POWER Outlook checking m Checking for ECU pin 1 48 if has damage BR L A4 12 SWITCH POWER Bl CAN HIGH Checking for ECU part number 15 as B2 3920A LGC7 E00 L R 2 B3 ENG CHECK R W B4 12V MEMORY Voltage inspection W L 2 CAN LOW Connect the meter probe to the c2 BA R W wire and the meter probe to the V G 1 C3 SENSOR GROUND 1 M3 G B wire to measure the voltage BR W 1 C4 ISC STEPB2 01 CRANK ANGLE MAP Edition No B W 02 TILT SENSOR GR L D3 15 STEPA1 6 0 ISC STEPA2 G W 1 EI CRANK ANGLE W R 2 GEAR D L E3 G B 2 E4 ISC STEPB1 Fl BRAKE SWITCH O B F2 MANIFOLD PRESSVRE BR W 2 F3 AIR INTAKE TEMP G L ENGINE COOLANT TEMP 61 LHCA ENGINE STOP SW V G 2 G2 SENSOR GROUND 2 Page 2 as picture dC KYMCO V B G3 G4 G L 2 H1 W B 2 H2 V H3 LG R H4 B R J2 L R 03 J4 B O 1 2 K2 W L 1 K4 R Y L1 L2 L3 W R 2 L4 B Y 1 M2 G B 1 M3 G B 1 M4 THROLLER POSITION K LINE GEAR B H SPEED SIGNAL GEAR C N FUEL RELAY DIFF LOCK INPUT GEAR A R OVERRIDE IGNITION RELAY FAN RELAY 4WD INPUT 12V SWITCHED POWER STARTER SOLENOID INJECTOR IGNITION COIL GROUND 1 GROUND 2 11 12 11 EFI SYSTEM CHECK ENGINE LAMP CELP When turning on the switch the
27. 14 Remove the left hand threaded nut holding the centrifugal clutch assembly CAUTION Care must be taken when removing the nut it has left hand threads MD1018 17 Remove oil pump drive gear Account for the pin 3 31 MD1017 18 Remove the snap ring holding the oil pump driven gear 1 7 she MD1019 BNOTE Always use a new snap ring when install ing the oil pump driven gear 19 Remove oil pump driven gear Account for the pin MD1020 gt AT THIS POINT To service clutch components see Servicing Right Side Components sub section H Oil Pump Oil Strainer BNOTE Steps 1 19 in the preceding sub sections must precede this procedure 20 Remove three Phillips head screws holding the oil pump and remove the oil pump Account for two alignment pins 3 32 MD1060 21 Remove the four cap screws securing the oil strainer cover then remove the Phillips head screws securing the oil strainer Account for the O ring BNOTE Note the directional arrow for installing purposes MD1207 gt AT THIS POINT To service center crankcase components only pro ceed to Separating Crankcase Halves Servicing Right Side Components MNOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoe for uneven wea
28. 2 Fan Motor aei Fuse Block Power Distribution Module Speed Sensor Ignition Switch Handlebar Control Switches Front Drive Selector Switch Front Drive Selector Actuator sse Gear Shift Position Switch enne SISIOE IDE uod E Sterlet Asay iere Lr edere 5 10 ae 17 ECU i Regulator Rectifier Neutral Start Front Drive Actuator Start i in Gear 2WD Relays Headlights Taillights Grakeights Running Lights Testing Electrical Conponatites m 5 2 5 3 o a8 5 4 eR UPC CR HN eos Du oo B9B odi 2 5 5 7 o B 5 9 9 9 2 10 e 8 11 0 11 4 11 Back Up iu casi nre d E Roc eee Troubleshooting eire rrr rre E b tnn 2 12 5 13 5 1 Electrical system This section has been organized into sub sections which show procedures for the complete servicing of the KYMCO electrical system NOTE Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions General Instructions The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON the excessive voltage may damage the ignition control module or ECU Always turn off the ignition switch before servicing A faulty ignition
29. 5 Disconnect the fan wiring from the main wiring harness then remove the radiator fan assembly and account for the grommets and collars 6 Remove the fan fan shroud assembly from the radiator gt CLEANING AND INSPECTING Whenever a part is worn excessively cracked or damaged way replacement is necessary 1 Flush the radiator with water to remove any contaminants 2 Inspect the radiator for leaks and damage 3 Inspect all hoses for cracks deterioration 4 Inspect all fasteners and grommets for damage or wear INSTALLING 1 Position the fan fan shroud assembly on the radiator then secure with existing hardware 2 Place on the radiator with grommets and collars into position on the frame then install the cap screws and nuts Tighten securely 3 Install the upper and lower coolant hoses then secure with hose clamps XS 7 2 190 11 wp 10 1 KYMCO 10 LIQUID COOLING SYSTEM MAXXER 450i 4 Install the front bumper and front fender panel 5 Fill the cooling system with the recommended amount of antifreeze Check for leakage 6 Connect the fan wiring to the main wiring harness Standard Radiator amp hoses 3000cc Coolant Reservoir 300cc HOSES THERMOSTAT REMOVING 1 Drain approximately one quart of coolant from the cooling system 2 Remove the two cap screws securing the thermostat housing
30. CHART Temp C Coolant 5 10 15 20 25 30 35 40 45 50 concentration 1 009 1 1096 11 018 1 107 1 017 1 016 1 015 1 014 0 013 1 011 1 009 1 007 1 005 1596 1 028 1 02 3 m c c c OO CS c OO m c 1 c ON m N c gt 92 m c c m O O 1 COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Distilled water 1200 1050 44 5 Use coolant of specified mixing rate 40 for mass production 10 3 10 LIQUID COOLING SYSTEM FAN REMOVING 1 Remove the radiator see Radiator in this section 2 Remove the fan assembly from the radiator INSTALLING 1 Position the fan assembly on the radiator then secure with existing hardware The fan wiring must be in the upper right position 2 Install the radiator WATER PUMP 1 Drain the coolant 2 Remove the four cap screws securing the water pump case Account for the O ring 3 Remove the impeller cap screw washer and gasket 4 Remove the mechanical seal using this procedure A Tap the tip of a small sheet metal screw into the inner metal edge of the seal B Grip the screw with a pair of vise grip pliers and pull the seal out Account for the pump drive seal CLEANING AND INSPECTING Whenever a part is worn excessively cracked or damaged way replaceme
31. Headlights in this section VOLTAGE Release the wire connector from the frame then release and separate the connectors BNOTE Perform this test on the wiring harness side of the connectors 2 Connect the black tester lead of the meter to the black wire then with the tester in the DC Volts position connect the red tester lead to the brown black wire 3 Turn the ignition switch to the LIGHTS position The meter must show battery voltage BNOTE If the meter does not show voltage inspect the LIGHTS fuse battery connections or troubleshoot the main wiring harness 5 12 Back Up Lights The back up lights connectors are located on the rear frame supports attached bv a metal tab They may be released from the frame by depressing the release with a small screwdriver VOLTAGE Release the wire connectors from the frame then disconnect the connectors ENOTE Perform this test on the main harness side of the connectors 2 Connect the black tester lead to the brown laven der wire then connect the red tester lead to the lavender red wire 3 Set the tester to DC VOLTS then tum the ignition switch to the ON position and move the shift lever to the reverse position The meter must show battery voltage BNOTE If the meter does not show battery volt age use the following procedure to troubleshoot 4 Remove the black tester lead from the brown lav ender wire and connect to a suitable ground
32. INSTALLINCG Install each wheel on its hub Tighten to 40 ENOTE Make sure each wheel is installed on its proper hub as noted in removing the rotation arrow if applicable must indicate forward direc tion of rotation 20 CHECKING INFLATING 1 Using pressure gauge measure the air pres sure each tire Adjust the air pressure as neces sary to meet the recommended inflation pressure 2 Inspect the tires for damage wear or punctures A WARNING Do not operate the ATV if tire damage exists ENOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally ENOTE Be sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe 1n and toe out and adjust as necessary see Section 8 4 Test drive dry level surface and note any pulling to the left or right during acceleration deceleration and braking ENOTE If pulling is noted measure the circumfer ence of the front and rear tires on the pulling side Compare the measurements with the tires on the opposite side If pulling Is noted during braking only check and adjust the brakes as necessary and recheck operation see Section 2 5 Increase the air pressure in the tires with small est circumference measurement until all tires are equal in circumference 6 Repeat steps 4 5 as necessary
33. Throttle position sensor 15 adjusted Throttle position sensor setting value problem Make sure if the connector of Throttle position sensor Is connected correctly Check if the Throttle position sensor is adjusted Throttle position sensor output range problem Throttle position sensor xs ite 1 Make sure if the connector of Throttle position Hipvemenr Spee sensor 15 connected correctly problem 2 Check if the Throttle position sensor 18 adjusted Battery voltage 1 Check if the batterv voltage is lower or higher malfunction 2 Check if the charge system 15 malfunction Intake air temperature Inlet air temperature sensor electric circuit circuit malfunction malfunction Idle air valve circuit Check 1f the connector of Idle air valve 1s loosen malfunction Check tf the resistance of valve is normal Check if the ISC steps range over 65steps Idle speed volume control range problem Check if the connector of Injector 15 loosen Check if the ECU is signal to Injector Check if the power source and resistance of Injector are malfunction Injector or electric 10 P0251 circuit problem 11 15 KYMCO 11 EFI SYSTEM MAXXER 450i Failure er a 4 Check if connector of ignition coil 1s loosen 11 P0350 One Check if the ECU 15 signaled to Ignition coil circuit malfunction Check if the power source and resistance is malfu
34. Troubleshooting Problem Engine will not start or is hard to start Compression too low Condition Remedy 1 Valve clearance out of adjustme nit 1 Adjust clearance 2 Valve quides worn 2 Heplace cylinder head 3 Valves mistimed 3 Adjust valve timing 4 Piston rings worn excessively 4 Heplace rings 5 Cylinder bore worn 5 Heplace rebore cylinder 5 Spark plug seating poorly 6 Tighten plug f Starter motor cranks too slowly does not turn Check replace starter motor Problem Engine will not start or is hard to start No spark Condition Remedy E Spark plug fouled 1 Clean replace plug 2 Spark plug wet 2 Clean dry plug 3 Magneto defective 3 Replace magneto 4 ECU detective 4 Heplace ECU unit 5 Ignition coil defective 5 Replace ignition coil m High tension lead open shorted Replace high tension lead Problem Engine will not start is hard to start No fuel reaching the carburetorfuel injector Condition Remedy 1 Gas tank vent hose obstructed Throttle body obstructed 3 Fuel hose obstructed vent hose Clean Throttle body Clean replace hose Clean replace inlet screen valve screen Replace fuel pump 4 Fuel screens obstructed 5 Fuel pump defective C hm Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 ECU unit defective 4 Throttle Body obstructed 5 Valve clearance
35. Using an impact screwdriver remove the three Phillips head screws holding the crankshaft bear ing retainer Remove the crankshaft bearing retainer 3 27 4 Install the cam stopper assembly 5 Install the gear shift shaft assembly and washer making sure to align the alignment marks MD1122 Installing Left Side 4 aa E MD1239 Components 6 Install starter idler gear No 2 and starter idler gear No 1 A Starter Idler Gears B Rotor Flywheel 1 Place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap screws securely MD1305 7 Place the key into its notch then slide the rotor flywheel with the ring gear in place over the crankshaft Tighten the nut to 107 ft Ib C Cover TM MD1122 2 Install the starter motor and tighten the two cap screws securely 8 Install two alignment pins and place the left side cover gasket into position Install the left side cover Noting the different lengthed 6 mm cap screws the position of the shifter bracket and the location of the long cap screw with the washer tighten cap screws in a crisscross pattern to 8 ft Ib BNOTE Steps 1 7 in the preceding sub section must precede this procedure 3 Install the shift detent cam making sure the spacer is properly positioned 9 Place the outer magneto cover into position on the left side cover then install and tighten the four cap
36. battery voltage 4 Remove the red tester lead from the white wire and connect to the lavender wire With the dimmer switch in the position the meter must show battery voltage ENOTE If battery voltage is not shown in any test inspect the fuses battery main wiring harness connectors or the left handlebar switch Taillights Brakelights VOLTAGE Taillights ENOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the LIGHTS position Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connect the red tester lead to the brown blue wire 3 The meter must show battery voltage If the meter does not show voltage inspect fuses wiring harness connectors and switches VOLTAGE Brakelights Perform this test on the main harness side of the connector Also the ignition switch should be in the ON position and the brake either foot pedal or hand lever must be applied Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connect the red tester lead to the green vellow WITC 3 The meter must show battery voltage ENOTE If the meter does not show voltage inspect bulb fuses wiring harness connectors and switches Hunning Lights The two running lights usc the same connectors as the headlights see
37. be above the illustrated L mark but not higher than the illustrated F mark CAUTION Do not over fill the engine with oil Always make sure that the oil level is above the mark but not higher than mark ATV 0100AA 14 Inspect the area around the drain plug and oil filter for leaks 15 Install the left side engine cover and the seat STRAINER 1 Remove the belly panel 2 Remove the cap screws securing the oil strainer cap then remove the cap Account for the O ring 3 Remove the two cap screws securing the strainer then remove the strainer 4 Place oil strainer into position beneath crankcase and secure with the cap screws Tighten securely 5 Place the strainer cap into position on the strainer making sure the O ring is properly installed then secure with the cap screws Tighten securely CC091D 6 Install the belly panel Front Differential Rear Drive Lubricant When changing the lubricant use approved SAE 80W 90 hypoid gear lube To check lubricant remove the rear drive filler plug the lubricant level should be 1 in below the threads of the plug If low add SAE approved 80W 90 hypoid gear lubricant as necessary To change the lubricant use the following procedure 1 Place the ATV on level ground 2 Remove each oil fill plug 0077 3 Drain the oil into drain by removing drain plug from each Front Differentia
38. be in the unlocked position for this procedure 5 8 VOLTAGE Select the 2WD position on the front drive selector switch then disconnect the connector on the actu ator wiring harness 2 With the ignition switch in the OFF position con nect the black tester lead to the black wire in the supplv harness then connect the red tester lead to the brown lavender wire in the supply hamess 3 Turn the ignition switch to the ON position The meter must show 12 DC volts 4 Connect the red tester lead to the white blue wire in the supply hamess The meter must show 12 DC volts 5 Select the 4WD position on the front drive selector switch then connect the red tester lead to the white blue wire in the supply harness The meter must show 0 DC volts ENOTE 4WD icon on the LCD should illumi nate 6 Connect the red tester lead to the brown lavender wire in the supply harness The meter must show 12 DC volts BNOTE If the voltage readings are as specified and the actuator does not function correctly replace the actuator see Section 6 Gear Shift Position Switch The gear shift position switch connector is located on the right side of the engine over the V belt housing Gear Shift Position Switch Connector iqger Col Connector To troubleshoot the switch use the following proce dure 1 Disconnect the gear shift position switch from the main harness at the connector then connect the black teste
39. bearing Replace tighten tie rod ends Replace tires Replace bushings Tighten bolts nuts Tires inflated unequally Front wheel alignment incorrect Wheel hub bearings worn broken Frame distorted Shock absorber defective Problem Tire wear rapid or uneven Adjust pressure Adjust alignment Replace bearings Repair replace frame Replace shock absorber 1 Wheel hub bearings worn loose 2 Front wheel alignment incorrect 3 Tire inflation pressure incorrect Problem Steering noise 1 Replace bearings 2 Adjust alignment 3 Adjust pressure 1 Cap screws nuts loose 2 Wheel hub bearings broken damaged 3 Lubrication inadequate 1 Tighten cap screws nuts 2 Replace bearings 3 Lubricate appropriate components 8 11 SECTION 9 CONTROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle iui 9 2 6 SR RON Lr 9 3 Hand Brake Lever Miaster Cylinder Assembly BNOTE The master cylinder is a non serviceable component it must be replaced as an assembly REIVIOVING 1 Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a container Remove the reservoir cover then open the bleeder valve Allow the brake fluid to drain completely BNOTE Compressing the brake lever several times will quicken the draining process
40. footwells and front body panel see Section 8 then disconnect the negative battery cable trom the battery 2 Remove the heat shield then remove the gas tank see Section 4 3 Disconnect the speedometer sensor then remove E clip securing the shift rod to the shift arm and disconnect shift rod Account for bushing and flat washer 3 7 5 Remove cap screws securing the exhaust pipe to the evlinder head then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe Account for grafoil seal and seal ring 1 Ae O lt day KC170 EL 1 d 2 l 2 qe KC255 4 Remove the inlet air duct air filter housing and air silencer duct then remove the carburetor and set aside leaving the throttle cable attached 6 Disconnect the gear shift position switch starter cable and engine ground cable then disconnect the trigger coil and stator coil connectors Gear Shift Position Gail Confiector switch Connector 3 8 Top Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment AT THIS POINT To service any one specific component only limited disassembly of components may be necessary Note 8 Remove the front and rear V belt cooling boots the AT TH
41. i 1 j t e nu Red WNOTE The ignition switch must be in the ON position VOLTAGE Harness Connector to Fan Motor Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the orange wire then connect the black tester lead to ground 3 The meter must show battery voltage ENOTE If the meter shows no battery voltage troubleshoot the battery fuse motor or the main wiring harness ENOTE the meter shows battery voltage the main wiring harness is good The connector should be checked for resistance RESISTANCE Fan Motor Connector Always disconnect the batlery when performing resistance tests to avold damaging the multimeter Set the meter selector to the OHMS position Connect the red tester lead to blue wire then connect the black tester lead to the black wire 3 The meter must show less than ohm 5 4 should be taken to keep clear of the fan blades ENOTE the meter shows more than 1 ohm of resistance troubleshoot replace the switch component the connector or the switch wiring harness ENOTE To determine if the fan motor is good connect the blue wire from the fan connector to the positive side of a 12 volt DC power supply then connect the black wire from the fan connector to the negative side The fan should operate Fuse Block Power Distribution Module The fuses are located in a po
42. lamp will be lighted for 2 seconds then off Let user to know the lamp is available and connect to ECU e But after then or during riding if the CELP start to blink or keep lighting it means something wrong with this vehicle you better do the further check to find out the failure code to know which part get trouble e are 3 kinds of priority grade let user to know what kind of trouble was happened Priority grade 1 CELP blinks continuously This is the most emergent situation like engine over heat User had better to slow down the riding and go to dealer for checking Priority grade 2 CELP lights all the time It means components gets trouble or circuit something wrong Do the further check to find out the failure code to know which part get trouble Priority grade 3 CELP just blinks once suddenly and then disappear It sometimes just warning like the RPM was too high in a short term 11 13 PRIORITY C KYMCO MAXXER 450i LAMP ACTION KYMCO 11 EFI SYSTEM MAXXER 450i How To Show Failure Code You can read the failure code by as below Turn switch on The CELP will be lighted for 2 seconds then off The CELP start to blink to show the failure codes The number of blinks from 1 to 22 If vehicle got more than one failure code the CELP will be shown from lower number failure code and then show the other higher number one after four seconds the failure codes wou
43. meter selector to the DC Voltage position 2 Connect the red tester lead to the starter terminal then connect the black tester lead to ground 3 With the starter button depressed the meter must show approximately 12 0 DC volts and the starter motor should operate ENOTE If the meter showed correct voltage but the starter did not operate or operated slowly the starter motor is defective 5 10 BNOTE If the meter showed no voltage inspect ground connections starter motor lead battery voltage at the battery starter relay or the neutral start relay REMOVING 1 Disconnect the battery Always disconnect the negative battery cable from the battery first then disconnect the positive cable 2 Remove the nut securing the positive cable to the starter then remove the cable from the starter 3 Remove the two cap screws securing the starter to the crankcase then remove the starter Account for an O ring INSTALLING Apply a small amount of grease to the O ring seal on the starter then install the starter into the crank case Secure with two cap screws making sure the engine ground is secured by the rear cap screws Tighten to 8 ft lb 2 Secure the positive cable to the starter with the nut Tighten to 8 ft lb 3 Connect the battery The regulator rectitter 15 located under the front rack and front fenders above the oil cooler TESTING 1 Start engin
