KYMCO MXER 50R Owner'S Manual Download | Manualshive

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F

Speed limiter for new riders.....................77
BRAKING..............................................78
TURNING YOUR ATV .............................79
CLIMBING UP SLOPE...........................80
RIDING DOWN SLOPE .........................86
PARKING..............................................87
WHAT TO DO IF....................................88
WHAT TO DO.......................................88

MXER

PERIODIC MAINTENANCE/

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

Engine oil (MXER 90R)...........................95
Transmission oil.....................................99
Spark plug inspection............................102

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

Valve clearance adjustment

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

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

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

PERIODIC MAINTENANCE AND
ADJUSTMENT.........................................89

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

PERIODIC MAINTENANCE/

LUBRICATION (

50R)....................91

Front and rear brake shoes (drum brake)
inspection...........................................110

Front brake lever free play adjustment....111

Rear brake lever free play adjustment

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

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

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

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

Drive chain slack adjustment.................120
Drive chain cleaning and Lubrication......122

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

Brake lever lubrication..........................123
Knuckle shaft and rear fork shaft
l u b r i c a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3
Draining the V-belt compartment
(MXER 90R)........................................123

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

Wheel removal.....................................124
Wheel installation.................................124
Battery .............................................125
Fuse replacement................................127

Troubleshooting ...............................131
Troubleshooting chart........................132

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Summary of Contents for MXER 50R

Page 1: ...OWNER S MANUAL KWANG YANG MOTOR CO LTD MXER 50R 90R ON ROAD...

Page 2: ......

Page 3: ...this vehicle Anyone who operates this vehicle should get proper instruction KXR 90 FOR ON ROAD USE ONLY The minimum recommended age for this ATV model is 12 Children under age 12 should never operate...

Page 4: ...is manual can result in SERIOUS INJURY or DEATH Indicates a strong possibility that serious injury or death may result if instructions are not followed CAUTION Indicates a possibility that equipment o...

Page 5: ...information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or mainten...

Page 6: ...R 31 Parking brake 50R 32 Fuel tank cap 34 Fuel valve 35 Locking steering 90R Seat 38 Flag pole bracket 39 Storage compartment 39 CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 SAFETY INF...

Page 7: ...MXER 50R 53 Parking 56 Parking on a slope 57 Accessories 58 Riding Your ATV 59 GETTINGTO KNOWYOURATV 60 RIDE WITH CARE AND Loading and Operational Guidelines 69 JUDGEMENT 61 GOOD Age Recommendation M...

Page 8: ...ATION 50R 91 Front and rear brake shoes drum brake inspection 110 Front brake lever free play adjustment 111 Rear brake lever free play adjustment Drum brake 113 Brake pedal adjustment MXER 90R 115 Br...

Page 9: ...G CLEANING AND STORAGE 133 A Cleaning 133 B Storage 135 SPECIFICATIONS MXER 50R 137 SPECIFICATIONS MXER 90R 141 INDEX 147 NOISE REGULATION 145 MAINTENANCE RECORD 146 Page...

Page 10: ...LOCATION OF THE WARNING AND SPECIFICATION LABELS 1...

Page 11: ...your KYMCO dealer for replacements 2 Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate Without proper training or instruction At speeds too fast for your skills the conditions Do not...

Page 12: ...set tire pressure over the recommended 2 22 28 kpa 0 22 0 28 kgf cm 3 2 4 0 psi 2 WARNING Operating this ATV if you are under the age of 12 increases your chance of severe injury or death operate thi...

Page 13: ...helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants A child under 12 years old should never operate an ATV wi...

Page 14: ...oth feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV...

Page 15: ...is manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go s...

Page 16: ...mes or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in t...

Page 17: ...e engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your machine in an area w...

Page 18: ...ION 9 1 Ignition switch key identification number 2 Steering lock key 90R MXER identification number Identification number records Record the keys identification number frame serial number engine seri...

Page 19: ...l number The frame serial number is stamped on the front of the frame The engine serial number is stamped on the left crankcase 1 1 1 Frame serial number 1 Engine serial number MXER 50R 2 Engine seria...

Page 20: ...ignal light 02 Rear brake lever 03 Left back mirror 04 Headlight 05 Right back mirror 06 Front brake lever 07 Right front turn signal light 08 Front wheel 09 Position light 11 01 03 04 05 06 07 02 Par...

