KYMCO MXU 450i User manual

FOR EW O RD
This I<YMCO Service MaOUill con!Q i ns service, maintenance, and troubleshooting information for the 2010
KYMCO MXU 4Q0i . Tho3 complete manual is des \gned to aid service. .personnel in service-or1ented
applications.
Thismanual is divided intco sections. Each section covers a specific ATV component or system and,
in addition to the standard service procedures, includes disassembling, inspecting, and assembling
Instructions, \M1en using lthis manual as a guide,
the technician should use discretion as lo how
much disassembly
is needed to correctany given condition.
The service technician
::•hould pecome familiar with the operatlon and construction of each
component
or system KYMCO. This manual will assist tl'le service technician In becoming more
aware
of and efficient Wi th servicing procedures. Such efficiency no! only helps build consumer
confidence
but also saves time and labor.
All KYMCO ATV publications and decals display the words warnrng, Cautton. Note. and At This
Pointto emphasize imoortant information.
The symbol @i!Hilii!J Identifi es personal safety-related Information.
Besure to follow the directive because itdeals
With the possibility of severe personallnjury or even
death. The symbol E '·
"ii!· l ll identifies unsafe practices which may result in ATV-related
damage. Follow the dfrecbve because
it dealswith the possibility of damaging part or parts of the
ATV.
The symbol • NOTE :; identifies supplementary lnformaiion worthy of particularattention.The
symbol @AT THIS POINT directs the tech- nician to certain and specific procedures to promote
efficlency and to improveclarity.
At the time of publication, all information, photographs, and illustrations were technically correct.
Some photographsused in this manual are used for clarity purposesonly and are not designed to
depict actual conditions. Because KYMCO Inc. constantly refines and improves its products, no
retroactive obligation
is i!'l(lllrred.
All materials and specificaotions are subject to change without notice. Keep this manual accessible
mthe shop area for reference.
K YMCO Inc.
® 20 10 KYMCO h ie.
October 2010
®"" Trademarks of KYMCO Inc., TaiWan

SECTION 1 -GENERAL
INFORMATION/ SPECIFICATIONS
TABLE OF
CONTENTS
General Specifications ... 1-2
Torque Specifications .....
.. ..... .. ... .. ..... .. ...... . .. 1-2
Tightening Torque (
Frame parts ........... .. ......... ... 1-3
Tightening Torque (
Engine parts ) ...................... ... 1-4
Break-In Procedure ................... ................ . .. 1-5
Gasoline -Oil -Lub ri cant ............. .. ............ 1-5
Genuine Parts ........................... ................ .
.. 1-5
Preparation For Storage ............ .. .. ........ .. ........ .. ... 1-6
Prepara ti on After Storage ............ .. . . 1-6
1 -1

Genera l Spec ifi cat io n s*
ENGINE AND DRIVE
Type
Four-Cycle/Liquid Cooled
Bore x Stroke
89mm*71 . 2mm (3 .56'2. 801n .)
D~SP~acemenl
442.9 cc (26.57 cu ln.)
lgmbon Type ECU
Spark Plug Type
NGKCR7E
Spark Plug Gap 07 -08mm(0028-0032n)
Brake Type
HyctauiiC
With Parking Brake & Foot Brake
Fuel Delivery
Electronic Fuel Injection (EFI)
I CHASSIS
Length (Overall)
21 1 em ( 83m)
He~ght (Overall)
118.5cm ( 47 1n)
Wtdlh (Overall)
110 em ( 43m)
SuspenSion Travel 19 cm(7. 5 1n)
Wheelbase
12 1.7 cm ( 48 m)
Tire Stze {Front)
24 '8 ·12
Ttre Stze {Rear) 24'10 ·12
Tire InflatiOn Pressure
0. 29 kg/cm2 ( 4 psi)
MISCELLANEOUS
Dry WetQht (Approx)
277.5kg (6111b)
Gas Tank Capactty (Rated) 15L(375US Gal)
Orfferenttal C
••
270 ml (9 1 ft oz)
Rear Onve Capacity 250 ml (8 5 ft OZ)
Eng1ne Oil Capaoty
285L (302US qt)
Engtne Od Changed Capaaty 22L(23US qt)
Eng1ne Oil Changed Capaoty
With Otl Filter Changed
24L (25US qt)
Gasoline (Recommended) 87 Octane
Regular Unleaded
Eng11e Oil (Recommended) SAE 5W.JO
Otf!erenttai!Rear Orrve
Lubncant SAE 00/V -00 Hypoid
Tat l hght/Brakeltght 1'NI5Wf21W
Headlight 1'N/35W
'Specifications subject to challflt wltllout IIOIIc. .
1-2

