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1. 147 FUSE REPLACEMENT 2 Remove the seat page 39 The fuse box 1 stored in the battery 3 Open the fuse box cap 2 AS under the seat 4 Pull the old fuse out of the fuse holder o replace a fuse 1 Make sure the ignition switch is OFF 5 Push the new fuse in to the fuse holder 6 Close the fuse box cap and install seat CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper 1 Fuse box 2 Fuse box cap Fuse specifications HEADLIGHT BEAM ADJUSTMENT DRIVE SHAFT BOOTS CAUTION Check the protective boots for holes or tears It is advisable to have a KYMCO dealer make Tan damage is found have them replaced by a this adjustment KYMCO dealer To adjust Turn the ignition switch at position and start the engine Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting screws 1 Drive shaft boots 149 CABLE INSPECTION AND LUBRICATION A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become fray
2. Page A ACCELERATING PUMP LEVER sissies 38 ACCESSORIES sees is ie ei 68 81 82 ACCESSORY SOGKET esse sessie SeSe 42 AGE RECOMMENDATION 0000ee ee A AIR CLEANER HOUSING DRAIN Es SA geese EO 135 AIR FILTER CLEANING iss sesse eebe 182 APPAREL essens sees Gie n ee ee be ee ee las B BATTERY OE N N 146 Battery remOVe sesse esse ee RE ER ee Gee 147 Battery installation see esse ese see ke Re es 147 sy od SR EE aa 32 48 BRAKE FLUID INSPECTION 139 BRAKE BAD eege ee ie 136 139 BRAKE PEDAL iis ee ie eN Ee Ee 32 Page C CABLE INSPECTION AND LUBRICATION ee ee ee ee ee ee ee ee 150 CHOKE KNOB osse nss SE ei ee eg ei eie 37 Eege 153 CLIMBING UPHILL dees es ees ne 98 COIN RR E D CONTROL EUNCTIONS ee ee ee 16 RE RRE 56 Coolant temperature warning indicator 18 COOLING SYSTEM INSPECTION 141 D DIFFERENTIAL GEAR OIL 52 127 DRIVE SELECT LEVER nisse 34 44 Drive select lever adjustment 46 DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING ss assssssss de es bee Eb EN ee 63 DRIVE SHAFT BOOT see ese esse 50 149 DURING OPERATION HE 92 Cont d 163 Page E ENGINE BREAKSAN asie ss eie EE 65 ENGINE OM as ese ee oi ie nee 51 118 ENGINE OVERHEATING aaannnannnnnnnnn 143 ENGINE SERIAL NUMBER 10 ENGINE STOP SWITEH osse esse eN ses nde 27 EXHAUST SYSTEM nss ie AN DE de 84 F FINAL e BE 52 125 FITTIN
3. este en si Gees 92 TURNING YOUR ALY is sessie sees oe ei eg 94 SLIDING AND SKIDDING 96 CLIMBING UPEHOE soe ese eed 98 Page RIDING DOWNHILL 104 CROSSINGASLOPE 0005 106 RIDING OVER ROUGH TERRAIN 108 CROSSING THROUGH SHALLOW WATER soene ese ie oes Ee Ke EN ne n 109 PARKING sis asses os ei n es di en ee 110 WHAT ODE bes ee EE 111 WHAT TO DO esse EE EG De 111 Page PERIODIC MAINTENANCE AND ADAUSTMENT ses esse 113 TOOL KIT TOOL KIT COMPARTMENT 113 PERIODIC MAINTENANCE BI Le OWN H 115 ENGINE OM sa sees et ere ere 118 FINAL GEAR OIE en bede 129 DIFFERENTIAL GEAR OI 127 SPARK PLUG INSPECTION 129 SPARK ARRESTER sus stiges pose 130 AIR FILTER CLEANING sessie Nes 132 AIR CLEANER HOUSING DRAIN Eeer 135 IDLE SPEED ADJUSTMENT 136 THROTTLE LEVER ADJUSTMENT 137 VALVE CLEARANCE ADJUSTMENT 138 FRONT BRAKE PADS INSPECTION 138 REAR BRAKE PADS INSPECTION 139 BRAKE FLUID INSPECTION 139 Page COOLING SYSTEM INSPECTION 141 Engine overheatmng 143 WHEEL REMOVAL oen iss ss Sk es 144 WHEEL INSTALLATION 144 BATTERY EE 146 Battery remove us EE ES SR de 147 Battery installation 147 FUSE REPLACEMENT 148 HEADLIGHT BEAM ADJUSTMENT 149 DRIVE SHAFT BOOTS oos sees vs 149 CABLE INSPECTION AND LUBRICATION esel soas ees ie ie ge 150 TROUBLESHOOTING ee esse
4. Rear gear box oil classification Quantity Engine oil Periodic oil change After draining and oil filter cartridge change Total amount Front gear case oil Periodic oil change Total amount Rear gear case oil Periodic oil change Total amount 158 MXU 500 MXU 500 IRS SAE 10W 30 SAE 10W 40 SAE 20W 40 SAE 20W 50 10 0 10 20 30 40 C API Service SJ type or higher SAE 80 SAE 90 SAE 80 3L 2 64 Imp qt 3 18 US qt 3 2 L 2 82 Imp gt 3 39 US qt 3 6L 3 17 Imp gt 3 82 US qt 0 13L 0 11Impqt 0 14USqt 0 25 L 0 22 Imp at 0 265 US qt 0 15L 0 13lmpqt 0 16USqt 0 27 L 0 24 Imp at 0 286 US qt 0 30L 0 26Impqt 0 32USqt 0 23 L 0 20 Imp at 0 243 US at 0 30L 0 26Impqt 0 32USqt 0 25 L 0 22 Imp at 0 265 US at Air filter for engine Wet type element Fuel Type UNLEADED FUEL Tank capacity 17 L 3 57 Imp gal 4 42 US gal Reserve amount 2 3 L 0 48 Imp gal 0 6 US gal Carburetor Type CVK KYMCO CARBURETTOR LFE9 Spark plug Type CR7E NGK Gap 0 6 0 7 mm 0 024 0 028 in Clutch Type Wet centrifugal automatic Brake Front brake type Disk brake Dual disk brake Rear brake type Disk brake Single disk brake 159 Suspension Front Rear Shock absorber Front Rear Electrical Ignition system Generator system Battery type Tire Type Size Front Rear Bulb voltage wattage quantity Headlight Brake light Taillight Position light Double wishbone Dua
5. T EN To reset tripmeter 1 Press and hold SET button for more than 2 seconds to select tripmeter A or tripmeter Ii 2WD OO desst CC mph kmh i Maii aTa Dr TRIP OOOO C mile bh Bh Ad hd ll km 2 Press and hold both the MODE button and SET button in the same time until the tripmeter is reset 200 1E 7 desst CC o oo lo KM PMI Rb TRIP l Ge I mile ikm TE EED LL 5 Digital clock Show the time hours and minutes while the ignition is ON To adjust the time manually proceed as follows db SE j CH CH 1 Turn the ignition switch ON ups LJ LI 2 Press and hold SET button for more than 2 EE fe 1E PMiE LI seconds to select ODO mode 3 Press and hold both the MODE button and SET button in the same time for more than 2 seconds The clock will be set in the adjust mode with the hour display flashing NOTE Digital clock can be adjust in ODO mode only never select TRIP A or TRIP B mode when you want to adjust your digital clock 23 5 Press the MODE button the minute display will 4 To set the hour press the SET button until the start flashing desired hour 24 7 To end the adjustment Press both the MODE 6 To set minute press the SET button until the button and SET button in the same time desired minute 25 LEFT HANDLEBAR SWITCHES 1 Headlight switch Headlight dimmer switch Turn the switch to the zp position to sw
6. being replaced E Remove the three fasteners 3 and then remove right side cover 4 F Remove the oil filter cartridge 5 with an oil cartridge wrench 3 Fasteners 4 Right side cover 5 Oil filter cartridge 122 G Apply alight coat of clean engine oil to the O ring 6 of the new oil filter cartridge NOTE An oil cartridge wrench is available at a nearby KYMCO dealer NOTE Make sure the O ring is seated properly H Install the new oil filter cartridge with an oil 5 O ring cartridge wrench and then tighten it to the specified torque Tightening torque Oil filter cartridge 10 N m 1 kgf m 7 2 IDf ft 123 Install right side cover J Reinstall the drain plug and tighten the drain plug to specification L Start the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the Tightening torque cause Drain plug engine M Turn the engine off and then check the oil 25 N m 2 5 kgf m 18 Ibf ft level through the inspection window 7 K Add the specified amount of recommended Me EE SAT engine oil and then install the engine oil filler cap and tighten it Recommended oil see page 158 Oil quantity see page 158 CAUTION Be sure no foreign material enters the crankcase 7 Engine oil inspection window 124 Rear Gear Box Oil Change
