KYMCO Maxxer 400 User Manual

Details general specifications for the ATV.

Lists torque values for various components.

Provides conversions for torque units.

Specific tightening torques for general bolts.

Steps for breaking in the new ATV.

Recommendations for fuel, oil, and lubricants.

Information on using genuine parts.

Procedures for preparing the ATV for storage.

Procedures for preparing the ATV after storage.

A chart detailing maintenance intervals.

Locations requiring lubrication.

Maintenance and testing of the battery.

Information about fuses.

Maintenance of the air filter.

Procedure to check valve clearance using a feeler gauge.

Procedure to adjust valve clearance.

Procedure for testing engine compression.

Inspection and replacement of the spark plug.

Maintenance of the muffler and spark arrester.

Adjusting the throttle cable free-play.

Procedures for engine oil and filter.

Lubrication of front/rear drive components.

Information on tires and tire inflation.

Inspection of suspension components.

Inspection of steering components.

Inspection of driveshaft and coupling.

Inspection of fasteners.

Checking and adjusting ignition timing.

Procedures for headlight and taillight bulbs.

Procedure for adjusting headlight aim.

Checking and adjusting the shift lever.

Inspection of frame, welds, and racks.

Checking electrical connections.

Checking and bleeding hydraulic brakes.

Procedure for checking and replacing brake pads.

Procedure for burnishing brake pads.

Procedure for checking and replacing the V-belt.

Overview of the engine/transmission section.

Lists special tools for engine/transmission service.

Detailed specifications for engine/transmission components.

Common engine/transmission problems and solutions.

Step-by-step removal of the engine/transmission.

Procedures for servicing top-side engine components.

Procedure for removing engine valves.

Procedures for measuring valve dimensions and runout.

Procedure for installing engine valves.

Measuring rocker arm dimensions.

Procedures related to piston assembly.

Cleaning and inspecting the piston.

Procedure for removing piston rings.

Measuring piston ring end gap.

Measuring piston pin and bore.

Measuring piston skirt and cylinder clearance.

Procedure for installing piston rings.

Procedures for cylinder and cylinder head assembly.

Cleaning and inspecting the cylinder head.

Measuring cylinder head distortion.

Procedure for honing the cylinder.

Measuring camshaft runout.

Measuring camshaft lobe height.

Inspecting camshaft bearing journals.

Measuring clearance between camshaft and cylinder head.

Inspecting camshaft spring and drive pin.

Procedures for installing top-side components.

Overview of left-side component servicing.

Steps to remove left-side components.

Overview of right-side component servicing.

Steps to remove right-side components.

Procedures for center crankcase components.

Procedure for separating crankcase halves.

Steps to disassemble the crankshaft half.

Procedure for checking gear backlash.

Procedure for checking tooth contact.

Procedure to correct tooth contact patterns.

Measuring connecting rod dimensions.

Measuring crankshaft runout and web-to-web dimensions.

Procedure for assembling the crankcase half.

Steps to install the engine and transmission.

Overview of fuel, lubrication, and cooling systems.

Lists special tools for fuel/lubrication/cooling service.

Diagram of the carburetor components.

Specifications for the carburetor.

Procedures for cleaning and inspecting carburetor parts.

Steps for installing the carburetor.

Removal and installation of the oil cooler.

Troubleshooting fuel and oil system issues.

Overview of the electrical system.

Lists special tools for electrical system service.

Information on the RPM limiter.

Procedures for testing electrical components.

Information on accessory connections.

Testing voltage on various components.

Testing the brakelight switch.

Testing the fan motor.

Information on the fuse block and PDM.

Procedures for testing and replacing fuses.

Testing the ignition coil.

Testing the spark plug cap.

Measuring peak voltage.

Information on the CDI unit.

Testing the speed sensor.

Testing the ignition switch.

Testing handlebar control switches.

Testing the front drive selector switch.

Testing the front drive selector actuator.

Testing the gear shift position switch.

Testing the stator coil.

Testing the trigger coil.

Testing the starter relay.

Testing the starter motor.

Information on the CDI unit.

Testing the regulator/rectifier.

Information on relays.

Testing headlights.

Testing taillights and brakelights.

Testing running lights.

Testing back-up lights.

Checking ignition timing.

Troubleshooting electrical system issues.

Overview of the drive system.

Procedures for the front drive actuator.

Procedures for the front differential.

Procedures for the drive axle.

Procedures for the rear gear case.

Procedures for hydraulic brake calipers.

Troubleshooting drive system issues.

Troubleshooting brake system issues.

Procedure for disassembling the input shaft.

Procedure for assembling the input shaft.

Procedure for disassembling the pinion gear.

Procedure for assembling the pinion gear.

Procedures for shim selection and installation.

Procedures for needle bearings.

Procedures for axle seals.

Procedure for installing the differential.

Procedures for removing and installing drive axles.

Steps to disassemble axles.

Procedure to install the rear drive axle.

Procedure to install the front drive axle.

Procedures for hub removal, inspection, and installation.

Procedures for hydraulic brake caliper service.

Common drive system problems and solutions.

Common brake system problems and solutions.

Overview of the suspension system.

Procedures for shock absorbers.

Procedures for front A-arms.

Procedures for rear A-arms.

Procedures for wheels and tires.

Troubleshooting suspension issues.

Information on tire inflation pressure.

Overview of steering and frame components.

Procedures for steering post and tie rods.

Procedures for handlebar grips.

Procedures for steering knuckles.

Procedures for the front rack.

Procedures for front body panel and fender.

Procedures for the exhaust system.

Troubleshooting steering and frame issues.

Procedure for measuring and adjusting toe-in.

Procedures for the front bumper assembly.

Procedures for the front rack.

Procedures for the exhaust system.

Procedures for the hand brake lever and master cylinder.

Procedures for throttle control.

Procedures for the LCD gauge.