1-3
Standard Torque
(frame Parts)
NO ITEM
THREAD SIZE
TORQUE
PR-t
AC HllQUE SPEC
THREAD D\JG NO
AND TYPE
Kgfl"'
NM
Kgfl'l
(FJ-LBSl
1
STEERlNG
HANDLEBAR END AND HANDLEBAR GRIP MBX1.25
0.9-1.3 9-13
1.1 8
90185-PIJB1-9000
HANDLEBAR AND STEERING POST M8XI . 25 2.4-3.2 24 -32
2.8 20
95801-08055-08
UPPER/LOVER HOUSING AND F"RAME M9Xl.25 2.4-3.2 24-32
2.8 20
95901-PVB!-9000
STEERING KNUCKLE AND TIE -ROD M10Xl25 3.5-4.8 35-48 42
30
90304-PIJB1 - 9000
STEERING STEM AND TIE -ROD M10X1.25
3.5-4.8 35-48
4.2 30
90304 -P\i'Bl- 9000
TIE-ROD NUT
M10X1.25
2.0-3.0 20-30
2.5
94001-PW'B1-8000
TlE -ROD NUT LH Ml0X1.25 2.0-3.0 20-30 2.5 94001-PIJBl-9000
STEERING POST LOIJER PIVOT M10Xl.25 5.0-6.1 50-61 5.5
40
95701-10020-08
FLANGE, BEARING AND FRAME M8XI.25
2.4-3.2 24-32
2.8
20
95701-08016-08
2
VHEEL
FRONT IJHEEL AND FRONT HUB M10X1.25
S. 0-6.1 S0-61
5.5 40
90301-PW'B1-9000
REAR WHEEL AND REAR HUB M10X1.25 5.0-6.1 50-61 5.5
40
90301-PW'B1-9000
FRONT ¥/HEEL HUB AND FRONT HA L FSHAFHCVJ)
M22X!.S
27-30 270-300
28 200 <MIN>
94011-P'w'Bl-9000
REAR \~HEEL HUB AND REAR HALFSHAH<CVJ)
M22X!.5
27-30 270-300
28
200 (MIN) 94011 - PIJBI-9000
FRON T ¥/HEEL HUB AND STUD AXLE(2\ID ON L Yl
M22X!.5
27-30 270-300
29
200 <MIN) 94011-PIJBI-9000
3
FR SUSPENSI!JN
FRONT SHOCK UPPER JOINT AND FRAME M10X1.25 4.1-5.6
41-56
4.8
35
90304-GL ¥10-9020-MI <U NUT
FRONT UPPER/LOIJER ARM AND FRAME
M10X1.25
4.t~5.6
41-56 4.8
35
90304-GL¥10-9020-Ml
FRONT SHOCK JOINT AND FRONT UPPER ARM M10X1.25
4.1-5.6 41-56
4.8 35
90304-GL¥10-9020-Ml
FRONT KNUCKLE AND FRONT UPPER/LO'w'ER ARM M10X1.25
4.1-5.6 41-56 4.8
35
95801-10035-06
4
RR SUSPENSION
REAR SHOCK UPPER JOINT AND F"RAME MlOX1.25 4. 1-5.6 41-56 4.8
35
90304-GL¥10-9020-MI (U NUT
REAR UPPER/LO'w'ER ARM AND FRAME M10X1.25 4.1-5.6 41-56 4.8
35
90304-GLIJ0-9020-Ml
REAR SHOCK JOINT AND REAR LOW'ER ARM M10X!.25
4. 1-5.6 41-56
4.8 35
90304-GL¥10-9020-MI
REAR KNUCKLE AND REAR UPPER/LOW'ER ARM M10X1.25
4.1~5.6
41-56
4.8 35
95801-10035-06
5
BRAKE
FRONT BRAKE DISC AND FRONT HUB
M6XI.O
1.7-2.5 17-25 2
15
90106-PW'B1-9000
REAR BRAKE DISC AND REAR HUB M6XI.O
1. 7-2.5 17-25 2
15
90106-PI.'Bl - 9000
FRONT/REAR CALIPER AND BRAKE HOSE END M10X1.25
2.4-3.2 24-32
2.8 20
90145-MKS9-6120-M1
MASTER CYLINDER AND BRAKE HOSE END M10X1.25 2.4-3.2 24-32 2.8
20
90145-MKS<.l-6120-Ml
SECONDARY MASTER CYLINDER AND FRAME M6Xt.O 0.9-1.3 9-13
1.1 8
96001-06035-08
TREE-IJAY JUNCTION AND BRAKE HOSE END M10X1.25 3.0-4.0 30-40
3.5
90145-LBA2-EOOO
S'w'ITCH-BRAKE PRESSURE - BANJO AND MASTER CYLINDER
-2.4-3.2
2.4~3.2
2.8 20
35340-P'w'Bl-9000
LEVER, FOOT BRAKE AND FRAME PIVOT
MBX1.25
2.4-3.2 24-32
2.8 20
95701-08016-08
CALIPER AND FR/RR KNUCKLE MBXI.25 2.4-3.2 24-32
2.8 20
90131-LDBS-EOOO
MASTER CYLINDER CLAMP M6Xt.O 0.7-0.9 7-9 0.8 5-6.7 -
MASTER CYLINDER COVER IIB-32 UNC-3A 0.07-0.09 0.7-0.9 0.08 0.5-0.66
-
MECHANJCAL CALIPER AND RR KNUCKLE
MBX1.25
2.4-3.2 24-32
2.8 20
90131-LF" A5-EOOO
6
FRAME
FOOTREST AND FRAME M8Xt.25 2.4-3.2 ('4-32
c.B
C'O
95701-08016-08
SKID PLATE
-
0.5-0.6 5-6
0.55
4 93903-P'w'B1-9000
FR BUMPER AND PLASTIC , BUMPER M&XI.O
0.9-1.3 9-13
1.1 8
95701-0&016-08
FR BUMPER AND FRAME M9Xl.25
2.4-3.2 24-32
2.8 20
95701-08016-06
FR BUMPER AND FRAME
M10X1.25 4.1-5.6 41-56
4.8 35
95701-10020-08
ENGINE ASSY AND FRAME MlOX1.25
5.0H6,1
50-61 5.5
40
95801-10185-06
MUFFLER EXH AND HEAD MBXI.25 2.4-3.2 24-32
2.8 20
95 701-08020 - 06
()]L COOLER AND FRAME
M6XI.O 1.4-2.0
14-20
1.7
12
19031-P\JBI-9000
DlL COOLER AND F"RAME M6Xl.O
1.4-2.0 14-20
1.7 12
94050-06060 (NUT)
SHAFT FLANGE AND ENG OUTPUT FLANGE
MBX1.25
2.4H3,2
24-32
2.8 20
95 701-08020-06
MUFF"LER PROTECTOR AND F"RAME
M6XI.O
0.9-1.3 9-13
1.1 8 96001-0601D-06
DlL HOSE AND JOINT
-
0.3-0.4
3~4
0.35 2.5
19504-LBA2-EOOO
GEARCASE AND FRAME M10X1.25
4.5-6.1 45-61
5.3 38
95801-10110-06
FUEL VALVE AND TANK
M6XI.O
0.6-0.8 6-8
0.7
4.5-5.4 94050-P'WA2-9000
SHIFT ASSY AND FRAME MBXI.25 2.4-3.2 24-32 2.8
20
95701-08012-06
FVD/REV SHJFT ASSY MBXI.25 0.9-1.3 9-13
1.1 8
95 701-08020-06
KNOB,FUEL ROTATE AND FUEL VALVE M4X0.7 0.1-0.2
1 - 2 0.
15
1.1
93500-04010 - 07