7. eCheck operation eReplace if damaged eCheck toe in eAdjust if necessary Drive shaft boots ote oie eReplace if damaged S eCheck operation ASPERSION eCorrect if necessary 116 Steering system Cont d INITIAL EVERY vou sl 2 Knuckle shaf l Stering e eLubricate every 6 months EE eCheck all chassis fittings and fasteners Fittings and Fasteners eCorrect if necessary It is recommended that these items be serviced by a KYMCO dealer Lithium soap base grease 117 ENGINE OIL 1 Engine oil level measurement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Check the oil level through the inspection window D The oil level should be between the maximum H and minimum L marks If the level is low add oil to raise it to the proper level NOTE Wait a few minutes until the oil level settles 3 Minimum level mark L 1 Engine oil inspection window 2 Maximum level mark H before checking 118 2 1 Engine oil replacement and oil filter cleaning A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and oil filter cap 2 to drain the oil CAUTION Be sure no foreign material enters the 1 Oil fill cap crankcase CAUTION When removing the oil filter cap the compression spring oil
8. LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS A 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 An accident can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper pre cautions SEVERE INJURY OR DEATH can result if you do not follow these instructions e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper training or instruction Beginners should receive training from a certified instructor Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never carry a passenger on an ATV e Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets e Never operate an ATV on any public street road or highway even a dirt or gravel one e Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants e Never consume alcohol or drugs before or while operating this ATV e Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain vis
9. Mm MK di SAE 20VV 50 1 0 0 10 20 30 40 C Recommended engine oil classification API Service SJ type or higher 51 CAUTION Besuretousemotoroilsthatdonotcontain anti frictionmodifiers Passengercarmotor oils often labeled Energy Conserving containanti frictionadditives which will cause starterclutchslippage resultingin reducedcomponentlifeand poorengine performance Oil quantity Engine oil Periodic oil change 3L 2 64 Imp dt 3 18 US qt Total amount 3 6L 3 17 Imp dt 3 82 US qt REAR GEAR CASE OIL Make sure the rear gear case oil at the specified level Add oil as necessary See page 125 126 Check for leaks Recommended rearl gear case oll Type hypoid gear oil Viscosity SAE 80 Oil quantity MXU 500 Rear gear case oll Periodic oil change 0 13L 0 114 Imp at 0 138 US qt Total amount 0 15 L 0 132 Imp qt 0 159 US qt Oil quantity MXU 500 IRS Rear gear case oil Periodic oil change 0 23 L 0 20 Imp qt 0 243 US qt Total amount 0 25L 0 22 Imp qt 0 265 US qt FRONT GEAR CASE OIL Make sure the front gear case oil atthe specified level Add oilas necessary See page 127 128 Check forleaks Recommended final gear oil Type hypoid gear oil Viscosity SAE 80 MXU 500IRS SAE 90 MXU 500 Oil quantity MXU 500 Front gear case oil Periodic oil change 0 30 L 0 264 Imp qt 0 318 US qt Total amount 0 30 L 0 264 Imp qt 0 318 US qt Oil
10. shift into neutral Shifting Neutral to high and high to low 1 Bring the ATV to a complete stop and return NOTE the throttle lever to the closed position Wake SR hahe diavesciectiaveric 2 Apply the brakes then shift by moving the completely shifted into position drive select lever along the shift guide 63 Shifting neutral to reverse and reverse to park 1 Bring the machine to a complete stop and return the throttle lever to the closed position 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a KYMCO dealer to inspect the machine 4 Check behind for people or obstacles then release the rear brake pedal 5 Open the throttle lever gradually and continue to watch to the rear while backing A WARNING POTENTIAL HAZARD Improperly operation in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When itis safe to proceed go slowly 64 ENGINE BREAK IN There is never a more important period in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Becau
11. P 10 Mode button 11 Differential lock indicator MXU 500 IRS version only 17 3 Coolant temperature warning indicator When the coolant temperature reaches a specified level this indicator comes on to warn that the coolant temperature is too hot If the indicator comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes 4 Set button This button is used to select ODO TRIPA and TRIP B This button is also used to adjust the time and reset the trip meter 5 Low range indicator light L This indicator light comes on when the drive select lever is in the L position 6 High range indicator light H This indicator light comes on when the drive select lever is in the H position 7 Neutral indicator light N This indicator light comes on when the drive select lever is in the N position 18 8 Reverse indicator light R This indicator light comes on when the drive select lever is in the R position 9 Park indicator light P This indicator light comes on when the drive select lever is in the P park position 10 Mode button This button is used to select km h mph km and mile This button is also used to adjust the time and reset the trip meter 11 Differential lock indicator MXU 500 IRS only The front axle is equipped with a lockable differential that allows the oper
12. an extended time be sure you thoroughly check the vehicle for needed repairs and have them corrected Otherwise the repairs may be forgotten by the time you remove the vehicle from storage In addition extended storage reduires that you take the following steps to reduce the effects of deterioration from non use of the vehicle 1 Change the engine oil 2 Drain the fuel tank and carburetor Be sure to drain the fuel in a well ventilated area not in a garage 155 A WARNING POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite HOW TO AVOID THE HAZARD Always refuel this ATV and handle fuel ina well ventilated area with the engine off Do not smoke or allow flames or sparks in the area where fuel is handled Do not overfill the tank Be careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting he engine A WARNING POTENTIAL HAZARD Prolonged contact of fuel with the skin Breathing fuel vapor WHAT CAN HAPPEN The fuel can cause skin irritation Fuel vapor could cause lung damage HOW TO AVOID THE HAZARD Avoid repeated or prolonged contact of fuel 4 Remove the battery page 147 And store it in an area protected from freezing temperatures and direct sunlight and out of the reach of children slow charge the batter