Page 21: ...01 Throttle lever 02 03 Instrument 04 Left rear turn signal light 05 06 Right Remote engine stop switch Rear wheel rear turn signal light 12 02 01 03 04 05 06 05...

Page 22: ...02 01 03 04 05 07 08 06 01 Flag pole bracket 02 Right footboard 03 Indicator lamps 04 Parking brake 90R 05 Parking brake 50R 06 Fuel fill cap 07 Left footboard 08 MXER MXER Taillight Stop light 13...

Page 23: ...01 Storage compartment containing Owner s manual Air pressure gauge Tool kit 02 Handlebar switches 03 Fuel vavle 04 Kick starter 05 Exhaust pipe 02 01 04 03 05 14...

Page 24: ...u have purchased may differ slightly from those shown in the figures of this manual 15 02 03 01 04 06 05 01 Speed limiter 02 Ignition switch 03 Seat 04 Seat lock lever 05 Brake pedal 06 Steering handl...

Page 25: ...switch positions are as follows ON The position and taillight can be turned on With the engine stop switch at run the engine can be started The key can not be removed OFF All electrical circuits are s...

Page 26: ...eam and the ignition switch is ON The low level indicator lights when the 2 stroke engine oil level is low 1 Right Left turn signal indicator lamps 2 High beam indicator lamp 3 Low oil level indicator...

Page 27: ...bol 2 3 4 5 6 Bar graph speed symbol Mode symbol Auto automatic start stop mode symbol Distance scale symbol Data display TM DST ODO CLOCK Instruments Display description ODO M O D E TM DST P T T S O...

Page 28: ...arted or stopped While the unit is operating the TM symbol flashes MODE ST STOP Button When the mode button and ST STOP button are pressed DST TM are cleared DST ODO CLOCK simultaneously MODE TM ODO D...

Page 29: ...n motion TM Elpased time is measures from the starting point of a trip DST Trip distance is measures traveled since the time of the last reset ODO Total distance Mileage is continuously measured accum...

Page 30: ...21 CLOCK The 24HR clock always displayed the current time on the screen...

Page 31: ...h mile h Press the MODE button and press the ST STOP button to setting wheel circumference the body to set wheel circumference is MXER 50R 1400mm MXER 90R 1570mm Press the MODE button and press the S...

Page 32: ...to another lane The turn signal light will wink when the switch is operated For turning to the For turning to the The instrument turn signal indicator light will also wink when the switch is operated...

Page 33: ...turned on only when the engine is running NOTE Headlight switch Turn the switch to the position to switch on the low beam Turn the switch to the position to switch on the high beam Turn the switch to...

Page 34: ...e switch is in OFF position the engine will not operate This switch is intended primarily as a safety or emergency control and it should normally remain in the RUN position If you stop your ATV by tur...

Page 35: ...at RUN See starting instructions prior to starting engine see page 50 for details CAUTION If the starter switch is pushed with the ignition switch and the engine stop switch the starter motor will be...

Page 36: ...the kick starter is operated with the ignition switch at and the engine stop switch the engine will not start To start the engine be sure to position the engine stop switch at NOTE Kick starter The ki...

Page 37: ...the engine by pulling a tethered core Practice using it when your youngster first starts riding See page 76 NOTE Make sure the tethered road lead is installed into the remote engine stop switch When...

Page 38: ...tion of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the oper...

Page 39: ...ATV POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an a...

Page 40: ...and rear brakes The front and rear brakes are operated by squeezing the front brake lever 1 31 Brake pedal MXER 90R The both front and rear brakes are operated at the same time by depressing the brake...

Page 41: ...ith the lock plate Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the rear brake lever until the lock plate releases Using the parking bra...

Page 42: ...it with the lock pin Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the front brake lever until the lock pin releases Using the parking br...

Page 43: ...not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performan...

Page 44: ...in this position fuel flows to the carburetor Normal riding is done with the lever in this position This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL...

Page 45: ...dlebar is released automatically The key can be taken out MXER 90R POTENTIAL HAZARD Improper use of the locking steering WHAT CAN HAPPEN The ATV could cause loss of control or overturn HOW TO AVOID TH...