1-4
Standard Torque
(engine Parts)
THREAD SIZE
TORQUE
PR
NO ITEM
AND TYPE
VALUES
REMARKS
THREAD DWG. NO.
N.m
kg f. m N
·m
I
CRANKCASE/
M6x I. 0
8.8~12.8
C. 9~ I.3 10.8
-----------
95701-06045-08
COVFR
------
SET
M6x I. 0
8.8~12.8
C. 9~ I.3 10.8 95701-06070-08
M8xl .25
28±5%
2. 9±5%
28
APPLY OIL
95701-08050-08
M8xl .25
28±5%
2. 9±5% 28
APPLY OIL 95701-08060-08
M8xl.25
28±5%
2. 9±5%
28
APPLY OIL
95701-06085-08
2
CYLINDER HEAD
BOLT UBS
37. 3±5% 3. 8±5%
37.3 APPLY OIL 90031-PWBI-9000
MIOxl70
BOLT UBS
37. 3±5%
3. 8±5%
37.3 APPLY OIL
90032-PWB 1-9000
MIOx 180
BOLT
I0 .8± I
I. 1±0.1 10.8
-----------
96001-06110-06
M6X I. 0
BOLT
10.8±1
I. 1±0. I 10.8
-----------
96001-06060-08
M6X I. 0
BOLT
I0. 8± I
I. 1±0. I 10.8
APPLY OIL
96001-06030-02
M6X I. 0
NUT
I0. 8± I
I. 1±0.1 10.8
-----------
9600 I- 06020-00
M6X I. 0
3 HEAD COVER
M6x I.0 9.
8± I I. 0±0. I 9.8
---------
96001-06020-06
4
SPARK PLUG
MI0xI. 0
9.8~13.7
I. O~ I. 4
II. 8
-----------
98059-57916-00
5
TAPPET ADJ.
M5x0.5
6.9~10.8
0. 7~ I. I 8.9
-----------
90206-001-0010
NUT
6
TENSIONER LIFTER
SHFM6xi.O
9.8~13. 7
I. O~ I. 4 II.8
-----------
96001-06018-06
7
SHAFT ROCKER SPECIAL SCREW
33. 4±5%
3. 4±5%
33.4
THREAD LOCK
90020-PWB I- 9000
ARM
M 14x I. 5
8
CAM CHAIN SPECIAL BOLT
14~16
I. 4~ I. 6 15
---------
14531-PWB I- 9000
TENSIONER PIVOT
M8xl .25
9
ACG ONE WAY
BOLT SOCKET
17.7~21.6
I. 8~2. 2
19. 7 THREAD LOCK
90205-LDBS-EOOO
M8xl.25
10
SPROCKET
M6x I. 0 14. 7± I I. 5±0. I 14.7
THREAD LOCK
90083-KED9-9000
CAMSHAFT
II
ACG FLYWHEEL
M IGX I. 5 I
45±5%
14.5±5% 145
-----------
90205-LDB5-EOOO
12
OIL FILTER
M20 X I.5
7. 8~ II. 8
C. 8~ I.2 9.8
-----------
1541A-PWBI-9000
13
OIL PUMP
MIOXI.25 49. 0±5% 5±5% 49.0 THREAD LOCK
9570 1-PWB I- 9000
DRIVE GEAR
14
NUT,FINAL SHAFT
M 16. I. 5 98±5%
I 0±5%
98.0 THREAD LOCK
90204-PWB I- 9000
15
R CASE
MI4X1.25 26. 5±5% 2. 7±5% 26.5
-----------
90036-PWBI-9000
OIL DRAIN PLUG
16
WET CLUTCH
M 18x I. 5 200±5%
20.4±5%
200 THREAD LOCK 94052-PWBI -9000
17
DRIVE FACE M 16x I. 5
115±5%
II. 7±5%
I 15 THREAD LOCK 9400 1-PWB 1-9000
18
PULLEY,DRIVEN M 16x I. 5
115±5%
II. 7±5% I 15
THREAD LOCK
94001-PWBI-9000
19
0I L, F ITT I NG
M6X I.0 7
.8± I
0. 8±0. I 7.8
APPLY OIL
96001-06012-08
20
BEVEL GEAR,
DRIVE
M20xi.O
98. 0±5%
I 0±5%
98.0
APPLY OIL
90202-PWBI-9000
21
BEVEL GEAR.
M22xi.O 137. 2±5%
14±5%
137.2
APPLY OIL
90203-PWBI-9000
DRIVEN
22
PLUG BY OIL FILTER
M 14X I. 5
27±5% 2. 7±5% 27
------
90081-0E35-00IO
ON THE LEFT CASE