13. and lock it with the lock lever Always POTENTIAL HAZARD set the parking brake when parking and before Improper use of the parking brake starting the engine To unlock the parking brake squeeze the front WHAT CAN HAPPEN brake lever until the lock lever releases The ATV could start moving unexpectedly Using the parking brake in freezing weather may if the parking brake is not applied before cause the brakes to freeze in the locked starting the engine This could cause loss position See page 66 of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the parking brake before you begin to ride 1 Lock lever 33 DRIVE SELECT LEVER The drive select lever is used to shift your ATV into the low high neutral reverse and park positions Refer to page 46 47 for drive select lever adjustment and operation NOTE Apply the rear brake and shift the shift lever into P position before turning off the engine when parking the vehicle on an incline if you park on an incline with shiftlever in H L or R position vehicle weight will make it difficult to shift into neutral 34 FUEL TANK CAP FUEL VALVE After refueling be sure to tighte
14. avery enjoyable activity providing you with hours of pleasure But itis essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely 12 Before you begin to ride be sure you have read this Owner s manual completely and understand the operation of the controls Pay particular attention to the safety information on pages 4 8 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners and inexperienced riders should get proper instruction on how to operate this ATV A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain 13 HOW TO AVOID THE HAZARD Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum performance until you are totally familiar with the machine s handling and performance characteristics Riding your machine requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Not recommended for children under 16 year of age A WARNING POTENTIAL HAZARD Failure to follow the age recom
15. avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways control can usually be regained if slippery surfaces since the ATV may slide If there is room to do so by steering in the unexpected and uncorrected sliding could lead direction of the slide Applying the brakes or to an accident accelerating is not recommended until you have To reduce the tendency for the front wheels to corrected the slide slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help T eS cu E Lee 7 D d SS Ke se om Ae Ke E ia is di KAP he VE 96 With practice over a period of time skill at controlled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost 97 A WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terra
16. fs O Ki Ta e N 107 RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident Be sure to keep your feet firmly mounted on the footboards at all time Avoid jumping the ATV as loss of control and damage to the ATV may result A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shallow water of up to a maximum of 20 cm 7 9 inches in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully A WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in yo
17. headlights are turned off before using the accessory socket otherwise you may drain the battery The accessory socket s rated capacity is DC 12V 120 Watts 10A or less If you exceed this limit you may blow a fuse When you are done using an accessory unplug it and cover the socket with the cap 1 Accessory socket 2 Cap PRE OPERATION CHECKS Before using this machine check the following points ITEM ROUTINE PAGE DRIVE SELECT LEVER e Check the lever for proper operation 44 47 e Check operation condition and brake fluid level Bes Fill with DOT 4 brake fluid if necessary EES e Check fuel level FUEL im o Fill with fuel if necessary 49 50 e Check oil level ENGINE OIL FINAL GEAR AND DIFFERENTIAL GEAR OIL Fill with oil if necessary 51 52 118 128 e Check for leakage DRIVE SHAFT BOOTS Check for damage BO THROTTLE Check for proper throttle cable operation NN EN WHEELS AND TIRES e Check tire pressure wear and damage DA 56 144 145 FITTINGS AND FASTENERS SWITCHES e Check for proper function Ba LIGHTS e Check for proper operation 53 149 e Check coolant leakage GAOLANT Fill with coolant if necessary od Varies 43 e Check all fitting and fasteners 53 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibillty of an accident or equipment damage HOW TO AVOID THE
18. high speed Avoid going down hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible e Never operate the ATV on hills too steep Practice on smaller hills before attempting larger hills Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual A WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flame
19. how much weight can be carried on your ATV NOTE The following weight limits apply to standard equipment only Modifying your ATV using non standard equipment or riding on terrain that is not flat and smooth could further reduce these limits MAXIMUM WEIGHT CAPACITY 220 kg 485 lbs Combined weight of rider all accessories and all cargo MAXIMUM TOWING CAPACITY 454 kg 1000 Ibs TONGUE WEIGHT 16 kg 35 Ibs MAXIMUM LOADING LIMIT REAR CARGO RACK 85 kg 187 lbs FRONT CARGO RACK 45 kg 100 Ibs Loading and Operational Guidelines This ATV is not designed to carry or tow a trailer If you decide to add accessories to allow you to carry cargo or tow atrailer use common sense Carrying cargo will affect how yourATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers Be sure to observe the weight limits and follow these guidelines Never ride with a passenger Do not tow another vehicle Make sure all cargo is secured before riding Allow extra room for starting stopping and turning whenever you carry cargo or pulla trailer 5 Avoid riding on steep slopes when carrying cargo or pilling a trailer 6 Never cross a slope when toeing a trailer ROND A A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling stability and braking which coul
20. or loose terrain WHAT CAN HAPPEN Could cause loss of traction or vehicle control which could resultin an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 88 When riding in an area where you might not easily be seen such as desert terrain mounta caution flag on the machine DO NOT use the flag pole bracket as a trailer hitch Ki Eed GR LC N R N ri 3 ER Li IN A WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mounta caution flag on the machine to make you more visible Watch carefully for other vehicles 89 FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only Do not ride in areas posted no trespassing Do not ride on private property without getting permission 90 Select a large flat area off road to become familiar with your ATV Make sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for off road use on
