KYMCO MXU 700i Owner'S Manual Download

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8.8. AIR FILTER CLEANING

The air cleaner accumulates dust and must be

cleaned periodically. If the ATV is ridden in dusty

areas, the air cleaner must be cleaned at more

frequent intervals than specified in the Maintenance

Schedule. If the ATV is submerged in water, the air

cleaner should be checked and water should be

drained from the air cleaner housing before starting

the engine. To clean the air cleaner:

Remove the seat.

Unlatch the six retainer clips (1) and remove

the air cleaner housing cover (2).

Remove the air cleaner element A (3).

(1)Retainer clips (2)Air cleaner housing cover

(3) Element A

120

Summary of Contents for MXU 700i

Page 1: ......

Page 2: ...ROL FUNCTIONS 18 4 1 IGNITION SWITCH 18 4 2 INSTRUMENTS AND INDICATOR 19 4 3 LEFT HANDLEBAR SWITCHES 30 4 4 ELECTRICAL POWER STEERING 33 4 5 RIGHT HANDLEBAR SWITCH 34 4 6 2WD 4WD Select Switch 34 4 7...

Page 3: ...GHTS 58 5 11 SWITCHES 58 5 12 TIRES 59 5 13 HOW TO MEASURE TIRE PRESSURE 60 5 14 TIRE WEAR LIMIT 61 5 15 COOLANT 61 6 OPERATION 63 6 1 STARTING A COLD ENGINE 63 6 2 STARTING A WARM ENGINE 66 6 3 WARMI...

Page 4: ...R BOX OIL 115 8 6 SPARK PLUG INSPECTION 117 8 7 SPARK ARRESTER 118 8 8 AIR FILTER CLEANING 120 8 9 IDLE SPEED INSPECTION 124 8 10 THROTTLE LEVER ADJUSTMENT 125 8 11 VALVE CLEARANCE ADJUSTMENT 126 8 12...

Page 5: ...ABLE INSPECTION AND LUBRICATION 140 8 26 TROUBLESHOOTING 141 9 CLEANING AND STORAGE 144 9 1 CLEANING YOUR ATV 144 9 2 STORAGE 148 9 3 SPECIFICATIONS 150 9 4 NOISE REGULATION 154 9 5 MAINTENANCE RECORD...

Page 6: ...ully read and understand the contents of this manual before riding the vehicle AGE RECOMMENDATION The minimum recommend age for this ATV model is 16 Children under age 16 should never operate this veh...

Page 7: ...e means ATTENTION BE ALERT YOUR SAFETY CAN BE AFFECTED Failure to follow instructions associated with a WARNING symbol could result in severe injury or death to the operator a passenger a bystander or...

Page 8: ...tion about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of...

Page 9: ...icle should read and understand this information before riding They contain important information for safe and proper operation of your ATV The labels should be considered as permanent parts of the ve...

Page 10: ...1 2 3 4 2...

Page 11: ...5 6 3...

Page 12: ...7 8 9 10 4...

Page 13: ...ad this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper training or instruction Beginners should receive training from a certified ins...

Page 14: ...sibility and operating conditions and your experience Never attempt wheel jump or other stunt Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow...

Page 15: ...ng on slopes as described in this manual Check the terrain carefully before you start down any slope Shift your weight backward Never go down a slope at high speed Avoid going down slope at an angle t...

Page 16: ...Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type...

Page 17: ...or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the O...

Page 18: ...ing the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your machine in an...

Page 19: ...__________________________ RIGHT STORAGE COMPARTMENT ______________________________________ LOCK AND OPEN KEY NO ______________________________________ FRAME NO ______________________________________...

Page 20: ...3 3 ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase Engine Serial Number 12...

Page 21: ...brake lever Front parking brake 02 Headlights Position lights 03 Rear brake lever 04 Right front turn signal light 05 Left front turn signal light 06 ATV Winch Optional NOTE The figures of machine you...

Page 22: ...07 08 08 09 10 11 12 07 Left rear turn signal light 08 Taillights Brake lights 09 Right rear turn signal light 10 Spark arrester 11 Trailer hitch 12 License light 14...

