KYMCO MXER 50R Owner's Manual
  1. Manuals
  2. Brands
  3. KYMCO Manuals
  4. Offroad Vehicle
  5. MXER 50R
  6. Owner's manual

KYMCO MXER 50R Owner's Manual

On-road
Hide thumbs
Table of Contents

Advertisement

Quick Links

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXER 50R/90R
ON-ROAD

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MXER 50R and is the answer not in the manual?

Questions and answers

Related Manuals for KYMCO MXER 50R

Summary of Contents for KYMCO MXER 50R

  • Page 1 OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. MXER 50R/90R ON-ROAD...

  • Page 3: Important Notices

    IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle. AGE RECOMMENDATION KXR 50: The minimum recommended age for this ATV model is 6.
  • Page 4 SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol . Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.
  • Page 5 PREFACE Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service. For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.

  • Page 6: Table Of Contents

    CONTENTS Page Page LOCATION OF THE WARNING AND Turn signal switch ........23 SPECIFICATION LABELS......1 Headlight switches ......24 Engine stop switch.......25 SAFETY INFORMATION......4 Stater button........26 Kick starter..........27 DESCRIPTION AND MACHINE Remote engine stop switch......28 IDENTIFICATION........9 Throttle lever........29 Key identification number..
  • Page 7 GETTING TO KNOW YOUR ATV....60 Fuel .............42 RIDE WITH CARE AND GOOD Engine (MXER 90R) and JUDGEMENT.........61 transmission oil ........44 Age Recommendation (MXER 50R)..62 Engine oil ( MXER 50R)......45 Age Recommendation (MXER 90R)..63 Chain ...........46 Never carry passenger on the carrier..64 Throttle lever.........46...
  • Page 8 Page Page Speed limiter for new riders.....77 Front and rear brake shoes (drum brake) BRAKING..........78 inspection...........110 TURNING YOUR ATV ......79 Front brake lever free play adjustment..111 CLIMBING UP SLOPE......80 Rear brake lever free play adjustment RIDING DOWN SLOPE ......86 (Drum brake)........113 PARKING..........87 Brake pedal adjustment (MXER 90R)..115 WHAT TO DO IF........88...
  • Page 9 Page CLEANING AND STORAGE.....133 A. Cleaning .........133 B. Storage ...........135 SPECIFICATIONS (MXER 50R)....137 SPECIFICATIONS (MXER 90R)....141 NOISE REGULATION......145 MAINTENANCE RECORD.......146 INDEX...........147...

  • Page 10: Location Of The Warning And Specification Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 11 Without proper training or instruction. parts of the vehicle. If a label comes off or At speeds too fast for your skills becomes hard to read, contact your KYMCO the conditions. dealer for replacements Do not operate the vehicle after consuming ALCOHOL OR DRUGS.
  • Page 12 MXER 50R) MXER 90R) WARNING WARNING UNDER UNDER Operating this ATV if you are under the Operating this ATV if you are under the age of 6 increases your chance of age of 12 increases your chance of severe injury or death. severe injury or death.

  • Page 13: Safety Information

    SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.
  • Page 14 Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. Never attempt wheel, jump, or other stunt.
  • Page 15 Always follow proper procedures for going down slopes and for braking 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 that would cause the vehicle to lean sharply to one side.
  • Page 16 WARNING WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Improper handling of gasoline. If you should swallow some gasoline or inhale WHAT CAN HAPPEN a lot of gasoline vapor, or get some gasoline in Gasoline can catch fire and you could be your eyes, see your doctor immediately.
  • Page 17 WARNING POTENTIAL HAZARD Starting or running 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 area with adequate ventilation.

  • Page 18: Description And Machine Identification

    DESCRIPTION AND MACHINE IDENTIFICATION Identification number records Keys identification number Record the keys identification number, frame The keys identification number is stamped on serial number, engine serial number and the hang tag as shown in the following model code information for assistance when illustration.

  • Page 19: Frame And Engine Serial Number

    Frame and engine serial number The engine serial number is stamped on the The frame serial number is stamped on the left crankcase. front of the frame. (1) Frame serial number (1) Engine serial number (MXER 50R) (2) Engine serial number (MXER 90R)

  • Page 20: Parts Location

    Parts location (07) (06) (05) (04) (03) (02) (01) (01) Left front turn signal light (02) Rear brake lever (03) Left back mirror (04) Headlight (05) Right back mirror (06) Front brake lever (07) Right front turn signal light (08) Front wheel (09) Position light (08) (09)
  • Page 21 (03) (02) (01) (01) Throttle lever (02) Remote engine stop switch (03) Instrument (04) Left rear turn signal light (05) Rear wheel (06) Right rear turn signal light (04) (05) (05) (06)
  • Page 22 (04) (03) (02) (01) (01) Flag pole bracket (02) Right footboard (03) Indicator lamps (04) Parking brake ( MXER 90R) (05) Parking brake ( MXER 50R) (06) Fuel fill cap (07) Left footboard (08) Taillight/Stop light (05) (06) (07) (08)
  • Page 23 (02) (01) (01) Storage compartment, containing Owner's manual Air pressure gauge Tool kit (02) Handlebar switches (03) Fuel vavle (04) Kick starter (05) Exhaust pipe (03) (04) (05)
  • Page 24 (03) (02) (01) (01) Speed limiter (02) Ignition switch (03) Seat (04) Seat lock lever (05) Brake pedal (06) Steering handlebar lock ( MXER 90R) NOTE: The machine you have purchased may differ (04) (05) (06) slightly from those shown in the figures of this manual.