44. missing Driveshaft Coupling The following drive svstem components should be inspected periodically to ensure proper operation Spline lateral movement slop B Coupling cracked damaged or worn 2 12 Suspension Shock Absorbers Bushings The following suspension svstem components should be inspected periodically to ensure proper operation Shock absorber rods not bent pitted or damaged B Rubber damper not cracked broken or missing Shock absorber body not damaged punctured or leaking D Shock absorber evelets not broken bent or cracked E Shock absorber evelet bushings not worn dete norated cracked or missing Shock absorber spring not broken or sagging Nuts Bolts Cap Screws Tighten all nuts bolts and cap screws Make sure nv ets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to specifica Hons Lights Rotate the ignition switch to the lights position the headlights and taillights should illuminate Test the brakelights by compressing the brake lever The brake lights should illuminate HEADLIGHTS BNOTE The bulb portion of a headlight is fragile HANDLE WITH CARE When replacing a headlight bulb do not touch the glass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing Skin oil residue on the bulb will shorten the life of
45. on the assembled cover assembly making sure to seat the O ring down around the circumference of the bearing flange 11 Making sure the O ring 15 properly positioned on the gear case cover assembly install the cover with existing hardware Account for the ID tag Tighten the cap screws to 23 ft lb MNOTE Grease can be applied to the O ring for ease of assembling BNOTE If a new gear case housing is being installed tighten the cap screws to 25 31 ft Ib Hemoving Needle Bearing BNOTE Removing the needle bearing is rarely necessary Avoid removing the needle bearing unless the bearing is clearly damaged BNOTE This procedure can be performed on a rear gear case 1 Place a 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft needle bearing housing CC885 2 Using a propane torch heat the area surrounding the needle bearing to soften the Loctite 6 11 886 3 Using flat nosed punch drive the bearing out of the housing 889 3 Install pinion shaft and secure with existing 48 mm lock collar Tighten to 125 ft lb CC887 Installing Needle Bearing 1 Apply green Loctite 609 to the outside of a new bearing then place the new bearing into the hous ing 888 2 Using a suitable driver install needle bearing into the gear case housing making sure the bearing is seated
46. pads and brake discs is adjusted automatically as the brake pads wear The only maintenance that 15 required 15 replacement of the b pads when they show execssive wear Check the thickness of each of the brake pads as follows 1 Remove a front wheel 2 Measure the thickness of each brake pad 3 If thickness of either brake pad is less than 1 0 mm 0 039 in the brake pads must be replaced PR377B E Install the wheel Tighten to 40 ft lb 5 Burnish the brake pads see Burnishing Brake Pads in this section PR376B BNOTE The brake pads should be replaced Burnishing Brake Pads set __ 4 replace brake pads use the following proce Brake pads both main and auxiliary must be bur dure nished to achieve full braking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure A Remove the wheel B Remove the cap screws securing the caliper holder to the knuckle then remove the pads WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss Brake loss can result in severe injury 1 Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat procedure on each brake system five times
47. screws securely MD1086 3 28 Right Side Components gt AT THIS POINT To service center crankcase components only pro ceed to Removing Right Side Components BNOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment gt THIS POINT To service any one specific component only limited disassembly of components may be necessary Note the AT THIS POINT information in each sub section BNOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A V Belt Cover B Driven Pulley Clutch Cover 1 If the engine 15 still in frame remove the screw securing the brake pedal to the pivot shaft Account for a flat washer KC149A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal out ward and remove the V belt cover Account for two alignment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crank shaft MD1033 4 Remove the movable drive face spacer Account for the movable drive face rollers and outer drive face cover MD1035 3 29 MD1034 _ MD1036
48. section CLEANING AND INSPECTING BNOTE Always clean and inspect the drive axle components to determine if any service or replace ment is necessary 1 Using a clean towel wipe away any oil or grease from the axle components 0019 2 Inspect boots for any tears cracks deteriora tion If a boot is damaged in any way it must be replaced with a boot kit 3 Inspect the gear case seals for nicks or damage DISASSEIVIBLING AXLES 1 Using side cutters or suitable substitute remove the large clamp from the boot CD020 2 Wipe away excess grease to access the retaining ring Using an awl remove the circlip CD021 3 Using a snap ring pliers remove the snap ring securing the bearing ring to the shaft Note the direction of the bearing for assembling purposes CD023 4 Note the difference inside each bearing ring end for assembling purposes then remove the bearing ring 6 15 MNOTE The recess of bearing must toward the housing CD022 5 Inspect the splines of the shaft the bearing ring and the housing for damage BNOTE If any damage is apparent to the splines the bearing ring and or the housing the drive axle must be replaced as an assembly 6 Using a side cutters or suitable substitute remove the small clamp from the shaft CD752 BNOTE At this point if the outside boot is dam aged continue with step 7 7 Using a si
49. sensor as a set ISC 11 7 KYMCO 11 EFI SYSTEM MAXXER 450i Screw T MAP sensor DISASSEMBLY Remove the screws and then remove the ISC Remove the screw Remove the T MAP sensor Remove the screw and then remove the TPS ASSEMBLY The throttle position sensor TPS and idle air bypass valve ISC have to reset when the throttle body T MAP sensor TPS ISC Screws or ECU has been reinstalled Screw Apply oil onto a new O ring When install the TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely T MAP sensor 11 8 KYMCO 11 EFI SYSTEM MAXXER 450i Apply oil onto a new O ring When install the T MAP sensor onto the throttle body being careful not to damage the O ring Always replace an O ring with a new one Install the set plate and tighten the screw securely Apply oil onto a new O ring When install the ISC and T MAP sensor onto the throttle body being careful not to damage the O ring DIAGNOSTIC TOOL CONNECTOR INSPECTION Remove front cover Make sure of moving shift lever into Sheath nonu Connector position ANLE Zr Remove diagnostic tool connector protect sheath Turn the ignition switch to ON Measure the voltage between the following terminals of the diagnostic tool connector G B Battery voltage Batt
50. snug MD1261 28 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 27 to 8 ft Ib 29 Adjust valve tappet clearance see Section 2 30 Place the two tappet covers with O rings into posi tion then install and tighten cap screws securely 31 Install the spark plug and tighten to 8 ft lb then install the timing inspection plug Left Side Components ENOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment THIS POINT To service any one specific component only limited of components may be necessary Note the AT THIS POINT information in each sub section ENOTE The engine transmission does not have to be removed from the frame for this procedure 3 25 Removing Left Side Components A Cover Stator Assembly 1 Remove the cap screws securing the outer mag neto cover and remove the cover 2 Remove the left side cover to crankcase mounting cap screws noting the location of the 8 mm cap screw with the washer near the middle of the left side cover Keep the different lengthed 6 mm cap screws in order for installing purposes MD1186 3 Using Side Case Puller and the 6 mm adapter remove the left side cover w stator assembly Account for the two alignment pins and the
51. switch component or connector RESISTANCE Switch Always disconnect the battery when performing resistance tests to avold damaging the multimeter 1 Remove the spade connectors from the brake switch 2 Set the meter selector to the OHMS position 3 Connect the red tester lead to one switch terminal then connect the black tester lead to the other switch terminal 4 When the brake pedal 1s depressed the meter must show less than ohm ENOTE the meter shows more than 1 ohm of resistance replace the switch THERMOSTATIC SWITCH Connect the meter leads selector in the OHMS position to the switch contacts 2 Suspend the switch and a thermometer in a con tainer of cooking oil then heat the oil BNOTE Neither the switch nor the thermometer should be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspend switch and thermometer A WARNING Wear insulated gloves and safety glasses Heated oll can cause severe burns Thermostatic Sch a Seer Lees 2 ter 733 554 3 When the coolant temperature is lower than 85 the thermostatic switch OFF When coolant temperature is over 90 the thermostatic switch ON 5 3 The connector is the black wire and the other is red located behind the fan assembly F I A k 71 Black
52. system is often related to poor connections Check those connections before proceeding Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present Specifications Spark Plug Type Spark Plug Gap 10 7 0 8 mm 0 028 0 032 in iSpark Plug Cap 4000 6000 ohms Ignition Coil primary Less than 1 ohm esistance terminal to terminal secondary 2900 3400 ohms high tension plug cap removed to ground ignition Coil primary CDI 250 375 DC volts Voltage black yellow to black Stator trigger 90 110 ohms green white to Resistance charging blue yellow Less than 1 ohm yellow to yellow Peak Voltage trigger 7 8 9 3 volts green to blue Generator no load 60 AC volts 9 3000 RPM Output black to black Generator Output approx 220W 5000 RPM Battery For battery related information see Section 2 5 2 Testing Electrical Components of the electrical tests should be made using the Fluke Model 73 Multimeter and when testing peak voltage the Peak Voltage Reading Adapter must be used If any other type of meter is used readings may vary due to internal circuitry When troubleshooting specific component always verify first that the fuse s are good that the bulb s are good that the connec tions are clean and tight that the battery is fully charged and
53. that all appropnate switches are acti vated NOTE For absolute accuracy all tests should be made at room temperature of 68 Accessory NOTE This test procedure is for either tacle or the connector VOLTAGE 1 Turn the ignition switch to the ON position then set the meter selector to the DC Voltage position 2 Connect the red tester lead to the red wire then connect the black tester lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse receptacle connec tor or the main wiring harness Brakelight Switch Pressure The brakelight switch ts located on the top of the aux brake master cylinder and is pressure activated bv the hand brake or the auxiliary brake pedal This switch also activates start in gear SIG relay in the power distribution module PDM ENOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Side 1 Set the meter selector to the DC Voltage position 2 Connect the red tester to the brown black wire then connect the black tester lead to ground 3 The meter must show battery voltage BNOTE the meter shows no battery voltage troubleshoot the battery fuse switch or the main wiring harness BNOTE If the meter shows battery voltage the main wiring harness is good proceed to test the
54. the battery After charging the battery for the specified time remove the battery charger and allow the battery to sit for 1 2 hours 9 Connect the multimeter and test the battery volt The meter should read 12 5 or more DC Volts If the voltage is as specified batterv 18 readv for service ENOTE If voltage in step 9 is below specifications charge the battery an additional 1 5 hours then retest 10 Place the battery in the compartment then coat the battery posts and cable ends with a light coat of multi purpose grease CAUTION Before installing the battery make sure the ignition switch is in the OFF position 2 4 11 Connect the battery cables positive cable first then install the battery hold down CAUTION Connecting cables reverse positive to negative ms negative to positive can cause serious damage to the electrical system Fuses The fuses are located in a power distribution module in front of the steering post In addition there is a 30 amp fuse on the starter relay under the seat next to the bat tery If there is any of electrical svstem failure always check the fuses first ENOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift out ET E 2982799882055 265 26 52 r Bree ele
55. the battery or damage may occur ae NESES SAY to the ignition system 9 Make sure the steering moves freely and does not bind CAUTION Connect the positive battery cable first then the 10 Check the spark plug Clean or replace as negative necessary 1 6 SECTION 2 PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Periodic Maintenance eee mtd Lubricali n e TR pipe Filter ids Valve T appet Clearance Feeler Gauge Procedure 2 6 Valve Tappet Clearance Valve Adjuster Procedure 2 Testing Engine 2 opark Plug T ane Muffler Spark Arrester Adjusting Throttle Cable UR Engine Transmission Cil Filter Sirainer erennere 259 Front Differential Rear Drive Lubricant 2 11 Tires ae Steering Components Driveshaft Coupling Suspension Shock Absorbers Bushings m Nuts Bolts Cap Screws TT CES te Lights shift Lever Frame Welds Racks ETE kieran 7 Electrical COPTIC BOTS 2 2 2 15 Hydraulic Brake Systems 2 15 Burnisning Brake 5
56. the two front cap screws securing the front rack to the bumper support tubes then remove two cap screws and nuts securing the bumper support tubes to the frame 2 Remove the through bolt and lock nut securing the bumper to the frame then remove the bumper CLEANING AND INSPECTING BNOTE Whenever part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all bumper components with parts cleaning solvent 2 Inspect all welds for cracking or bending INSTALLING 1 Place the front bumper assembly into position and install the through bolt Start the lock nut and fin ger tighten only 2 Install the existing fasteners in the upper support tubes to frame and the front rack cap screws Tighten the lock nut from step 1 to 35 ft Ib then tighten the cap screws securely Front Body Panel Fender REMOVING 1 Remove the seat and both side panels 2 Remove the front rack then disconnect the head licht running light connectors located on the frame 4 Remove the shift knob then remove the shift mechanism splash shield 5 Remove the screws securing the front body to the front body supports then remove the left side and right side footwell fasteners 3 Remove the cap screws then remove rem stallable rivets B and remove the tank cover Remove the panel then disconnect the LCD gauge connector ignition switch and acces sory outlet
57. to the cylinder head Account for an O ring and a thermostat INSPECTING Whenever a part is worn excessively cracked or damaged in way replacement is necessary 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the thermostat for proper operation A Suspend the thermostat in a container filled with water B Heat the water and monitor the temperature with a thermometer C The thermostat should start to open at 80 84 C 176 183 F fully open at 95 C 203 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear All coolant hoses and clamps should be replaced every four years or 4000 miles 10 2 GQ KYMCO 10 LIQUID COOLING SYSTEM MAXXER 450i INSTALLING 1 Place the thermostat and O ring into the thermostat housing then secure the thermostat housing to the cylinder head with the two cap screws 2 Install the crossover coolant hose onto the water pump and engine water inlet Secure with the two hose clamps 3 Slide the upper hose onto the thermostat housing and radiator Secure with the two hose clamps 4 Install the lower coolant hose onto the water pump housing and radiator Secure with the two hose clamps 5 Fill the cooling system with the recommended amount of antifreeze Check for leakage COOLANT GRAVITY
58. to the throttle control lever AF677D 4 Remove the actuator arm and account for a bush ing Note the position of the return spring for installing purposes AFG amp D INSTALLING I Place retum spring into the throttle control then place the bushing and actuator arm into tion Secure with the cap screw lock washer and washer v AF679D 2 Using a of needle nose pliers place the spring into position on the actuator arm AFGBOD 3 Place the two halves of the throttle control onto the handlebars and secure with the two machine Screws ADJUSTING To adjust throttle cable free play see Section 2 LCD Gauge REPLACING To replace the LCD gauge use the following proce dure 1 Remove the electric panel and disconnect the LCD gauge connector then remove three mounting screws two in front and one in back of gauge and remove the gauge 2 Install the new gauge and secure with the mount ing screws then connect the gauge to the main harness and install the electric panel 9 4 GQ KYMCO 10 LIQUID COOLING SYSTEM MAXXER 450i The coolant level should be checked periodically RADIATOR 1 Drain the coolant at the engine 2 Remove the front bumper and front fender panel see Section 8 Remove the upper and lower coolant hoses 4 Remove the cap screws and nuts securing the radiator to the frame
59. toward the left side crankcase half when separating the halves 01313 Disassembling Crankcase Half 1 Remove the secondary and primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss next to the pinion gear MD1317 ENOTE Note the location of the bearing alignment pin on the secondary output shaft 2 Remove the reverse idler gear spacer and sleeve Account for the washer MD1325 3 Remove the driveshaft 3 37 MD1326 4 Remove the shift fork shaft and the outer shift fork ad MD1327 5 Remove snap ring and gear from the output side of the gear cluster Remove the gear cluster and the inner shift fork together Account for snap ring gear and washer MD1328 6 Noting the position of the slot on the end remove the shift cam assembly Account for inner and outer washers 3 38 KC325 7 Remove the counterbalance gear Account for the key 8 Remove the counterbalance shaft 1024 9 Using Crankcase Separator Crankshaft Remover remove the crankshaft MD1330 CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary If the shaft is removed the shaft nut must be replaced with a new one and the shaft must be re shimmed 10 Remove the secondary drive gear secondary driven gear retaining nut From inside the crank case using a rubbe
60. 0 Support the axle to not allow it to drop or hang The axle must be supported If the axle is allowed to drop or hang damage to the inner CV joint may occur KC289 12 Remove the cap screws from the drive coupler flange then remove the upper and lower mounting cap screws and remove the differential from the frame KC291A Disassembling Input Shaft BNOTE This procedure be performed on rear gear case however some components may vary from model to model The technician should use discretion and sound judgment 1 Remove the cap screws securing the front drive actuator and remove the actuator then remove the cap screws securing the pinion housing CD102 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assembling purposes CD103 CD106 3 Using a side cutter or suitable substitute remove the boot clamps then remove the boots and splined drive from the input shaft 4 Remove the input shaft from the pinion housing CD107 5 Using a seal removal tool remove the input shaft seal Account for a spacer 6 Remove the snap ring securing the input shaft AF982 bearing then place the pinion housing in a press and remove the bearing 6 5 AF983 AF993 994 2 Install input shaft seal making sure it 1s flush with the edge of the housing 3
61. 11 22 KYMCO 11 FUELSYSTEM MXU 450i B Press the Down button and then turn to first page C Press the Enter button to check the DTC failure code 11 23 KYMCO 11 FUELSYSTEM MXU 450i D Press the Enter button Diagnostic Tool F Display what s DTC number on this DTC List Press the Enter button and then turn to the previous page 11 24 GQ KYMCO FUEL SYSTEM Press the UP button Y Diagnostic To I Press UP button 11 25 GQ KYMCO 11 FUEL SYSTEM ane J Press the Enter button and then turn to the first page inspec Ana 11 26 KYMCO FUEL SYSTEM 3 DTC CLEAR PROCEDURE A Check the DTC B Press the Enter button Choose Load DTC Press the Down button T 4 35 iiid Too 11 27 GQ KYMCO FUEL SYSTEM an D Press the Enter button and the indicator 1s lighting Version inspe Ana luze Adjust 11 28 GQ KYMCO FUEL SYSTEM an 4 DATA ANALYSIS PROCEDURE A Press the Down twice MET Diagnostic Tool Y 5 scd SN E EH E LGC7 5 DIC Ins DATA Ana tik Tf c B Choose Data Analyze Press the Enter button to ent