21. strainer and O ring will fall out Take care not to lose these parts 2 Oil filter cap 119 E Clean the oil strainer with solvent H Fillthe engine with oil and install the oil fill F Inspect the O ring and replace if damaged cap G Reinstall the O ring oil strainer compression spring and oil filter cap Tighten the oil filter cap to specification Oil quantity Periodic oil change 3L 2 64 Imp qt 3 18 US qt Total amount 3 6L 3 17 Imp dt 3 82 US qt Recommended oil see page 158 CAUTION Before reinstalling the drain plug be sure to install the O ring compression spring and oil strainer CAUTION Be sure no foreign material enters the crankcase Tightening torque Oil filter cap engine 14 7 N m 1 5 kgf m 11 Ibf ft Warm up the engine for several minutes at idle speed Check for oil leakage while warming up CAUTION If oil leakage is found stop the engine immediately and check for the cause 120 2 2 Engine oil replacement with or without oil filter cartridge replacement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and drain plug 2 to drain the oil CAUTION Be sure no foreign material enters the 1 Oil fill cap crankcase 2 Oil drain plug 121 NOTE Skip steps E to if the oil filter cartridge is not
22. the right to make changes at any time without notice and without incurring any obligation CONTENTS Page Page LOCATION OF THE WARNING AND CONTROL FUNCTIONS ee 16 SPECIFICATION LABELG 1 IENITIOMNS WITTE Ese sesse ese Ee 16 INSTRUMENTS AND INDICATOR 17 Multi function displaY iese esse see 19 HANDLEBAR SWITCHES osse sessie 26 SAFETY INFORMATION 4 endie dimmer der ee 26 Start DUH OIE ER eN N ne 26 Engine Stop SWIG susse EE ee aca 27 DESCRIPTION AND MACHINE snr meen tee IDENTIFICATION 9 EE e Si IDENTIFICATION NUMBER RECORD En AE Ee Ee ee ee 9 Pe LEED ee ee ee e KEY IDENTIFICATION NUMBER 9 THROTTLE LEVER iese n Se ese Soe 30 FRAME SERIAL NUMBER 10 SPEED LIMITER sesse ees ee ee es EN ENGINE SERIAL NUMBER 10 PARTS LOGCATION soes s Sessie se SEN 11 Cont d FRONT BRAKE LEVER eis SERE ENG 32 PRE OPERATION CHECKG 43 REAR BRAKE LEVER ee esse ees ee 32 DRIVE SELECT LEVER iss isei es ies 44 BRAKE PEDAL 32 Drive select lever adjustment 46 PARKING BRAKE is ese ede n oe 33 MA ER ERASE O EE P sl EO OE ED ors 49 DRIVE SELECT LEVER ems asses e eg 34 DRIVE SHAFT BOOTS 50 W IT 35 ENGINE OIL iese Nee ees Ge e 51 FUEL VALVE ee 35 PINAL GEAR OU eise ersi EE Are 02 CHOKE KNOR ass ane etos anaes 37 DIFFERENTIAL GEAR OIL 52 THROTTLE LEVER knie moei eie 53 BTS ERAT ren re GENE oe ge FITTINGS AND EASTENERG 53 Eege EE EE 39 LIGHTS 53 FLAG
23. to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder 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 If electrode erosion becomes excessive you should replace the spark plug with one of the proper type Standard spark plug NGK CR7E Before installing the spark plug measure the electrode gap with a feeler gauge and adjust to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in A Spark plug gap When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten to the specified torque Tightening torque Spark plug 17 2 N m 1 72 kgf m 13 Ibf ft 129 SPARK ARRESTER Be sure the exhaust pipe and muifler are cool before cleaning the spark arrester 1 Remove the bolts 2 Remove the three bolts 1 the spark arrester 2 and the gasket 3 from the muffler 2 Spark arrester 3 Gasket 130 A WARNING POTENTIAL HAZARD 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The Improper cleaning of th
24. unable to continue up the hill dismount the ATV on the uphill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply either brake abruptly If you are in 2WD apply only the front brake When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground The ATV would easily tip over backwards Apply both the front and rear brakes gradually or dismount the ATV immediately on the uphill side A WARNING 101 POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Shift to the parking position P after you are stopped If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while rolling backwards Apply the front brake 4WD Apply both front and rear brakes gradually When fully stopped shift to the parking position P Dismount on uphill
25. with a commercially available lubricant to prevent premature wear and corrosion 137 VALVE CLEARANCE ADJUSTMENT The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional KYMCO service technician FRONT BRAKE PADS INSPECTION A wear indicator is provided on each brake The indicators allows checking of brake pads wear Check the position of the indicator Ifthe indicator reaches the wear limit line ask a KYMCO dealer to replace the pads 138 REAR BRAKE PADS INSPECTION A wear indicator is provided on each brake The indicators allows checking of brake pads wear Check the position of the indicator Ifthe indicator reaches the wear limit line ask a KYMCO dealer to replace the pads 1 Wear indicator 2 Rear brakes MXU 500 IRS version 139 BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection window 1 Wear indicator 2 Rear brakes MXU 500 version Se j PeT le P UP a s 1 Lower level mark Hand brake lever 1 Lower level mark Foot brake pedal 2 Upper level mark Foot brake pedal 140 NOTE COOLING SYSTEM INSPECTION As the brake pads wear brake fluid level 1 Remove the two fasteners 1 and then drops automatically compensating for wear remove front cover 2 Ther
26. 4WD select switch is located above the throttle lever To select the drive mode push the 2WD 4WD select switch to the desired position 1 2WD 4WD select switch MXU 500 To check your present drive mode look at the Multi function display 2WD mode 2D CH CH BERK 1 2WD 4WD Select switch ME ye Win OD S TRIP mph ko m PM 9 99 4WD am am PY La LI eg g ik mm sd 1 MXU 500 IRS version IE Multi funtion display 28 1 Recoil starter 29 RECOIL STARTER The recoil starter is on the right side of the ATV It is used to start the engine when the battery is low See using the recoil starter page 61 1 Pull the grip up briskly and fully 2 After the engine starts put the grip back to Original position and seal the hole NOTE Do not allow water enter the right case always put the recoil starter to original position and seal the hole THROTTLE LEVER lt is operated by the thumb Pressing the lever opens the throttle When pressure is released spring tension automatically closes the throttle Regulate the speed of the machine by varying the throttle position 1 Throttle lever MXU 500 IRS version 30 A WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID T