  • Page 25: Control Functions

    CONTROL FUNCTIONS Ignition switch Functions of the respective switch positions are as follows: OFF: All electrical circuits are switched off. The key can be removed in this position. ON ( The position and taillight can be turned on. With the engine stop switch at run ( ), the engine can be started.

  • Page 26: Indicator Lamps

    ( )and the ignition switch is ON ( Low oil level indicator " " (MXER 50R) The low level indicator lights when the 2-stroke engine oil level is low. CAUTION: If the low oil level indicator comes on while riding, stop riding and shut the engine off.

  • Page 27: Instrument

    Instruments Display description AUTO km h km h AUTO km h mile h mile h mile h 1. Display 1. TM start symbol 2. MODE button Bar-graph speed symbol 3. ST./STOP button Mode symbol Auto (automatic start/stop) mode symbol Distance scale symbol Data display (TM, DST, ODO, CLOCK)
  • Page 28 MODE AUTO MODE MODE MODE MODE km h km h km h km h km h mile h MODE ST./STOP MODE ST./STOP 1. Button function ST./STOP ． km h km h MODE Button: Each press of button converts TM and DST are cleared the screen to display will be changed to other ST./STOP MODE...
  • Page 29 2. Function ． Speed: Current speed is displayed continuously when the motor in motion. ． TM: Elpased time is measures from the km/h starting point of a trip. ． DST: Trip distance is measures traveled since the time of the last reset. km/h ．ODO: Total distance: Mileage is continuously measured accumulated and displayed until...
  • Page 30 ．CLOCK: The 24HR clock always displayed the current time on the screen.
  • Page 31 MXER 90R ST./STOP button to setting wheel circumference, the body to set wheel km/h km/h circumference is (MXER 50R: 1400mm) (MXER 90R: 1570mm). ． Press the MODE button and press the ST./STOP button to setting clock. km/h ． hen the MODE button and ST./STOP button are pressed simultaneously and press the ST./STOP button to setting auto...

  • Page 32: Handlebar Switches

    Handlebar switches Horn button ． When the ignition switch is in the " " position, push the horn button and it will sound. Turn signal switch Use the turn signal switch while turning to another direction or shifting to another lane. The turn signal light will wink when the switch is operated, "...

  • Page 33: Headlight Switches

    Headlight switch Turn the switch to the " " position to switch on the low beam. Turn the switch to the " " position to switch on the high beam. Turn the switch to the " " position to switch off the headlight.

  • Page 34: Engine Stop Switch

    Engine stop switch When the switch is in the RUN ( ) position, the engine will operate. When the switch is in OFF ) position, the engine will not operate. This switch is intended primarily as a safety or emergency control, and it should normally remain in the RUN ( ) position.

  • Page 35: Stater Button

    Stater button To starter the engine, apply brake and press the starter button, with the ignition switch ON ( ) and the engine stop switch at RUN ( CAUTION: See starting instructions prior to starting engine (see page 50 for details). NOTE: (1) Start button If the starter switch is pushed with the ignition...

  • Page 36: Kick Starter

    Kick starter The kick starter cranks the engine when the kick starter is operated. CAUTION: See starting instructions prior to starting engine (see page 50 for details). NOTE: If the kick starter is operated with the ignition ． switch at " " and the engine stop switch " ", the engine will not start.

  • Page 37: Remote Engine Stop Switch

    Remote engine stop switch The ATV has a remote engine stop switch. This allows the supervisor to follow close behind and stop the engine by pulling a tethered core. Practice using it when your youngster first starts riding. (See page 76.) NOTE: Make sure the tethered road lead is installed into the remote engine stop switch.

  • Page 38: Throttle Lever

    Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a KYMCO dealer if you can't find or solve the problem yourself. (1) Throttle lever...

  • Page 39: Speed Limiter

    Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle.

  • Page 40: Front And Rear Brake

    Front and rear brakes Brake pedal (MXER 90R) The front and rear brakes are operated by The both front and rear brakes are operated at squeezing the front brake lever. the same time by depressing the brake pedal. (1) Rear brake pedal (1) Front brake lever...

  • Page 41: Parking Brake ( Mxer 50R)

    Parking brake ( MXER 50R) To set the parking brake, squeeze the rear brake lever and lock it with the lock plate. Always set the parking brake when parking and before starting the engine. To unlock the parking brake, squeeze the rear brake lever until the lock plate releases.