Page 23: ...rvoir water tank 14 Front brake fluid reservoir 15 Right rearview mirror 16 Rider Seat Passenger Seat Optional 17 Brake pedal fluid reservoir 18 Seat lock lever 19 Oil level inspection window 20 Tool...

Page 24: ...23 22 29 30 31 22 Exhaust system 23 Battery Fuse 24 Tool kit 25 Fuel pump 26 Left rearview mirror 27 Rear brake fluid reservoir 28 Accessory socket seat 29 Front cargo rack 30 Drive select lever 31 Re...

Page 25: ...al storage 35 Right foot peg 36 Rear brake pedal 37 Flag pole bracket 38 Headlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch 39 Instrument and indicators 40 2WD 4WD sel...

Page 26: ...f the respective switch positions are as follows OFF All electrical circuits are switched off except hazard light The key can be removed in this position ON All electrical circuits are switched on The...

Page 27: ...re gauge 12 Engine tachometer 13 EPS Warning Light 1 Multi Function Display The display includes the following functions Speedometer Odometer Tripmeter Digital clock 4WD indicator EFI system electric...

Page 28: ...reset the tripmeter 6 Mode Button This button is used to select km h mph km and mile This button is also used to adjust the time and reset the trip meter 7 Battery Voltage Too Low Warning Indicator W...

Page 29: ...gauge comes on to warn that the coolant temperature is too hot If the indicator comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10...

Page 30: ...r 2 4WD LOCK indicator 3 Fuel gauge 4 Odometer Trip meter 5 Digital clock 6 Gear select display 7 Engine running time 1 Speedometer Shows riding speed in km h or mph Press and hold MODE button for mor...

Page 31: ...he differential is in lock manner The lock indicator will be activated 2 2 4WD indicator Shows the drive mode is in the 4WD Shows the drive mode isn t in the 2WD 2 3 EFI system electric parts fault in...

Page 32: ...in a graduated display The normal operating fuel range is with the section between the segment F and segment E When the segment E or the fuel indicator 3 flashes fuel will be low and you should refill...

Page 33: ...otal mileage in Km or in mph The tripmeter shows the trip distance in Km or in mph There is tripmeters Press and hold ADJ button for more than 2 seconds to select ODO TRIP Press and hold MODE button f...

Page 34: ...To reset tripmeter A Press and hold SET button for more than 2 seconds to select tripmeter B Press and hold both the MODE button and SET button in the same time until the tripmeter is reset 26...

Page 35: ...Press and hold ADJ button for more than 2 seconds to select ODO mode 3 Press and hold both the MODE button and ADJ button in the same time for more than 2 seconds The clock will be set in the adjust...

Page 36: ...4 To set the hour press the ADJ button until the desired hour 5 Press the MODE button the minute display will start flashing 28...

Page 37: ...6 To set minute press the ADJ button until the desired minute 7 To end the adjustment Press both the MODE button and ADJ button in the same time 29...

Page 38: ...The turn signal light will flash when the switch is operated and ignition switch is ON For turning to the left For turning to the right The instrument turn signal indicator light will also flash when...

Page 39: ...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 CAUTION When you turn on the ignition switch and engine is not running the...

Page 40: ...d switch is pressed again the right and left turn signal lights go out together CAUTION Turn on this switch when parking or there is a special condition After the hazard switch is turned on it will no...

Page 41: ...re regular maintenance by users Do not tamper with the electronic control unit ECU or loosen the fittings of steering actuator or the neutral position setting of the steering will be adversely affecte...

Page 42: ...select switch to the desired position To check your present drive mode look at the Multifunction display Differential lock switch The Differential lock switch is located above the throttle lever The...

Page 43: ...e has one 4 Don t let the other end touch metal It to the positive terminal of the good battery Connect Use a remote positive terminal if the vehicle has one 5 Now connect the black negative cable to...

Page 44: ...POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID T...

Page 45: ...f the ATV 1 Adjuster 2 Locknut 3 13mm 0 52in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation coul...