27. GS AND FASTENERG 68 58 FLAG POLE BRAGCKET eise Ses be dossier 40 FRAME SERIAL NUMBER sesse esse Ee sis 10 POE eon ee Ge ee ee ee Se EG EE 49 Fuel OMGEE ie EE ae eg 20 FUEL TANK CAP essens eks N sesse sed eke Ede Ni 35 FUEL VAL VEG ee Sooo ees ee 35 FUSE REPLACEMEN NEE 148 l IDLE SPEED ADJUSTMENT 136 IGNITION SWITCH ese esse es ese ee ee ee ees 16 IMPORTANT NOTICES issie es ss es ee DR Ee ie A INSTRUMENTS AND INDICATOR 17 H HANDIERBARGWITCHES 26 28 HEADLIGHT BEAM ADJUSTMENT 149 Headlight dimmer switCh sees esse see ee 26 High beam indieatOF ad Eise N Ne ee 17 High range indicatorligh ees se ee ee ee 18 Cont d 164 Page K KEY IDENTIFICATION NUMBER 9 L Bied RE N EN TE N J3 LOADING EE 69 81 Low range indicator light ee ee ee ee 18 LUBRICATION ME 115 150 M MAINTENANCERECORD esse ees 162 MODE ERR TON WEE 18 MODIFICATIONS sissies ss sedes dad sien ie ie 83 Multi function displaV EE 19 N Neutral indi atoF sussies ss hi gedeit ee eN NEE N 18 No Modilli a et sesse EE ER AS Se ee 83 NOISE REGULATION D 161 Odometer OPERATION OWNER S MANUAL STORAGE COMPARTMENT P Park indicator lighE ee sees ee ee ee PARKING PARKING BRARE esse esse esse ee ee Parking on a slope PASSING SIGNAL SWWITCH PARTS LOGATION ees ese ee ese PERIODIC MAINTENANCE LUBRICATION ME PERIODIC MAINTENANCE AND ADJ
28. HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 44 DRIVE SELECT LEVER CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged Check operation of the lever before start the engine 1 Make sure moving the shift lever into the N position of the shift guide 2 Turn the ignition switch to ON and check the neutral indicator lamp comes on 3 If the neutral indicator lamp does not come on then see page 46 47 for adjustment A WARNING POTENTIAL HAZARD Operating with improperly adjusted drive select lever WHAT CAN HAPPEN You may lose control of the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N position and neutral indicator lamp comes on before start the engine 1 Drive select lever N Neutral 45 Drive select lever adjustment 1 Turn the ignition switch is ON and make sure 3 Loosen the locknuts 3 of rod 4 Shift the gear to neutral by moving the shift lever and or turn the rod The neutral indicator lamp comes on the engine stop 2 Remove 3 fasteners 1 then remove the left side cover 2 1 Fastene
29. HE HAZARD 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 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 A WARNING the maximum engine power available and decreases the maximum speed of the ATV POTENTIAL HAZARD E Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 13 mm 0 52 in Always make sure the throttle lever free play is adjusted to 3 5 mm 0 12 0 2 in See page 137 1 Adjuster 2 Locknut A 13mm 0 52in 31 FRONT BRAKE LEVER BRAKE PEDAL The front brake lever is next to the right Operating the brake pedal applies the rear handgrip brake The front brakes are operated by squeezing the front brake lever REAR BRAKE LEVER The rear brake is operated by squeezing the rear brake lever near left handgrip 1 Rear brake pedal 7 es OE RE Th Ve 1 Front Gem lever 2 Rear Sa lever 32 PARKING BRAKE A WARNING To set the parking brake squeeze the front brake lever
30. ID THE HAZARD Tire pressures must be equal on both sides 1 The tires listed below have been 3 Tire pressure below the minimum specified approved by Kwang Yang Motor Co Ltd could cause the tire to dislodge from the for this model Other tire combinations rim under severe riding conditions are not recommended The following are minimums Front 25 kpa 0 25 kgf cm 3 5 psi MXU 500 size Type Rear 25 kpa 0 25 kgf cm 3 5 psi Front 32 kpa 0 32 kgf cm 4 6 psi MXU 500 IRS Rear 29 kpa 0 29 kgf cm 4 1 psi 25X8 12 a 54 4 Higher pressures may cause the tire to How to measure tire pressure burst Inflate the tires very slowly and Use the low pressure tire gauge Tool kit carefully Fast inflation could cause the tire to burst NOTE The low pressure tire gauge is included as Set pressure tires cold standard equipment Make two Set tire pressures to the following measurements of the tire pressure and use the second reading Dust or dirt in the gauge MXU Recommended stonge KEE 50 0 pressure could cause the first reading to be incorrect 28 kpa 25 kpa 32 kpa Front 0 28 GE 0 25 kgficm 0 32 kgf cm 3 92 psi 3 5 psi 4 5 psi 28 kpa 25 kpa 32 kpa 0 28 kgf cm 0 25 kgf cm 0 32 kgf cm 3 92 psi 3 5 psi 4 5 psi M X U Recommended Mini inimum Front 0 35 kgf cm 0 32 kgficm 0 38 kgf cm 5 0 psi 4 6 psi 5 4 psi 32 kpa 29 kpa 35 kpa 1 Low pressur
31. MCO Use extra caution when riding anATV with to test all non KYMCO accessories nor have accessories The ATV may handle differently any control over the quality or suitability of than it does without accessories them Choose a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV 68 LOADING As originally equipped this ATV can carry cargo or tow a trailer you must use common sense and good judgment Keep the following points in mind e Never exceed the weight limit shown An overloaded ATV can be unstable e Maximum load Rear cargo rack 85 kg 187 Ibs Front cargo rack 45 kg 100 Ibs Trailer Maximum towing capacity 454 kg 1000 Ibs 3 Trailer MXU 500 Tongue weight 16kg 35 Ibs 3 Trailer MXU 500 IRS has not this fittings 1 Rear cargo rack 2 Front cargo rack If you need this accessories Please ask your dealers 69 Load cargo on the cargo racks as close to the center of the vehicle as possible Put cargo at the rear of the front cargo rack and at the front of the rear cargo rack Center the load from side to side e Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around e A shifting load can cause an accident e Make sure the load does not interfere with controls or
32. MXU 500 MXU 500 IRS ATV o mo KYMCO 2008 KYMCO All rights reserved Printed in Taiwan www kymco com Version T200 LAAOCA US AS 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 The minimum recommended age for this ATV model is 16 Children under age 16 should never operate this vehicle RIDER TRAINING Anyone who operates this vehicle should get proper instruction FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only This machine is designed and manufactured for OFF ROAD use only lt is illegal and unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine 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 N Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH Indicates a strong possibility that serious injury or death may re
33. ONS SPARK PLUG NGK CR7E OF 1 5 G KM HC NOX 35 G KM CO AND SPARK PLUG GAP 0 6 0 7mm CALIFORNIA REGULATIONS OF FUEL UNLEADED GASOLINE ONLY 86 R M 2 1 2 G KM HC FOR 2009 MODEL YEAR OCTANE NEW ATV IL 5W 30 SEE THE OWNER S MANUAL S 0 ENGINE EXHAUST CONTROL SYSTEM MANUFACTURED 12 2008 MONTH YEAR KWANG YANG MOTOR CO LTD To KYMCO USA Inc _ TAIWAN kymco Spartanburg SC 29307 USA Never carry passenger on This carrier Maximum load 45 Kg 100 Ibs NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged Operating this ATY if you are under ihe age of 16 inereases your chang Os of severe injury ar death NEVER operate his ATW if you are under ihe age of 16 A WARNING Never carry passenger on This carrier Maximum load 85 Kg 187 lbs 6 a MXU 500 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold Recommended FRONT 25 32kpa 0 25 0 42kaf cm 3 5 4 5psi REAR 25 J32kpa 0 25 0 32kgf cm 3 5 4 5psi s Never set tire pressure below recommended LOADING e Maximum Ve