62. 17 TABLE OF CONTENTS Section General Information Specifications Periodic Maintenance Engine Transmission Lubrication Electrical System Drive System Suspension Steering F rame Controls Indicators Cooling System EFI System FOREWORD This KYMCO Service Manual contains service maintenance and troubleshooting information for the 2010 KYMCO Maxxer 450i The complete manual is designed to aid service personnel in service oriented applications This manual is divided into sections Each section covers a specific ATV component or system and in addition to the standard service procedures includes disassembling inspecting and assembling instructions When using this manual as a guide the technician should use discretion as to how much disassembly is needed to correct any given condition The service technician should become familiar with the operation and construction of each component or system KYMCO This manual will assist the service technician in becoming more aware of and efficient with servicing procedures Such efficiency not only helps build consumer confidence but also saves time and labor All KYMCO ATV publications and decals display the words Warning Caution Note and At This Point to abe gp important information The symbol 00508 identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death The symbol i
63. 25 ft lb ENOTE On a front differential the lock collar has right hand threads On a rear gear case the lock collar has left hand threads CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the shift fork shaft w spring into the gear housing making sure the shaft O ring 15 positioned to the inside 6 10 Yi CC892 6 Install the shift fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket then install the gasket CC893 7 Place the input shaft housing assembly onto the gear housing then secure with the existing cap screws Tighten to 23 ft lb If a new gear housing is being installed tighten the cap screws to 28 ft lb CD103 b CD110 8 Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear Install the ring gear in the housing then install the outside shim with the chamfer side of the shim toward the ring gear BNOTE The spider and ring gear assembly must be replaced as a complete unit CC897 9 Install left bearing flange bearing assembly and seat it firmly into the cover CF267A 10 Apply a liberal amount of grease to the O ring then install it
64. 8 7 7 Remove front body panel fender panel CLEANING AND INSPECTING BNOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary Clean all fender components with warm soap and water 2 Inspect fenders for cracks and or loose nvets 3 Inspect for any missing decals INSTALLING Making sure the shift spring is in place and shift lever is properly positioned place the front body pancl fender panel onto the ATV With the front rack in place loosely install the front rack hardware Connect the electrical connectors under the elec panel then connect the light connectors and attach onto the framc 3 Install the screws secunng the front body to the front body supports then install the left side and right side footwell fasteners Do not tighten at this time 4 Place the gas tank cover into position and secure with the existing hardware then install the two cap screws securing the rear of the pancl to the frame Tighten all cap screws and fasteners securely at this time uh Install the electric panel side panels and scat Exhaust System REIVIOVING IVIUFFLER Remove two exhaust springs at muf fler exhaust pipe juncture E KCT70 2 Slide the muffler rearward to clear the mounting lugs and remove the muffler Account for a grafoil seal INSPECTING MUFFLER BNOTE Whenever part is worn excessive
65. AF637D 2 Place an absorbent towel around the connection to absorb brake fluid Remove the banjo fitting bolt from the master cylinder Account for two crush washers and a banjo fitting bolt N CAUTION Brake fluid is highly corrosive Do not spill brake fluid on any surface of the ATV 3 Remove the clamp screws securing the brake housing to the handlebar then remove the assem bly from the handlebar INSPECTING BNOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pin securing the brake lever for wear 2 Inspect the brake lever for elongation of the pivot hole 3 Inspect the reservoir for cracks and leakage 9 2 4 Inspect the banjo fitting and bolt for cracks and deterioration and the condition of the fittings threaded and compression INSTALLING 1 Position the brake housing on the handlebar Secure with clamp screws then tighten securely 2 Using two new crush washers connect the banjo fitting to the master cylinder then secure with the banjo fitting bolt Tighten to 20 ft Ib 3 Bleed the brake system see Section 2 Throttle Control REMOVING 1 Remove the two machine screws securing the throttle control to the handlebar 2 Slide the grommet out of the lower half of the throttle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm
66. Battery After being in service batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life The following procedure is recommended for cleaning and maintaining lead acid batteries Always read and follow instructions provided with battery chargers and battery products WARNING Anytime service is performed on a battery the fol lowing must be observed keep sparks open flame cigarettes or any other flame away Always wear safety glasses Protect skin and clothing when handing a battery When servicing battery in enclosed space keep the area well ventilated 1 Remove the battery hold down then disconnect the battery cables negative cable first 2 Remove the battery from the battery compartment then thoroughly wash the battery and battery com partment with soap and water tad NOTE If battery posts cable ends or the battery case has a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water 4 Using a wire brush clean the battery posts and cable ends removing all corrosive buildup Replace damaged cables or cable ends WARNING Battery acidis harmful if it contacts eyes skin or clothing Care must be taken whenever handling a battery CAUTION Never use electrolyte sulfuric acid to top off the battery Use only distilled water or severe battery damage may occur 5
67. Connections The electrical connections should be checked penodi callv for proper function In case of an electrical fail ure check fuses connections for tightness corrosion damage and or bulbs If an electrical component needs to be tested for proper function see Section 5 Hydraulic Brake Systems CHECKING BLEEDING The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydraulic brake svstem use the following procedure With the master cylinder in a level position check the fluid level in the reservoir On the hand brake if the level in the reservoir i adequate the sight glass will appear dark If the level is low the sight glass will appear clear On the auxiliary brake the level must be between the MIN and M X lines on the reservoir 2 15 Brake Fluid Sight Wi 2 Compress the brake lever pedal several times to check for a firm brake If the brake 15 not firm the svstem must be bled 3 To bleed the brake system use the following pro cedure Remove the cover and fill the reservoir with DOT 4 Brake Fluid Install and secure the cover then slowly com press the brake lever several times Remove the protective cap mstall one end of a clear hose onto one FRONT bleeder screw and direct the other end into a container then while holding slight pressure on the brake lever open the bleeder screw and watch for air bubbles Close the bleeder
68. Do not push the bearing too far into the housing 6 12 CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Hemoving Installing Axle Seal BNOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool J Cccoo0 3 Using a press install the new bearing into the housing EM drea apr tum co901 NOTE Prior to installing the seal apply High Per formance 2 Molybdenum Disulphide Grease to the seal outside diameter 4 Using an appropriate scal installation tool evenly press the scal into the cover bore until seated Make sure the tool is free of nicks or sharp edges or the seal will be damaged 5 Repeat steps 1 4 for opposite side INSTALLING DIFFERENTIAL Align the input flange with the front output flange then place the differential into position on the frame and install the cap screws and nuts Tighten to 38 ft lb KC281A 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb Pua SS 3 Install the front axles sce Drive Axles in this sec thon 6 13 AF610D 4 Install the brake calipers and secure with the patch lock cap screws tightened to 20 ft lb AF894D 5 Install wheels an
69. IS POINT information in each sub section from the V belt housing NOTE The engine transmission does not have to 9 Remove the cap screws from the front and rear removed from the frame for this procedure output flanges then remove the front and rear engine mounting through bolts Removing Top Side Components Valve Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appropriate wrench rotate the crankshaft to top dead center of the compression stroke B NOTE KYMCO recommends the use of new gaskets lock nuts and seals and lubricating all internal components when servicing the engine transmission 1 Remove the cap screws securing the two tappet covers Remove the two tappet covers Account for the O rings KC243 10 Lift the rear of the engine transmission and swing to theright then tilt the assembly sufficiently to remove through the right side frame opening ENOTE Keep the mounting hardware with the cov 4 Remove the cam chain tensioner pivot cap screw and washer ers for assembly purposes 2 Remove the valve cover cap screws the rub ber washers on the four top side cap screws remove the valve cover Note the onentation of the cylinder head plug and remove it Note the loca tion of the two alignment pins 5 Bend the washer tabs and remove the two cap screws securing the sprocket to t
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71. NOSTIC TOOL e This tool is developed by KYMCO and for KYMCO vehicle only e Please refer to the specification when serving this vehicle This tool is without battery inside The power is provided from vehicle e This software can be updated with computer for new model through the USB cable The power required of tool 1s connected with 12V battery For connection please connect this tool with the connector of ECU It s available when turning on the ignition switch e The function includes ECU version model name data analysis ECU version includes model name ECU number identifications number and software version Failure codes DTC reading DTC clearing and troubleshooting Data analysis For ECU s software inspection Adjust The adjust function setting is not allowed ECU Version ECU Jersion Model No DTC Inspect DTC Inspect DATA Analyze m DATA Ana luze Adjust Adjust UP Button Down Button Power indicator Enter or Exit DTC indicator Failure codes 11 21 KYMCO 11 FUEL SYSTEM MXU 450i 2 DTC INSPECTION PROCEDURE Show four functions on the screen when switching power n Diagnostic Tool LGC E LGC7 is for MXU450i 1 A ECU version Including of model name ECU number identifications number and software version Press the Enter button Press the Enter button Diagnostic Tool is for MXU4501
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73. Top Side Components sub section Cylinder Piston ENOTE Steps 1 11 the preceding sub section must precede this procedure 12 Remove the two nuts securing the nght side of the cylinder to the right side crankcase half 13 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account for the gasket and two alignment pins THIS POINT To service cylinder see Servicing Top Side Compo nents sub section When removing the cylinder be sure to support the piston to prevent damage to the crankcase and pis ton 14 Using an awl remove piston pin circlip Take care not to drop it into the crankcase 3 12 15 Using Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston ENOTE It is advisable to remove the opposite side circlip prior to using the puller MD1219 BNOTE Support the connecting rod with rubber bands to avoid damaging the rod or install a con necting rod holder the crankcase If the rod is down Inside the crank case and the crankshaft 15 rotated severe damage will result ENOTE the existing rings will not be replaced with new rings note the location of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence Starting w
74. While holding the valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained ENOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub section for the proper valve tappet clearance ENOTE Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002 in per mark 7 While holding the adjuster dial at the proper clear ance setting tighten the jam nut securely with the valve adjuster handle 8 Place the two tappet covers with O rings into posi tion then tighten the covers securely 9 Install the spark plug then install the timing inspection plug Testing Engine Compression To test engine compression use the following proce dure Remove the high tension lead from the spark plug 2 Using compressed air blow any debris from around the spark plug WARNING Always wear safety glasses when using compressed air 3 Remove the spark plug then attach the high ten sion lead to the plug and ground the plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit BNOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open position crank the engine over with the electric starter until the gauge shows a peak reading of 170 227 psi five to 10 compression st
75. arcke HUR POM POWER DISTRIBUTION MODULE Always replace a blown fuse with a fuse of the same type and rating Air Filter Use the following procedure to remove the filter and inspect and or clean it CLEANING AND INSPECTING FILTEH 1 Rotate the three locking tabs free of the lugs on the air filter cover then rotate the cover forward and away from the filter housing 4 Dry element 5 Put the element in a plastic bag then pour in air filter and work the oil into the element Insert the forming spring into the element with the closely wrapped end of the spring toward the open end of the element CAUTION A torn air filter element can cause damage to the ATV KC147 engine Dirt and dust may get inside the engine if the 2 Remove the foam filter element from the air filter element is torn Carefully examine the element for housing and separate the foam element from the tears before and after cleaning it Replace the element spring with a new one if it is torn 6 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburetor if equipped 7 Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter element straight in the hous ing CAUTION Failure to properly seat and align the filter element may cause severe engine damage 8 Install the air filter housing cover and secure with th
76. ase components ng proceed to Installing Right Side Components to Installing Left Side Components and to Installing Top Side Components Installing Engine Transmission From the right side place the engine transmission into the frame tilting the top side forward to clear the frame member 2 Install the front and rear engine mounting through bolts and secure with the flange nuts Tighten to 40 ft lb 3 Align the front and rear output flanges with the 5 Connect the stator coil trigger coil and gear shift dnve couplers then secure with serews and position switch connectors then attach the engine tighten to 20 ft lb ground cable and starter cable and secure with cap screws and nuts Tighten to 8 ft lb Gear Shift Position Trigger xx Switch Connector KC243 4 Install the front and rear V belt cooling boots and secure with the existing hardware 6 Set the inlet air silencer into the frame then install the exhaust pipe using a new exhaust pipe seal and seal Tighten the cap screws evenly to 20 ft lb and install the muffler retainer springs 235 KC235 3 45 9 Install the shift rod onto the shift arm with bushing and flat washer and secure with an E clip then connect the speedometer sensor plug KC170 7 Place the carburctor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe then tighten the clamp secur
77. bearing If the bearing is allowed to fall it will be damaged and will have to be replaced CLEANING AND INSPECTING MNOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all knuckle components 2 Inspect the bearing for pits gouges rusting or premature wear 3 Inspect the knuckle for cracks breaks or porosity 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the bearing then install the snap ring mak ing sure it seats into the knuckle PR287A 2 Install the knuckle to the upper and lower ball joints and secure with the two cap screws Tighten to 35 ft lb KC313A 3 Install the tie rod end and secure with the nut Tighten to 30 ft lb then install a new cotter pin and spread the pin BNOTE During assembling new cotter pins should be installed 4 Apply a small amount of grease to the hub splines 5 Install the hub assembly onto the splines of the shaft 6 Secure the hub assembly with the nut Tighten only until snug KC305 7 Secure the brake caliper to the knuckle with the patch lock cap screws Tighten to 20 ft lb KC283 8 Pump the hand brake lever then engage the brake lever lock 9 Secure the hub nut from step 6 to the shaft Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin to secure the nut 11 Install the wheel then using a crisscross pattern ti
78. ce when resurfacing the valve cover Water or parts cleaning solvent must be used In conjunction with the wet or dry sandpaper or dam age to the sealing surface may result Hemoving Valves BNOTE Keep all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original location during installation l Using a valve spring compressor compress valve springs and remove the valve keepers Account for an upper spring retainer 3 13 2 Remove valve seal and lower remaining 2 Acceptable diameter range intake valve must be spring seat Discard the valve seal within specifications 3 Acceptable diameter range exhaust valve must be within specifications Measuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face L 1004 2 Acceptable width must be at above specifica tions Measuring Valve Face Radial Runout CC136D oe en ae 1 Mount a dial indicator on the surface plate then ENOTE The valve seals must be replaced place the valve stem on a set of V blocks 3 Remove the valve springs then invert the cylinder 2 Position the dial indicator contact point on the out head and remove the valves side edge of the valve face then zero the indicator Measuring Valve Stem Runout 1 Support each valve stem end with the V Blocks then check the valve stem r
79. correct 3 Drain system replace with correct fluid 4 Piston seal cup worn 4 Replace master cylinder Problem Brake fluid leaking Condition 1 Connection joints loose 1 Tighten joint 2 Hose cracked 2 Replace hose 3 Piston seal worn 3 Replace brake caliper 6 22 SECTION 7 SUSPENSION TABLE OF CONTENTS SUSDSFISIOL une 7 2 Shock AbsorberS 7 2 7 2 7 3 Wheelsand oi cine eed Ere Ex Dor ee ieee 7 4 e 7 6 Suspension BNOTE Critical torque specifications are located in Section 1 Shock Absorbers REIVIOVING 1 Secure the on a support stand to elevate the wheels and to release load on the suspension A WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Remove the two cap screws and nuts securing each front shock absorber to the frame and the upper A arm Account for bushings and sleeves from each CAUTION Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur 3 Remove the two cap screws and nut securing each rear shock absorber to the frame and lower A arm Account for bushings and sleeves from each ENOTE The shock absorbers are not serviceable components If leaking dented or there are miss ing or broken parts
80. ctor disconnected and on the selector side of the connector RESISTANCE Always disconnect the battery when performing resistance tests to avold damaging the multimeter Set the meter selector to the OHMS position 2 Connect the one tester lead to the brown lavender wire then connect the other tester lead to the white lavender wire 3 With the selector switch in the 2WD position the meter must show less than ohm 4 With the selector switch in the 4WD position the meter must show an open circuit BNOTE If the meter does not show as specified replace the front drive selector switch VOLTAGE ENOTE The battery must be connected when per forming voltage tests 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the negative bat terv terminal 3 Connect the red tester lead to the brown lavender wire on the hamess side of the connector 4 Turn the ignition switch to the RUN position 5 The meter must show battery voltage ENOTE If the meter shows other than specified check the harness connector 30 amp fuse and battery connections Front Drive Selector Actuator ENOTE With the engine stopped and the ignition switch in the OM position a momentary whirring sound must be noticeable each time the selector switch is moved to 2WD and 4WD Test the switch 30 amp fuse and wiring connections prior to test ing the actuator The differential must
81. d tighten to 40 ft lb 6 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differential and install the filler plug Tighten to 16 ft lb 7 Remove the ATV from the support stand Drive Axles REMOVING REAR DRIVE AXLES 1 Secure the on a support stand to elevate wheels A WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Pump up the hand brake then engage the brake lever lock 3 Remove the rear wheels 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock 5 Remove the brake caliper right side only ENOTE Do not allow the brake caliper to hang from the hose CAUTION The caliper should be supported If the calipers are allowed to hang from the hose damage may occur 6 Slide the hub off the shaft and set aside 7 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard the lock nut KC284 BNOTE Never reuse a lock nut Once a lock nut has been removed it must be replaced with a new lock nut 8 While holding the drive axle stationary pull the top of the knuckle out and down until it is free of the drive axle 285 9 Place drain pan under the to contain any oil leakage then using a slide hammer remove the drive axle REMOVING FRONT DRIVE AXLE BNOTE For removing a front drive axle see Front Differential in this
