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KYMCO MXU 375, Owner'S Manual

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KYMCO MXU 375 Owner'S Manual Download Page 54

Remember that regardless of experi-

ence,  you  should  never  let  anyone

under  the  age  of  16  operate  your

Supervision

KYMCO  and  the  ATV  Safety  Institute

recommend that all ATV operators ride

the appropriate-sized ATV according to

Age (Years)

Engine Size (cc)

Speed Limitations (MPH)

10 - Governed

15 - Maximum

15 - Governed

30 - Maximum

According to Local 

Regulations

Up to 70

Up to 90

Over 90

16 and Older

12-15

6-11

16 and

Older

52

WARNING

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

ATV.

age.

Summary of Contents for MXU 375

Page 1: ...ER S MANUAL MXU 375 400 Do not remove this Owner s Manual from this ATV according to the guidelines and agreement with the U S Consumer Product Safety Commission Read this manual carefully It contains impotant safety information ...

Page 2: ...cularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the operator a passenger a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage t...

Page 3: ... intervals All information in this manual is based on the latest product data and specifications available at the time of printing KYMCO Inc reserves the right to make product changes and improvements which may affect illustrations or explanations without notice KYMCO and the ATV Safety Institute recommend that all ATV operators ride the appropriate sized ATV according to age Age Years 6 11 12 15 ...

Page 4: ...old Start 60 Gas Vent Hoses 60 Carburetor Float Bowl Drain 61 Oil Level Stick 61 Seat Latch 61 Safety Flag Bracket 62 Rack Loading Front and Rear 62 Trailering and Towing 62 Transporting ATV 63 Gasoline Oil Lubricant 63 Break In Procedure 64 GENERAL MAINTENANCE 66 80 Maintenance Schedule 67 Oil Cooler 68 Shock Absorbers 68 General Lubrication 68 Hydraulic Hand Brake 70 Auxiliary Brake 71 Protectiv...

Page 5: ...throttle suddenly or make sudden gear changes Never go over the top of any Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the ATV to lean sharply to one side Go strai...

Page 6: ...lling a trailer and allow greater dis tance for braking No one under the age of 16 should operate this ATV Some operators at the age of 16 may not be able to oper ate an ATV safely Parents should supervise the use of the ATV at all times Parents should permit continued use only if they determine that the operator has the ability to operate the ATV safely WARNING Indicates a potential hazard that c...

Page 7: ...out adult supervision Children need to be observed carefully because not all children have the strength size skills or judgment to operate an ATV safely Always avoid paved surfaces ATV s are not designed to be used on paved surfaces and may seri ously affect handling and control Never operate an ATV on a public road even a dirt or gravel one because you may not be able to avoid colliding with othe...

Page 8: ...1 DECAL OF EPA For US WARNING Indicates a potential hazard that could result in a serious injury or death 6 HANGTAG OF EPA For US 2 CERTIFICATE LABEL OF SVIA For US 1 2 LOCATION For US ...

Page 9: ...d read and understand this The labels should be considered as per manent parts of the ATV If a label comes off or becomes hard to read contact your KYMCO ATV dealer for a replacement 7 WARNING Indicates a potential hazard that could result in a serious injury or death information before riding 2255 741A For France 2256 475 For Europe For U S REVISED ...

Page 10: ...Warning Labels 8 WARNING Indicates a potential hazard that could result in a serious injury or death For U S For France For Europe 1 1 1 2 2 2 3 1 2 4 4 3 3 3 REVISED REVISED ...

Page 11: ...9 Warning Labels WARNING Indicates a potential hazard that could result in a serious injury or death 7 5 6 8 7 7 7 8 8 8 6 6 6 For U S 5 For France 5 5 For Europe For Canada 5 REVISED NEW ...

Page 12: ...le Limiter 14 Throttle Lever 15 DC Power Outlet 16 Taillight Brakelight 17 Headlight HI LO Switch 18 Engine Starter Button 19 Engine Stop Switch 20 2WD 4WD Selector Switch 21 Gas Tank Valve 10 NOTE The ATV you have purcha sed may differ slightly from those shown in the figures of this manual WARNING Indicates a potential hazard that could result in a serious injury or death 1 2 2 4 5 13 9 21 KC004...