34. POLE BR EKER issie keen 40 SWITCHES va soen ede oog ee ie 53 TRAILER HITCH AO WR zo one se ia AE EE N OE 54 OWNER S MANUAL STORAGE de to ie ae tire pressure i ire wear limite ED eevee ease estore II COOLANT cecececscecsesecseseseeeseeeseseseee 56 ACCESSORY SOGKET esse Goeie 42 Cont d Page OPERATION ies ss oe iese En 58 STARTING A COLD ENGINE 58 Using the recoil starter 61 STARTING A WARM ENGINE 62 WARMING UP esse dee EE Soe SE De 62 DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING sesse 63 Shifting neutral to high and high to IOW ATR EE EE inn 63 Shifting neutral to reverse and revereetopark 64 ENGINE Er DER 65 PARKING ie sees dees nee ei si N eg 66 Parking on aslope ss DK 67 ACCESSORIES ss ies need Dee Ee een Ge 68 LOADING sins es ER ER ee Ge AS 69 RIDING YOUR ATV ee ee ee 71 GETTING TO KNOW YOUR ATV 72 RIDE WITH CARE AND GOOD JUDG EME NT soes sees eos sie sei sos ede 73 APPAREL oeste ses sesse se ee es oge ee 15 PRE OPERATION CHECKG 79 Speed limiteF ss sesse ee cece eee 80 LOADING AND ACCESSORIEG 81 Load LIES sy ase ae EER ES 81 Loading and operational guidelines 81 ACCESSOFGS ese Sage EEN SE Ses ee GN 82 MODIEIGATIONS sesse sesse see NR ee aces 83 No MOCINCANONS tesis ses 83 EXHAUST SYSTEM sissies 84 BE CAREFUL WHERE YOU RIDE 85 FOR OFF ROAD USE ONLY 90 DURING OPERATION
35. T CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is acontrol or function you do not understand ask your KYMCO dealer STARTING A COLD ENGINE A WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Set the parking brake 2 Turn the fuel valve to ON 3 Turn the ignition switch to ON position and the engine stop switch to C 4 Shift the drive select lever into the neutral or park position 58 M Use the accelerating pump if the cold engine start ambient temperature below 15 C 0 F Using the accelerating pump Remove the seat page 39 then press the accelerating pump lever twice 1 Accelerating pump 59 NOTE The engine can be started in any gear if the brake lever is applied However it is recommended to shift into neutral or park before starting the engine e When the select lever is in the neutral or park position if either indicator light does not come on ask a KYMCO dealer to inspect its electric circuit 6 Use the choke knob in reference to the figure MXU 500 version only Position Cold engine start ambient tem
36. USTMENT 00 ccceee eee es PREFACE PRE OPERATION CHECKG 165 R RECOIL START E RR siese isi se ge 29 61 Reverse indicator light ee se ee see Ee Ee 18 RIDING DOWN E 104 RIDING YOUR AT esse Se ee oe se se 11 RIGHT HANDLEBAR SWITCH 28 2WD 4WD eelectswitch 28 S SAFETY INEORMATION gtt gege 4 SEAT oe EN Ede N yee Ee 39 SET BUT ON ies A EE od 18 SPARK ARRES TER esse ses esse 130 SPARK PLUG INSPECTION 129 SPECIALMESSAGES a B eieiei une KE 157 SPEEDLIMITER us sessie sones seed De 31 80 Speedometer ss ee esse EE EE ER ER EE ER ee 19 Starter TK e EE 26 STARTING A COLD ENGINE 58 STARTING A WARMENGINE 62 SORA GS Boece ov cass ESE ee ee EE De SE 159 NES LE 53 Page T THROTTLE LEVER e eege eegne 30 53 THROTTLE LEVER ADJUSTMENT 137 TIRES EE 54 Tire wear mt 56 TOOL KIT 113 TRAILER HITCH 40 TPMS iss GE Eg ie gA 21 TROUBLESHOOTING ss EE Ee see 151 Troubleshooting chat 152 TURNING vOURATIM nananana 94 W Warning information ccccce ee ee ee ee ee 1 WARMING UP iese ae Es Ge De Ge Ge GE RE 62 WHEEL INSGSTIALLATION 144 WHEEL REMOVAL cece ee 144 V VALVE CLEARANCE ADJUSTMENT 138 166 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kaohsiung Taiwan Republic of China Telephone 886 7 3822926 FAX 886 7 3950021 By KWANG YANG Motor Co Ltd First Edition DEC 2008 All rights reser
37. al f 35 Flag pole bracket 36 Tool storage MXU 500 IRS version only Wi DI a i NOTE TT ke I WE SE The machine you have purchased may differ SNE WAG slightly from those shown in the figures of this manual 31 32 33 34 35 36 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 All electrical circuits are switched on The engine can be started The key can not be removed LU w The ignition switch is ON while the position light and taillight will light All electrical circuits are switched on The engine can be started The Key can not be removed 16 1 Ignition switch 2 Key INSTRUMENTS AND INDICATOR 1 Multi function display The display includes the following functions Speedometer d CW CH CH Odometer Tripmeter EET TITEL LI LI Digital clock id kmh 2WD 4WD indicator PM ig Fuel gauge 2 High beam indicator The ignition switch is at the ZC position the high beam indicator will light when the headlight switch to select High beam Z0 1 Multi function display 2 High beam indicator 3 Coolant temperature warning indicator 4 Set button 5 Low range indicator light L 6 High range indicator light H 7 Neutral indicator light N 8 Reverse indicator light R 9 Park indicator light
38. ator to choose between an open differential or a closed differential in low traction situations Pulling the lock lever to the left To lock the differential on the 4WD move the 4WD differential Button Multi function display 2 1 Zeg Op i TT I l ODO TRIP AB A km h 1 Speedometer 2 2WD 4WD indicator 3 Fuel gauge 4 Odometer Tripmeter 5 Digital clock 1 Speedometer Shows riding speed in km h or mph Press and hold MODE button for more than 2 seconds to select mph or km h bf 7 EI aama D da mph km h 19 2 2WD 4WD indicator 3 Fuel gauge Shows the drive mode is in the 2WD or 4WD The fuel gauge shows the approximate fuel supply available in a graduated display The normal operating fuel range is with the section between the segment F and segment E When the segment E or the fuel indicator 2WD 3 flashes fuel will be low and you should Dess AWD refill the tank as soon as possible STITT 1 Segment F 3 Fuel indicator 2 Segment E 20 4 Odometer Tripmeter The odometer shows the total mileage in Km or in miles The tripmeter shows the trip distance in Km or in miles There are two tripmeters tripmerer A and tripmeter B Press and hold SET button for more than 2 seconds to select ODO TRIP Aor TRIP B Press and hold MODE button for more than 2 seconds to select mile or km TD CO ap OC ME CH eau LI LL m mph km h PMiG GD MIDD OOOO Omi nooooone
39. battery CAUTION Do not attempt to remove the caps from the battery cells as this may damage the battery e Although the battery is sealed it vents explosive gases and should be handled with appropriate care 146 A WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery WHAT CAN HAPPEN Gases may explode and possibly cause injury HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery NOTE e When the ATV is to be stored for an extended period remove the battery from the vehicle and charge it fully Then store it in a cool dry place If the battery is to be left on the vehicle disconnect the negative cable from the battery terminal Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Battery remove 1 Make sure the ignition switch is OFF 2 Remove the seat page 39 3 Release the rings and remove the rubber band 1 4 Disconnect the negative terminal lead 2 from the battery first then disconnect the positive terminal lead 3 5 Remove the battery Battery installation 1 Rubber band 1 Install in the reverse order of removal 2 Negative terminal lead 2 After installing the battery check to see if the 3 Positive terminal lead battery cables are routed correctly NOTE First connect the positive cable and then negative cable to avoid short circuit