82. de cutters or suitable substitute remove both outside boot clamps from the shaft Note the position of the different sized clamps for assembling purposes CD751 6 16 8 Apply 40 grams 1 3 of contents of grease from the Grease Pack into the knuckles and the new out side boot ATV 1052 BNOTE Grease Pack contains 120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the out side bell type requires approximately 35 55 grams When replacing boots use 2 3 of the pack for inside boots and 1 3 of the pack for outside boots CAUTION Do no over fill the joint as boot damage may occur resulting in joint failure 9 Slide the new outside boot onto the shaft with the new clamps positioned as shown Note the differ ent sized clamps from removal BNOTE The boot is positioned correctly when the small end of the boot seats down into the recessed groove CD754 10 Using the CV Boot Clamp Tool secure both out side boot clamps CAUTION It is important that the clamps are positioned cor rectly or they may loosen when in motion 0024 ASSEMBLING AXLES 1 Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly The boot is positioned correctly when the small end of the boot seats down into the recessed groove CD754 2 Using the boot clamp pliers secure the small clamp of
83. dentifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary information worthy of particular attention The symbol AT THIS POINT directs the tech to certain and specific procedures to promote efficiency and to improve clarity At the time of publication all information photographs and illustrations were technically correct some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because KYMCO Inc constantly refines and improves its products no retroactive obligation is incurred All materials and specifications are subject to change without notice Keep this manual accessible in the shop area for reference KYMCO Inc 2010 KYMCO Inc January 2010 Trademarks of KYMCO Inc Taiwan SECTION 1 GENERAL INFORMATION SPECIFICATIONS TABLE OF CONTENTS General Specifications 1 2 Torque Specifications 1 2 Torque Conversions ft Ib N m 1 3 Tightening Torque General Bolts 1 3 Break In Procedure 1 4 Gasoline Oil Lubricant 1 4 Genuine 1 5 Prepara
84. dness 16 the difference between the highest and lowest reading Maximum trueness out of roundness must not exceed specifications 1270 2 Wash cylinder in parts cleaning solvent 3 Inspect the cylinder for pitting scoring scuffing and corrosion If marks are found repair the sur face using a ball hone MNOTE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean cylinder after honing using soap and hot water Dry with compressed air then immedi ately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder j Nha f S CC390D 4 If any measurement exceeds the limit bore the cylinder and install an oversized piston or replace the cylinder BNOTE Oversized piston and rings are available The oversized piston and rings are marked for identification 0 5 mm 2 5 ATV 1068A Measuring Camshaft Runout ENOTE If the camshaft is out of tolerance it must be replaced 1 Place the camshaft on a set of V blocks then posi tion the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum tolerance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe
85. dy High RPM cut against RPM limiter Shift into higher gear decrease speed Valve springs weak Replace springs Valve timing out of adjustment Adjust timing Cams rocker arms tappets worn Replace cams arms tappets spark plug gap too narrow Adjust gap Ignition coil defective Fuel Injector obstructed Air cleaner element obstructed Fuel hose obstructed Fuel pump defective Replace ignition oil Clean Fuel Injector Glean element Clean or replace hose fuel pump DO A C m Problem Exhaust smoke dirty or heavy Condition Remedy Drain excess oil replace oil Replace service rings cylinder Replace cylinder head Replace service cylinder Heplace valves Replace seals Oil in the engine overtilled contaminated Piston rings cylinder worn Valve guides worn Cylinder wall scored scuffed Valve stems worn 6 Stem seals defective d C h Problem Engine lacks power Condition Remedy Valve clearance incorrect Adjust clearance 1 1 2e Valve springs weak 2 Replace springs 3 Valve timing incorrect 3 He lime valve gear 4 Piston ring s cylinder worn 4 Replace service rings cylinder 5 Valve seating poor Hepair seats 6 Spark plug fouled 6 Clean replace plug 7 Rocker arms shafts wo
86. e blue yellow wire Crank the engine over using the electric starter 4 The meter reading must be within specification e Starter Relay EN Remove the seat then using the multimeter set to the DC Voltage position check the relay as fol lows 2 Connect the red tester lead to the positive battery terminal then connect the black tester lead to the starter cable connection on the starter relay The meter must show battery voltage 5 9 ENOTE Make sure that the ignition switch is in the position transmission in neutral brake lock released and the emergency stop switch in the RUM position 3 Depress the starter button while observing the multimeter The multimeter should drop to 0 volts click should be heard from the relay and the starter motor should run ENOTE click is heard and any voltage is indi cated by the multimeter replace the starter relay If no click is heard and the multimeter continues to indicate battery voltage test the neutral start relay Starter Motor BNOTE The starter is a non serviceable compo nent If the following test does not result as speci fied the starter must be replaced TESTING VOLTAGE Perform this test on the starter motor positive terminal To access the terminal slide the boot away BNOTE The ignition switch must be in the ON position the emergency stop switch in the RUN position and the shift lever in the NEUTRAL posi tion Set the
87. e end of the handlebar then tap lightly on the head to dislodge the handlebar plug 2 Grasp the end and remove the screw plug and end cap KC308 3 Using a sharp utility knife split the handlebar grip from end to end and peel off the rubber 4 Using an adhesive solvent clean all glue residue from the handlebar INSTALLING 1 Apply a liberal amount of Handlebar Grip Adhe sive to the inside of the new grip 2 Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up 3 Wipe off any excess glue then secure the grip with the plug end cap and cap screw Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the ATV a support stand to elevate the wheel then remove the wheel A WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Remove the wheel cap from the hub then remove the cotter pin from the nut Remove the nut securing the hub Remove the brake caliper Remove the hub assembly ON A Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap ring from the knuckle then remove the bearing PR287A PR288 CAUTION Use extreme care when removing the
88. e and warm up to normal operating temperatures then connect a multimeter to the bat terv as follows 2 Select the DC Voltage position then connect the red tester lead to the positive batterv post and the black tester lead to the negative battery post 3 Start the engine and slowly increase RPM The voltage should increase with the engine RPM to a maximum of 15 5 DC volts ENOTE If voltage rises above 15 5 DC volts the regulator is faulty or a battery connection is loose or corroded Clean and tighten battery connec tions or replace the regulator rectifier If voltage does not rise check Voltage Charging Coil No Load in this section If charging coil voltage is normal replace the regulator rectifier Neutral Start Front Drive Actuator Start in Gear 2WD Relays The relays are identical plug in type located the power distribution module Relay function can be checked by switching relay positions The relays are interchangeable ENOTE The module and wiring harness are not a serviceable component and must be replaced an assembly Headlights VOLTAGE ENOTE Perform this test on the main harness side of the connectors Also the ignition switch must be in the LIGHTS position 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connect the red tester lead to the white wire 3 With the dimmer switch in the LO position the meter must show
89. e cylinder head then using a feeler gauge check the distortion factor between head and straightedge 3 Maximum distortion must not exceed specifications CC141D Cleaning Inspecting Cylinder Wash the cylinder in parts cleaning solvent 3 18 2 Inspect the cylinder for pitting scoring scuffing warpage and corrosion If marks are found repair the surface using a cylinder hone sec Honing Cyl inder this sub section 3 Place the cylinder on the surface plate covered with 400 grit wet or drv sandpaper Using light pressure move the ecvlinder in a figure cight motion Inspect the sealing surface for any indica tion of high spots A high spot can be noted by a bight metallic finish Correct high spots before assembly by continuing to move the cylin der in a figure eight motion until a uniform bright metallic finish is attained Water or parts cleaning solvent must be used in conjunction with the wet or dry sandpaper or dam age to the sealing surface may result Inspecting Cam Chain Guide cam chain guide for cuts tears breaks chips 2 If the chain guide 1 damaged must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or snap gauge measure the cylinder bore diameter in three locations from top to bottam and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of roun
90. e locking tabs KC143 3 Fill a wash pan larger than the element with a non flammable cleaning solvent then dip the ele 2 5 ment in the solvent and wash it KC12 CHECKING AND CLEANING DRAIN 1 Inspect the drain on the filter housing cover and clean out any dirt or debris KCO056C 2 Replace any drain that is cracked or shows any signs of hardening or deterioration 3 Wipe any accumulation of oil or gas from the filter housing and drain Valve Tappet Clearance Feeler Gauge Procedure To check and adjust valve tappet clearance use the following procedure ENOTE The seat left side and right side engine covers and gas tank must be removed for this pro cedure 1 Remove the timing inspection plug and spark plug then remove the tappet covers for more detailed information see Section 3 Servicing Top Side Components 2 Rotate the crankshaft to the TDC position on the compression stroke BNOTE At this point the rocker arms and adjuster screws must not have pressure on them 2 6 3 Using a feeler gauge check each valve tappet clearance If clearance 1s not within specifications loosen the Jam nut and rotate the tappet adjuster screw until the clearance 15 within specifications Tighten each Jam nut securely after completing the adjustment The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance Failure to measure t
91. e nght side of the cylinder head nearest the cam sprocket longer than the two cap screws on left spark plug side Tighten only until snug Install the two lower nuts securing the cylinder head to the cylinder one in front and one in rear 9 a ensscross pattern tighten the four cylinder head cap screws from step 7 to 27 5 fi lb Tighten the two lower cylinder head nuts from step 8 to 20 ft lb and the cylinder to crankcase nuts from step 4 to 8 ft Ib 10 With the timing inspection plug removed and the cam chain held tight rotate the crankshaft until the piston 15 at top dead center 11 While holding the cam chain sprocket to the side install the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer 12 With the alignment pin installed in the camshaft and the cam lobes directed down toward the pis ton place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface ENOTE When the camshaft assembly is seated make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket 13 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the camshaft lobes onto the camshaft and place it into position with the cam chain ov
92. e substitute beneath the pis ton skirt and square the piston in respect to the crankcase MD1344 3 21 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase CAUTION The cylinder should slide on easily Do not force the cylinder or damage to the piston rings cylinder or crankshaft assembly may occur 4 Looselv install the two nuts securing the cylinder to the right side crankcase half ENOTE The cylinder to crankcase nuts will be tightened in step 9 C Cylinder Head Camshaft D Valve Cover Rocker Arms ENOTE Steps 1 4 in the preceding sub section must precede this procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder SEIT cx ut zm 7 Care should be taken that the bottom of the chain quide 5 secured in the crankcase boss 6 Place a new gasket into position on cylinder Place the alignment pins into position then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity Keep tension on the the crankcase boss 7 Install the four cylinder head cap screws with washers Note that the two cap screws on th
93. ead the pin to secure the nut 11 Install the wheel and tighten to 40 ft Ib 12 Remove the ATV from the support stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels A WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock 5 Remove the caliper right side only Do not allow the brake caliper to hang from the hose 6 Remove the cap screws and lock nut securing the shock absorber to the frame and lower A arm then remove the shock absorber 7 3 0100 7 Slide hub out of the knuckle and set aside 8 Remove the cap screws and lock nuts securing the knuckle to the A arms Discard the lock nuts BNOTE Never reuse a lock nut Once a lock nut has been removed it must be replaced with a new lock nut 9 Remove the cap screws and lock nuts securing the A arms to the frame then remove the A arms BNOTE removing the upper right A arm it will be necessary to disconnect the brake hose from the A arm CLEANING AND INSPECTING ENOTE Whenever part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all A arm components using a pressure washer 2 Inspect A arm for bends crack
94. ears Replace bearings bushing Problem Engine noisy Noise seems to come from secondary bevel gear and final driven shaft 1 Gears worn rubbing Splines worn 3 Primary gears worn rubbing 4 Bearings worn 5 Bushing worn gu i0 n Condition Remedy 1 Drive driven bevel gears damaged worn 1 Replace gears Backlash excessive Adjust backlash Tooth contact improper Adjust contact Bearing damaged Heplace bearing Gears worn rubbing Heplace gears Splines worn Replace shaft s 7 Final driven shaft thrust clearance too large Replace thrust washer s U amp oL oC Problem Engine idles poorly Condition Remedy 1 Valve clearance out of adjustment 1 Adjust clearance 2 Valve seating poor Heplace service seats valves 3 Valve guides defective 3 Heplace cylinder head 4 Rocker arms arm shaft worn 4 Replace arms shafts 5 Magneto defective 5 Replace magneto ECUunit defective 6 Replace ECU unit Spark plug fouled gap too wide 7 Adjust gap replace plug 8 Ignition coil defective 8 Replace ignition 9 Fuel Pump defective 9 Replace Fuel Pump 10 Fuel injector obstructed 10 Clean Fuel injector 11 screw setting improper 11 CO screw can t allowed to be adjusted 12 Fuel injector obstructed 12 Replace fuel injector 3 5 Problem Engine runs poorly at high speed Condition Reme
95. ely KC245A 8 Install the air filter housing onto the frame then connect the inlet air duct air silencer duct and intake housing to Throttle Body and tighten all hose clamps securely 3 46 10 Connect the Water Temerpature Sensor connector then 11 the brake pedal was removed during disassem connect the TPS connector bling apply grease to the brake pedal pivot stud then install the brake pedal and secure with a washer and screw Tighten to 20 ft lb KC149A 12 Install the heat shield then install the gas tank see Section 4 13 Install the front body panel front rack and foot wells see Section 8 14 Pourthe appropriate quantity and grade oil into the crankcase then connect the negative battery cable and move the ATV outside to a well ventilated area 15 Start engine and allow the engine to warm up while checking for oil leaks then shut the engine off and check the oil level Add oil as required 3 47 4 LUBRICATION SYSTEM GQ KYMCO MAXXER 450i OIL FLOW CHARTS Drive Shaft Gears amp reverse Gears Bevel Gears 4 1 Intake amp Exhaust Cam Faces Intake Rocker Arm Shaft Camshaft Cylinder Head Cover Cylinder Head Cylinder 4 Oil Gallery Oil Filter Oil Pump Oil Strainer SUMP drive chain i d Starter Clutch 4 Connect Crankshaft 4
96. embly 6 Remove the four cap screws securing the brake disc CLEANING AND INSPECTING ENOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all hub components 2 Inspect all threads for stripping or damage 3 Inspect the brake disc for cracks or warping 4 Inspect the hub for pits cracks loose studs or spline wear INSTALLING 1 Secure the brake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 15 ft lb 2 Apply grease to the splines in the hub 6 19 3 Install hub assembly onto shaft 4 Secure the hub assembly with the nut Tighten only until snug 5 Secure the brake caliper to the knuckle with the two cap screws Tighten the caliper to 20 ft lb KC283 6 Tighten the hub nut from step 4 to 200 ft lb then install and spread a new cotter pin making sure each side of the pin 15 flush to the hub nut KC305 7 Install the wheel and tighten to 40 ft lb 8 Remove the ATV from the support stand Hydraulic Brake Caliper MNOTE The brake calliper is a non serviceable component it must be replaced as an assembly REIVIOVING DISASSEIVIBLING 1 Secure on a support stand to elevate the wheel then remove the wheel A WARNING sure ATV is solidly supported sup port stand to avoid injury 6 20 2 Drain the brake fluid from the caliper hose and
97. eplace it with a new one 4 Inspect the perimeter of each piston for signs of blowby indicated by dark discoloration Blowby is caused by worn piston rings exces sive carbon in ring grooves or an out of round cylinder Removing Piston Rings Starting with the top ring slide one end of the ring out of the ring groove 2 Remove each ring by working it toward the top of the piston while rotating it out of the groove ENOTE If the existing rings will not be replaced with new ones note the location of each ring for proper installation When installing new rings install as a complete set only Cleaning Inspecting Piston Hings Take an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up Improper cleaning of the ring grooves by the use of the wrong type of ring groove cleaner will result in severe damage to the piston 3 16 Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder Using feeler gauge measure each piston ning end Acceptable nng end gap must be within specifications 3 i SN Measuring Piston Pin Outside Diameter and Piston Pin Bore
98. eptable gap range must be within specifica tions Measuring Connecting Rod Big End Width 1 Using a calipers measure the width of connecting rod at the big end bearing 2 Acceptable width range must be within specifica tions Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicator contact at point 1 of the crankshaft ATV 1074 3 Zero the indicator and rotate the crankshaft slowly CAUTION Care should be taken to support the connecting rod when rotating the crankshaft 4 Maximum runout must not exceed specifications ENOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator con tact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the outside edge of one web to the outside edge of the other web gt 1017 2 Acceptable width range must be within specifica tions COUNTERSHAFT CAUTION When disassembling the countershaft care must be taken to note the direction each major component dog gear faces If a major component is installed facing the wrong direction transmission damage may occur and or the transmission will malfunction In either case complete disassembly and assembly will be required Disassembling 1 Remove the reverse dri
99. er the sprocket MD1358 14 Place the C ring into position m its groove in the cylinder head ENOTE At this point oil the camshaft bearings cam lobes and the three seating journals on the cylinder head ENOTE Note the position of the alignment marks on the end of the camshaft They must be parallel with the valve cover mating surface If rotating the camshaft is necessary for alignment do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position 15 When the camshaft assembly 15 seated ensure the following 3 23 A Piston still at top dead center B Camshaft lobes directed down toward the pis ton C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned CAL If any of the above factors are not to step 13 and carefully proceed 16 Place the tab washer onto the sprocket making sure covers the pin in the alignment hole Alignment correctly to cover the alignment hole on the sprocket If the alignment pin falls out severe engine damage will result 17 Apply red Loctite 271 to first cap screw securing the sprocket and tab washer to the cam shaft then install the cap screw and tab washer Tighten cap screw only until snug 3 24 18 Rotate the crankshaft until the
100. er page 01 lt Diagnostic Tool C Down page 01 The measure figures including of Engine speed Battery voltage and Engine speed Press the Down button to enter page 02 ET Diagnostic Tool 11 29 I1 FUEL SYSTEM O KYMCO MXU 450i D Down page 02 The measure figures including of TPS position TPI idle adapted and ISC step Press the Down button to enter page 03 E Down page 03 The measure figures including of engine temperature air temperature and intake pressure Press the Down button to enter page 04 F Down page 04 The measure figures including of atmosphere temperature fuel injector interval and ignition advance Press the Down button to enter page 05 OG Diagnostic Too 11 30 GQ KYMCO 11 FUELSYSTEM MXU 450i G Down page 05 The measure figures including of gear position and gear ratio Press the Down button to enter page 06 Diagnostic Tool H Down page 06 The measure figures including of rollover voltage The function setting is not allowed Press the Down button to enter page 07 I Down page 07 The measure figures including of ECU counter J Press the UP to the previous page 11 31 4501 WIRING DIAGRAM GEAR CHANGE SW REG RECT ASSY HEAD LIGHT COMB SW 12V 35W 35W SENSOR START MAG RH FR WINKER ANGLE EEEE 12V 10W DETECT AAA lt teers