  • Page 42: Parking Brake (Mxer 90R)

    Parking brake ( MXER 90R) To set the parking brake, squeeze the front brake lever and lock it with the lock pin. Always set the parking brake when parking and before starting the engine. To unlock the parking brake, squeeze the front brake lever until the lock pin releases.

  • Page 43: Fuel Tank Cap

    Fuel tank cap WARNING After refueling, be sure to tighten the fuel tank POTENTIAL HAZARD cap. Improper use of the parking brake. TO refuel refer to page 42~43. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine.

  • Page 44: Fuel Valve

    Fuel valve The fuel valve supplies fuel from the fuel tank to the carburetor. The fuel valve has three positions. OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this position when the engine is not running.

  • Page 45: Locking Steering (Mxer 90R)

    Locking steering (MXER 90R) WARNING Turn the steering handlebar left to full and turn POTENTIAL HAZARD the key clockwise, the steering handlebar is locked. Improper use of the locking steering. The key can be taken out. WHAT CAN HAPPEN Turn the key counterclockwise, the steering handlebar is released automatically.

  • Page 46: Starter (Choke) (Mxer 90R)

    Starter (choke) ( MXER 90R) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction (A) to turn on the starter (choke). Move in direction (B) to turn off the starter (choke).

  • Page 47: Seat

    To install the seat, align the tabs on the seat with Seat the grommets on the frame and press the seat To remove the seat, pull upward the seat lock down until it locks. lever and pull up the seat the rear. NOTE: Make sure that the seat is securely fitted.

  • Page 48: Flag Pole Bracket

    Flag pole bracket Storage compartment To mount a flag pole in the bracket. The storage compartment is located under the seat. To remove the seat, see page 38. NOTE: Flag poles are required in some riding areas. Be careful not to flood this area when washing Check local regulations before riding.

  • Page 49: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ROUTINE PAGE ITEM Check operation, condition, free play (drum brake) and brake fluid level (disk brake). 41～42 ～ , 110 117 Brake Adjust (drum brake) if necessary. Fill with DOT 4 brake fluid (disk brake) if necessary.

  • Page 50: Front And Rear Brakes

    WHAT CAN HAPPEN feeling when the brake is applied. If not, have Increases the possibillty of an accident or the machine inspected by a KYMCO dealer. equipment damage. Disk brake HOW TO AVOID THE HAZARD Make sure there is no brake fluid leakage.

  • Page 51: Fuel

    Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a KYMCO dealer. (1) Filler neck Recommended fuel: UNLEADED FUEL Fuel tank capacity: Total: 5.5L(1.16 lmp gal, 1.4 US gal)
  • Page 52 Your KYMCO engine has been designed to use WARNING regular unleaded gasoline with a pump octane POTENTIAL HAZARD number of 86 or higher, or research octane Improper care when refueling. number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or WHAT CAN HAPPEN premium unleaded fuel.

  • Page 53: Transmission Oil

    Engine ( MXER 90R)and transmission oil CAUTION: Make sure the engine and transmission oil at the Be sure to use motor oils that do not specified level. Add oil as necessary. (See page contain anti-friction modifiers. Passenger 95~101.) car motor oils (often labeled "Energy Check for leaks.

  • Page 54: Engine Oil ( Mxer 50R)

    Genuine KYMCO NOTE: 2-Stroke Oil has been specifically designed When filling, do not let dirt or other foreign and tested in KYMCO ATV and is a proper oil. materials enter the tank.

  • Page 55: Chain

    Repair as necessary for proper operation. Fittings and fasteners Always check the 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.

  • Page 56: Tires

    2.The tires should be set to the Tires recommended pressure: WARNING Recommended tire pressure POTENTIAL HAZARD Front: 25 kpa (0.25 kgf/cm , 3.6 psi) Operating this ATV with improper tires, or Rear: 25 kpa (0.25 kgf/cm , 3.6 psi) with improper or uneven tire pressure. Check and adjust tire pressures when the tires are cold.

  • Page 57: How To Measure Tire Pressure

    Set pressure tires cold. 4.Never set tire pressure over the Set tire pressures to the following recommended Front: 28 kpa (0.28 kgf/cm , 40 psi) Recommended Rear: 28 kpa (0.28 kgf/cm , 40 psi) Minimum Maximum pressure Higher pressures may cause the tire to 25 kpa 22 kpa 28 kpa...

  • Page 58: Tire Wear Limit

    Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. A. 3mm (0.12 in)

  • Page 59: Operation

    KYMCO dealer. 1. Select a level surface and lock the parking brake (see page 32 or 33) before starting the engine.
  • Page 60 6.With the throttle closed, push the starter 5. Use the starter (choke) in reference to the button. Release the starter button as soon as figure: the engine starts. Position :Cold engine start-ambient temperature below 5C (40F). NOTE: Position :Cold engine start-ambient Do not use the electric starter for more than 5 temperature at 0C (30F)~30C(90F) seconds at a time.
  • Page 61 Starting a warm engine (MXER 90R) To start the engine without the electric starter. To start a warm engine, refer to the "Starting a 1. Follow steps 1 through 5. cold engine" section. The starter (choke) should 2. With the throttle closed, operate the kick not be used.