Break-In Procedure
A new ATV and an overhauled ATV engine
require a "break-in" period. The first 10 hours
(or
200 miles) are most critical to the life of this AT\/.
Proper operation during this break-in period will
help assure maximum life and performancefrom
theA
TV.
During the first 10 hours (or 200 miles) of
operation. always use less than 1/2 throttle.
Varying the engine
RPM during the break-in
period allows the components to "load" (aiding
the mating process) arid then "unload" (allowing
components to cool). Although it is essential to
place some stress
on the engine components
during break-in. care should
be taken not to
overload the engine too often.
Do not pull a
trailer
or carry heavy loads during the 10-hour
break-in period.
When the engine starts, allow
it to warm Lip
properly. Idle the engine several minutes until
the engine has reached
norm-al operating
temperature, Do not idle the engine for
excessively long periods oftime.
During the brea.k-in period. a maximum
of 1/2
throttle is recommended: however, brief full-
throttle accelerations and variations in driving
speedscontribute to good engine break-in.
After the completion
of the break-in period, the
engine oil and oil filtershould be changed.
other
maintenance after break-in should include
checking
of all pre- scribed adjustments and
tightening of all fasteners.
Gasoline - Oil -
Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimurn
octane regular unleaded.
In many areas.
oxygenates (eitherethanol
or MTBE) are addedto
the gasoline. Oxygenated gasolines containing
up
to 10% ethanol. 5% methane. or 5% MTBE are
acceptable gasolines.
Wlen using ethanol blended gasoline. it is not
necessary to add a gasoline antifreeze since
ethanol will prevent the accumulation
of moisture
in thefuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils Vvilich
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not
recommended are
racing', vegetable, non-detergent,
and castor-based oils.
The recommended oil that using of any API
certified SM 5W50 oil is acceptable.
ENGINE
OIL
oc -30 ·2 0 -10 0 10 20 30 40
TEMP °F ·22 -4 14 32 50 68 86 104
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is KYMCO Gear
Lube or
an equivalent gear lube which is SAE
approved 80W90 hypoid. This lubricant meets
all ofthe lubrication requirements
of the KYMCO
ATV front differentials and rear drives.
CAUTION
Any lubricant used in place of the recommended
lubricant could cause seriousfront differential/rear drive
damage.
1-5

FILLING GAS TANK
WARNING
Always fill the gas tank in a well-ventilated area.
Never
add fuel to the ATV gas tank near any open
flames or With the engine running. DO NOT
SMOKE while filling the gas tank.
ATV0049B
Since gasoline expands as its temperature rises,
the gas tank must be filled to its rated capacity
only. Expansion room must be maintained in the
tank particularly if the tank is filled with cold
gasoline and then moved to a warm area.
WARNING
Do not overflow gasoline when filling the gas ta nk. A
fire hazard
co uld materialize. Always allowthe engine
to cool before filling the gas tank.
Tighten the gas tank cap securely afterfilling the
tank.
Genuine Parts
When replacement of parts is necessary, use
only genuine KYMCO ATV parts. They are
precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated
Parts Manual for the correct part number,
quantity, and description.
Preparation For Storage
CAUTfON
Prior to storing th e AT V, it must be properly seN iced to
prevent
ru sting a nd component deterioration.
KYMCO recommends the following procedure to
prepare the ATV for storage.
1-6
1.Ciean the seat cushion (cover and base) with
a damp cloth and allow it
to dry.
2.Ciean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO
NOT get water into any part ofthe engine or air
intake.
3.Either drain the gas tank or add Fuel Stabilizer
to the gas in the gas tank. Remove the air filter
housing cover and air filter. Start the engine
and allow it
to idle; then using KYMCO Engine
Storage Preserver, rapidly inject the preserver
into the air filter opening for a period of 10
to
20 seconds; then stop the engine. Install the
air filter and housing cover.
CAUTION
If the interior of the air filter housing is dirt y, clean t he
area before starting the engine.
4.Empty the fuel in the fuel tank.
5.Piug the exhaust outlet on the muffler with a
clean cloth.
6.Apply light oil to the upper steering post
bushing and plungers ofthe shock absorbers.
7. Tighten all nuts, bolts, cap screws, and
screws. Make sure rivets holding components
together are tight. Replace all loose rivets.
Care must be taken that all calibrated nuts,
cap screws, and bolts are tightened to
specifications.
8,Disconnect the battery cables; then remove
the battery, clean the battery posts and
cables, and store in a clean, dryarea.
9. Store the ATV indoors in a level position.
CAUTION
Avoid storing outside in direct sunlight and avo id
using a plastic cover as moisture wi ll collect on the
ATV causing rusting.
Preparation After
Storage
Taking the ATV out of storage and correctly
preparing it will assure many miles and hours of
trouble-free riding. KYMCO recommends the
following procedure to prepare the ATV.
1. Clean the
ATV thoroughly:
2. Clean the engine. Remove the cloth from the
muffler.