40. cessive speeds As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footpeg to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly Lean towards inside of turn Support your weight on the sd 7 outer footboard P i ei j Ef VEE SG TE d FO This procedure should be practiced at slow speed many times in a large off road area with no obstacles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the procedure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat 95 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to
41. d fall a footpeg your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footpegs of your ATV during operation Avoid wheelies and jumping You may lose control of the machine or overturn A 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 Don t try to show off 93 TURNING YOUR ATV To achieve maximum traction while riding off 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 Aspecial turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or overturn 94 HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions Do not turn at ex
42. d lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer 82 Accessories Genuine KYMCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and using non KYMCO accessories Always follow the loading instructions above plus the following 1 Carefully inspect the accessory to make sure it does not block any lights reduce ground clearance or limit Suspension travel steering travel or other controls 2 Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls 3 Do not add electrical equipment that will exceed the vehicle s electrical system capacity A blown fuse could cause a loss of lights or engine power MODIFICATIONS No Modifications Modifying this ATV or removing original A WARNING equipment may render the vehicle unsafe or POTENTIAL HAZARD illegal Spark arresters and mufflers are Operating this ATV with improper required in most areas Don t modify your modifications exhaust system or emission control system comp
43. d position 3 Certainly locked position 2 Lock lever 66 Parking on a slope A WARNING POTENTIAL HAZARD Parking ona hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 67 1 Bring the machine to a stop by applying the brakes 2 Stop the engine 3 With the brake applied shift the drive select lever into the park position 4 Apply the parking brake ACCESSORIES Accessories can affect the handling and control Do not mount an accessory where it could of your ATV Keep the following in mind when interfere with your ability your to control the considering an accessory or operating an ATV ATV Examples include but are not limited to which has accessories a heavy or bulky object attached to the e Choose only accessories designed for your handlebars which could make steering ATV Your KYMCO dealer has a variety of difficult an accessory that limits your ability genuine KYMCO accessories Other to move around on the seat or one that limits accessories may also be available on the your view market However itis not possible for KY
44. different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Use unleaded fuel only because it produces fewer engine and spark plug deposits and extends the life of the exhaust system Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank 1 Fuel neck Recommended fuel UNLEADED FUEL Fuel tank capacity Total 17L 3 57 Imp gal 4 42 US gal Reserve 2 3L 0 48 Imp gal 0 6 US gal 49 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot 50 DRIVE SHAFT BOOTS Check the rubber drive shaft boots for damage or leaking grease If necessary have your KYMCO dealer replace them DACA KS 1 Drive shaft boots ENGINE OIL Make sure the engine oil at the specified level Add oil as necessary See page 118 124 Check for leaks in 30 O 110 F eme _ men 1 g emm
45. e ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual T9 A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle on pages 54 56 Always maintain proper tire pressure as described in the Owner s Manual on page55 Do not operate at speeds too fast your skills or the conditions A WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go ata speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders inexperienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiter limits the power and top speed of the machine Turning the screw in decreases top speed and turning it out increases top speed 1 Adjuster 2 Locknut 80 LOADING AND ACCESSORIES Load Limits There are limits to
46. e are no adjustments to perform but fluid level and pad wear must be inspected periodically The system must be inspected frequently to ensure there are no fluid leaks If the brake lever travel become excessive and the brake pads are not worn beyond the recommended limit page 138 139 There is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service CAUTION To prevent damage to the brake system use only fluid from a sealed container Never allow contaminants dirt water etc to enter the brake fluid reservoir Brake fluid can damage paint and plastic so handle the fluid with care When adding brake fluid be sure the reservoir is horizontal before removing the cover to prevent accidental spilling Use only DOT 4 brake fluid from a sealed container 1 Fasteners 2 Front cover 141 2 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature The coolant level should be between the maximum and minimum marks 3 If the level is low remove the coolant reservoir cap and then add coolant or distilled water to raise it to the specified level 4 If your ATV overheats see page 143 for i details 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark CAUTION Hard water or salt water is harmful to the engine You may use distilled water if rou can
47. e fuel Turn the fuel Restart engine Some fuel valve to RES tank Clean filter element and fuel tank Water or dirt mixed in fuel Turn the fuel valve to Turn the fuel valve to OFF f Wa the fuel valve Check fuel flow Remove the fuel There is fuel Engine t r Clean fuel valve 2 Battery bied Check fluid recharge check connections over slowly Use electric starter Engine turns Batt over duickly ele gers Ask a KYMCO dealer to inspect 3 Ignition Wet Wipe clean with dry mag just pl Remove plug and cloth seed ee check electrode Ee F 1 e I ach plug cap an Use electric Spark weak ground to chassis Pe WE Spark good Ignition system normal Use electric starter Ask a KYMCO dealer to inspect to see if there is ee Compression normal 152 4 Compression CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the machine A Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used B Make sure the spark plug and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprockets or wheel axles 3 Rinse the dirt and degrea