Page 46: ...proper operation See page 50 MXER 1 Fully open 2 Half open 3 Closed A Starter choke 1 2 3 A B B CAUTION Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life o...

Page 47: ...seat pull upward the seat lock lever and pull up the seat the rear To install the seat align the tabs on the seat with the grommets on the frame and press the seat down until it locks Make sure that t...

Page 48: ...ons before riding 1 1 Flag pole bracket NOTE 1 1 Flag pole bracket Storage compartment The storage compartment is located under the seat To remove the seat see page 38 Be careful not to flood this are...

Page 49: ...uid disk brake if necessary 41 42 110 117 Fuel Check fuel level Fill with fuel if necessary 42 43 Check oil level Fill with oil if necessary Engine oil and Transmission oil 44 45 95 101 Drive chain Ch...

Page 50: ...is incorrect adjust it See pages 110 117 Check operation of the levers They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a KY...

Page 51: ...blem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the ATV inspected by a KYMCO dealer Fuel Fill the fuel tank when necessary and make sure...

Page 52: ...em Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill wh...

Page 53: ...motor oils often labeled Energy Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance 44 CAUTION SAE 20W 5...

Page 54: ...oil level indicator lights it means the oil level in the oil tank is low stop the engine and fill the oil tank as soon as possible MXER To fill lift seat see page 38 remove the cap from the oil tank...

Page 55: ...ration of the switch engine stop switch remote engine stop switch and any other switches Repair as necessary for proper operation taillight stop light Throttle lever Check to see that the throttle lev...

Page 56: ...nations are not recommended 2 The tires should be set to the recommended pressure Recommended tire pressure Front 25 kpa 0 25 kgf cm 3 6 psi Rear 25 kpa 0 25 kgf cm 3 6 psi Check and adjust tire press...

Page 57: ...following 4 Never set tire pressure over the recommended Front 28 kpa 0 28 kgf cm 40 psi Rear 28 kpa 0 28 kgf cm 40 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and...

Page 58: ...Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire A 3mm 0 12 in 49...

Page 59: ...les in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control...

Page 60: ...F 30C 90F and warming up position Position Cold engine start ambient temperature above 25C 80F and warm engine start position 1 Fully open 3 Closed 2 Half open a Starter choke 7 If the engine is start...

Page 61: ...he starter choke turned off Do not operate the throttle open and close rapidly as the ATV will move forward suddenly causing possible loss of control Do not leave the ATV unattended while the engine i...

Page 62: ...he tethered road lead remote engine stop switch see page 32 or 33 is installed into the 5 With the throttle closed push the starter button Release the starter button as soon as the engine starts 6 Be...

Page 63: ...od in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an exces...

Page 64: ...of operation Vary the speed of the machine from time to time Do not operate it at full throttle position 2 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the...

Page 65: ...brake Make sure the lock pin into the locked position To set the parking brake see page 33 MXER 1 1 Locked position Parking 50R When parking stop the engine Turn the fuel lock to OFF and apply the par...

Page 66: ...or other inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park t...

Page 67: ...f them Choose a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you a...

Page 68: ...Riding Your ATV 59...

Page 69: ...ce over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pl...

Page 70: ...ce until you are totally familiar with the machine s handling and performance characteristics POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is...

Page 71: ...ren use ATVs that are not recommended for their age severe injury or death can result Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills...

Page 72: ...ren use ATVs that are not recommended for their age severe injury or death can result Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills...

Page 73: ...HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger on the carrie...

Page 74: ...of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your...

Page 75: ...s POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perceptio...

Page 76: ...rating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneve...

Page 77: ...ident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders inexperienced with this model this mo...

Page 78: ...ct how your ATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers Be sure to observe the weight limits and follow these guidelines 1 Do not tow anothe...

Page 79: ...MCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and usin...

Page 80: ...s and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction If you have question con...

Page 81: ...g operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg your foot or leg may come into contact...

Page 82: ...achine or overturn POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts su...

Page 83: ...ine in a place where pedestrians or children are not likely to touch it POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burne...

Page 84: ...t the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in cont...

Page 85: ...e by pulling a tethered core Practice using it when the beginner first starts riding Pull the tether after the ATV is moving The ATV may continue to roll for some distance Watch the distance until the...