Page 46: ...ing the front brake lever 4 11 REAR BRAKE LEVER The rear brake is operated by squeezing the rear brake lever near left handgrip 1 Rear brake lever 2 Front brake lever 4 12 BRAKE PEDAL This ATV is equi...

Page 47: ...ntil the lock lever releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position 1 Lock lever Rear parking brake To set the rear parking brake move the le...

Page 48: ...the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting...

Page 49: ...select lever is used to shift your ATV into the low high neutral reverse and park positions Refer to CH 5 1 1 for drive select lever adjustment and operation L Low R Reverse H High P Park N Neutral N...

Page 50: ...Intake air leak Fuel contaminated deteriorated Pinched or clogged fuel hose Faulty fuel pump Engine stall hard to start rough idling Intake air leak Fuel contaminated deteriorated Pinched or clogged...

Page 51: ...d then clean off any abrasive particles The plug may also be to other suitable tool If the insulator is cracked replace the plug Use the standard plug 4 19 BATTERY INSPECTION Checking the battery volt...

Page 52: ...he seat pull the passenger seat lock lever upward and pull up the seat To install the seat align the tabs on the seat with the grommets on the frame and press the seat down until it locks NOTE Make su...

Page 53: ...g areas Check local regulations before riding 1 Flag pole bracket 4 22 TRAILER HITCH The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball as specified...

Page 54: ...the front fender Store your tools or drink in the storage compartment 3 at the left side of the front fender 1 Owner s manual 2 Right storage compartment 3 Left storage compartment To open the compar...

Page 55: ...shing your ATV To use the accessory socket 1 Turn the ignition switch ON then start the engine 2 Turn the headlights OFF 3 Open the accessory socket cap 2 and then insert the accessory power plug into...

Page 56: ...essary 5 3 ENGINE OIL FINAL GEAR DIFFERENTIAL GEAR OIL Check oil level Fill with oil if necessary Check for leakage 5 6 7 8 3 5 DRIVE SHAFT BOOTS Check for damage 5 4 THROTTLE Check for proper throttl...

Page 57: ...schedules described in the Owner s Manual 5 1 DRIVE SELECT LEVER CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the s...

Page 58: ...g with improperly adjusted drive select lever WHAT CAN HAPPEN You may lose control of the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N posit...

Page 59: ...s and then remove the right left side cover 3 Shift the transmission into neutral Verify the length of the right shift rod is 150mm 0 5mm To adjust the length by loosening the lock nuts 1 and rotating...

Page 60: ...ift mode lever 3 is in the N If the neutral light does not illuminate in the N loosen the locknuts 4 on the ends of the left shift rod 5 Rotate the shift rod clockwise or counterclockwise until the ne...

Page 61: ...re they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear See CH 8 13 15 POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN...

Page 62: ...ded gasoline with a pump octane number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel...

Page 63: ...AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely...

Page 64: ...s Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance Oil...

Page 65: ...case oil Periodic oil change 0 23 L 0 20 Imp qt 0 243 US qt Total amount 0 25 L 0 22 Imp qt 0 265 US qt 5 7 FRONT GEAR CASE OIL Make sure the front gear case oil at the specified level Add oil as nec...

Page 66: ...tightness of chassis fittings and fasteners before a ride Take the machine to a KYMCO dealer or refer to the Service Manual for correct tightening torque 5 10 LIGHTS Check the headlight and taillight...

Page 67: ...Tubeless Rear AT26X10 14 Tubeless 2 The tires should be set to the recommended pressure Recommended tire pressure Front 35 41 kpa 0 35 0 41 kgf cm2 5 1 5 9 psi Rear 32 38 kpa 0 23 0 28 kgf cm2 3 2 4...

Page 68: ...35 kpa 0 35 kgf cm 2 5 0 psi 32 kpa 0 32 kgf cm 2 4 6 psi 38 kpa 0 38 kgf cm 2 5 4 psi 5 13 HOW TO MEASURE TIRE PRESSURE Use the low pressure tire gauge Tool kit NOTE The low pressure tire gauge is in...

Page 69: ...engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if it is between the FULL and LOW marks on the tank If the coolant level is at or below the LOW le...