101. ery voltage W L 1V 11 9 11 EFI SYSTEM TPS ISC RESET If close or open the throttle grip randomly the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled It can cause hard to start engine or idling speed is not smooth when engine installation e SC has a motor inside which controls ISC valve to obtain smooth idling speed The ECU may record the incorrect ISC position during the engine speed isn t working when the ECU or the throttle body has been reinstalled It can cause engine stop hard to start engine or rough idling speed The throttle position sensor TPS and idle air bypass valve ISC have to be reset when throttle body T MAP TPS ISC or ECU has been reinstalled TPS ISC RESET PROCEDURE start the engine till engine temperature to 85 C over on idle condition ECU will automatic learn engine new condition GC KYMCO MAXXER 450i 11 10 11 EFI SYSTEM ELECTRIC CONTROL UNIT ECU Do not disconnect or connect ECU connector during the ignition switch ON it may cause the ECU damaged The throttle position sensor TPS and idle air bypass valve ISC have to be reset when throttle body MAP TPS ISC or ECU has been reinstalled Disconnect the ECU connector and remove the ECU from the frame Installation is in the reverse order of the removal REMOVAL C KYMCO MAXXER 450i ECU Connector 11
102. es or severe engine damage occur Measuring Rocker Arm Inside Diameter Using a dial calipers measure the inside diameter of the rocker 2 Acceptable inside diameter range must be within specifications Measuring Rocker Arm Shaft Outside Diameter l Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves l Apply grease to the inside surface of valve scals then place a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert cach valve into its original valve location 3 Install the valve springs with the painted end of the spring facing awav from the evlinder head ENOTE If the paint is not visible install the ends of the springs with the closest wound coils toward the head 4 Place a spring retainer over the valve springs then using the valve spring compressor compress valve springs and install the valve keepers 3 15 PISTON ASSEMBLY BNOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the top of the piston Id Inspect the piston for cracks in the piston pin boss top and skirt areas 3 Inspect the piston for seizure marks or scuffing If piston 1 scored or galled r
103. from the V belt housing and cover INSTALLING 1 Place the V belt onto the driven pulley making sure the arrows point in the direction of rotation then pinch the belt together in front of the driven pulley and place it over the clutch shaft 135 Sipe KC131 2 Install the bushing over the clutch shaft then install the movable drive face assembly on the clutch shaft KC128 KC138 3 With two drops of red Loctite 271 on the threads and with the splines of the clutch shaft protruding through the movable drive face install the nut and tighten to 147 ft lb KC152A KC141 4 Remove the cap screw from the fixed driven face then rotate the pulleys counterclockwise until the driven pulley faces are together 5 With the two alignment pins installed in the V belt housing and a new V belt cover gasket in place install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A 2 19 6 Slide the auxiliary brake pedal fully onto the pivot stud engaging the master evlinder then secure with the flat washer and cap screw and tighten to 20 ft lb 2 20 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 9 0 Spach E esnan Troubleshooting Tabla of Contanis urere Engine Transmission This section has been organized into sub sections which show
104. ft the transmission into cach of the gear posi tions and note that the gear position indicated on the LCD corresponds to the gear position selected by the lever If the indicator does not correspond to the selected gear it will be necessary to test drive the to deter mine if the gear shift position switch is faulty or the shift lever needs adjustment If the ATV functions in the gear selected by the shift lever troubleshoot the gear shift position switch see Section 5 If the ATV functions but the shift lever does not corre spond with the gear indicated on the LCD adjust the shift linkage To adjust proceed to ADJUSTING ADJUSTING Remove the seat then remove the left side engine cover 2 With the ignition switch in the ON position loosen jam nut A left hand threads then loosen jam nut C and with the shift lever in the reverse posi tion adjust the coupler B until the transmission is in reverse and the R icon appears on the LCD EA KC194A 3 Tighten the jam nuts securely then shift the trans mission to each position and verify correct adjust ment 4 Install the left side engine cover and seat making sure the seat locks securely in place Frame Welds Racks The frame welds and racks should be checked penod ically for damage bends cracks detenoration broken components and missing components If replacement or repair constitutes removal see Section amp Electrical
105. ghten to 40 ft lb 12 Remove the ATV from the support stand Mieasuring Adjusting Toe In 1 Thoroughly wash the ATV to remove excess weight mud etc 2 Refer to the specifications and ensure the tires are properly inflated to the recommended pressure Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur 3 Place the in a level position taking care not to push down or lift up on the front end then turn the handlebar to the straight ahead position When measuring and adjusting there should be a normal operating load on the ATV without an operator but with Arctic Cat approved accessories 4 Measure the distance from the outside edge of each handlebar grip to equal reference points on each side 5 Adjust the handlebar direction until the two mea surements are equal then secure the handlebar ENOTE Care must be taken not to allow the han dlebar to turn while securing it BNOTE The front wheels do not have to be removed to adjust the tie rod Also care should be taken not to disturb the handlebar position 8 5 6 Using a permanent marker of some type mark center of each front tire at a height parallel to the belly panel AF789D 7 Measure the distance between the marks at a height parallel to the belly panel at the front side then record the measurement 8 Push the ATV forward until the marks are paralle
106. he valve clearance accurately could cause valve com ponent damage VALVE TAPPET CLEARANCE MN CCO07DC 4 Install the timing inspection plug 5 Place the two tappet covers with O rings into posi tion then tighten the covers securely 6 Install the spark plug then install the timing inspection plug Valve Tappet Clearance Valve Adjuster Procedure To check and adjust valve tappet clearance use the following procedure BNOTE The seat left side and right side engine covers and gas tank must be removed for this pro cedure 1 Remove the timing inspection plug and spark plug then remove the tappet covers for more detailed information see Section 3 Servicing Top Side Components 005 2 Rotate crankshaft to the TDC position on compression stroke BNOTE At this point the rocker arms and adjuster screws must not have pressure on them ENOTE Use Valve Clearance Adjuster for this pro cedure 3 Place the valve adjuster onto the jam nut securing the tappet adjuster screw then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw 4 While holding the valve adjuster dial in place use the valve adjuster handle and loosen the jam nut then rotate the tappet adjuster screw clockwise until friction is felt Align valve adjuster handle with one of marks on the valve adjuster dial 6
107. he camshaft MD1354A 3 Loosen the cap screw on the end of the cam chain tensioner then remove the two cap screws secur ing the cam chain tensioner assembly Remove the tensioner assembly and gasket 3 10 6 Using an awl rotate the C ring in its groove until it 15 out of the cylinder head then remove the C ring ENOTE Care should be taken not to drop the C ring down into the crankcase 7 Noting the timing marks for installing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cvlinder head Account for an alignment BNOTE Loop the chain over the cylinder and secure it with a wire to keep it from falling into the crankcase 8 Remove the cam chain tensioner by lifting it from the chain cavity then remove the two lower nuts securing the cvlinder head to the cylinder one in front and one in rear 9 Remove the four cylinder head cap screws and washers Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left spark plug side 0241 10 Remove the cvlinder head from evlinder remove the gasket and account for two alignment pins THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section 11 Remove the cam chain guide THIS POINT To inspect cam chain guide see Servicing
108. he front drive actuator is located on the side of the front drive input housing With the engine stopped and the ignition switch in the ON position momentary whiting sound can be heard each tme front drive selector switch is shifted If no sound is heard see Section 5 If the actuator runs constantly or makes squealing or grinding sounds the actuator must replaced REMOVING 1 Disconnect the connector on the actuator harness 2 Remove the mounting cap screw from the drive shatt side of the actuator 3 Remove the mounting cap screw from below the actuator on the suspension side KC2904A 4 Loosen but do not remove the mounting cap screw at the front of the actuator then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft INSTALLING Pd Lubricate the O ring on the actuator then ensure that all mounting surfaces are clean and free of debris Align the actuator with the selector shaft and slide it forward onto the shaft taking care to engage the cap screw in the slot of the front mounting tab ADOu25 While holding the actuator firmly forward tighten the front cap screw to hold the actuator in place then install but do not tighten the two remaining Cap Screws 4 Loosen the front cap screw then tighten the cap screw on the driveshaft side ENOTE is important to tighten this cap screw while the others are loose to ensure proper sea
109. height ATV1013A 2 The lobe heights must not exceed minimum speci fications 3 19 Inspecting Camshaft Bearing Journal 1 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting 15 found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Remove the adjuster screws and jam nuts ii CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely ENOTE Do not rotate the camshaft when measur ing clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and camshaft MD1261 5 Match the width of plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and valve cover clear ance 3 20 1450 6 If clearance is excessive measure journals of the camshaft CC287D BNOTE If the journals are worn replace the cam shaft then measure the clearance again If it is still out of tolerance replace the cylinder head Inspecting Camshaft Spring Drive Pin 1 Inspect the spring and unloader pin for damage CF061A BNOTE With the weight extended the unloader pin should be flat side out with the weight retracted the unloader
110. hen unload allowing components to cool Although it is essential to place some stress on the engine components during break in care should be taken not to overload the engine too often Do not pull a trailer or carry heavy loads during the 10 hour break in period When the engine starts allow it to warm up properly Idle the engine several minutes until the engine has reached normal operating temperature Do idle the engine for excessively long periods of time During the break in period a maximum of 1 2 throttle 1 recommended however brief full throttle accelerations and variations in driving speeds contribute to good engine break in After the completion of the break in period the engine oil and oil filter should be changed Other maintenance after break in should include checking of all pre scribed adjustments and tightening of all fasteners Gasoline Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane 5 are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system 1 4 RECOMMENDED ENGINE TRANSMISSION OIL CAUTION Any oil used in place of the reco
111. hinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim BNOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart Backlash Measurement Shim Correction Decrease Shim Thickness Under 0 05 mm 0 002 in At 0 05 0 33 mm 0 002 0 013 in Over 0 33 mm 0 013 in No Correction Required Increase Shim Thickness Checking Tooth Contact BNOTE After correcting backlash of the second ary driven bevel gear it is necessary to check tooth contact 1 Remove the secondary driven output shaft assem bly from the left side crankcase half 2 Clean the secondary driven bevel gear teeth of old oil and grease residue 3 Apply a thin even coat of a machinist layout dye to several teeth of the gear 4 Install the secondary driven output shaft assembly 5 Rotate the secondary driven bevel gear several revolutions in both directions 6 Examine the tooth contact pattern the dye and compare the pattern to the illustrations Incorrect contact at tooth Top ATV 0103 ATV 0105 3 39 Correct ATV 0104 Correcting Tooth Contact If tooth contact pattern is comparable to the correct pattern illustration no correction is necessary If tooth contact pattern is comparable to an incorrect pattern correct tooth contact according to the follow ing chart
112. ignition coil 15 on the frame above enginc To access the coil the left side panel must be removed RESISTANCE Always disconnect the battery when performing resistance tests to avoid damaging the multimeter ENOTE For these tests the meter selector should be set to the OHMS position and the primary wire s should be disconnected Primary Winding Connect the red tester lead to either terminal then connect the black tester lead to the other terminal 2 The meter reading must be within specification Secondary Winding 1 Remove the plug cap from the high tension lead then connect the red tester lead to the high tension lead 2 Connect the black tester lead to ground 3 The meter reading must be within specification BNOTE If the meter does not show as specified replace ignition coil Spark Plug Cap Connect the red tester lead to one end of the cap then connect the black tester lead to the other end of the cap 2 The meter reading must be within specification If the meter does not read as specified replace the spark plug cap PEAK VOLTAGE BNOTE All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter If any other type of tester is used readings may vary due to internal circuitry BNOTE The battery must be at full charge for these tests 5 5 3 Install new speed sensor mto the housing with new O ring
113. intenance Chart clean the spark arrester using the following pro cedure Wait until the muffler cools to avoid burns Remove the cap screws securing the spark arrester assembly to the muffler then loosen and remove arrester 2 Using a suitable brush clean the carbon deposits rom the screen taking care not to damage Screen ENOTE If the screen or gasket is damaged in way it must be replaced 3 Install the spark arrester assembly with gasket then secure with the cap screws Tighten to 48 in lb KC145 Adjusting Throttle Cable To adjust the throttle cable tree play follow this proce dure 1 Slide the rubber boot away then loosen the jam nul from the throttle cable adjuster 6110 2 Turn the adjuster until the throttle cable has proper free play of 3 6 mm 1 8 1 4 in at the lever Jam Nut 3 6 mm 1 8 1 4 in ATV 0047 3 Tighten the jam nut against the throttle cable adjuster securely then slide the rubber boot over the adjuster Engine Transmission Filter Strainer OIL FILTER The engine should always be wann when is changed so the oil will drain easily and completely 1 Park the ATV on level ground 2 Remove the seat and lefl side engine cover 3 Remove oil level stick fller plug b 4 E lt 0 4 Remove drain plug from the bottom of the engine and drain the oil into a drai
114. into the crankcase making sure the two gears shim washer and nut are the correct order MD1199 MD1079 2 Apply red Loctite 271 to the threads of the output shaft Install and tighten the nut 59 ft lb Using a punch peen the nut 1333 3 42 3 Apply a liberal amount of oil to the crankshaft bearing Using a propane torch heat the bearing until the oil begins to smoke then slide the crank shaft assembly into place ont MD1334 BNOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft installer 4 Rotate the crankshaft so the counterweight is toward the rear of the engine Install the counter balance shaft MD1024 5 Keeping the counterbalance gear timing mark aligned with the one on the crankshaft gear install the key and the counterbalance gear CD826A 6 Keeping the slot directed as shown install the shift cam and inner and outer washers 9 Install the input driveshaft KC325 7 Align inner shift fork with gear cluster and with the inner washer in place install the gear cluster and inner shift fork While holding gear 10 Install the washer spacer sleeve and reverse idler cluster in place install the washer gear and snap gear ring MD1357 11 Install the secondary and primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss nex
115. itch the position the meter must show less than ohm ENOTE the meter shows more than 1 ohm of resistance replace the switch RESISTANCE LO Beam Connect one tester lead to the brown black wire then connect the other tester lead to the white wire 2 With the dimmer switch in the LO position the meter must show an open circuit ENOTE If the meter reads resistance replace the switch RESISTANCE Emergency Stop Set the meter selector to the OHMS position 2 Connect the one lead to the red white Wire then connect the other tester lead to the yellow black wire 3 With the switch in the OFF position the meter must show an open circuit 4 With the switch in the RUN position meter must show less than ohm ENOTE If the meter shows more than 1 ohm of resistance replace the switch RESISTANCE Reverse Override Set the meter selector to the OHMS position 2 Connect one tester lead to one lavender red wire then connect the other tester wire to the green red wire The meter must show less than ohm Depress and hold the reverse overnde button The meter must show an open circuit ENOTE the meter does not show as specified replace the switch Front Drive Selector Switch The connector 15 the snap lock one in front of the steering post To access the connector the electrice cover must bc removed 5 7 ENOTE Resistance tests should be made with the conne
116. ith the top ring slide one end of the ring out of the ring groove B Remove cach by working it toward the dome of the piston while rotating it out of the groove THIS POINT To service piston Servicing Top Side nents sub section AT THIS POINT service center crankcase components only ceed to Removing Left Side Components Servicing Top Side Components BNOTE Whenever part is worn excessively cracked or damaged in any way replacement is necessary VALVE ASSEIVIBLY When servicing valve assembly inspect valve secats valve stems valve faces and valve stem ends for pits bum marks or other signs of abnormal wear BNOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Valve Cover BNOTE If the valve cover cannot be trued the cyl inder head assembly must be replaced Wash the valve cover in parts cleaning solvent 2 Place the valve cover on the Surface Plate covered with 400 wet or drv sandpaper Using light pressure move the valve cover in a figure cight motion Inspect the sealing surface for any indica tion of high spots A high spot can be noted by a bnght metallic finish Correct high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish 18 attained surface or damage to the camshaft will result Always check camshaft clearan
117. kwise to secure then place the socket into the light hous ing and tum clockwise to secure P m r 1 1 E a mE r nstall CHECKING ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizon tally The geometric center of the HIGH beam light zone 15 to be used for vertical and horizontal aiming 1 Position the on a level floor so the headlights are approximately 6 1 20 ft from an aiming surface wall or similar aiming surface ATWV DOTOC ENOTE There should be an average operating load on the ATV when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each headlight E Using the measurements obtained in step 2 make horizontal marks on the arming surface Make vertical marks which intersect the horizontal marks on the aming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam 15 on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the ver tical mark 5 cm 2 in below the horizontal mark the aiming surface j Adjust each headlight by tuming the adjuster knob counterclockwise to raise the beam or clockwise to lower the beam Shift Lever CHECKING ADJUSTMENT With the engine stopped and the brake lever lock engaged tum the ignition switch to the ON position then shi