  • Page 62: Starting Engine (Mxer 50R)

    Starting engine ( MXER 50R) WARNING 5.With the throttle closed, push the starter button. Release the starter button as soon as POTENTIAL HAZARD the engine starts. Freezing control cables in cold weather. NOTE: WHAT CAN HAPPEN Do not use the electric starter for more than 5 seconds at a time.

  • Page 63: Engine Break-In

    2. Open the throttle slightly (1/8 1/4) while can rid itself of the temporary build up of heat. starting the engine . If the throttle limiter Is If any abnormality is noticed during this period, adjusted as delivered, open the throttle fully. consult a KYMCO dealer.
  • Page 64 1. 0~10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at full throttle position. 2.

  • Page 65: Parking

    Parking ( MXER 50R) Parking ( MXER 90R) When parking, stop the engine. Turn the fuel When parking, stop the engine. Turn the fuel lock to "OFF" and apply the parking brake. lock to "OFF" and apply the parking brake. Make sure the lock plate into the locked Make sure the lock pin into the locked position.

  • Page 66: Parking On A Slope

    Parking on a slope 1. Bring the machine to a stop by applying the brakes. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the brake applied, apply the parking brake. Parking on a slope or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident.

  • Page 67: Accessories

    Choose only accessories designed for your difficult, an accessory that limits your ability to ATV. Your KYMCO dealer has a variety of move around on the seat, or one that limits genuine KYMCO accessories. Other your view.

  • Page 68: Riding Your Atv

    Riding Your ATV...

  • Page 69: Getting To Know Your Atv

    WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This Manual completely and understand the section, riding your ATV, provides general ATV operation of the controls. Pay particular riding instructions for recreational riding.

  • Page 70: Ride With Care And Good Judgement

    RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Become familiar with this ATV at slow Get training if you are inexperienced. speeds first, even if you are an experienced Beginners and inexperienced riders should get operator. proper instruction on how to operate this ATV. Do not attempt to operate at maximum performance until you are totally familiar with the machine's handling and...

  • Page 71: Age Recommendation (Mxer 50R)

    Age Recommendation (MXER 50R) HOW TO AVOID THE HAZARD The minimum recommended age for this ATV A child under 6 should never operate this model is 6. For safety, never let children under 6 ATV. years old operate this vehicle. Children under Never allow a child under 16 to operate an 16 should be supervised by an adult.

  • Page 72: Age Recommendation (Mxer 90R)

    Age Recommendation (MXER 90R) HOW TO AVOID THE HAZARD The minimum recommended age for this ATV A child under 12 should never operate this model is 12. For safety, never let children under ATV. 12 years old operate this vehicle. Children Never allow a child under 16 to operate an under 16 should be supervised by an adult.

  • Page 73: Never Carry Passenger On The Carrier

    Never carry passenger on the carrier. WARNING POTENTIAL HAZARD Carrying a passenger on the carrier. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger on the carrier.

  • Page 74: Apparel

    Apparel Operating without protective clothing WARNING increases your chances of severe injury in POTENTIAL HAZARD the event of an accident. Operating this ATV without wearing an approved motorcycle helmet, eye HOW TO AVOID THE HAZARD protection and protective clothing. Always wear an approved motorcycle helmet that fits properly.

  • Page 75: Do Not Operate After Consuming Alcohol Or Drugs

    Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator's performance capability is reduced by Operating this ATV after consuming the influence of alcohol or drugs. alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.

  • Page 76: Pre-Operation Checks

    Pre-operation checks Always perform the pre-operation checks listed on page 40 before riding for safety and proper WARNING care of the machine. POTENTIAL HAZARD Operating this ATV with improper tires, or WARNING with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before operating.
  • Page 77 Do not operate at speeds too fast your skills Speed limiter or the conditions. For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits WARNING the power and top speed of the machine. POTENTIAL HAZARD Turning the screw in decreases top speed, and Operating this ATV at speeds too fast for...

  • Page 78: Loading And Accessories

    Loading and accessories Loading and Operational Guidelines Use extra caution when riding the machine with Carrying cargo will affect how your ATV handles additional loads, such as accessories or cargo. and greatly reduce its ability in accelerating, braking and making turns and other maneuvers. The machine's handling may be adversely affected.

  • Page 79: Accessories

    WARNING Genuine KYMCO accessories have been specifically designed for and tested on this POTENTIAL HAZARD vehicle. Because KYMCO cannot test all other Overloading this ATV or carrying or towing accessories, you are personally responsible for cargo improperly. properly selecting, installing, and using non- KYMCO accessories.