Page 70: ...T CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the ca...

Page 71: ...er 6 1 STARTING A COLD ENGINE POTENTIAL HAZARD Freezing control cables 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...

Page 72: ...engine can be started in any gear if the brake lever is applied However it is recommended to shift into neutral or park before starting the engine When the select lever is in the neutral or park posit...

Page 73: ...switch again Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt If the battery is discharged Changing new one to start...

Page 74: ...hrottle normally 6 4 DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to t...

Page 75: ...te stop and return the throttle lever to the closed position 2 Apply the brakes then shift by moving the drive select lever along the shift guide L Low R Reverse H High P Park N Neutral NOTE Make sure...

Page 76: ...light should be on If the light does not come on ask a KYMCO dealer to inspect the machine 4 Check behind for people or obstacles then release the rear brake pedal 5 Open the throttle lever gradually...

Page 77: ...e operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can r...

Page 78: ...he parking brake The front brake lever has three locked position that allow it to be used as a parking brake To set the front parking brake see page 36 1 Locked position 2 Lock lever 3 Certainly locke...

Page 79: ...you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on slo...

Page 80: ...a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding coul...

Page 81: ...iler Maximum towing capacity 150 kg 330 lbs Tongue weight 16kg 35 lbs 1 Front cargo rack 2 Rear cargo rack LOADING One rider with passenger model As originally equipped this ATV can carry cargo or tow...

Page 82: ...rry the slower you should go Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain careful...

Page 83: ...7 RIDING YOUR ATV 75...

Page 84: ...cquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providin...

Page 85: ...ow to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Become familiar with this ATV at slow speeds first even if you are an experienced opera...

Page 86: ...d under 16 should never operate an ATV with engine size greater than 90cc Never carry passenger on the cargo racks POTENTIAL HAZARD Carrying a passenger on the cargo racks WHAT CAN HAPPEN Greatly redu...

Page 87: ...event 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 increase...

Page 88: ...drugs POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perce...

Page 89: ...n safe operating 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 imprope...

Page 90: ...an accident 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 t...

Page 91: ...th passenger model REAR CARGO RACK 25kg 55 lbs FRONT CARGO RACK 45 kg 100 lbs 7 5 1 Loading and operational guidelines Carrying cargo will affect how your ATV handles and greatly reduce its ability in...

Page 92: ...CO 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 using...

Page 93: ...arts 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...

Page 94: ...during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a foot peg your foot or leg may come into co...

Page 95: ...he machine 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 stunt...

Page 96: ...e machine 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...

Page 97: ...will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position and shift the drive...

Page 98: ...er or turn close the throttle fully and slow the ATV down by applying both front and rear brakes at the same time POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causin...

Page 99: ...u to lose 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 AV...

Page 100: ...slopes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopes with excessively slippery or loose surfaces Shift your weight forward Ne...

Page 101: ...e loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any slope until you have mastered the turning technique as described in the Owner s Manua...

Page 102: ...re in 2WD apply only the front brake When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brak...

Page 103: ...on P after you are stopped Lock parking brake If you begin rolling backwards Keep weight up slope 2WD Never apply the rear brake while rolling backwards Apply the front brake 4WD Apply both front and...

Page 104: ...t brake lever 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 slope using the front brake lever to control speed...

Page 105: ...faces Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the...

Page 106: ...wn slopes as described in this Owner s Manual Note a special technique is required when braking as you go down a slope Always check the terrain carefully before you start down any slope Shift your wei...

Page 107: ...doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight...

Page 108: ...ion adjustment and lubrication are explained on the following pages POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causin...

Page 109: ...m routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer The tool kit includes the following items 1 Air pressure gaug...

Page 110: ...n some situation could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be g...

Page 111: ...ear oil Check oil level oil leakage Replace every 12 months Air filter element for engine and V belt compartment Clean More often in wet or dusty areas Replace if necessary Throttle body Check idle sp...

Page 112: ...m Check leakage Retighten if necessary Replace gasket if necessary Spark arrester Clean Wheels Check balance damage runout Replace if necessary Wheel bearings Check bearing assembly for looseness dama...