118. l ATV0082A 737 651B 4 After all the oil has been drained install the drain plugs and tighten to 45 in Ib 5 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole 6 Install the fill plugs BNOTE the differential rear drive oil is contami nated with water inspect the drain plug filler plug and or bladder CAUTION Water entering the outer end of the axle will not be able to enter the rear drive unless the seals are dam aged 2 11 Tires TIRE SIZES The 1 equipped with low pressure tubeless tires of the size and type listed see Section 1 Do not under any circumstances substitute tires of a different type or SIZE WARNING Always use the size and type of tires specified Always maintain proper tire inflation pressure TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0 4 5 68 psi Steering Components The following steenng components should be inspected periodically to ensure safe and proper operation A Handlebar grips not worn broken or loose B Handlebar not bent cracked and has equal and complete full left and full risht capability Steering post bearing assemblv bearing housing not broken worn or binding D Ball joints not worn cracked or damaged E rods not bent or cracked Knuckles not worn cracked or damaged G Cotter pins not damaged or
119. l to the belly panel on the back side then measure the distance between the marks 9 The difference in the measurements must show 1 8 1 4 in toe in the front measurement 1 8 1 4 in less than the rear measurement 10 If the difference in the measurements is not within specifications adjust both tie rods equally until within specifications BNOTE Prior to locking the jam nuts make sure the ball joints are at the center of their normal range of motion and at the correct angle Pod _ Ar lt 733 559A Front Hack REIVIOVING 1 Remove the cap screws and lock nuts securing rack to the frame and front fender panel 2 Remove front rack from 8 6 CLEANING AND INSPECTING BNOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all rack components using a pressure washer 2 Inspect all welds for cracking or bending 3 Inspect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals and or reflectors INSTALLING 1 Place the rack into position on the frame and front fender panel Install the cap screws and lock nuts and finger tighten only 2 Install the two cap screws and lock nuts securing the rack to the fenders Tighten all hardware securely Front Bumper Assembly REMOVING 1 Remove
120. l cover Account for an O ring BNOTE If the cover is difficult to remove pry on the cover in more than one recessed location 4 Remove the left gear case bearing flange assembly and account for a shim Mark the shim as left side 6 7 178 5 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as right side CC876 7 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing KX179 N KX181 878 6 Using 48 mm Internal Hex Socket remove 8 Secure the pinion gear in a bearing puller then lock collar securing the pinion gear assembly remove the pinion bearing using a press Account for a collar and a bearing ENOTE On a front differential the lock collar has right hand threads On a rear gear case the lock collar has left hand threads CC879 6 8 gears are being replaced use exist ing shims The numbers are scribed onto the gears the ring gear has the number on the oppo site side of the gears and the pinion gear has the number on the end of the pinion gear shaft by the splines no number is present it should be con sidered as being in the 0 category BNOTE If the gear case housing is being replaced proceed to following Shimming Proce dure Shim Selection sub section Shimming Procedure Shim Selection
121. ld be shown repeatedly How To Reset Failure Code After repairing the trouble you should clear the failure code or it will still exist in the ECU memory When you maintain this vehicle next time it will show again and you get confuse Turn switch on The CELP will be lighted for two seconds then off The CELP begins to blink to show the failure codes The self diagnosis memory data will erased when all the failure codes has showed for 4 cycles Example failure codes 1 and 2 E i y T T l d d 6 i T 4 t 5 5 I E m n d B il ui gt wi 3 05 1 050505 3 0505050 3 ll COT E a iat Code 24 and Code 12 iesi B on fer tons B fap tor z oF 11 14 11 EFI SYSTEM MAXXER 450i CELP FAILURE CODES LIST prar Failure p pae Slow down the vehicle and go to workshop for temperature checking immediately overheat Confirm if the engine temperature sensor or electric circuit 1 abnormality Check the connector of crankshaft position sensor if is loosen Check if the Rotor 15 align to Crankshaft position sensor during the crankshaft running Crankshaft position sensor or circuit malfunction Make sure if the connector of Throttle position sensor Is connected correctly Check if the
122. lightly coated with multi purpose Speed sensor grease then secure the sensor with the cap screw threads coated with blue Loctite 242 Tighten securely 1 Set the meter selector to the DC Voltage position 2 With appropriate needle adapters on the meter leads connect the red tester lead to the voltage lead then connect the black tester lead to the ground lead G CDOT 1 Ignition Switch KC248A a nao The igm on switch hamess connects to switch 3 Tum the ignition switch to the ON position with a three pin connector To access the connector 4 Themeter must show 12 0 volts remo ve the access panel in front of the handlebar 5 Leavethe black Lester lead connected then con the red tester lead to the signal lead pin 5 6 Slowly move the ATV forward or backward the meter must show 0 and 6 volts alternately HOTE the sensor tests are within specifica tions the speedometer must be replaced see Sec tion 8 To replace a speed sensor use tlie following procedure 1 Disconnect the three wire connector from the speed sensor then remove the cap screw securing sensor ta the sensor housing VOLTAGE 2 Remove the sensor from the sensor housing B NOTE har accounting for an O ring RE Perform n s 1 Set tlie meter selector to the DC Voltage position 2 Connect the red meter lead to the red white wire then connect the black meter lead to ground
123. ll A arm components using a pressure washer 2 Clean the ball joint mounting hole of all residual Loctite grease oil or dirt for installing purposes 3 Inspect the A arm for bends cracks and worn bushings 4 Inspect the ball joint mounting holes for cracks or damage 5 Inspect the frame mounts for signs of damage wear or weldment damage INSTALLING 1 Apply green Loctite 609 to the entire outside diameter of the ball joint then install the ball joint into the A arm and secure with the circlip 2 Install the A arm assemblies into the frame mounts and secure with the cap screws Only fin ger tighten at this time 3 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to 35 ft lb 4 Secure the A arm assemblies to the frame mounts from step 2 Tighten the cap screws to 35 ft Ib CAUTION Do not tighten the nut beyond the 35 ft Ib specifica tion or the shock eyelet or mount WILL be damaged 5 Install the knuckle assembly onto the ball joints and secure with cap screws Tighten to 35 ft Ib 6 Apply grease to the hub and drive axle splines then install the hub assembly onto the drive axle 7 Secure the hub assembly with the nut Tighten only until snug 8 Secure the brake caliper to the knuckle with the two patch lock cap screws Tighten to 20 ft Ib 9 Secure the hub nut from step 7 to the shaft axle Tighten to 200 ft Ib 10 Install a new cotter pin and spr
124. ly cracked or damaged in any way replacement is necessary Inspect muffler externally for cracks holes and dents 2 Inspect the muffler intemally by shaking the muf fer back and forth and listening for rattles or loose debris inside the muffler ENOTE For additional details on cleaning the muf fler spark arrester see Section 2 INSTALLING MUFFLER Using new grafoil seal place the muffler into position engaging the mounting lugs into the grommets then slide the muftler forward 2 Install the two exhaust springs 3 Remove the auxiliary brake reservoir from the body but do not disconnect the hose then route Hear Body Panel Rack and secure the hose and reservoir out of the way making sure not to spill brake fluid REMOVING Remove the rear rack then remove two cap screws securing the rear body pancl fender to the side frame and the cap screws secunng the rear fenders to the footwells 4 Using a small screwdnver remove the light con nectors from the frame then disconnect both con nectors and remove the rear body panel fender 2 Disconnect the battery negative cable first and remove from the battery compartment then dis connect the starter relay wires and route the wiring out of the compartment CLEANING AND INSPECTING ENOTE Whenever part is worn excessively cracked or damaged in way replacement is necessary 4 Clean all rear body panel components with
125. ly after filling the tank WARNING Do not over fill the gas tank Genuine Parts When replacement of parts is necessary use only genuine KYMCO ATV parts They are precision made to ensure high quality and correct fit Refer to the appropriate Illustrated Parts Manual for the correct part number quantity and description Preparation For Storage Pn th prevent rusting and component deterioration KYMCO recommends the following procedure to prepare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water into any part of the engine or air intake 3 Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank Remove the air filter housing cover and air filter Start the engine and allow it to idle then using KYMCO Engine Storage Preserver rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds then stop the engine Install the air filter and housing cover T If the interior of the air filter housing is dirty clean the area before starting the engine 4 Empty the fuel in the fuel tank S3 Plug the exhaust outlet on the muffler with clean cloth 6 Apply light to the upper steenng post bushing and plungers of the shock absorbers T Tighten all n
126. mmended oil could cause serious engine damage Do not use oils which contain graphite or molybdenum additives These oils can adversely affect clutch operation Also recommended are racing vegetable non detergent and castor based oils The recommended oil that using of any certified SM 5W 50 oil is acceptable ENGINE 30 20 10 0 10 20 30 40 14 32 50 68 86 104 RECOMMENDED FRONT DIFFERENTIAL REAR DRIVE LUBRICANT The recommended lubricant is KYMCO Gear Lube or an equivalent gear lube which is SAE approved 80W 90 hypoid This lubricant meets all of the lubrication requirements of the KYMCO ATV front differentials and rear drives CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential rear drive damage FILLING GAS TANK WARNING Always fill the gas tank in a well ventilated area Never add fuel to the gas tank near any open flames with the engine running DO SMOKE while filling the gas tank 00498 since gasoline expands as its temperature rises the gas tank must be filled to its rated capacity only Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area WARNING not overflow gasoline when filling the gas tank A fire hazard could materialize Always allow the engine to cool before filling the gas tank Tighten the gas tank cap secure
127. must show 60 AC volts CAUTION Do not run the engine at high RPM for more than 10 seconds NOTE both charging coil tests failed check all connections etc and test again If no voltage is present replace the stator assembly RESISTANCE Charging Coil CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter 1 Set the meter selector to OHMS position 2 Test between the three yellow wires for a total of three tests 3 The meter reading must be within specification RESISTANCE Trigger Coil CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter 1 Disconnect the gray four pin connector on the right side of the engine just above the starter motor 2 Set the meter selector to the OHMS position 3 Connect the red tester lead to the green white wire then connect the black tester lead to the blue yellow wire The meter reading must be within specification PEAK VOLTAGE BNOTE All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter If any other type of tester is used readings may vary due to internal circuitry BNOTE The battery must be at full charge for these tests Trigger Coil 1 Setthe meter selector to the DC Voltage position 2 Connect the red tester lead to the green white wire then connect the black tester lead to th
128. n Section 1 torque specifications are NOTE Specifications regarding the gear cases Capacities lubricant type etc can be found in Section 1 of this manual Ring Gear Backlash 0 28 0 38 mm 0 011 0 015 In Ring Gear End Play 0 1 0 2 mm 0 004 0 008 in GENERAL INFORMATION All gear cases are tagged beneath a cover bolt This tag is marked with a production date code sequence code and a ratio code The 1 or 3 1 on the lower right comer indicates a 3 1 1 gear set ratio 11 34 teeth The die cast aluminum housings have been assembled with thread rolling screws trilobular When assem bling with these screws start the screws carefully into the housing then use the following torque values Torx 30 Recess 8 9 5 ft Ib 6 5 9 1 6 MB Tore 1 40 Recess 25 31 6 21 25 1 6 Torx F50 Recess 37 45 5 ft Ib 31 38 ft Ib 6 2 SPECIAL TOOLS A number of special tools must be available to technician when performing service procedures in this section Description CV Boot Clamp Tool Internal Hex Socket Pinon Gear shaft Removal Tool Slide Hammer Kit Gear Case seal Installer Tool NOTE Special tools are available from the KYMCO Spare Parts Department Front Drive Actuator The actuator is not a serviceable compo nent If it is defective it must be replaced BH NOTE The actuator will operate only when the ignition switch is in the ON position T
129. n pan 2 9 Oil Drain Plug View from Beneath 733 441A 5 Remove the oil filter plug from the filter mounting boss located on the front side of the transmission case and allow the filter to drain completely Install the plug and tighten securely 6 Using the adjustable Oil Filter Wrench and a suit able wrench remove the old oil filter BNOTE Clean up any excess oil after removing the filter 7 Apply oil to a new filter seal ring and check to make sure it is positioned correctly then install the new oil filter Tighten securely 8 Install the engine drain plug and tighten to 20 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug CAUTION Any oil used in place of the recommended oil could cause serious engine damage Do not use oils which contain graphite or molybdenum additives These oils can adversely affect clutch operation Also not recommended are racing vegetable non detergent and castor based oils 9 Start the engine while the 15 outside on level ground and allow it to idle for a few minutes 10 Turn the engine off and wait approximately one minute 11 Remove the oil level stick and wipe it with a clean cloth 12 Install the oil level into engine case BNOTE The oil level stick should be threaded into the case for checking purposes 2 10 13 Remove the oil level stick the engine oil level should
130. nction Fuel pump relay or Check if the connector of relay 1s loosen P0230 Jelectric circuit Check if the ECU 15 signaled to relay malfunction Check the fuel pump relay resistance 13 P0219 Po219 pagine oe ee 2 if the of CVT 1s broken eae top speed AN if ECU output DCSV to sensor P1560 Sensor don t receive Check if the power source of all sensor is DCSV power source from ECU Replace a new ECU if the CELP still blinks even the output power source of ECU 18 normal Engine starting speed P0700 CVT speed Don t use it at present limited Engine temperature Check if the connector of sensor is loosen 0115 sensor or electric circuit Check if ECU pin 15 broken malfunction 3 Check if the resistance of sensor 1s malfunction Temperature gauge 17 P1561 Jelectric circuit 2 Not available malfunction 18 P0650 CELP electric circuit 3 Check if the lamp of CELP is broken malfunction Check if the wires of CELP are broken m Atmospheric Pressure Check if the connector of sensor 1s loosen P0105 Sensor Circuit Check if ECU pin is broken Malfunction Check if voltage of sensor is fit in specification Check 1f the sensor installation direction 1s correct 22 P0110 RON aa a iai 2 Check if voltage of sensor 15 fit in specification circuit malfunction Check if ECU pin is broken 11 16 KYMCO 11 EFI SYSTEM MAXXER 450i TILT SWITCH ROLL SENSOR INSPECTION Support ATV level
131. nization The throttle body is preset in KYMCO factory do not disassemble it by a wrong way Do not loosen or tighten the painted bolts and screws for the throttle body Loosen or tighten them can cause the throttle and idle valve to synchronization failure e TPS and ISC have to be reset after the throttle body T MAP TPS ISC or ECU has been reinstalled T MAP SENSOR INSPECTION Support the scooter on a level surface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON position Measure if the ECU voltage outputs to the T MAP sensor between the following terminals of the MAP connector Terminal Normal NEN _ VRO VGO 11 6 dC KYMCO 11 EFI SYSTEM MAXXER 450i TPS INSPECTION Support the ATV on a level surface Turn the ignition switch to Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector Terminal Normal VIR V G Throttle position sensor TPS resistance 3500 6500 at 20 C 68 F Cable Ends REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from throttle seat Adjusting Nuts TPS Sensor Sensor Disconnect the TPS ISC and T MAP sensor connectors Loosen the air cleaner connecting hose band screw Loosen the intake manifold band screw Remove the throttle body T MAP sensor TPS sensor and ISC
132. nstall the wheel Tighten to 40 ft Ib 7 Remove the ATV from the support stand and ver ify brake operation 6 21 Troubleshooting Drive System Problem Power transmitted from engine to wheels 1 Rear axle shafts serration worn broken 1 Replace shaft Problem Power transmitted engine either front wheel Replace gear s Secondary drive driven gear teeth broken Propeller shaft serration worn broken Coupling damaged Replace shaft Replace coupling Coupling joint serration worn damaged Replace joint Front drive driven bevel gears broken damaged Front differential gears pinions broken damaged Sliding dogs shaft fork worn damaged Front drive axle worn damaged Front drive axle serration worn damaged Replace gear s Replace gears pinions Replace gear s Replace axle O ON OO FW NY O ON OO FW PND Replace axle Troubleshooting Brake System Problem Braking poor Condition Pad worn Replace pads Pedal free play excessive Replace pads Brake fluid leaking Repair replace hydraulic system component s Hydraulic system spongy Bleed hydraulic system correct or repair leaks Master cylinder brake cylinder seal worn Replace master cylinder Problem Brake lever travel excessive Condition 1 Hydraulic system entrapped air 1 Bleed hydraulic system 2 Brake fluid low 2 Add fluid to proper level 3 Brake fluid in
133. nt is necessary 1 Clean all pump components in solvent 2 Inspect the mechanical seal and pump drive seal for damage If the mechanical seal and or pump drive seal are damaged they must be replaced as a set GQ KYMCO MAXXER 450i 10 4 GQ KYMCO 10 LIQUID COOLING SYSTEM MAXXER 450i 3 Inspect the impeller for corrosion or damage ASSEMBLING INSTALLING Treat seals and O ring with clean anti freeze for initial lubrication 1 Press the mechanical seal with pump drive seal into the impeller by hand 2 Install the mechanical seal assembly onto the water pump shaft and secure with the cap screw washer and gasket Tighten the cap screw securely 3 Place the washer pump case into position and secure with the four screws 4 Fill the cooling system with the recommended amount of antifreeze While the cooling system 15 being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engine off and then fill the cooling system 5 Check the entire cooling system for leakage 10 5 dC KYMCO 11 EFI SYSTEM MAXXER 450i FUEL INJECTION SYSTEM FUEL PUMP FUEL LEVEL SENSOR 11 2 WATER TEMPERATURE SENSOR 11 5 THROTTLE BODY T MAP SENSOR ISC TPS 11 6 DIAGNOSTIC TOOL CONNECTOR 11 9
134. nto the steering knuckle Secure with a cap screw tightened to 35 ft lb 2 Slide the hub w brake disc into position in the steering knuckle followed by a washer and hex nut Tighten finger tight at this time 3 Install the brake caliper on the steering knuckle Tighten to 20 ft lb then pump up the hand brake lever and engage the brake lever lock 6 18 KC169 3 Remove the two cap screws and lock nuts securing the rear gear case to the frame then remove the gear case through the left side KC288A gt THIS POINT For servicing the input shaft pinion gear needle bearing and axle seal see Front Differential in this section INSTALLING 1 Slide the gear case into position through the left side of the frame then secure it to the frame with cap screws and lock nuts Tighten to 45 ft lb 2 Secure the engine output shaft to the rear gear case input flange with four cap screws coated with red Loctite 271 and lock nuts Tighten to 20 ft lb 3 Install the rear drive axles see Drive Axles in this section Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel A WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Remove the cotter pin from the nut ENOTE During assembly new cotter pins should be installed 3 Remove the flange nut securing the hub 4 Remove the brake caliper 5 Remove the hub ass
135. o align the drive pin with the slot in the shift shaft KC325A B Clutch Cover Fixed Drive Face D Movable Drive Face MNOTE Steps 1 9 in the preceding sub section must precede this procedure 10 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 11 Tighten the clutch cover cap screws to 8 ft lb MD1117 12 Install the air intake plate Apply red Loctite 271 to the threads of the three Phillips head cap screws then install and tighten securely MD1342 13 Place the driven pulley assembly into position and secure with the nut threads coated with red Loc tite 271 Tighten to 147 ft lb MD1068 14 Slide fixed drive face assembly onto front shaft 15 Spread the faces of the driven pulley by threading a V belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V belt to drop into the pulley approxi mately 3 4 in KC137 The arrows the V belt should point in direction of engine rotation 16 Making sure the movable drive face rollers are in position pinch the V belt together near its center and slide the spacer and movable drive face onto the shaft KC127 17 Coat the threads of the nut with red Loctite 271 then making sure the splines of the clutch shaft protrude through the cover plate secure with the nut and tighten to 147 f