Page 13: ...HE HAZARD WARNING A child under 16 should never operate this ATV POTENTIAL HAZARD Allowing anyone under age 16 to operate this ATV WHAT CAN HAPPEN Use of an ATV by children can lead to severe injury or death of the child Children under the age of 16 may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD WARNI...

Page 14: ...er operate the ATV on any paved surfaces including sidewalks driveways parking lots and streets WARNING Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate an ATV on public streets roads or highways POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HO...

Page 15: ...is ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly You should also wear Eye protection goggles or face shield Gloves Boots Long sleeved shirt or jacket Long pants Operating w...

Page 16: ...pting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including a rollover HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off WARNING WARNING Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in ...

Page 17: ...tions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD WARNING WARNING WARNING Indicates a potential hazard that could result in a serious injury or death POTENTIA...

Page 18: ...to turn at faster speeds Do not turn at excessive speed POTENTIAL HAZARD Operating on steep hills WHAT CAN HAPPEN The ATV can overturn more easily on steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills 16 Warnings WARNING Indicates a potential ha...

Page 19: ...edures for climbing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person c...

Page 20: ...urning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in this Owner s Manual Avoid hills with slippery or loose surfaces Shift your weight to the uphill side of the ATV 18 Warnings WARNING Indicates a potential hazard that could result in a serious injury or death WARNING WARNING Never attempt to turn th...

Page 21: ...njury or death POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Engage the brake lever lock after you are stopped If you begin rolling backwards Keep we...

Page 22: ...rson behind you resulting in serious injury HOW TO AVOID THE HAZARD Before you engage reverse gear make sure there are no obstacles or people behind you When it is safe to proceed go slowly 20 Warnings WARNING Indicates a potential hazard that could result in a serious injury or death WARNING WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also ...

Page 23: ...d and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in this Owner s Manual for carrying cargo or pulling a trailer 21 WARNING Indicates a potential hazard that could result in a serious injury or death WARNING WARNING HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or improper use...

Page 24: ...ects and branches Along with pro viding skin protection gloves will shield your hands from harsh weather Wear gloves that are weather resistant and have a gripping suface to keep them from sliding off the handlebars Off road style gloves with knuckle pads are the best for comfort and pro Gloves Wear a boot that covers the largest pos sible area of your leg preferably up to your knee and can handle...

Page 25: ...Riding pants with kneepads a jer sey and shoulder pads provide the best 23 Prevention WARNING Indicates a potential hazard that could result in a serious injury or death Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head These helmets should provide full face If you drop or damage your helmet get a new one immediately Your helmet may not p...

Page 26: ...vention WARNING Indicates a potential hazard that could result in a serious injury or death The second step in Prevention is check ing the condition of your ATV Chances are good that you ll be using your ATV in some rough terrain and there s no way you want your brakes to go out when riding downhill You need to check the following parts on your ATV before every ride ...

Page 27: ...akes could fail during a ride if One easy way to remember what parts you need to check is by using the acronym T CLOC It stands for T TIRES AND WHEELS CONTROLS AND CABLES LIGHTS AND ELECTRIC OIL AND FUEL CHASSIS C L O C Prevention Correct tire pressure is crucial Consult the Specifications section of this Owner s Manual for tire pressure guide lines Incorrect tire pressure can cause poor handling ...

Page 28: ...am 3 Taillight brakelight 4 Status warning indicators 26 WARNING Indicates a potential hazard that could result in a serious injury or death LIGHTS AND ELECTRIC Turn the hi beam and lo beam on and off to make sure they work At the same time check that the taillight and brakelight work Also check the status warning indicators reverse neutral and hi lo beam on the handlebars when you start the ATV D...

Page 29: ...uld include ban dages antiseptic spray gauze tape etc WARNING Indicates a potential hazard that could result in a serious injury or death Tools Water Identification First Aid Kit Cellular Phone Maps GPS Emergency Kit with Flashlight and First Aid Kit You need to prepare for the unex pected Emergencies and accidents are traumatic enough but they re even worse when you re not prepared for them At th...

Page 30: ...ock 3 Shift into neutral 4 Turn on the ignition 5 Move the emergency stop switch to RUN 6 Press the starter button 7 Let the engine warm up 28 WARNING Indicates a potential hazard that could result in a serious injury or death Overview flipping the ATV Active riding and basic maneuvers are the foundation of your ATV ride With out basic skills it s impossible to move to this level active riding The...