Page 113: ...Km 150 1000 2000 MONTH 1 6 12 Knuckle shafts Steering shaft Lubricate every 6 months Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary It is recommended that these...

Page 114: ...e engine for several minutes and stop it C Check the oil level through the inspection window D The oil level should be between the maximum H and minimum L marks If the level is low add oil to raise it...

Page 115: ...l minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and oil filter cap 2 to drain the oil CAUTION Be sure no foreign material enters the crankcase CAUTION When remov...

Page 116: ...kgf m 11 lbf ft H Fill the engine with oil and install the oil fill cap Recommended oil see CH 9 3 Oil quantity Periodic oil change 2 4 L 2 11 Imp qt 2 54 US qt After draining and oil filter cartridge...

Page 117: ...t A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and drain plug washer 2 to drain the oil CA...

Page 118: ...TE Skip steps E to I if the oil filter cartridge is not being replaced E Remove the three fasteners and then remove right side cover F Remove the oil filter cartridge 3 with an oil cartridge wrench 11...

Page 119: ...TE An oil cartridge wrench is available at a nearby KYMCO dealer NOTE Make sure the O ring is seated properly H Install the new oil filter cartridge with an oil cartridge wrench and then tighten it to...

Page 120: ...tall the engine oil filler cap and tighten it Recommended oil see CH 9 3 Oil quantity see CH 9 3 CAUTION Be sure no foreign material enters the crankcase L Start the engine and warm it up for several...

Page 121: ...e when specified by the Maintenance Schedule Change the oil with the rear gear box warm and the ATV on level ground to assure complete and rapid draining Rear gear box oil replacement To drain the oil...

Page 122: ...Oil quantity Periodic oil change 0 23 L 0 20 lmp qt 0 243 US qt 4 Remove the oil level check bolt washer 3 Make sure the oil level reaches the oil level check hole 5 Install the oil filler cap and oil...

Page 123: ...e Change the oil with the front gear box warm and the ATV on level ground to assure complete and rapid draining Front gear box oil replacement 1 To drain the oil first place an oil drain pan under the...

Page 124: ...90 Oil quantity Periodic oil change 0 25 L 0 22 lmp qt 0 265 US qt 6 Remove the oil level check bolt washer Make sure the oil level reaches the oil level check hole 7 Install the oil filler cap and oi...

Page 125: ...ove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of t...

Page 126: ...ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the three bolts 1 the spark arrester 2 and the gasket 3 from the muffler 1 Bolts 2 Spark arrester 3 G...

Page 127: ...the gasket in the muffler and tighten the three bolts securely POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Coul...

Page 128: ...in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cle...

Page 129: ...4 Remove the air cleaner element B 4 5 Remove the air cleaner element C 5 4 Element B 5 Element C 121...

Page 130: ...ents for cleaning ATV parts WHAT CAN HAPPEN A fire or explosion could result HOW TO AVOID THE HAZARD Use only a nonflammable or high flash point solvent to clean ATV parts 7 Soak the air cleaner an eq...

Page 131: ...g through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the drain tube 1 Remove the drain tube 1 by...

Page 132: ...2 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttl...

Page 133: ...k nut 3 then turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear th...

Page 134: ...NT BRAKE PADS The clearance between the brake pads and brake discs is Adjusted automatically as the pads wear The only maintenance that is required is to replace brake pads when they become worn To ch...

Page 135: ...to have brake pads replaced 3 Reinstall the wheel and tighten the lug nuts to 61N m 8 14 BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection window 1...

Page 136: ...the brake pads are not worn beyond the recommended limit CH 8 14 There is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service CAUTION To prevent dama...

Page 137: ...perature The coolant level should be between the maximum and minimum marks If the level is low remove the coolant reservoir cap and then add coolant or distilled water to raise it to the specified lev...

Page 138: ...level mark NOTE 1 If water is added have a KYMCO dealer check the antifreeze content of the coolant as soon as possible 2 The radiator fan operation is completely automatic It is switched on or off a...