136. on BNOTE The chrome silver ring should be installed in the top position MD1343A N CAUTION Incorrect installation of the piston rings will result in engine damage CYLINDER CYLINDER HEAD ASSEIVIBLY BNOTE If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecting Cylinder Head N CAUTION The cylinder head studs must be removed for this procedure 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape or damage the combustion chamber or the sealing surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil insert 3 17 Place the cylinder head on the surface plate cov with 400 grit wet or dry sandpaper Using light pressure move the evlinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted bright metallic finish Correct any high spots before assembly by continuing to move the cylin der head in a figure eight motion until a uniform bright metallic finish is attained Water or parts cleaning solvent must be used in conjunction with the wet or dry sandpaper or dam age to the sealing surface may result Measuring Cylinder Head Distortion Remove any carbon buildup in the combustion chamber 2 straightedge across th
137. out of adjustment Clean plug Replace magneto Replace ECU unit Clean Throttle Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 1 Adjust clearance 2 Valve spring s weak broken 2 Replace spring s 3 Rocker arm rocker arm shaft worn 3 Replace arm shaft 4 Camshaft worn 4 Replace camshaft 5 Valve tappets worn 5 Replace tappets Problem Engine noisy Noise seems to come from piston Condition Remedy 1 Piston cylinder worn 2 Combustion chamber carbon buildup 3 Piston pin bore worn 4 Piston pin worn 5 Piston rings ring groove s worn Replace service piston cylinder Clean chamber Replace piston Heplace piston pin Replace rings piston 0 n 3 4 Problem Engine noisy Noise seems to come from timing chain Condition Remedy 1 Chain stretched 1 Replace chain 2 Sprockets worn 2 Replace sprockets 3 Tension adjuster malfunctioning Repair replace adjuster Problem Engine noisy Noise seems to come from crankshaft Condition Remedy 1 Bearing worn burned 1 Replace bearing 2 Lower rod end bearing worn burned 2 Replace crankshaft 3 Connecting rod side clearance too large 3 Replace crankshaft Problem Engine noisy Noise seems to come from transmission Condition Remedy Replace gears Replace shaft s Heplace g
138. pen Regulator rectifier defective Battery voltage low 0 ho Cell plates battery defective Problem Magneto charges but charging rate is below the specification Remedy 9 n3 Remedy 1 replace tighten lead wires 2 Heplace magneto coils 3 Replace regulator rectifier 1 tighten lead wires Heplace stator coils Heplace regulator rectifier Recharging battery Replace battery 2 13 Problem Magneto overcharges Condition 1 Internal battery short circuited 2 Regulator rectifier damaged defective 3 Regulator rectifier poorly grounded Remedy 1 Replace battery 2 Replace regulator rectiher 3 Clean tighten ground connection Problem Charging unstable Condition 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier defective Problem Starter button not effective Remedy 1 Heplace lead wire 2 Replace magneto 3 Replace regulator rectifier Condition Battery charge low 2 Switch contacts defective 3 Starter motor brushes not seating 4 Starter relay defective 5 Emergency stop ignition switch off Wiring connections loose disconnected Problem Battery sulfation Acidic white powdery substance or spots on surfaces of cell plates Condition 1 Charging rate too low too high 2 Batter
139. pin should be round side out CF060A 2 If damaged the camshaft must be replaced Installing Top Side Components A Piston B Cylinder BNOTE If the piston rings were removed install them in this sequence A Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration 2 sc ia End Gap Oil Ring Expander End Gap ATV 1085B MNOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation B Install the compression rings 1 and 2 so the letter s on the top surface of each ring faces the top of the piston Rotate the rings until the ring end gaps are on directly opposite sides of the piston according to the illustration MNOTE The chrome silver ring should be installed in the top position MD1343A CAUTION Incorrect installation of the piston rings will result in engine damage 1 Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip 15 directed upwards or down wards MNOTE The piston should be installed so the arrow points towards the exhaust F MD1213 2 Place the two alignment pins into position Place a new cylinder gasket into position then place a pis ton holder or suitabl
140. posi tion of the shifter bracket for installing purposes 3 26 MD1188 NOTE Inspect the inside of the left side cover for any shaft washers that may have come off with the cover Make sure they are returned to their respec tive shafts and that the starter idler gear spacer is on the shaft or in the cover B Rotor Flywheel C Starter Motor BNOTE Steps 1 3 in the preceding sub section must precede this procedure 4 Remove the rotor flywheel nut MD1365 6 Using Magneto Rotor Remover break the rotor flywheel assembly loose from the crankshaft Remove the remover the crankshaft protector the rotor flywheel and the starter clutch gear Account for the key Care must be taken that the remover is fully threaded onto the rotor lywheel or damage may MD1305 8 Remove the gear shift shaft assembly and washer from the left side crankcase Mote the positions of the alignment marks and washer for installing pur poses then release the cam stopper spring tension MD1239 9 Remove the shift detent cam Note position of spacer for installing purposes 10 Remove the cam stopper assembly 11 Remove two starter motor cap screws 2 Remove starter motor by tapping lightly with a MD1370 mallet Remove the starter idler gear No and starter idler gear 2 The starter motor is non serviceable component and must be replaced as an assembly 13
141. progression for the complete servicing of the KYMCO engine transmission To service the center crankcase halves the engine transmission must be removed from the frame To service top side left side and right side compo nents the engine transmission does not have to be removed from the frame NOTE KYMCO recommends the use of new gaskets lock nuts and seals and lubricating all internal components when servicing the engine transmission NOTE Some photographs illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions B NOTE Critical torque specifications are located in Section 1 3 2 SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section Clutch Sleeve Hub Holder Connecting Rod Holder Crankcase Separator Crankshaft Remover Magneto Rotor Remover Oil Filter Wrench Piston Pin Puller Side Case Puller Spanner Wrench Surface Plate Valve Clearance Adjuster V Blocks NOTE Special tools are available from the KYMCO Spare Parts Department Specifications VALVES AND GUIDES intake 130 6 mm 1 20 in exhaust 27 0 mm 1 06 in intake 0 10 mm 0 004 in exhaust 0 17 mm 0 007 in Face Diameter vake Tappat Clearance cold engine Vabe Gulde Stem Clearance intake 0 04 mm 0 0016 in exhaust
142. r chips cracks or discoloration 2 Inspect the depth of the grooves in the clutch shoes If any shoe is worn to the bottom of the groove replace the complete set CAUTION Always replace clutch shoes as a complete set or severe imbalance could occur Inspecting clutch shoe groove ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1 Inspect the clutch housing for burns marks scuffs cracks scratches or uneven wear 2 If the housing 15 damaged any way the housing must be replaced INSPECTING PRIMARY ONE WAY DRIVE 1 Insert the drive into the clutch housing 2 Rotate the inner race by hand and verify the inner race rotates only one direction 3 If the inner race is locked in place or rotates both directions the drive assembly must be replaced INSPECTING OIL PUMP 1 Inspect the pump for damage 2 It is inadvisable to remove the screw securing the pump halves If the pump is damaged it must be replaced The oil pump 1 a non serviceable compo nent and must be replaced as a complete assem bly DRIVEN PULLEY ASSEIVIBLY BNOTE The driven pulley assembly is a non ser viceable component and must be replaced as a complete assembly Installing Right Side Components A Oil Strainer Oil Pump 1 Place the oil strainer into position beneath the crankcase Tighten Phillips head screws coated with red Loctite 271 securely MD1337 2 Place the strainer co
143. r Screw 2 Brake Disc 3 Wheel Hub Front 4 Hub Stud 5 Wheel Hub Rear 6 7 8 Nut Cotter Pin Wheel i 9 Mounting Nut 10 Tire 11 Valve Stem 0742 948 TIRE SIZE A WARNING Use only KYMCO approved tires when replacing tires Failure to do so could result in unstable ATV operation The ATV is equipped with low pressure tubeless tires of the size and type listed in Section 1 Do not under any circumstances substitute tires of a different type or size WARNING Do not mix tire tread patterns Use the same pattern type on front and rear Failure to heed warning could cause poor handling qualities of the ATV and could cause excessive drive train damage not covered by warranty TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0 4 kg cm 5 7 psi REMOVING Secure the a support stand to elevate wheels WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury 2 Remove the wheels Keep left side and right side wheels sepa rated for installing them on their proper sides CLEANING AND INSPECTING ENOTE Whenever part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the wheels and hubs using a pressure washer bJ Inspect each wheel for cracks dents or bends Inspect each tire for cuts wear missing lugs and leaks
144. r lead to a suitable ground 2 Select the OHMS position the tester and con nect the red tester lead to the lavender red wire then move the gear shift lever to the R reverse position The meter must read less than ohm 3 Move the red tester lead and shift lever in turn to the light green red wire and N neutral position white black wire and H high position and white red wire and L low position The meter must read less then 1 ohm in all positions If not the gear shift linkage must be adjusted see Sec tion 2 or the switch must be replaced Stator Coll VOLTAGE AC Generator Regulated Output 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the positive battery post then connect the black tester lead to the nega tive battery post 3 With the engine running at a constant 3000 RPM with the headlights on the meter must show 14 15 5 DC volts CAUTION Do not run the engine at high RPM for more than 10 seconds NOTE If voltage is lower than specified test charging coil no load VOLTAGE Charging Coil No load The connector is the yellow three pin one on the right side of the engine just above the starter motor NOTE Test the engine side of the connector 1 Set the meter selector to the AC Voltage position 2 Test between the three yellow wires for a total of three tests 3 With the engine running at the specified RPM all wire tests
145. r mallet drive out the output shaft assembly Account for the output shaft a shim a washer and the nut gt AT THIS POINT To service crankshaft assembly see Servicing Cen ter Crankcase Components sub section Servicing Center Crankcase Components MNOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary SECONDARY GEARS When checking and correcting secondary gear backlash and tooth contact the universal joint must be secured to the front shaft or false measurements will occur Checking Backlash MNOTE The rear shaft and bevel gear must be removed for this procedure Also always start with the original shims on the rear shaft 1 Place the left side crankcase cover onto the left side crankcase half to prevent runout of the secondary transmission output shaft 2 Install the secondary driven output shaft assembly onto the crankcase 3 Mount the indicator tip of the dial indicator on the secondary driven bevel gear centered on the gear tooth 4 While rocking the driven bevel gear back and forth note the maximum backlash reading on the gauge 5 Acceptable backlash range is 0 05 0 33 mm 0 002 0 013 in Correcting Backlash BNOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new t
146. rn 7 Replace arms shafts 8 Spark plug gap incorrect B Adjust gap replace plug 3 Fuel Injector obstructed 9 Clean Fuel Injector h Fuel Pump defective Air cleaner element obstructed Replace Fuel Pump Clean element oll 6 12 in the engine overfilled contaminated 12 Drain excess oil change oil 13 Intake manifold leaking air 13 Tighten replace manifold 14 Cam chain worn 14 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 1 Clean piston Oil low Octane low gasoline poor pump defective circuit obstructed Engine Coolant too low Intake manifold leaking air Fan malfunctioning Fan switch malfunctioning Add oil Drain replace gasoline Replace pump Clean circuit Fill Engine Coolant to the upper limit Tighten replace manifold Check fan fuse replace fan Heplace fan switch 2 4 5 6 7 8 Jg Table of Contents Removing Engine Transmission Top Side Components Ce Seen ee lt Removing Top Side Components Servicing Top Side Components THIRD E AE Installing Top Side Components 3 21 Left Side Components 3 25 Removing Left Side Components DIEN 57 v Installing Left Side Components oss 2 28 Right Side Components
147. rokes 6 If compression is abnormally low inspect the following items A Verify starter cranks engine over at normal speed approximately 400 RPM B Gauge functioning properly C Throttle lever in the full open position D Valve tappet clearance correct E Valve not bent or burned F Valve seat not burned ENOTE To service valves see Section 3 7 Pour 29 5 ml 1 fl oz of oil into the spark plug hole reattach the gauge and retest compression 8 If compression is now evident service the piston rings see Section 3 2 7 Spark Plug A light brown insulator indicates that a plug 15 correct A white or dark insulator indicates that the engine may need to be serviced or the carburetor may need to be adjusted To maintain a hot strong spark keep the plug free of carbon Before removing a spark plug be sure to clean the area around the spark plug Dirt could enter engine when removing or installing the spark plug Adjust the gap to 0 7 0 8 mm 0 028 0 032 in for proper ignition Use a feeler gauge to check the gap 0 7 0 8 mm m 0 028 0 032 in ATVOOS2C When installing the spark plug be sure to tighten securely A new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug should be tightened 1 8 1 4 turn once the washer contacts the cylinder head 2 8 Muffier Spark Arrester Al the intervals shown in the Penodic Ma
148. ront Body Panel Fender 8 7 Exhaust SY SION 8 8 Rear Body 8 9 Bios c m 8 11 Steering Frame BNOTE Critical torque specifications are located in Section 1 Steering Post Tie Rods REIVIOVING Remove the front body panel fender see Front Body Panel Fender in this section 2 Remove the steenng post cover then remove the cap screws securing handlebar caps and move the handlebar out of the wav Account for the two handlebar caps 3 Remove the cap screws securing the upper steer ing post to the frame Account for the housing cap outer housing and inner housing Housing Housing 4 Remove cotter pins from the inner tie rod ends then remove the nuts and disconnect the inner tic rod ends B 2 KC184A ENOTE If tie rods are to be completely removed remove the outer tie rod ends from the knuckles at this time 5 Remove the cap screw securing the lower steering post to the beanng Account for a flat washer Remove the steenng post from the ATV CLEANING AND INSPECTING BNOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary Wash the tie rod ends in parts cleaning solvent Dry with compressed air Inspect the pivot area for wear Apply a low temperature grease to the ends
149. s and worn bushings 3 Inspect the frame mounts for signs of damage wear or weldment damage INSTALLING 1 Install the A arm assemblies into the frame mounts and secure with the cap screws and new lock nuts Only finger tighten at this time 2 Slide the knuckle onto the drive axle and into posi tion on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to 35 ft lb 3 Tighten the hardware securing the A arms to the frame mounts from step 1 to 35 ft lb 4 Apply grease on the drive axle splines then install the hub assembly onto the drive axle Secure hub assembly with the nut Tighten only until snug 7 4 6 Secure the brake caliper to the knuckle with the two cap screws right side only Tighten the cali per to 20 ft lb 7 Compress the hand brake lever and engage the brake lever lock then secure the hub nut from step 5 to the drive axle Tighten to 200 ft lb 8 Install a new cotter pin and spread the pin to secure the nut 9 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten to 35 ft lb 10 Secure the shock absorber to the lower A arm with cap screw and new lock nut Tighten to 20 ft lb Secure the boot guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheel and tighten to 40 ft lb 13 Remove the ATV from the support stand Wheels and Tires KEY 1 Shoulde
150. screw before releasing the brake lever Repeat this procedure until no air bubbles are present 2 16 Bleeder Screw ENOTE During the bleeding procedure watch the reservoir sight glass very closely to make sure there is always a sufficiant amount of brake fluid When the sight glass changes from dark to light refill the reservoir before the bleeding procedure is continued Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the sys tem D Repeat step C until the brake lever 15 firm E At this point perform step B and D on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same pro cedure 4 Carefully check the entire hydraulic brake system that all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present Brake fluid that has been drained or bled from the brake system must NEVER be re used or severe brake system corrosion and damage may occur Always discard used brake fluid in an appropriate manner This hydraulic brake quete is designed to use DOT 4 brake fluid only brake fluid must be added care must be taken as brake fluid is very corrosive to painted surfaces INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING PADS The clearance between the brake
151. se 6 Remove the from the support stand and release the brake lever lock To assure proper seating of the axle give it a light pull the axle should remain clipped in place 7 Check the front differential oil level and add oil as necessary 2 Swing the knuckle up and onto the drive axle then place the knuckle into place in the upper A arm Secure the knuckle to the A arm with a cap screw and a new lock nut Tighten to 35 ft lb 3 Place the hub into position on the axle followed by a hex nut Tighten the hex nut finger tight at this time 4 If the brake caliper was removed position it on the knuckle and secure with existing cap screws Tighten the brake caliper cap screws to 20 ft lb 5 Pump up the hand brake lever then engage the CFi13A brake lever lock 6 Tighten the hub hex nut from step 3 to 200 ft Ib then install and spread a new cotter pin making Rear Gear Case sure each side of the pin 15 flush to the hub nut 7 Install the wheel Tighten to 40 ft Ib nstall the wheel Tighten to REMOVING 8 Remove the ATV from the support stand and release the brake lever lock 1 Remove both of the rear drive axles see Drive Axles in this section INSTALLING FRONT DRIVE AXLE 2 Remove the four cap screws securing the engine 1 Position the drive axle in the gear case and steer output shaft to the rear gear case input flange ing knuckle then insert the upper A arm ball joint i
152. second cap screw secunng the sprocket to the camshaft can be installed then install the cap screw threads coated with red Loctite 271 Tighten to 11 ft lb then bend the tab to secure the cap screw 19 Rotate the crankshaft until the first cap screw from step 17 eae the sprocket to the cam shaft can be addressed then tighten to 11 ft lb Bend the tab to secure the cap screw 20 Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards 21 Remove the cap screw from the end of the chain tensioner 22 Depress the spring loaded lock and push the plunger into the tensioner 23 Place cam chain tensioner assembly and gasket into the cylinder making sure the ratchet side is facing toward the top of the cvlinder and secure with the two cap screws 24 Install the cap screw and spring into the end of the cam chain tensioner Tighten securely 25 Loosen the adjuster screw jam nuts then loosen the adjuster screws on the rocker arms in the valve cover 26 Apply a thin coat of Three Bond Sealant to the mating surface of the valve cover then place the valve cover into position Note that the two align ment pins arc properly positioned ENOTE At this point the rocker arms and adjuster screws must not have pressure on them disassemt 27 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until
153. stem fuel economy e Pinched or clogged fuel hose e Clogged fuel injector e Faulty fuel injector e Faulty spark plug or wrong type e Clogged Airflow Bypass Valve e Wet spark plug Engine stall hard to start rough idling e Intake air leak e Fuel contaminated deteriorated e Pinched or clogged fuel hose e Idle speed miss adjusted e Wet spark plug 11 18 KYMCO 1 EFI SYSTEM 4501 Diagnostic Report GQ KYMCO DiagnosticReport LGC7 SF Customer Eng No Production Service Date Date Reason of repair maintenance breakdown 2 Reference 0 ae e pooo O Mileage identification Marking AA4LGCTOKAC 5 __ 062005 V aning pew Throttle closed opened fully O 67V20 05 3 6V Throttle closed opened fully Wrrempco environtemp 22 C Atom Pressure Kpa 101353kPa Battery Voltage 1400 100rpm E 9 17 BIL dog 1003 Hoja Jie da ayy usuy Report ID Report Version Feb 22 2010 11 19 KYMCO 11 FUEL SYSTEM MXU 450i 47477 Diagnostic Tool FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 EO0 ENGLISH VERSION version V 1 0 7 11 20 KYMCO FUEL SYSTEM MA 1 FI DIAG