3. Check all control cables for signs of wear or
fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Charge the battery; then install. Connect
the battery cables.
CAUTION
The ignition switch must be in the OFF position
prior to installing the battery or damage may occur
to the ignition system.
CAUTION
Connect the positive battery cable first, then the
negative.
6.Check the entire brake systems (fluid le vel,
pads, etc.), all controls, lights, and
headlight aim; adjust or replace as
necessary.
?.Tighten all nuts, bolts, cap screws, and
screws making sure all calibrated nuts, cap
screws, and bolts are tightened to
specifications.
8.Check tire pressure, Inflate to recommended
pressure as necessary.
9.Make sure the steering moves freely and
does not bind.
1O.Check the spark plug. Clean or replace as
necessary.
1-7

SECTION 2-
PERIODIC MAINTENANCE
TABLE OF
CONTENTS
Periodic Maintenance Chart .. .. .. .. .. .... .. ............ .. .. .... 2 -2
Periodic Maintenance........................... .. ................. 2-3
Lubrica
ti on Points.................................................... 2-3
Battery ..................................................................... 2-3
Fuses ..................................................................
.. .. 2 -4
Air Filter................................................................... 2-4
Va lve/Tappet Clearance
(Feeler Gauge Procedur
e) ........ ........................... 2-6
Valve/Tappet Clearance
(Va
lv e Adjuster Procedure) ...... .. ........ .. ................ 2-6
Testing Engine Comp
re ssion .. .. ............................. .. 2-7
Spark Plug.............................................
.. ............. ... 2-8
Muffler/Spark Arrester ............................................. 2-8
Adjusting
Thr ottle Cable ....................... .. ................. 2-9
Engine/Transmission O
il - Filter - Strainer .............. 2-9
Front Differential/Rear Dri
ve Lubricant .................. 2 -11
Tires ......................................................................2- 12
Steering Components .......................... .. ...............2 -1 2
Driveshaft/Coupling
.. .. .............. .. .. .........................2 -1 2
Suspension
/S h oc k Absorbers/Bushings ...............2-12
Nuts/Bo
lt s/Cap Screws..........................................2 -1 2
Lights.........................................
.... ......... .. .............2 -1 3
Shift Lever .............................................................2 -1 5
Frame/Welds/Racks .............................................. 2-15
Electrical
Con nec ti ons............ .. . ...... ......................2 -1 5
Hydraulic Brake Systems .......... .. ..........................2 -1 5
Burnishing Brake Pads.......................................... 2-17
Checking/Re pl ac in g V-B elt ...................... .. ...........2 -1 7
2-1

Periodic Maintenance
Chart
A =Adjust I = Inspect
C
=Clean L =Lubr icate
D = Drain R = Replace
T
=T ighten
Initial Service I Every I Every
31 Every 6
Item After Break-In Every Month or Months
or Monthsor
(First
Moor Day Every 100 Every 300 Every 500
100 Mi) Miles Miles Miles
Battery I I
Fuses I
Air Filter/Drain Tube I I
c•
Valverrappet Clearance I I
Engine Compression
Spark Plug I I
Muffler/Spark Arrester c
GasNent Hoses I I
Throttle Cable I I C-L
Coolant I Cooling System
I I
Engine-Transmission Oil Level I
Engine-Transmission Oil/Filter R R*
Oil Strainer I I
Front Differential/Rear Drive Lubricant I I
Tires/Air Pressure I I
SteeringComponents I I I
V-Belt I I
Suspension (Ball joint boots. drive I I
axle boots front and rear.tie rods.
differential and rear drive bellows)
Nuts/Cap Screws/Screws I T
Throttle Body/EMS Sensor I I
Lights I I
Switches I I
Shift L eve r I
Handlebar Gr ip s I
Handlebars I I
Gauges/Indicators I I
Frame/Welds/Racks I I
Electrical Connections I I
Complete Brake System
(Hydraulic & Auxiliary) I I c
Brake Pads I I*
Brake Fluid I I
Brake Hoses I I
*Service/Inspect more frequently when operating inadverse conditions.
2-2
Every Year
or Every As Needed
1500 Miles
c
R
R
A
I
R (4000 Mi
or 18 Mo)
R
R
(2 Yrs)
A-R
R
(2 Yrs)
A
R
c
R (4 Yrs)
R
R
R
R
A
c
R
R
A-L
R
R
R
c
L-R
R
R (2 Yrs)
R (4 Yrs)

Periodic Maintenance
This section has been organized into sub-sections
which show common maintenance procedures for the
KYMCO ATV
• NOTE: KYI\,IK;O recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
• NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual
conditions.
• NOTE: Critical torque specifications are located
in Section 1.
SPECIAL TOOLS
A number of special tools must be available to the
technician when performing service procedures in this
section.
Description p/n
Compression Tes te r Kit
Oil Fi Iter Wrench E052
Tach ometer
Valve C le arance Ad juster E012
• NOTE: Special tools are available from the
KYMCO Spare Parts Department.
Lubrication Points
It is advisable to lubricate certa in components period-
ically to ensure free movement. Apply light oil to the
components using the
fo llowing li st as reference.
A. Throttle Le ve r Pivot/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Auxiliary Brake Cable Ends
D. Shift Lever Cable End
Battery
Aft er being in service, batteries req ui re regular
cleaning and recharging in order to deliver peak
performance and maximum service
lif e. The following
procedure is recommended for cleaning and
maintaining
le ad-acid batteries. Al wa ys read a nd foll ow
instructions provided wi th battery chargers and battery
products.
WARNING
Anytime service is performed on a battery, the fol-
lowing must
be observed: keep sparks, open flame,
cigarettes,
or any other flame away. Always wear
safety glasses. Protect skin and
clothing when
handing a battery. When servicing battery in
enclosed space, keep the area well-ventilated.
1. Remove the battery hold-down; then disconnect the
batterv cables (negative cablefirst).
2. Remove the battery from the battery compartmen t;
3. then thoroug hl y wash the ba tt ery and 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.
4. Using a wire brush, clean the battery posts and cable
ends removing a
ll corrosive buildup. Repla ce
damaged cables or cable ends.
WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
CAUTION
Never use electrolyte (sulfuric acid) to "top off " the
battery. Use
only distilled water or severe battery
damage may occur.
5. Using a multimeter, t est th e battery voltage. The
meter must read 12.5 or more DC
Vo lts for a fully
charged battery.
• NOTE: At this point , if the meter reads as speci-
fied, the battery may be returned to service (see
step 10).
6. If the meter re a ds less than spe ci fied voltage, charge
the battery using the
fo ll owing g ui delines.
2-3