Page 139: ...vers B Fuses in the harness may have blown There are several reasons that the fuses may blow Refer to the Fuse section in this chapter for details C Battery voltage has dropped Voltage drop can happen...

Page 140: ...sure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap...

Page 141: ...EEL INSTALLATION When reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Be sure the tapered side of the wheel nuts 1 face the wheel rim 2 Wheel nut torque Fron...

Page 142: ...tion of the wheel 1 Arrow mark Without arrow mark POTENTIAL HAZARD Installing wheels improperly WHAT CAN HAPPEN A wheel may come loose possibly leading to an accident HOW TO AVOID THE HAZARD Carefully...

Page 143: ...cells as this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care POTENTIAL HAZARD Allowing open flames or sparks near the batter...

Page 144: ...tery first and then disconnect the positive terminal lead 3 5 Remove the battery 8 20 2 Battery installation 1 Install in the reverse order of removal 2 After installing the battery check to see if th...

Page 145: ...use box cap 2 Remove the seat 3 Open the fuse box cap 2 4 Pull the old fuse out of the fuse holder 5 Push the new fuse in to the fuse holder 6 Close the fuse box cap and install seat POTENTIAL HAZARD...

Page 146: ...and type If a replaced fuse blows again there can be trouble with the ECU or harness connectors See an authorized dealer for inspection You can check 40 A fuse if it is blown at the top of the fuse PO...

Page 147: ...Turn the ignition switch at ON position Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting button 1 Adjusting button 8 24 DRIVE SHAFT BOOTS Check the protective...

Page 148: ...an also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the...

Page 149: ...hip have the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can...

Page 150: ...8 26 1 Troubleshooting chart 142...

Page 151: ...EPS model only 143...

Page 152: ...and others to operate 1 Before cleaning the ATV A Block the end of the exhaust pipe to prevent water entry Use a commercially available tapered rubber plug or a plastic bag with a strong rubber band...

Page 153: ...reaser off with a garden hose under normal pressure Use only enough water pressure to rinse the engine clean 4 Once the majority of the dirt has been rinsed off wash all of the surfaces with warm wate...

Page 154: ...as they may contain abrasives which may mar the paint or protective finish 11 When finished start the engine and allow it to idle for several minutes to evaporate any residual moisture POTENTIAL HAZA...

Page 155: ...e cover and then remove mud accumulated in the cover with water Where shall be careful Avoid spraying water in the electrical connectors Avoid spraying water with any great force near the following pl...

Page 156: ...tank 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 ignit...

Page 157: ...for a few seconds to distribute the oil and then reinstall the spark plug 4 Remove the battery and store it in an area protected from freezing temperatures and direct sunlight and out of the reach of...

Page 158: ...00 in 1220 mm 48 03 in 1265 mm 49 80 in 920 mm 36 22 in 1297 mm 51 88 in 275 mm 10 83 in 3450 mm 135 83 in Basic weight With oil and full fuel tank 379 kg 835 6 lbs Engine Type Cylinder arrangement Di...

Page 159: ...Quantity Engine oil Periodic oil change After draining and oil filter cartridge change Total amount Front gear case oil Periodic oil change Total amount Rear gear case oil Periodic oil change Total a...

Page 160: ...unt UNLEADED FUEL 16 5 L 3 47 lmp gal 4 29 US gal 3 5 L 0 735 lmp gal 0 91US gal Carburetor Type PTA1 KYMCO Spark plug Type Gap CR7E NGK 0 7 0 8 mm 0 028 0 031 in Clutch Type Wet centrifugal automatic...

Page 161: ...pe ECU automatic control A C magneto 12V 18AH MF Tire Type Size Front Rear Tubeless BIAS AT26X8 14 AT26X10 14 Bulb voltage wattage quantity Headlight Brake light Taillight Turn signal light Position l...

Page 162: ...e or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle afte...

Page 163: ...accordance 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 SERV...

Page 164: ...g Taiwan Republic of China Telephone 886 7 3822526 FAX 886 7 3950021 By KWANG YANG Motor Co Ltd First Edition JAN 2018 All rights reserved Any reproduction or unauthorized use without the written perm...

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