Page 31: ...ghts etc then rotate the ignition switch key to the first position ON leaving the headlights OFF Note that the N is dures indicated on the LCD 1 the primer the seat and right side NOTE Pump the primer three 0 C 32 F or colder To access heat shield must be removed times when the temperature is at CAUTION Allow 30 seconds between starting attempts for the starter motor to cool Continuous starter mot...

Page 32: ...ransmission has a dual range transmis sion with reverse To shift the ATV fol 30 WARNING Indicates a potential hazard that could result in a serious injury or death Braking Stopping Always allow plenty of room and time to stop safely Sometimes quick stops are inevitable so always be prepared Whether you re stopping slowly or stopping quickly do this Squeeze the brake lever on the left handlebar to ...

Page 33: ...ownhill Sidehilling Traversing Swerving Crossing Obstacles Active Riding 31 WARNING Indicates a potential hazard that could result in a serious injury or death CAUTION 3 and rearward into the R position CAUTION WARNING Parking Parking involves following the previ ous rules for braking then After the ATV stops shift into neu tral Stop the engine using the engine stop switch Turn off the ignition If...

Page 34: ...hift more of your body weight to the side that s lifting and make the Active Riding Starting Once the engine s warm the ATV is ready to go 1 Keep your feet on the footrests and both hands on the handlebar 2 Hold the brake lever and release the brake lever lock 3 Shift into first gear 4 Release the brake slowly and apply the throttle Leaning Weight Shift 32 WARNING Indicates a potential hazard that...

Page 35: ...e turns practice ATV 0038 ATV 0039 ATV 0040 1 Ease off the throttle as you approach the turn to slow down 2 ACTIVE RIDING 3 Gradually increase your speed as you come out of the turn 2 Use the principles of leaning weight shifting and balancing shift your body weight to the inside of the turn 5 Gradually increase your speed as you come out of the turn 4 If shifting your weight and balance aren t en...

Page 36: ...ase off the throttle as you appr oach the turn to slow down 4 For multiple turns repeat this movement as needed 3 Follow this with slight acceleration 2 Turn the handlebars shift your weight and balance at the same time as you enter the turn use the principles of leaning weight shifting and balancing shift your body weight to the inside of the turn 5 To make your turn quicker try raising yourself ...

Page 37: ...35 ATV 0036 ATV 0037 ACTIVE RIDING 10 Start the engine and follow the method for riding downhill 9 Get back on the ATV from the uphill si de and keep your weight shifted uphill when you sit down 8 Reapply the brakes 7 Let the ATV roll to your right side until it faces slightly downhill 6 Partially release the brake but lightly hold the brake lever 5 If you re to the left of the ATV turn the handle...

Page 38: ... THAN 25 DOWN HILLS STEEPER Maximum 25 Shift down and accelerate before you start climbing then maintain a steady pace 1 Lean as far forward as possible For steeper hills come off your seat to stand and lean forward 2 If you lose speed quickly shift to a lower gear At the same time release the throttle so your front tires don t lift OR 3 If that doesn t work and you still have forward motion and t...

Page 39: ...result in a serious injury or death this method Sidehilling Traversing 1 Shift your body weight as far back on the seat as possible ATV 0018 ATV 0030 ATV 0031 ATV 0017 ATV 0028 ATV 0029 3 Lightly apply the brake and ease up on the throttle 2 Keep it in a low gear stay out of ne utral ACTIVE RIDING 4 If the ATV feels like it s tipping turn the handlebar downhill If that s not possible because of th...

Page 40: ...urn don t accelerate if you swerve Swerving 38 WARNING Indicates a potential hazard that could result in a serious injury or death ATV 0043 ATV 0042 ATV 0041 3 Keep your hand off the brake until the emergency is over and you re back in control 2 Turn the handlebar At the same time shift your weight and balance as you swerve Use the principles of leaning weight shifting and balancing shift your bod...

Page 41: ...uld result in a serious injury or death Crossing Obstacles ATV 0016 ATV 0026 ATV 0027 1 Keep your speed way down less than 5 mph To clear a single track only one tire cont acts obstacle follow the same rules exc ept ACTIVE RIDING 8 If the ATV starts tipping shift your weight to keep it in balance 7 Keep your body loose to absorb any shock 6 Lean forward and release the throttle when the front tire...