A.When using an auto m at ic batt ery C·harger,
al ways fo ll ow the charger man u factu rer s
in str uctions.
B. Wh
en using a constant-cur rent battery charge r,
u se t he fo ll owing B attery Ch arg ing Chart .
..&. CAUTION
Neverexceedthe standardcharging rate.
A WARNING
An overheatedbattery couldexplode causing severe
injury or death. Always monitor charging times and
charge rates carefully. Stop charging
if the battery
becomes very warm
to the touch . Allow it to cool
beforeresuming charging.
Battery Ch arging Chart (Constant-Current Charger)
Battery Voltage Charge Ch ar ge Time Req uir ed
(DC) State (at 1.5-2.0 Amps)
12.5 or more 100% None
12.2-12.4
75 %-99% 3-6 hours
12.0-12.2 50%-74%
5-11 hours
11 .0-11.9 25%-49% 13 hours (minimum)
11 ,5 or less 0-24% 20 hours (minimum)
•NOTE : If the battery voltage is 11.5 DC Volts or
less , some chargers may '' cut off " and fail to
charge. Itt this occur s, connect a fully char ged
booster battery in parallel (positive to positive and
negati ve to negative) for a short period of time with
the chargerconnected. After 10-15 minutes, di s con-
nect the booster battery leaving the charger con-
nected and the charger should continue to charge.
If the charger" cuts off ;' replacethe battery.
8. After charging th e battery for the spec ified time .
remov e the battery charger and all ow the battery to
si t for 1-2 ho ur s.
9.
Connect the multim eter and test the battery vo lt-
age . The me ter sh ould r ead 1 2.5 or m ore DC Vo lts.
l
ft he voltage is as specified. the battery is ready
fo r service.
•NOTE : If voltage in step 9 is below specification s,
charge the battery an additional 1-5 hours ; then
retest.
10. Place the battery in the b attery co mpartment: then
coat the battery posts an d ca ble ends with a light
coat ofmul ti- pu.rpose grease.
& CAUTION
Before installing the battery, make sure the ignition
switch
is in theOFF position.
2-4
II. Connect the battery cab l es (positive cable first):
then install the ba tt ery bo ld- do\. vn.
A CAUTION ~
Connecting cables in reverse (positive to negative
and negative
to positive) can cause serious damage
to the elec trical system.
Fuses
The fuses are located in a powe r distribution mod ul e in
front
of the stee ring post. In addition , there is a 30 amp
fi t se on the starter relay 1 mder the seat next to the bat-
tery.
If t he re is any type of electricaJ system failu.re , al ways
check the fuses first.
•NOTE: To remove a fuse, compress the locking
tabs on either side of the fuse case and lift out.
"'"
=
;;o::;o;;oO::o;;o::o;;z:J OJCD;=:.Or-r-
--.-.--.-.-.:::o~-...,--
-< ~ =Cil.:::eC')-<- -=N-
- ~ - --
11 81 82 Bl U (I <• 0 tl OJ OJ t l A1 &I
NEUTRAY S WI TC H ED 2WDI4W D
RELAY POWER RE L AY
RE L AY
& CAUTION ~
Always replace a blown fuse with a fuse of the sarne
typeand rating.
Air Filter
Use the following procedure to r emove the filter and
inspect and/or cl ean it.
CLEANING AND INSPECTING
FILTER
1. Rotate the th r ee locking ta bs free of the lu gs on th e
air filter cover: th en rotate the cover fo r war d and
away from the filter housing.

KC0056A
4. Dry the ele ment.
5.
Put the element in a plastic bag; then pour in air
filter oil and work the oil into the el ement. Insert
the
forming spring into the element with the
closely wrapped end of the spring toward the open
end
of the ele ment.
2
CAUTION
KC147
2. Remove the foam filt er el ement from the ai r filter
housing a nd separa te th e foam eleme n t from the
spring.
KC148
A torn air filter element can cause damage to the ATV
engine
. Dirt and dust may get inside the engine if the
element
is torn. Carefully examine the element for
tears
before and after c l eaning it. Replace the element
with
a new one if it is torn.
6. Clea n any dirt or debris from inside the ai r clea ner.
Be
sure no dirt enters the carburetor (if equipped).
7.
Place the filter assembly in the air filter housing
making sure it is proper l y positioned and properly
seated
with the filter element straight i n the hous-
ing.
CAUTION
KC147
KC143
3. Fill a wash pan la rger than the element with a non-
flammable
clea ning solvent; then dip the el e-
ment
in the solvent and wash it .
Failure to properly seat and align the filter element
may
cause severe engine damage .
8. Install the air filter housing cover and secure with
the l ocking tabs.
KC143
2-5