  • Page 80: No Modifications

    Never modify this ATV through improper installation or use of accessories. All parts 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, consult...

  • Page 81: During Operation

    During operation WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the Removing hands from handlebars or feet rear wheels. from footboards 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 footpeg, your foot or leg may come...
  • Page 82 Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.

  • Page 83: Exhaust System

    Exhaust system The exhaust on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system...

  • Page 84: Riding

    RIDING WARNING Select a flat area to become familiar with your POTENTIAL HAZARD ATV. Make sure that this area is free of Starting or running the engine in a closed obstacles and other riders. You should practice area. control of the throttle, brakes, shifting before trying more difficult terrain.

  • Page 85: Remote Engine Stop Switch For New Riders

    Remote engine stop switch for new riders The ATV has a remote engine stop switch (page 28). This allows the supervisor to follow close behind and stop the engine by pulling a tethered core. Practice using it when the beginner first starts riding.

  • Page 86: Speed Limiter For New Riders

    Speed limiter for new riders To adjust the throttle limiter: Your ATV has an adjustable throttle limiter. 1. Loosen the lock nut. The screw and locknut in the lower throttle 2. Turn the throttle limiter screw clockwise to housing can be adjusted to limit throttle lever reduce throttle lever movement or movement.

  • Page 87: Braking

    BRAKING Pulling one or both brake levers or/and Practice starting and stopping at slow speeds. depressing brake pedal too hard may cause the Gradually work up to faster starts and stops. front and/or rear wheels to skid or slide out of control.

  • Page 88: Turning Your Atv

    TURNING YOUR ATV To achieve maximum traction while riding on-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. When approaching a corner or turn, close the throttle fully, and slow the ATV down by applying both front and rear brakes at the same time.

  • Page 89: Climbing Up Slope

    CLIMBING UP SLOPE WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on slopes. Be sure that you can Operating on excessively steep slopes. maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
  • Page 90 An obstacle or a sharp drop could be on the WARNING other side of the slope. POTENTIAL HAZARD Climbing slopes improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing slopes as described in this Owner's Manual.
  • Page 91 If you are climbing a slope and you find that you When crossing the side of a slope: have not properly judged your ability to make it Always follow proper procedures as to the top, you should turn the ATV around while described in the Owner's Manual.
  • Page 92 If your ATV has stalled or stopped and you WARNING believe you can continue up the slope, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improperly wheels which could cause you to lose control. If dismounting while climbing a slope.
  • Page 93 Apply the front brake. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on up slope side or to a side if pointed straight up slope. Turn the ATV around and remount, following the procedure described in the Owner's Manual.
  • Page 94 If the slope is not too steep and you have good footing, you may be able to walk the ATV back down slope . Make sure your intended path is clear in case you lose control of the ATV . If you decide you can walk the ATV safely: 1.

  • Page 95: Riding Down Slope

    RIDING DOWN SLOPE WARNING When riding your ATV down slope, shift your POTENTIAL HAZARD weight as far to the rear and up slope side of the Going down a slope improperly. ATV as possible. Move back on the seat and sit with your arms straight.

  • Page 96: Parking

    PARKING Always choose a level place to park. After bringing your ATV to a stop, hold the brakes. Then set the parking brake and turn the ignition switch OFF. If you're through riding for the day, also turn the fuel valve OFF.

  • Page 97: What To Do If

    WHAT TO DO IF If your ATV can't make it up a slope you are This section is designed to be a reference guide trying to climb: only. Be sure to read each section on riding techniques completely. Turn the ATV around if you still have forward speed.

  • Page 98: Periodic Maintenance And Adjustment

    Have KYMCO dealer perform service if you PERIODIC MAINTENANCE AND are not familiar with machine service. ADJUSTMENT Periodic inspection, adjustment and lubrication Tool kit will keep your machine in the safest and most A tool kit is provide with your ATV.
  • Page 99 The tools in the kit are sufficient to perform WARNING routine maintenance and simple repairs. Any POTENTIAL HAZARD extensive work requiring additional tools should be performed by your authorized KYMCO Operating this ATV with improper dealer. modifications. The tool kit includes the following items:...

  • Page 100: Lubrication ( Mxer 50R)

    PERIODIC MAINTENANCE/LUBRICATION ( MXER 50R) INITIAL EVERY ITEM ROUTINE year month months months months Check and adjust slack/alignment/clean/lube. Drive chain Check fuel hose for cracks or damage. Fuel line* Replace if necessary. Check oil level/oil leakage. Transmission oil Replace every 12 months. Check operation.
  • Page 101 Adjust if necessary. Knuckle shafts/ Lubricate every 6 months. Steering shaft* Check all chassis fittings and fasteners. Fittings and Fasteners* Correct if necessary. : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

  • Page 102: Lubrication (Mxer 90R)