Page 42: ... your weight forward If you lose control after hitting sand ice mud or water Skidding or Sliding 3 Backing down hills is a bad idea do a U turn or K turn instead to turn around 2 Keep your handlebar straight 1 Go slowly It s hard to see behind you 1 Turn your handlebar into the direction of the slide 2 Keep your hand off the brakes until you re out of the skid If you use the right method for ridin...

Page 43: ...rozen to the discs Before riding manually move the ATV forward and backward to make certain that all wheels roll freely 3 If the brakes are frozen take the ATV to a warmer area to thaw out the brakes Do not attempt to free frozen brakes by pouring warm water on the brake pads and housings NOTE After the brakes thaw dry them by applying them several times while riding slowly 41 WARNING Indicates a ...

Page 44: ...ed or ice covered area at slow speeds before driving on snow cov ered or ice covered trails 42 WARNING Indicates a potential hazard that could result in a serious injury or death WARNING Stopping The ATV To stop the ATV first release the throttle lever Next apply the brake Stopping The Engine To stop the engine turn the ignition switch key to the OFF position or set the emergency stop switch to th...

Page 45: ... on the adrenaline rush you get from speeding and dangerous situations 1 2 3 Never Sometimes Often 8 Do you hurt yourself because you do things that are out of your ability range 1 2 3 Never Sometimes Often WARNING Indicates a potential hazard that could result in a serious injury or death 21 30 You re taking your chances Time to reconsider a lot of the judg ments you make You re destined to put y...

Page 46: ...time Fences can be constructed and excavatio ns dug in a short period of time Weather climate and development take their toll Terrain You need to consider the weather It is da ngerous to ride your ATV when the weath er is bad or potentially bad Keep abreast with weather forecasts Weather The thing about terrain is that sometimes you don t know it s changed until you get there Whether it s familiar...

Page 47: ...could result in a serious injury or death Trail Riding Use sound judgment when trail riding that means riding on a trail that fits your ability level If the trail is pretty rugged standing up on your footrests will make it easier for you to endure the rough terrain Outsloped trails trails that slant to allow rain to run off make trail riding a bit more challenging Accepting that challenge means ke...

Page 48: ... dif ficult to control About 50 of all ATV accidents involve passengers Other Vehicles Depending on where you re riding you might encounter other ATV s bikes or motor vehicles on public lands Respect the presence of cars if you re crossing roads or riding in public areas and make yourself be seen If you can t see other vehicles coming that means can t predict or control Hikers With the renewed int...

Page 49: ...why passengers are prohib ited on ATV s is because their presence throws off the weight and balance of the ATV Cargo can do the same if it weighs too much Limit the ATV to the load capacity ratings identified in the following chart for the particular model being operated So if you re weighing in at over 200 lb 91kg when you ride leave some of that extra cargo at home The combined weight limit incl...

Page 50: ...ly follow the instructions provided in each kit Speedrack 48 WARNING Indicates a potential hazard that could result in a serious injury or death WARNING NOTE Use extra caution when operating an ATV with additional loads such as accessories and or cargo Handling of the ATV may be adversely affected Reduce speed when adding additional loads Towing Capacity Total weight of trailer and all cargo in th...

Page 51: ...n Substances to avoid when riding 1 Alcohol 2 Over the counter or prescription drugs 3 Illegal mood altering drugs 1 2 DRINKS 3 4 DRINKS 5 DRINKS 49 WARNING Indicates a potential hazard that could result in a serious injury or death Be aware of prescription and over the counter medications Drowsiness and impaired judgment can be caused by a wide variety of medications The same is true of allergy c...

Page 52: ...If you are involved in an ATV accident when you re speeding you have a 25 chance of landing yourself in the hospi tal The faster you go the more likely you are to destroy your head and inter nal organs and skip the wheelies jumps stunts and any other showboat ing Laws and Regulations regulations Group Behavior People always do crazier and riskier things in a group than they would con sider doing b...

