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 cable
first).
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
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