    PERIODIC MAINTENANCE/LUBRICATION ( MXER 90R) INITIAL EVERY ITEM ROUTINE year month months months months Replace (Warm engine before draining). Engine oil Clean. Oil strainer* Replace if necessary. Check oil level/oil leakage. Transmission oil Replace every 12 months. Check operation. V-belt* Replace if damage or excessive wear.
  • Page 103 Adjust if necessary. Knuckle shafts/ Lubricate every 6 months. Steering shaft* Check all chassis fittings and fasteners. Fittings and Fasteners* Correct if necessary. : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

  • Page 104: Engine Oil (Mxer 90R)

    Engine oil ( MXER 90R) E. Remove the dipstick and inspect the oil level. 1.Engine oil level measurement F. The oil level should be between the maximum A. Place the machine on a level place. and minimum marks. If the level is low, add oil B.
  • Page 105 2-1. Engine oil replacement and oil filter CAUTION: cleaning ．Be sure no foreign material enters the A. Place the machine on a level place. crankcase. B. Warm up the engine for several minutes and stop it. ．When removing the drain plug, the C.
  • Page 106 H. Fill the engine with oil and install the oil filler 2-2. Engine oil replacement cap. A. Place the machine on a level place. B. Warm up the engine for several minutes Recommended oil: see page 136. and stop it. Oil quantity: C.
  • Page 107 Tightening torque: Drain plug (engine): 30 Nm (3.0 m-kg, 21.6 ft-lb) CAUTION: Be sure no foreign material enters the crankcase. Recommended oil: see page 142. Oil quantity: see page 142. (1) Drain plug E. Reinstall the drain plug and tighten the drain plug to specification.

  • Page 108: Transmission Oil

    If the level is low, add oil to raise it to the proper level. C. Reinstall the oil filler bolt and tighten to specification. Tightening torque (1) Oil filler bolt/measurement hole (MXER 50R) Oil filler bolt: 15 Nm (1.5 m-kg, 11 ft-lb) (1) Oil filler bolt/measurement hole ( MXER...
  • Page 109 C. Remove the oil filler bolt and drain plug to drain the oil. D. Reinstall the drain plug and tighten to Specification. Tightening torque Drain plug: 1. Drain plug (MXER 50R) 15 Nm (1.5 m-kg, 11 ft-lb) (1) Drain plug (MXER 90R)
  • Page 110 E. Fill the engine with oil and install the oil filler bolt. Recommended oil : See page 138 or 142 Oil quantity: Periodic oil change: 0.11L (0.10Imp qt, 0.12US qt) Total amount: 0.12L (0.11Imp qt, 0.13US qt) CAUTION: Be sure no foreign material enters the 1.

  • Page 111: Spark Plug Inspection

    Do not attempt to diagnose such problems yourself. Instead, take the machine to a KYMCO dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 112: Air Filter Cleaning

    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...
  • Page 113 3. Remove the air filter element, and separate it WARNING from the box. POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element.
  • Page 114 To clean the air cleaner (MXER 50R): 6. Inspect the element. If damaged, replace it. 1. Remove the air filter case cover. 7. Apply quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used.
  • Page 115 2. Remove the air filter element, and separate it WARNING from the box. POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element.

  • Page 116: Valve Clearance Adjustment (Mxer 90R)

    To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional KYMCO service NOTE: technician. The element should be wet but not dripping.

  • Page 117: Idle Speed Adjustment

    Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. 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 throttle.

  • Page 118: Throttle Lever Adjustment

    Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. To adjust throttle free play: 1. Slide the rubber sleeves back to expose the throttle cable adjuster. 2. Loosen the lock nut, then turn the adjuster to obtain the correct free play.

  • Page 119: Front And Rear Brake Shoes (Drum Brake) Inspection

    (1~2cm), it indicator reaches the wear limit line, ask a means the brake shoe is worn out. Go to our KYMCO dealer to replace the pads. designated distributors or service stations for brake shoe replacing.

  • Page 120: Front Brake Lever Free Play Adjustment

    Front brake lever free play adjustment The front brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. If the free play is incorrect, adjust as follows: (1) Upper locknut (2) Upper adjusting bolt (3) Lower locknut (4) Lower adjusting bolt 2.
  • Page 121 Make sure the brakes do not drag. (1) Cable joint ( A) Cable length Replacement of brake components requires professional knowledge. These procedures 6. Tighten the upper locknut. should be performed by KYMCO dealer.

  • Page 122: Rear Brake Lever Free Play Adjustment (Drum Brake)

    Rear brake lever free play adjustment Turn the adjusting nut on the brake hub in (Drum brake) direction A to decrease play, and in direction B to The rear brake lever free play should be increase play. adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever.
  • Page 123 Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Replacement of brake components requires (1) Arm pin (2) Adjusting nut professional knowledge. These procedures should be performed by KYMCO dealer.