Page 53: ...ow much experience your family members have with ATV s they don t have experience with your ATV Let experienced riders get familiar with your ATV show them the basics before they take off You don t want it on your conscience that someone got hurt because you didn t tell them how to use your ATV Experienced Trained Riders 51 WARNING Indicates a potential hazard that could result in a serious injury...

Page 54: ...mmend that all ATV operators ride the appropriate sized ATV according to Age Years Engine Size cc Speed Limitations MPH 10 Governed 15 Maximum 15 Governed 30 Maximum According to Local Regulations Up to 70 Up to 90 Over 90 16 and Older 12 15 6 11 16 and Older 52 WARNING Indicates a potential hazard that could result in a serious injury or death ATV age ...

Page 55: ...ivision II of this Owner s Manual was prepared b y t h e S e r v i c e D e p a r t m e n t o f KYMCO Inc You have chosen a quality KYMCO ATV designed and manufactured to give dependable service Be sure as the owner operator of an KYMCO ATV to become thoro ughly familiar with its basic operation maintenance and storage procedures Read and understand the entire Own er s Manual before operating the A...

Page 56: ...3 4 in 119 2 cm 46 9 in 19 0 cm 7 5 in 121 7 cm 47 9 in 24 x 8 12 24 x 10 12 0 28 kg cm 4 0 psi MISCELLANY Dry Weight Approx Gas Tank Capacity Rated Differential Capacity Rear Drive Capacity Engine Oil Capacity Gasoline Recommended Engine Oil Recommended 15 L 3 75 U S Gal 270 ml 9 1 fl oz 250 ml 8 5 fl oz 2 8 L 3 0 U S qt 87 Octane Regular Unleaded SAE 5W 30 Taillight Brakelight Headlight Starting...

Page 57: ...n Switch CONTROL LOCATIONS The ignition switch has three positions 55 The KYMCO ATV has two identifica tion umbers Vehicle Identification Number VIN and Engine Serial The VIN is located on the lower front Number ESN crossmember VIN The ESN is located on the rear of the engine crankcase and is visible from the side rect registration information replacement key K MC Y O K MC Y O AND FUNCTIONS OFF po...

Page 58: ...ing to shift from one range to the other or into reverse Always shift on level ground or engage the brake lever lock before shifting into another range or into Shifting Always shift into low range when operating on wet or uneven terrain when towing or pushing heavy loads and when using a plow Fail ure to follow this caution may result in premature V belt failure or in damage to related drive syste...

Page 59: ... flat dry hard surfaces two wheel drive should be sufficient In situations of aggressive trail condi tions four wheel drive would be the To either engage or disengage the front wheels move the switch to the 4WD position or to the 2WD position desired choice Apply the brake by compressing the brake lever toward the handlebar To engage and release the brake lever lock use the following procedure The...

Page 60: ...in the ON position the transmission is in neutral and the brake lever lock is engaged NOTE This ATV has safety inter lock switches which prevent the starter motor from activating when the transmission is not in neutral ATV 0053 Throttle lever travel may be limited by adjusting the throttle limiter screw The throttle limiter should be adjusted according to the operator s skill and experience To adj...

Page 61: ...proximately ten seconds after releasing the but tons the display will return to nor mal operating mode Mode Button Used to toggle between Clock Hour Meter Odometer and Trip Meter in the display 5 on the LCD In con junction with the Adjust Set Button 1 sets the clock or resets the trip meter to zero 2 3 Gear Position Indicator Indicates which gear position is selected R reverse N neutral L low rang...

Page 62: ...idly by holding the Mode But ton 2 down for three seconds After the correct hour is attained momentarily press the Adjust Set Button 1 to toggle the clock to the minute display minutes flashing then press the Mode Button 2 to set the minutes After approximately ten seconds the minute display will stop flashing and the gauge will return to normal operation C KC0007A D KC0011 CF123A The primer is lo...

Page 63: ... latch release located at the rear of the seat then raise the rear of the seat and slide it rearward CARBURETOR FLOAT BOWL DRAIN OIL LEVEL STICK SEAT LATCH 61 AF925 Periodically the float bowl should be drained to remove condensation To drain the float bowl use the following procedure WARNING ATV 0100AA There is an oil level stick for checking the engine oil level To check the oil level use the fo...