Page 86: ...e to reduce throttle lever movement or counterclockwise to increase throttle lever movement 3 Hole the screw in place and tighten the lock nut 77 Speed limiter for new riders Your ATV has an adjustabl...

Page 87: ...ble reduce speed or brake before entering a turn Closing the throttle or braking in mid turn may cause wheel slippage which will reduce control of your ATV BRAKING Practice starting and stopping at sl...

Page 88: ...otboard to the outside of the turn opposite your desired direction and lean your upper body into the turn After completing the turn open the throttle Gradually to accelerate the ATV 79 POTENTIAL HAZAR...

Page 89: ...se control POTENTIAL HAZARD Operating on excessively steep slopes WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep slopes than on level surfaces or small slopes HOW TO AVOID THE...

Page 90: ...pes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopels with excessively slippery or loose surfaces Shift your weight forward Never...

Page 91: ...ual Avoid slopes with excessively slippery or loose surfaces Shift your weight to the up of slope side of the ATV POTENTIAL HAZARD Improperly crossing slopes or turning on slopes WHAT CAN HAPPEN Could...

Page 92: ...e the rear brake to stop The ATV could easily tip over backwards Instead dismount the ATV immediately on the up of slope side POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting whil...

Page 93: ...fully stopped apply rear brake as well and then lock parking brake Dismount on up slope side or to a side if pointed straight up slope Turn the ATV around and remount following the procedure describe...

Page 94: ...er with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the using the front brake lever to control speed 5 If you lose con...

Page 95: ...ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear POTENTIAL HAZARD Going down a slope improperly WHAT CAN HAPPEN Could...

Page 96: ...Always choose a level place to park After bringing your ATV to a stop hold the brakes Then set the parking brake and turn the ignition switch OFF If you re through riding for the day also turn the fue...

Page 97: ...eight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 79 If your ATV can t make it up a slope you are trying to climb Turn the ATV a...

Page 98: ...intenance unless otherwise specified PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient condition possible Safet...

Page 99: ...uld be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized KYMCO dealer WARNING T...

Page 100: ...ry Check specific gravity Check breather hose for proper operation Correct if necessary if necessary if necessary Carburetor Check idle speed starter operation Adjust if necessary Drive chain Check an...

Page 101: ...ace if damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Knuckle shafts Steering shaft Lubricate every 6 months Fittings and Fasteners Check all chassis fitti...

Page 102: ...reas Brake Check operation and brake fluid cable Replace brake pads shoes if necessary Battery Check specific gravity Check breather hose for proper operation Correct if necessary Carburetor Check idl...

Page 103: ...mage runout Replace if necessary Wheel bearings Check bearing assembly for looseness damage Replace if damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Knuck...

Page 104: ...the filler hole without screwing it in MXER E Remove the dipstick and inspect the oil level F The oil level should be between the maximum and minimum marks If the level is low add oil to raise it to...

Page 105: ...foreign material enters the crankcase When removing the drain plug the compression spring oil strainer and O ring will fall out Take care not to lose these parts CAUTION 1 Oil filter cap CAUTION 1 Tig...

Page 106: ...material enters the crankcase If oil leakage is found stop the engine immediately and check for the cause I Warm up the engine for several minutes at idle speed Check for oil leakage while warming up...

Page 107: ...h oil and install the oil filler cap G Warm up the engine for several minutes at idle speed Check for oil leakage while warming up Tightening torque Drain plug engine 30 Nm 3 0 m kg 21 6 ft lb Be sure...

Page 108: ...e oil level It should be up to the brim of the hole If the level is low add oil to raise it to the proper level C Reinstall the oil filler bolt and tighten to specification 1 Oil filler bolt measureme...

Page 109: ...lace B Place a container under the engine C Remove the oil filler bolt and drain plug to drain the oil D Reinstall the drain plug and tighten to Specification 1 Drain plug MXER 50R 1 Tightening torque...

Page 110: ...nd stop the engine immediately and check for the cause Recommended oil See page 138 or 142 Oil quantity Periodic oil change 0 11L 0 10Imp qt 0 12US qt Total amount 0 12L 0 11Imp qt 0 13US qt Be sure n...

Page 111: ...e spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the proper type Sta...