154. surface Turn the ignition switch to OFF Remove the screws washers and tilt switch Do not disconnect tilt switch connector during inspection Place the tilt switch vertical as shown and turn the ignition switch to Measure the voltage between the following terminals of the tilt switch connector with the connector connected V R 4 G 5 V ECU voltage B W G 0 4 1 4 V Incline the tilt switch 65 10 degrees to the left or right with the ignition switch turned to P Measure the voltage between the following Bis S terminals of the tilt switch connector with the 3 X connector connected En V R G 5 V ECU voltage BW GO If repeat this test first turn the ignition switch to OFF then turn the ignition switch to Roll Sensor REMOVAL INSTALLATION Disconnect connector and remove two screws Remove the Tilt switch Installation is in the reverse order of removal Install the tilt switch with its mark facing up Tighten the mounting screws securely 11 17 KYMCO 11 EFI SYSTEM MAXXER 450i TROUBLESHOOTING Engine won t start Backfiring or misfiring during acceleration e Battery voltage too low Ignition system malfunction e Fuel level too low e Pinched or clogged fuel hose Poor performance drive ability and poor e Faulty fuel pump operating sy
155. t lb KC138 3 36 o XS KC141 At this point the cap screw can be removed from the driven pulley face 18 Rotate the V belt and drive driven assemblies until the V belt is flush with the top of the driven pulley 19 Install two alignment pins and place a new V belt cover gasket into position on the clutch cover Install the V belt cover noting the position of the long cap screws and rubber washer and two wire forms In a crisscross pattern tighten cap screws to 8 ft lb KC142A Center Crankcase Components BNOTE This procedure cannot be done with the engine transmission in the frame Complete Removing procedures for Top Side Left Side and Right Side must precede this procedure BNOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the left side and right side cap screws securing the crankcase halves noting the position of the different sized cap screws for joining pur poses MD1006 MD1012 2 Using Crankcase Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crankcase halves Account for two alignment pins CC869 To keep the shaft gear assemblies intact for identification tap the shafts
156. t lb N m ft lb 254 1054 1047 SS 28 381 106 1 394 54 734 79 1074 _ 741 22 2 102 2 2 8 109 33 449 83 112 9 122 34 462 _ pepe Eng x a Se 6 1 s 197 Bo e 54 4 EE E 90 1224 218 55 8 1 123 42 571 92 125 1 43 585 93 1265 O BO a 2 ss 1202 OGO Z 29 9 63 9 72 979 1319 31 3 65 3 73 133 6 49 566 99 134 6 50 68 75 102 100 Tightening Torque General Bolts Thread Diameter Type of Bolt Conventional or4 Marked Bolt A 12 36 in Ib 36 60 in b 8 7 11 ft lb 10 16 25 ft lb 7 Marked Balt 5 24 48 in Ib 6 8 ftlb 13 20 ft lb 29 43 ft lb 1 3 Break In Procedure A new ATV and an overhauled engine require a break in period The first 10 hours or 200 miles are most critical to the life of this ATV Proper operation during this break in period will help assure maximum life and performance from the ATV During the first 10 hours or 200 miles of operation always use less than 1 2 throttle Varying the engine RPM during the break in period allows the components to load aiding the mating process and t
157. t to the pinion gear BNOTE Align the bearing alignment pin on the secondary output shaft MD1198 8 Install the outer shift fork and the shift fork shaft MD1316 MD1327 3 43 Joining Crankcase Halves Verify that the two alignment pins are in place and that both case halves are clean and grease free Apply Three Bond Sealant to the mating surfaces Place the nght side half onto the left side half 2 Using a plastic mallet lightly tap the case halves together until cap screws can be installed 3 From the nght side install the crankcase cap screws noting the location of the different sized cap screws then tighten only until snug ENOTE Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws 4 From the left side install the remaining crankcase cap screws then tighten only until snug ENOTE Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws 5 In crisscross case to case pattern tighten the 8 mm cap screws until the halves are correctly joined then tighten to 21 ft lb BNOTE Rotate the shafts back and forth to ensure no binding or sticking occurs In a erisseross case to case pattern tighten the 6 mm cap screws to 10 ft Ib BNOTE Rotate the shafts back and forth to ensure no binding or sticking occurs THIS POINT After completing center crankc
158. the bulb Do not attempt to remove a bulb when it is hot Severe burns may result To replace the headlight bulb use the following proce dure 1 Remove the protective cover from the rear of the headlight housing then remove the wiring harness connector from the back of the headlight bulb 2 Remove the headlight bulb assembly from the headlight housing 3 Install the new headlight bulb into the headlight housing being careful not to get fingerprints or other contaminates on the glass 4 Connect the winng hamess connector to the bulb then install the protective cover making sure it seals completely on the headlight harness TAILLIGHTS BRAKELIGHTS To replace a taillight brakelight bulb use the follow ing procedure Turn the bulb socket assembly counterclockwise and remove from the housing 2 Press in and tum the bulb counterclockwise to remove Press in and turn clockwise to install the bulb 3 Insert the bulb socket assembly into the housing and it clockwise to secure RUNNING LIGHTS BACK UP LIGHTS The running lights are located outboard of the head lights and the back up lights are outboard of the tail hghts brakelights To replace bulbs use the following procedure 1 Rotate the bulb socket counterclockwise to release from light housing then press in on the bulb and turn counterclockwise to release from the socket 2 Install new bulb and press in rotating cloc
159. the inner boot ATV 1048 3 Apply 80 grams 2 3 of contents of grease from the pack into the bearing housing 4 Install the bearing onto the shaft making sure the recess of the bearing is facing the housing CD022 The bearing ring must go onto the shaft with the side without splines facing toward the small clamp of the inner boot or severe damage will result 5 Secure the bearing ring with the snap ring making sure the sharp side of the snap ring faces away from the boot 0023 6 Making sure marks made during disassembling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and install the circlip MNOTE Pull the bearing ring out of the housing until it contacts the circlip then slide the ring in half way This will purge air from the housing and ensure the bearing is packed properly 0021 7 Slide the boot over the housing then using boot clamp pliers secure the boot with the clamp 6 17 4 Tighten hub hex nut from step 2 to 200 ft lb then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut CD024 8 Inspect the axle components for correct position ing of the four clamps Also inspect the boots for being correctly positioned on the shaft INSTALLING REAR DRIVE AXLE 5 Install the wheel and tighten to 40 ft lb KC305 1 Slide the drive axle into place in the gear ca
160. then turn the ignition switch to the ON position Note that the fuel pump runs momentarily and the fuel gauge indicate the proper fuel level 5 With the transmission in neutral and brake level lock engaged start the engine and checks for normal operation Check for any fuel leaks 6 Install any wire ties that were removed then install the rear fenders rack and seat making sure the seat locks securely 11 4 KYMCO 11 EFI SYSTEM MAXXER 450i WTS SENSOR Water Temperature Sensor REMOVAL INSTALLATION Drain the coolant from the cooling system Disconnect the WTS sensor connector from the sensor Remove the WTS sensor and O ring Install a new O ring and WTS sensor Always replace an O ring with a new one Tighten the WTS sensor to the specified torque Torque 1 2 kgf m 12 8 6 Connect the WTS sensor connector Fill the cooling system with the recommended coolant INSPECTION Measure the resistance at the WTS sensor terminals STANDARD O ring 11 5 KYMCO 11 EFI SYSTEM MAXXER 450i THROTTLE BODY SENSOR ISC TPS TPS Sensor T MAP Sensor eTurn off the ignition switch while replacement Check and confirm if the voltage is over 12V by a voltmeter after replacement Check and confirm if the other connectors are installed correctly after replacement not damage the throttle body it may cause the throttle and idle valve isn t synchro
161. ting of the actuator 5 Tighten the remaining cap screws then connect the electrical plug to the main hamess Tum the ignition switch to the ON position and check the operation by shifting the selector switch several times Secure winng hamess to the frame with nylon cable tie Front Differential REMOVING DIFFERENTIAL Secure the ATV a support stand to elevate the WARNING Make the ATV 15 solidly supported on the sup port stand to avoid injury 2 Remove the drain plug and drain the gear lubncant into drain then reinstall the plug and tighten Front Differential View from Beneath 0082 3 Remove front wheels 4 Pump up the hand brake then engage the brake lever lock 5 Remove the cotter pin securing the hex nut then remove the hex nut 6 Release the brake lever lock It is not necessary to remove the brake hoses from the calipers for this procedure 7 Remove the left and right brake calipers Account for the four cap screws KC187A 8 Remove the upper and lower ball joint cap screws taking care not to strip the threads CAUTION Apply pressure to hold the ball joint firmly in the knuckle or the threads will be stripped when the retaining cap screws are removed 6 4 AF628D 9 Pull the steering knuckle away from the axle tak ing care not to damage the seals as the axle clears the knuckle KC314 1
162. tion For 1 5 Preparation After 1 5 1 1 General Specifications EXHAUST COMPONENTS Torgue Part Part Bolted To ft4b ENGINE AND DRIVE BL lal E EE Four Cycle Liquid Cooled Spark Arrester Muffler 55 89 71 2 3 56 2 801 ELECTRICAL COMPONENTS Displacement 9 cc 26 57 cu in Frame 12 16 lgnition Type IDi Inductive Discharge Ignition E E Spark Plug Type EEG EE 0 7 0 8 mm 0 028 0 032 in Frame 20 27 Brake Type Hydraulic Handlebar Cap Steering Post 20 27 with Parking Brake amp Foot Brake Lower Steering Post Bearing steering Post alg STEERING COMPONENTS Cap Screw Fuel Delivery Electronic Fuel Injection EFI Tie Rod Steering Postam 30 BRAKE COMPONENTS CHASSIS Brake Disc Hub 15 20 Length Overall 190 5 76 Brake Hose Caliper 20 27 Height Overall 121 0 48 Brake Hose Master Cylinder 20 27 Width Overall 123 0 cm 49 In Auxiliary Brake suspension TraveliFRARR 19 9 8 Din 20 3 em 8 1 Master Cylinder Rear Frame 8 11 Wheelbase 122 5 49 Master Cylinder Clamp Tire Size Front 21 8 12 ors Master Cylinder 5 5 8 gt TRITUM Front 2310 12 en
163. to ensure proper handling 7 5 Troubleshooting Problem Suspension too soft 1 Spring s weak 1 Replace spring s 2 Shock absorber damaged 3 Shock absorber preload too low 2 Replace shock absorber 3 Adjust shock absorber preload Problem Suspension too stiff 1 A arm related bushings worn 1 Replace bushing 2 Shock absorber preload too high 2 Adjust shock absorber preload Problem Suspension noisy 1 Cap screws suspension system loose 1 Tighten cap screws 2 A arm related bushings worn 2 Replace bushings Problem Rear wheel oscillation 1 Rear wheel hub bearings worn loose 1 Replace bearings 2 Tires defective incorrect 2 Replace tires 3 Wheel rim distorted 3 Replace rim 4 Wheel hub cap screws loose 4 Tighten cap screws 5 Auxiliary brake adjusted incorrectly 5 Adjust brake 6 Rear suspension arm related bushing worn 6 Replace bushing 7 Rear shock absorber damaged 7 Replace shock absorber 8 Rear suspension arm nut loose 8 Tighten nut SECTION 8 STEERING FRAME TABLE OF CONTENTS 8 2 Steering Post Tie Rods 8 2 Hardlebar Gm ie 8 3 Steering KmUGKIeS eiiis indices trama tette deese 8 4 Measuring Adjusting 8 5 FONT RACK arseen a E 8 6 Front Bumper 8 6 F
164. unout using a dial indi cator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications Measuring Valve Guide Valve Stem ATV 1082 Deflection Wobble Method 2 Maximum runout must not exceed specifications 1 Mount a dial indicator and base on the surface Measuring Valve Stem Outside plate then place the cylinder head on the surface Diameter plate 2 Install the valve into the cylinder head then posi tion the dial indicator contact point against the out side edge of the valve face Zero the indicator 1 Using a micrometer measure the valve stem out side diameter 3 14 221210 3 Push valve from side to side then from top to bottom 4 Maximum wobble deflection must not exceed specifications Measuring Valve Guide Inside Diameter Insert a snap gauge 1 2 way down into each valve guide bore then remove the gauge and measure it with micrometer Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance the cylinder head must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacement Arctic Cat recommends that the com ponents be taken to a qualified machine shop for ser vicing valves are discolored or or the seating surface is worn the valve must be replaced Do not attempt to grind the valv
165. uts bolts cap screws screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications Disconnect the battery cables then remove the battery clean the battery posts and cables and store in a clean dry area 9 Store the ATV indoors in a level position Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the causing rusting Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding KYMCO recommends the following procedure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the muffler 3 Check all control cables for signs of wear or 6 Check the entire brake systems fluid level fraying Replace if necessary pads etc all controls lights and headlight aim adjust or replace as 4 Change the engine transmission oil and filter necessary 7 Tighten all nuts bolts cap screws 5 Charge the battery then install Connect screws making sure all calibrated nuts cap the battery cables screws and bolts are tightened to CAUTION The ignition switch must be in the OFF position specifications 8 Check tire pressure Inflate to recommended i i i r r n ry prior to installing
166. ven gear dog then remove the circlip securing the reverse driven gear 2 Remove the reverse driven gear and account for the washer bushing and bearing 3 Remove the low driven gear washer then remove the low driven gear Account for the bushing and bearing 4 Remove the washer then remove the circlip secur ing the sliding dog Remove the sliding dog 5 Remove the high driven gear circlip then remove the high driven gear Account for the washer bushing and bearing Assembling 1 Place the high driven gear onto the countershaft making sure the bearing bushing and washer are properly positioned Secure with the circlip 2 Place the sliding dog onto the countershaft then secure with the circlip Place the washer next to the circlip 3 Place the low driven gear onto the countershaft making sure the bearing and bushing are properly positioned then place the washer onto the shaft 4 Place the reverse driven gear onto the countershaft making sure the bearing bushing and washer are properly positioned then secure with the circlip 5 Place the reverse driven gear dog onto the counter shaft BNOTE The countershaft is now completely assembled for installation 3 41 Assembling Crankcase Half For ease of assembly install components on the right side crankcase half If the output shaft was removed make sure that the proper shim is installed 1 Install the output shaft
167. ver into position on the crank case making sure the O ring 15 properly installed and secure with the four cap screws then tighten the oil drain plug to 20 ft lb MD1208 3 Place two alignment pins and the oil pump into position on the crankcase and secure with the Phil lips head screws coated with blue Loctite 243 Tighten to 8 ft lb 3 33 1060 4 Place the pin into position oil pump shaft install the pump driven gear making sure the recessed side of the gear 15 directed inward and secure with a new snap ring BNOTE Always use a new snap ring when install ing the oil pump driven gear MD1019 5 Install the cam chain BNOTE Keep tension on the cam chain to avoid damaging the crankcase boss 6 Place the pin into position install the oil pump drive gear and tighten the cap screw coated with red Loctite 7271 to 63 ft Ib 3 34 MD1018 7 Install the clutch shoe assembly on the crankshaft then install the flange nut left hand thread coated with red Loctite 271 Tighten to 147 ft lb The flat side of the flange nut should be directed towards the clutch shoe CAUTION Care must be taken when installing the flange nut it has left hand threads 8 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase MD1286 9 Install gear shift position switch spacer and switch making sure t
168. warm soap and water Inspect side panels and rear body panel for cracks and loose rivets Inspect threaded areas of all mounting bosses for stripping Inspect for missing decals INSTALLING Place the rear body pancl fender in place on the then secure with the cap screws on the side frame and the rear rack assembly Tighten all fas teners securely 8 10 2 Connect the light connectors and secure to the frame then install the battery starter relay and auxiliary brake Connect all wiring making sure to connect the positive cables first 3 Secure the rear fenders to the footwells and tighten the nuts securely 4 Install the side panels and seat Troubleshooting Problem Handling too heavy stiff 1 Front wheel alignment incorrect 2 Lubrication inadequate 3 Tire inflation pressure low 4 Tie rod ends seizing 5 Linkage connections seizing Problem Steering oscillation Adjust alignment Lubricate appropriate components Adjust pressure Replace tie rod ends Repair replace connections Tires inflated unequally Wheel s wobbly Wheel hub cap screw s loose missing Wheel hub bearing worn damaged Tie rod ends worn loose Tires defective incorrect A arm bushings damaged Bolts nuts frame loose Problem Steering pulling to side Adjust pressure Replace wheel s Tighten replace cap screws Replace
169. wer distribution module PDM in front of the steering tube If there is anv type of electrical system failure always check the fuses first KC210A ENOTE The ignition switch must be in the LIGHTS position 1 Remove all fuses from the distribution module Set the meter selector to the DC Voltage position 3 Connect the black tester lead to ground 4 Using the red tester lead contact each end of the fuse holder connector terminals individually 5 The meter must show battery voltage from one side of the connector terminal ends BNOTE Battery voltage will be indicated from only one side of the fuse holder connector terminal the other side will show no voltage ENOTE When testing the HI fuse holder the head light dimmer switch must be in the HI position when testing the LIGHTS fuse holder the headlight dimmer switch can be in either position ENOTE the meter shows no battery voltage troubleshoot the battery switches distribution module or the main wiring harness l Set the meter selector to the OHMS position 2 Connect the red tester lead to one spade end of the fuse then connect the black tester lead to the other spade end 3 The meter must show less than ohm resistance If the meter reads open replace the fuse BNOTE Make sure the fuses are returned to their proper position according to amperage Hefer to the fuse block cover for fuse placement Ignition Coil The
170. y run down damaged Problem Battery discharges too rapidly Remedy 1 Charge replace battery Replace switcn 2 3 Replace starter motor 4 Replace relay 5 Turn on switches 6 Connect tighten repair connections Remedy 1 Replace battery 2 Replace battery Condition E Charging system not charging 2 Cell plates overcharged damaged 3 Battery short circuited Problem Battery polarity reversed Remedy 1 Check magneto requiator rectifier connections 2 Heplace battery correct charging system 3 Replace battery Condition 1 Battery incorrectly connected 9 14 1 Reverse connections replace battery repair damage SECTION 6 DRIVE SYSTEM TABLE OF CONTENTS Drive 6 2 Front Drive AGUA 6 2 Front Differential 6 3 TT 6 14 Rear Gear Case 6 18 6 19 Hydraulic Brake 6 20 Troubleshooting Drive System 6 22 Troubleshooting Brake System 6 22 Drive System NOTE Some photographs and illustrations used in this section used for clarity purposes only and are not designed to depict actual conditions NOTE Critical located i
171. ylinder Head Distortion Cylinder Head Cover Distortion CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 060 0 073 mm 0 0024 0 0029 in Piston Diameter 15 mm 0 6 in 88 06 88 98 from Skirt End Piston Ring Free End Gap min 3 558 3 559 in 1st 8 0 mm 0 3150 in 2nd 8 3 mm 0 3268 in 189 712 mm 3 56 2 80 in Bore x Stroke Cylinder Truenass Piston Ring End Gap Installed 0 15 0 30 mm 0 006 0 012 in Piston Ring to Groove 0 06 mm 0 002 in Clearance max Piston Ring Groove Width ist 1 01 1 03 mm 0 0398 0 0406 in 2nd 1 21 1 23 mm 0 0476 0 0484 in oil 2 01 2 03 mm 0 0791 0 0799 in 150 1 01 1 03 mm 0 0404 0 0412 in 2nd 1 17 1 19 mm 0 0468 0 0476 in Piston Ring Thickness Piston Pin Bore max 20 008 mm 0 7877 iin Piston Pin Outside Diameter min 19 994 mm 0 7872 in CRANKSHAFT Connecting Rod max 20 021 mm small and inside diameter 0 7882 in Connacting Rod 10 10 0 55 mm big end side to side 10 004 0 022 in Connecting Rod big end width 21 95 22 00 mm 0 8642 0 8661 in Connecting Rod max 0 3 mm 0 012 in small end deflection Crankshaft web to web 60 8 60 9 mm 2 393 2 397 In Crankshaft Runout Specifications subject to change without notice max 0 01 mm 0 0004 in max 0 03 mr 0 001

11. fuel system

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