Page 64: ...h must be purchased Make sure that the load in the trailer is properly secured and will not shift while moving Also do not overload the trailer Never exceed any of the ATV weight restrictions Always maintain a slow speed when trailering and towing and avoid sudden accelerations quick maneuvers and sudden stops Braking distance will be affected when towing a trailer When towing a trailer always mai...

Page 65: ... oil viscosity is SAE 5W 30 Ambient tem perature should determine the correct weight of oil See the viscosity chart or an authorized KYMCO ATV dealer TRANSPORTING ATV GASOLINE OIL Recommended Gasoline LUBRICANT When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the Recommended Engine Transmission Oil 63 WA...

Page 66: ...lling the gas tank Do not overfill the gas tank Since gasoline expands as its tempera ture increases the gas tank must be filled to its rated capacity only Expan sion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area The recommended lubricant front dif ferential and rear drive when applica ble is SAE approved 80W 90 hypoid This ...

Page 67: ...ESS nished CEDURE Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop Accelerate to 30 mph then com press brake lever to decelerate to 0 5 mph Repeat procedure 5 times WARNING When the engine starts allow it to warm up properly Idle the engine sev eral minutes until the engine has reached normal operating temperature Do not idle the engine for excessively Du...

Page 68: ...n of any component of this ATV is detected DO NOT OPERATE THE ATV Take the ATV to an authorized KYMCO ATV dealer for inspection and adjustment or repair If the owner operator does not feel qualified to perform any of these main tenance procedures or checks take the ATV to an authorized KYMCO ATV dealer for professional service NOTE The following instruc tion and information refer to spe cific item...

Page 69: ...al rear drive 69 Replace every 4 years V Belt 77 I I Muffler spark arrester 78 C Tires air pressure 77 I Inspect every time before riding Brake components 70 71 I Inspect every time before riding Brake fluid 70 I Replace every 2 years Brake hoses 71 I Replace every 4 years Steering I Inspect every time before riding Suspension Ball joint boots drive axle boots front and rear tie rods differential ...

Page 70: ...ock rod If any one of these con ditions is detected replacement is nec essary NOTE When the ATV is operated in extremely cold weather 23 C 10 F or colder a small amount of leakage may be present Unless the leakage is excessive replacement is not necessary The shock absorber has a spring force adjustment sleeve with five adjustment positions to allow the spring to be adjusted for different riding a...

Page 71: ... re use oil filter Remove the oil filter plug from the filter mounting boss located on the front right side of the transmission case and allow the filter to drain completely 4 5 733 441A CF107B Inspect and change the gear lubricant in each according to the Maintenance Schedule When changing the lubri cant use approved SAE 80W 90 hypoid oil and use the following procedure Apply oil to the new filte...

Page 72: ...ways maintain brakes according to the Maintenance Schedule Check the brake fluid level in the brake fluid reservoir If the level in the reser voir is not visible in the sight glass add DOT 4 brake fluid 5 Pour recommended oil into each fille hole HYDRAULIC HAND BRAKE Brake Fluid 70 CF106C CAUTION NOTE If the gear case has a level plug fill to the threads of the level plug If the gear case has only...

Page 73: ...s or other damage If found take the ATV to an authorized KYMCO ATV dealer to have the brake hoses replaced Brake Pads Install the wheel and tighten to 40 ft lb NOTE The brake fluid reservoir is located under the seat 71 NOTE If the sight glass appears dark there is a sufficient amount of fluid in the reservoir CAUTION Check to make sure the brake lever lock engages properly and that the brake when...

Page 74: ... ball joint boots for cracks tears or perforations 3 Check the ball joint for free play by grasping the steering knuckle and turning it from side to side and up and down 4 If boot damage is present or ball joint free play seems excessive contact an authorized KYMCO ATV dealer for service 5 CC791 CC792 CC793 Secure the ATV on a support stand to elevate the front wheels Remove both front wheels Insp...

Page 75: ...nd battery com partment with soap and water NOTE If battery posts cable ends or the battery case has a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water Using a multimeter test the battery voltage The meter must read at least 12 5 DC Volts for a fully charged battery NOTE At this point if the meter reads as specified the batt...

Page 76: ... charger cuts off replace the battery Connect the multimeter and test the battery voltage The meter should read at least 12 5 DC Volts If the voltage is as specified the battery is ready for service Before installing the battery make sure the ignition switch is in the OFF position Battery Charging Chart Constant Current Charger 74 When using an automatic bat tery charger always follow the charger ...