Page 112: ...d at more frequent intervals than specified in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing befo...

Page 113: ...w flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to...

Page 114: ...filter oil is not available motor oil may be used 8 Reinstall the element to the 9 Reinstall the element assembly and parts removed for access air filter case The element should be wet but not drippi...

Page 115: ...g low flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent...

Page 116: ...the element assembly and parts removed for access air filter case The element should be wet but not dripping NOTE 107 Valve clearance adjustment 90R The correct valve clearance changes with use resul...

Page 117: ...lly rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle...

Page 118: ...the adjuster to obtain the correct free play 1 4 mm or 0 04 0 16 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear that could cause s...

Page 119: ...the brake shoe is worn out Go to our designated distributors or service stations for brake shoe replacing 110 2 1 1 Wear indicator 2 Rear brake Rear brake pads inspection Disk brake A wear indicator i...

Page 120: ...of the brake lever 1 Loosen the upper locknut and fully turn in the adjusting bolt A Free play 10 20 mm 0 4 0 8 in A 1 Upper locknut 3 Lower locknut 2 Upper adjusting bolt 4 Lower adjusting bolt 1 2 3...

Page 121: ...POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure...

Page 122: ...o 10 20 mm 0 4 0 8 in at the tip of the brake lever If the free play is incorrect adjust as follows Turn the adjusting nut on the brake hub in direction A to decrease play and in direction B to increa...

Page 123: ...perly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that...

Page 124: ...ke cam levers to make sure that the brake does not drag after adjusting Adjust 1 Keep front brake lever free play at 10 20 mm 0 4 0 8 in 2 Loosen the locknuts R L front lower brake cables 1 2 2 1 Brak...

Page 125: ...locknuts R L front lower brake 1 Bolts 2 Cable joint case cover 1 2 1 A B 1 Cable joint A Left front lower cable length B Right front lower cable length 116 1 3 2 7 Loosen the locknut Brake pedal cabl...

Page 126: ...ility which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of br...

Page 127: ...e POTENTIAL HAZARD Brake fluid contacting the skink or eyes WHAT CAN HAPPEN May cause irritation HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes In case of contact flush tho...

Page 128: ...ommended limit page 110 There is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service To prevent damage to the brake system use only fluid from a seal...

Page 129: ...the position shown in the figure The normal vertical deflection is approximately 10 20 mm 0 4 0 8in If the deflection exceeds 20 mm 0 8 in adjust the chain slack Drive chain slack adjustment 1 Loosen...

Page 130: ...Retighten the upper and lower axle holding bolts Too little of chain slack will overload the engine and other important parts Keep the slack within the specified limit Tightening torque Axle holding...

Page 131: ...age the O rings 1 O rings Cable inspection and lubrication POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables...

Page 132: ...pivot points using a grease gun Recommended lubricant Lithium soap based grease 123 Draining the V belt compartment 90R If water leaks into V belt compartment such as when the machine is drive in wate...

Page 133: ...he frame 2 Remove the nuts from the wheel 3 Remove the wheel assembly Wheel installation When installing the wheel reverse the removal procedure Pay attention to the following Wheel nut torque Front 4...

Page 134: ...s this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care NOTE When the ATV is to be stored for an extended period remove the ba...

Page 135: ...negative terminal lead from the battery first then disconnect the positive terminal lead 5 Remove the battery Battery installation 1 Install in the reverse order of removal 2 Check all bolts and other...

Page 136: ...r the seat The specified fuses are 7A To prevent accidental short circuiting turn off the ignition switch before checking or replacing a fuse POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An...

Page 137: ...1 Lift the seat See page 38 2 Open the fuse holders and lift out the fuse with the clips 3 Slide the old fuse out of the clips and discard it 1 2 1 Fuse holder 2 Clip 128...

Page 138: ...is on the battery cover Do not pry the clips open to get a fuse out you could bend them and cause poor contact with the new fuse A loose fuse could cause damage to the electrical system and even start...

Page 139: ...stment Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting screw CAUTION 1 Adjusting screw 1 Indicates a stron...

Page 140: ...ve the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead t...