CHECKING AND CLEANING DRAIN
1. Inspect the drain on the fi lt er housing cover and
clean out any dirt ordebris.
2. Replace any drain that is.crac.ked or shm•
vs any
signs
of hardening or detenoratJon.
3. Wipe any accumulation
of oil orgas from the filter
housing
and drain.
Valve/Tappet Clearance
(Feeler Gauge Procedure)
To check and adjust va lve/tappet clearance, use the
following procedure.
•NOTE: The seat, left-side and right -si de engine
covers, and gas tank must be removed for this pro-
cedure.
1. Remove the timing inspection plug and spark
plug: then
remO\ ~ e the tappet .covers (for J??re
deta.iled infom1atton, see SectJOn 3 - Serv1cmg
T
op -Side Components).
2. Rotate th e crankshaft to the TDC position on the
com
pr ession stroke.
•NOTE: At this point , the rocker arms and adjuster
screws must not have pre ssure on them.
2-6
3. Using a feeler gauge, check. e~c h v a! ve/ t~pp et
cl ea rance. If clearance is not w 1thm spec rfi ca~tons,
loosen the jam nut and r ~tate .t h ~ tapp e.t adj~1ster
screw lmtil the cl ea rance IS w 1thm spec rfi c~tJons.
Tighten each jam nut secur ely after completJng the
adjustment.
& CAUTION
The feeler gauge must be positioned at the same
angle as the valve and valve adjusterfor an accurate
measurement of clearance. Failure to measure the
valve clearance accurately could cause valve com-
ponent damage.
VALVE/TAPPET CLEARANCE
Intake J 0.10
mm
Exhaust J 0.17
mm
4. Install the tinting inspection plug.
5. Place the two tappet covers with 0-rin gs into po si-
tion: then tighten the covers securely.
6. Install
th e spark plug: then install the timing
in spection plug.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
To check and adjust val ve /tapp et clearance, use the
foliO\\ri.ng procedure.
•NOTE : The seat, left-side and right-side engine
covers , and gas tank must be removed for this pro-
cedure.
l. Remove the tim in g in spec t.ion plug and spark
plug: then remove the tappet.covers (for
~?re
detailed information. see S ectiO n 3 - Serv 1cm g
Top-Side Components).

CF005
2. Rotate the crankshaft to th e TDC position on the
co
mpr ession stroke.
•NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
•NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. Pl ace th e va lve adjuster onto the jam nut securing
th e tappet adjuster scr ew ; then rotate th e valve
adjuster dial clockwise until the end is seated
in
the tappet ad just er sc re· w.
4. While holding the va lve adjuster dial in place, use
the
va l ve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster scr
ew clocl"'visc
tm til friction is fe lt .
5. Align the valve adjuster handle
wit h one of the
marks on the valve adjuster dial.
6. Whi le holding the valve adjuster handle in pl ace.
ro tate the valve adjuster dial countercl ockw ise
unt il proper valve/tappet clearance is attained.
•NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.
•NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
7. W11iJ e holding the adjuster dial at the proper clear-
ance setting, tighten the ja m nut securely with the
valve adjuster handle.
8. Pla
ce the two tappetcovers wi th 0-rin gs into posi-
tion: then tighten the covers securely.
9.
ln sta ll th e spark plug: th en install the timing
inspection plug.
Testing Engine
Compression
To t est engine compression, use the fo ll owing proce-
dure.
l. Re mo ve the high te nsion l ea d from the spark plug.
2. Using com pr essed ai r., blow an y d eb ris from
arOL rnd the sparkplug.
Always wear safety glasses when using compressed
3. Remove th e spark plug; then attach t he high t en-
sion l ea d to the plug and grotmd th e plug on the
cylind
er head we ll away from the spa rk plug hole.
4. Attach the Co mpr ession Tester Kit.
•NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. Whi le holding th e throttle lever in th e full-open
positioll. crank the engine over with th e electric
start
er u nti l th e ga uge shows a peak reading of
170·227 psi (five to I0 compression st ro kes).
6.
If co mpr ession is abnormally low, insp ec t the
following
it ems.
A. V
er if y st art er cra nks engine over at normal
speed (approximately 400 RPM).
B. Gauge functioning properly.
C. 1brottle lever in the full-open position.
D. Valve/tappet clearance conect.
E. Valve n
ot bent or burned.
F. Valve seat not bumed,
•NOTE : To service valves, see Section 3.
7. Pour 29.5 ml (I fl oz) of oil into the spark plug
hole. reattach the gauge, and retest compression.
8. If com pr ession is now ev id en t, service tbe piston
rings (sec Section 3).
2-7

Spark Plug
A light brov.rn i.nsuJalor indicates that a plug is conect.
A\\ bite or dark insulator incticates that the engine ma y
need to be serviced
or the carburetor mav need to be
adjusted. To maintain a hot, strong spark. keep the
plug free
of carbon.
ATV-0051
A CAUTION
Before removing a spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for
nr nt~l"r ionilinn l i e:,..~ f,.,.f,.r O!:IIIOP In r h l"rl.- lhP o<o"
t'' .... l"'"'' - •t::J•._ ..... ..., .. .........u ..... - ...... ...,,._,_ b-._.o.., ·- ........... ...,_ .... "" "" --o"'t-"'
ATV0052C
When instaJling the spa rk plug, be sure to ti ghten it
securely. A n
ew spark plug shou ld be tightened 1/2
tum once the washer contacts
tJ1e cy linder head. A
used spark pl
ug shouJd be tightened 1i 8- 1/4 tum once
the washer contacts the cylinder head.
2-8
Muffler/S1,ark Arrester
At the intervaJs shown in the Periodic Maintenance
Chart, clean thespark arrester using the following pro-
cedure.
I. Remove the cap scr·ews secw·ing the sparkarrester
assembly to the muffler: then loosen
and remove
the arrester. .
2. Using a suitable brush. clean the carbon deposits
frnl'n lhP <>f' t 'PI"n l<'ll:ino r!'trP nn'l' In ti!'ln ·H'IOI" lhP
.... . ...,._._ ............ ... ..... ,.. -- · ·· "" ... ' """-b .... -..... , _._ ...:,.r,., ... -.... \. ... .IJ-o- ,.. .....
screen.
•NOTE : If the screen · or gasket is damaged in any
way, it must be replacHd.
3. Install the spark arrester assembl) with gasket ~
then secure with the cap screws. Tighten to 48
in.-lb.
KC145