  • Page 124: Brake Pedal Adjustment (Mxer 90R)

    Brake pedal adjustment (MXER 90R) 3. Turn the adjusting bolts until the front The brake pedal free play should be adjusted Lower brake cables is tensed. to 5~10 mm (0.2~0.4 in) at the brake pedal 4. Apply the front brake lever and check front pivot.
  • Page 125 5. While remove the cable joint case cover and 7. Loosen the locknut. (Brake pedal cable) applying the brake pedal, make sure the left 8. Turn the adjusting bolt until the specified free and right front lower cable lengths (A and B) play is obtained.
  • Page 126 HOW TO AVOID THE HAZARD After servicing: Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by KYMCO dealer.

  • Page 127: Brake Fluid Inspection (Disk Brake)

    Brake fluid inspection (Disk brake) Check if the fluid level is below the lower level mark through the brake fluid reservoir (under the rear fender right side). WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation.
  • Page 128 (page 110), There is prevent accidental spilling. probably air in the brake system and it must Use only DOT 4 brake fluid from a sealed be bled. See your authorized KYMCO dealer container. for this service.

  • Page 129: Drive Chain Slack Check

    Drive chain slack check Drive chain slack adjustment Inspect the drive chain while all tires are 1.Loosen the upper and lower axle holding touching the ground. Check the slack at the position shown in the figure. The normal vertical deflection is approximately 10~20 mm (0.4~0.8in).
  • Page 130 2.Turn the adjusting nut, to decrease or increase 3.Retighten the upper and lower axle holding chain slack. bolts. Tightening torque: Axle holding bolts (upper): 70 Nm (7.0 m-kg, 48 ft-lb) 1. Adjust nut CAUTION: Too little of chain slack will overload the engine and other important parts.

  • Page 131: Drive Chain Cleaning And Lubrication

    Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a KYMCO dealer to replace them. Recommended lubricant: 1. O-rings KYMCO chain and cable lube or SAE 10W40 motor oil...

  • Page 132: Brake Lever Lubrication

    Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a Knuckle shaft and rear fork shaft lubrication KYMCO dealer to inspect. Lubricate the pivot points using a grease gun. Recommended lubricant:...

  • Page 133: Wheel Removal

    Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. Wheel nut torque: 2. Remove the nuts from the wheel. Front: 40 Nm (4.0 m-kg, 30 ft-lb) 3. Remove the wheel assembly. Rear: 40 Nm (4.0 m-kg, 30 ft-lb) (1) Safe nut Wheel installation When installing the wheel, reverse the removal...

  • Page 134: Battery

    If battery. the battery seems weak, see your authorized KYMCO dealer for information on recharging or WHAT CAN HAPPEN Gases may explode and possibly cause replacement. If you replace the battery, choose one injury.
  • Page 135 Battery remove Battery installation 1. Make sure the ignition switch is OFF. 1. Install in the reverse order of removal. 2. Remove the seat (page 38) 2. Check all bolts and other fasteners are secure. 3. Remove the battery cover, by removing the mount 3.

  • Page 136: Fuse Replacement

    When frequent fuse failure occurs, it usually under the seat. indicates a short circuit or an overload in the The specified fuses are: 7A electrical system. See your authorized KYMCO dealer for repair. CAUTION: To prevent accidental short-circuiting, turn off the ignition switch before checking or replacing a fuse.
  • Page 137 3. Slide the old fuse out of the clips and discard 1. Lift the seat. (See page 38) 2. Open the fuse holders and lift out the fuse with the clips. (1) Fuse holder (2) Clip...
  • Page 138 CAUTION: 4. Slide the clips onto the ends of the new fuse, ． Do not pry the clips open to get a fuse out; push them back into the fuse holder, and you could bend them and cause poor close the fuse holder. contact with the new fuse.

  • Page 139: Headlight Beam Adjustment

    Headlight beam adjustment CAUTION: It is advisable to have a KYMCO dealer make this adjustment. Vertical adjustment: Turn the ignition switch ON and start the engine. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting screw.

  • Page 140: Troubleshooting

    The troubleshooting chart describes a WHAT CAN HAPPEN quick, easy procedure for making checks. If your Fuel can ignite or explode, causing severe machine requires any repair, take it to a KYMCO dealer. injury or property damage. HOW TO AVOID THE HAZARD...

  • Page 141: Troubleshooting Chart

    Check fluid, recharge, check connections. over slowly. Use electric starter. Engine turns Battery good. over quickly. Ask a KYMCO dealer to inspect. 3. Ignition Wipe clean with dry Adjust plug gap or cloth. Remove plug and No spark. replace plug.

  • Page 142: Cleaning And Storage

    CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend the bills have resulted from improper high useful life of many components.
  • Page 143 7. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after washing. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid WHAT CAN HAPPEN combination cleaner-waxes.

  • Page 144: Storage

    B. STORAGE WARNING Before storing your ATV for an extended time, be POTENTIAL HAZARD sure you thoroughly check the vehicle for Refueling this ATV or handling fuel needed repairs and have them corrected. improperly. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage.
  • Page 145 4. Remove the battery (page 126) And store it in WARNING an area protected from freezing temperatures POTENTIAL HAZARD and direct sunlight and out of the reach of Prolonged contact of fuel with the skin. children, slow charge the battery once a Breathing fuel vapor.