Page 77: ...nstalling the spark plug be sure to tighten it securely A new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug should be tightened 1 8 1 4 turn once the washer contacts the cylinder head ATV 0052 To properly adjust the idle a tachome ter is necessary If one is not available take the ATV to an authorized KYMCO ATV dealer NOTE The idle adjustment s...

Page 78: ...in dusty wet or muddy conditions inspect and service the filter more frequently Use the fol lowing procedure to remove the filter and inspect and or clean it 1 Fill a wash pan larger than the ele ment with a non flammable sol vent then dip the element in the solvent and wash it 3 Squeeze the element by pressing it between the palms of both hands to remove excess solvent Do not twist or ring the el...

Page 79: ... an authorized KYMCO ATV dealer or a qualified tire repair station DRAINING V BELT COVER TIRES Tire Tread Condition Tire Replacement When breaking the tire bead loose from the wheel be extremely care ful not to damage the inner wheel surface or the tire bead 77 KC0049A NOTE If the ATV has been driven through water the V belt cover must be drained of any water Place the ATV on a level surface Remov...

Page 80: ...embly to the muffler then remove the spark arrester The wattage rating of each bulb is shown in the chart When replacing a burned bulb always use the same watt age rating Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is damaged in any way it must be replaced LIGHT BULB REPLACEMENT Use only specified bulbs indicate...

Page 81: ...e hous ing and rotate it completely clock wise Install the wiring harness connec tor 1 2 3 4 CAUTION To replace the taillight brakelight bulb use the following procedure Rotate the socket counterclock wise and remove it from the hous ing To remove the bulb from the socket push in and rotate counter clockwise To install the bulb push in and turn clockwise Insert the socket into the housing and rota...

Page 82: ...minals for electrical accessories are located on the front and rear wiring harnesses The accessory plug is located on the front body panel Always use electrical accessories less than 180W Adjust each headlight until correct aim is obtained by turning the adjuster clockwise to lower or counterclockwise to raise the beam FUSES NOTE To remove the fuse com press the locking tabs on either side of the ...

Page 83: ...o idle then using KYMCO Engine Preserver rapidly inject the preserver into the air fil ter opening for a period of 10 to 20 seconds Install the air filter and housing cover 3 CAUTION Drain the carburetor float bowl Plug the hole in the exhaust system with a clean cloth Apply light oil to the upper steering post bushing and plungers of the shock absorbers Tighten all nuts bolts cap screws and screw...

Page 84: ... filter Charge the battery then install Connect the battery cables making sure to connect the positive cable first 1 2 3 4 5 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace if necessary 6 Check the tire pressure Inflate to recommended pressure as neces sary 7 Tighten all nuts bolts cap screws and screws making sur...

Page 85: ...MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED NOTES 83 ...

Page 86: ...roper maintenance generally includes replacement and service at the own er s choosing such items as air filter oil and oil filter or any other part item or device related to emissions control as specified in the Owner s Manual It is the owner s re sponsibility to ensure that the ATV is used in a manner for which it was designed Miscellaneous Items Used in Aforementioned Systems Clamps 84 KYMCO war...

Page 87: ...4 Lubrication General 68 Maintenance General 66 Maintenance Record 83 Maintenance Schedule 67 Mounting the ATV 28 Muffler Spark Arrester 78 Oil and Filter 68 Oil Level Stick 61 Oil Recommended Engine Transmission 63 Operating Maneuvers Basic 28 Operation Maintenance 53 Parking 31 Parts 53 Parts and Controls Locations 10 Prevention 22 Primer Cold Start 60 Protect Your Sport 1 Quick Turns 34 Rack Lo...

Page 88: ...ovid ed to assist you in ordering parts from your authorized KYMCO ATV dealer or for reference in case the ATV is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 ENGINE SERIAL NUMBER The key identification number is stamped on the key as shown in the illustration Record this number in the space provided for reference if you ever need a new key WARNING CO KYMCO KYM ...

Page 89: ...ns of this manual are used under license from Arctic Cat Inc KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kaohsiung Taiwan Republic of China Telephone 886 7 3822526 FAX 886 7 3950021 Issued 2008 03 For U S ...

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