Page 141: ...ilter element and fuel tank Check fuel flow No fuel Fuel valve Clean fuel valve Turn the fuel valve to OFF Turn the fuel valve to RES Supply fuel 1 Fuel Remove the fuel hose from the fuel valve Check...

Page 142: ...les 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmissio...

Page 143: ...tain abrasives which may mar the paint or protective finish When finished start the engine and let it POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduc...

Page 144: ...and carburetor Be sure to drain the fuel in a well ventilated area not in a garage POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite HOW...

Page 145: ...arter for a few seconds to distribute the oil then reinstall the spark plug Make sure the engine stop switch is OFF before pressing the starter POTENTIAL HAZARD Prolonged contact of fuel with the skin...

Page 146: ...mm 32 23 in 900 mm 35 46 in 620 mm 24 37 in 900 mm 35 46 in 75 mm 2 96 in Basic weight With oil and full fuel tank 111 kg 244 2 lbs Engine Type Cylinder arrangement Displacement Bore x stroke mm Comp...

Page 147: ...oil 2 stroke engine oil Transmission oil Periodic oil change Total amount SEA90 API Service SE SF SG type or higher 1 0 L 0 9 lmp qt 1 1 US qt over 0 11 L 0 10 lmp qt 0 12 US qt 0 12 L 0 11 lmp qt 0 1...

Page 148: ...ar brake type Operation Drum brake Right hand operation Drum brake Left hand operation 139 MAXXER 50 Model Air filter for engine Wet type element Fuel Type Tank capacity Reserve amount UNLEADED FUEL 5...

Page 149: ...nt Rear Coil spring Oil damper Coil spring Oil damper Electrical Ignition system Generator system Battery type C D I C D I Magneto 12V 4AH Tire Type Size Front Rear Tubeless 16X8 7 16X8 7 Bulb voltage...

Page 150: ...35 65 in 925 mm 36 45 in 650 mm 25 61 in 970 mm 38 22 in 100 mm 3 94 in Basic weight With oil and full fuel tank 129kg 283 8 lbs Engine Type Cylinder arrangement Displacement Bore x stroke Compressio...

Page 151: ...oil change Total amount Transmission oil Periodic oil change Total amount API Service SE SF SG type or higher SEA 90 0 7 L 0 62 lmp qt 0 74 US qt 0 8 L 0 70 lmp qt 0 84 US qt 0 11 L 0 10 lmp qt 0 12 U...

Page 152: ...unt UNLEADED FUEL 5 5 L 1 16 lmp gal 1 40 US gal 1 5 L 0 32 lmp gal 0 38 US gal Carburetor Type PB Spark plug Type Gap NGK C7HSA 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automatic Brake F...

Page 153: ...Front Rear Coil spring Oil damper Coil spring Oil damper Electrical Ignition system Generator system Battery type C D I C D I Magneto 12V 4AH Tire Type Size Front Rear Tubeless 18X7 8 18X9 8 Bulb vol...

Page 154: ...le for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or...

Page 155: ...with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENACE INTERVAL DATE OF SERVICE MILEAGE...

Page 156: ...Page Page Cont d 147 D E DESCRIPTION AND MACHINE IDENTIFICATION 9 Display description 18 Do not operate at speeds too fast your skills or the conditions 68 Do not operate after consuming alcohol or d...

Page 157: ...tches 23 Headlight switch 24 Headlight beam adjustment 130 High beam indicator lamp 17 Horn button 23 Page Page Cont d 148 I K L Identification number records 9 Idle speed adjustment 108 Ignition swit...

Page 158: ...CE C PRE OPERATION CHECKS 40 67 Page Page Cont d 149 R S READ THIS MANUAL CAREFULLY A Rear brake lever free play adjustment Drum brake 113 Remote engine stop switch 28 76 RIDE WITH CARE GOOD JUDGEMENT...

Page 159: ...e wear limit 49 Tool kit 89 Transmission oil 99 Troubleshooting 131 Troubleshooting chart 132 Turn signal switch 23 TURNING YOUR ATV 79 Valve clearance adjustment MXER 90R 107 Warning information 2 WH...

Page 160: ...reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4121 LBD3 4 U02 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kaoh...

Page 161: ......

Page 162: ...OR DRUGS ALWAYS Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns For your safety wear gear to include helmet gloves and foot protection Gasoline is flamm...

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