  • Page 146: Specifications (Mxer 50R)

    SPECIFICATIONS ( MXER 50R) MXER 50R Model Dimension: Overall length 1385 mm (54.5 in) Overall width 820 mm (32.23 in) Overall height 900 mm (35.46 in) Seat height 620 mm (24.37 in) Wheel base 900 mm (35.46 in) Minimum ground clearance 75 mm (2.96 in)
  • Page 147 Model MXER 50R Engine oil/transmission oil: Type Engine oil classification: 2-stroke engine oil Transmission Oil classification: 110 F SAE 5W － SAE 10W 30 － SAE 10W 40 － SAE 20W 40 － SAE 20W 50 -1 0 40 C...
  • Page 148 Model Model MAXXER 50 MXER 50R Air filter: Air filter: for engine for engine Wet type element Wet type element Fuel: Fuel: Type Type UNLEADED FUEL UNLEADED FUEL Tank capacity Tank capacity 5.5L(1.16 lmp gal, 1.4 US gal) 5.5L(1.16 lmp gal, 1.4 US gal)
  • Page 149 Model MXER 50R Suspension: Front Swing axle Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Battery type 12V, 4AH Tire: Type Tubeless Size: Front 16X8-7 Rear 16X8-7...

  • Page 150: Specifications (Mxer 90R)

    SPECIFICATIONS ( MXER 90R) Model MXER 90R Dimension: Overall length 1435 mm (56.54 in) Overall width 905 mm (35.65 in) Overall height 925 mm (36.45 in) Seat height 650 mm (25.61 in) Wheel base 970 mm (38.22 in) Minimum ground clearance 100 mm (3.94 in) Basic weight: With oil and full fuel tank...
  • Page 151 Model MXER 90R 110 F Engine oil/transmission oil: Type SAE 5W － SAE 10W 30 Recommended engine oil classification: － SAE 10W 40 － SAE 20W 40 － SAE 20W 50 -1 0 40 C API Service SE, SF, SG type or higher Recommended transmission Oil classification: SEA#90...
  • Page 152 Model MXER 90R Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED FUEL Tank capacity 5.5 L (1.16 lmp gal, 1.40 US gal) Reserve amount 1.5 L (0.32 lmp gal, 0.38 US gal) Carburetor: Type Spark plug:...
  • Page 153 Model MXER 90R Suspension: Front Swing axle Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Battery type 12V, 4AH Tire: Type Tubeless Size: Front 18X7-8 Rear 18X9-8 Bulb voltage, wattage*quantity: Headlight 12V35/35W...

  • Page 154: Noise Regulation

    NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device 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 after such device or element of design has been removed or rendered inoperative by any person.

  • Page 155: Maintenance Record

    MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in 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.

  • Page 156: Index

    Drive chain slack check ......120 During operation........72 Cable inspection and lubrication....122 Engine break-in........54 Chain............46 Engine oil (MXER 50R)......45 CLEANING..........133 Engine oil (MXER 90R)......95 CLIMBING UP SLOPE.......80 Engine (MXER 90R) and transmission oil..44 CONTENTS..........D Engine stop switch........25...
  • Page 157 Page Page Identification number records.....9 Fittings and fasteners....... 46 Idle speed adjustment ......108 Flag pole bracket........39 Ignition switch..........16 FOR ON-ROAD USE ONLY......A IMPORTANT NOTICES......A Frame and engine serial number ....10 Indicator lamps........17 Front and rear brake shoes Instruments..........18 (drum brake) inspection.
  • Page 158 Riding Your ATV........59 OPERATION ........... 50 Right/Left turn signal indicator lamps..17 PARKING .......... 56, 87 SAFETY INFORMATION......4 Parking brake (MXER 50R)......32 Seat ............38 Parking brake (MXER 90R)......33 Spark plug inspection......102 Parking on a slope ........57 SPECIAL MESSAGES ......B Parts location...........11...
  • Page 159 Page Throttle lever........29, 46 Throttle lever adjustment......109 Tires............47 Tire wear limit.......... 49 Tool kit.............89 Transmission oil ........99 Troubleshooting ........131 Troubleshooting chart ......132 Turn signal switch........23 TURNING YOUR ATV........79 Valve clearance adjustment (MXER 90R)..107 Warning information ........2 WHAT TO DO...........88 WHAT TO DO IF........88 Wheel installation........124...
  • Page 160 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 By KWANG YANG Motor Co., Ltd. First Edition, Nov 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.
  • Page 162 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN NEVER USE APPROVED HELMET WITH DRUGS AND PROTECTIVE OR ALCOHOL GEAR NEVER operate : Without proper training or instruction. At speeds too fast for your skills or the conditions. Do not operate the vehicle after consuming ALCOHOL OR DRUGS.

This manual is also suitable for:

Mxer 90r

Table of Contents