Oillevelstick

2-10
733-441A
5. Remove the oil filter plug from the filter mounting
boss (located on the front side of the transmission
case) and allow the filter to drain completely.
Install the plug and tighten securely.
6. Using the adjustable Oil Filter Wrench and a suit-
able wrench, remove the old oil filter.
NOTE: Clean up any excess oil after removing
the filter.
7. Apply oil to a new filter seal ring and check to
make sure it is positioned correctly; then install the
new oil filter. Tighten securely.
8. Install the engine drain plug and tighten to 20 ft-lb.
Pour the specified amount of the recommended oil
in the filler hole. Install the oil level stick/filler
plug.
9. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
10. Turn the engine off and wait approximately one
minute.
11. Remove the oil level stick and wipe it with a clean
cloth.
12. Install the oil level into engine case.
NOTE: The oil level stick should be threaded into
the case for checking purposes.
13. Remove the oil level stick; the engine oil level
should be above the illustrated “L” mark but not
higher than the illustrated “F” mark.
ATV-0100AA
14. Inspect the area around the drain plug and oil filter
for leaks.
15. Install the left-side engine cover and the seat.
STRAINER
1. Remove the belly panel.
2. Remove the cap screws securing the oil strainer
cap; then remove the cap. Account for the O-ring.
CC091D
3. Remove the two cap screws securing the strainer;
then remove the strainer.
! CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These
oils can adversely affect clutch operation. Also, not
recommended are racing, vegetable, non-detergent,
and castor-based oils.
! CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” mark but not
higher than the “F”mark.

2-11
2
CC163D
4. Place the oil strainer into position beneath the
crankcase and secure with the cap screws. Tighten
securely.
5. Place the strainer cap into position on the strainer
making sure the O-ring is properly installed; then
secure with the cap screws. Tighten securely.
CC091D
6. Install the belly panel.
Front Differential/Rear
Drive Lubricant
When changing the lubricant, use approved SAE
80W-90 hypoid gear lube.
To check lubricant, remove the rear drive filler plug;
the lubricant level should be 1 in. below the threads of
the plug. If low, add SAE approved 80W-90 hypoid
gear lubricant as necessary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each oil fill plug.
KC0077A
3. Drain the oil into a drain pan by removing the
drain plug from each.
ATV0082A
737-651B
4. After all the oil has been drained, install the drain
plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of approved SAE
80W-90 hypoid gear lubricant into the filler hole.
6. Install the fill plugs.
NOTE: If the differential/rear drive oil is contami-
nated with water, inspect the drain plug, filler plug,
and/or bladder.
 AT THIS POINT
To check/service oil strainer, see Section 3.
! CAUTION
Water entering the outer end of the axle will not be
able to enter the rear drive unless the seals are dam-
aged.

Tires
TIRE SIZES
The ATV is equipped with low-pressure tubeless tires
of the size and typelisted (see Section 1). Do not under
any circumstances substitute tires
of a different type or
stze.
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
TIRE INFLATION PRESSURE
Front a nd rear tire inflation pressure should be 0 .28
kg-cm2 ( 4.0 psi).
Steering Components
The following steering components sh ou ld be in spected
periodically to ensure safe and proper operation.
A. Handlebar grips not worn, broken, or
lo ose.
B. Handlebar not bent, c
ra cked, and ha s equal and
complete full-left and full-ri
ght capabili ty.
C. Steering postbearing assembly/bearing housing
not broken, wo rn , orbinding.
D.Ball joints
not worn, cracked, or damage d.
E. Tie rods n ot bent or cracked.
F. Knuckles not wo rn , cracked, or damage d.
G Cotter p in s not da ma ged or missing.
Driveshaft/Coupling
The following drive system components sh ou ld be
inspected periodically to ensure
proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, dama ge d, orworn.
2-12
Suspension/:Shock
Absorbers/Bushings
The foll ow in g suspension system components sho uld
be in spected periodically to ensure proper operation.
A. Shock absorber rods not be
nt , pitted, ordamaged.
B. Rubber dampernot cracked, broken, or miss in g.
C. Shock absorber body
not damaged, punctured,
or leaking.
D. Shock absorber eyelets not broken, be nt , or
c
ra cked.
E. Shock absorber eyelet bushings
not worn , dete-
riorated, cracked, or
mi ss in g.
F. Shock absorber spring not brokenor sagging.
Nuts/Bolts/Cal=• Screvvs
Tighten all nut s, bolt s, and cap screws. Make su re riv-
ets holding components together are tight. Replace all
loose rivets. Care
must be taken that all calibrated
nuts, bolts, a
nd cap screws are tightened to specifica-
tions.