48. e spark arrester spark arrester must be free of breaks and Hot exhaust system holes Replace if necessary Check the gasket Replace if necessary WHAT CAN HAPPEN 4 Install the spark arrester and the gasket inthe Could injure the eyes muffler and tighten the three bolts securely Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system 131 AIR FILTER CLEANING The air cleaner accumulates dust and must be cleaned periodically If the ATV is ridden in dusty areas the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner 1 Remove the seat See page 39 2 Unlatch the six retainer clips 1 and remove the air cleaner housing cover 2 3 Loosen the screw 3 and remove the air cleaner assembly 4 from the air cleaner housing 4 Unscrew the clamp 5 132 3 Screw 4 Air cleaner assembly TT 5 Clamp 9 10 11 5 Remove the outer air cleaner 7 6 Remove the screw washers 6 and remove the air cleaner assembly f
49. e tire gauge 0 32 kgf cm 0 29 kgficm 0 35 kgf cm 4 5 psi 4 1 psi 4 9 psi 55 Tire wear limit When the tire groove decreases to 4 mm 0 16 in due to wear replace the tire A Standard 4mm 0 16 in 56 COOLANT Check the coolant level in the reservoir tank when the engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if itis between the FULL and LOW marks on the tank If the coolant level is at or below the LOW level add tap water soft water to bring the level up to FULL Change the coolant every two years See page 141 143 for details CAUTION Hard water or salt water is harmful to the engine You may use distilled water if you can not get soft water Lt REN Ka d 2 Maximum level mark 3 Minimum level mark 1 Coolant reservoir cap 57 A WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Should be serviced by your authorized KYMCO dealer when changing the coolant OPERATION A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHA
50. ed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a KYMCO dealer to replace them Recommended lubricant KYMCO chain and cable lube or SAE 10W40 motor oil 150 TROUBLESHOOTING Although KYMCO machines receive a rigid inspection before shipment from the factory trouble may occur during operation Any systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a KYMCO dealer The skilled technicians ata KYMCO dealership have the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills 151 A WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces Troubleshooting chart Supply fuel Check if there is fuel in th
51. hicle Load 220 Kg 485 lbs Including weight of operator cargo and accessories 6 b MXU 500 IRS 7 Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 5 0 psi 35 kPa Rear 4 5 psi 32 kPa Maximum weight capacity 485 lbs 220 kg 87505 LFE9 M35 Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate A WARNING Exceeding vehicle towing limit could lead to an without proper training or instruction at speeds too fast for your skills or the accident Reduce speed when towing a trailer conditions Read owner s manual for details MAXIMUM TOWING CAPACITY 454kg 1000Ibs TONGUE WEIGHT 16kg 35 Ibs on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns Exceeding vehicle s towing limit could cause an accident Reduce speed when towing a trailer Read operator s manual for details MAXIMUM TONGUE WEIGHT 35 Ibs 16 kg MAXIMUM TOWING CAPACITY 1000 Ibs 454 kg 87514 LFE9 M35 avoid paved surfaces pavement may seriously affect handling and control
52. ibility and operating conditions and your experience Never attempt wheel jump or other stunt Always inspect your ATV each time you use it to make Sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at
53. in On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control CLIMBING UPHILL Use proper riding technidues to avoid vehicle overturns on hills Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes Try more difficult climbs only after you have developed your skill In all cases avoid inclines with slippery or loose surfaces or obstacles that might cause you to lose control 98 A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills Itis important when climbing a hill to make sure that tour weight is transferred forward on the ATV This can be accomplished by leaning forward and steeper inclines standing on the footboards and leaning forward over the handlebars A WARNING POTENTIAL HAZARD Climbing hills 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 hills as described in this Owner s Manual Always check the terrain carefully before you sta
54. in tube 1 Remove the drain tube 1 by removing the clip 3 2 Drain the deposits 3 Reinstall the drain tube securing it with the clip 1 Drain tube 2 Air cleaner housing 3 Clip 135 IDLE SPEED ADJUSTMENT NOTE A diagnostic tachometer must be used for this procedure 1 Remove the seat see page 39 2 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 3 Connect the tachometer and set the idle to the specified idling speed by adjusting the idle adjusting screw Turn the screw in to increase engine speed and out to decrease engine speed Specified idle speed 1 400 1 600 rom min 136 S 1 Idle adjusting screw MXU 500 IRS THROTTLE LEVERADJUSTMENT NOTE Adjust the engine idling speed before adjusting the throttle lever free play To adjust throttle free play 1 Slide the rubber sleeve 1 back to expose the throttle cable adjuster 2 2 Loosen the lock nut 3 then turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 1 Rubber sleeve 2 Cable adjuster 3 Tighten the locknut and reinstall the sleeve 3 Locknut 4 Throttle lever A 3 5 mm 0 12 0 2 in Other checks Check the throttle cable for kinks and signs of wear that could cause stretching or failure Lubricate the throttle cable
55. itch on the low beam Turn the switch to the gt position to switch on the high beam Turn the switch to the position to switch off the headlight 2 Starter button Stater button To starter the engine press the starter button with the transmission in neutral the ignition switch ON and the engine stop switch At RUN CH CAUTION See starting instructions prior to starting engine see page 58 for details 26 3 Engine stop switch Engine stop switch When the switch is in the RUN position the engine will operate When the switch is in OFF SX 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 Q position NOTE If you stop your ATV by turning the engine stop switch OFF Sal be sure to turn the ignition switch OFF to prevent battery discharge 27 pi D Vi P _ j a m j a e r F mr D i O i ME d d F i j ri a j B 4 Passing signal switch Passing signal switch When passing if there are cars coming from the opposite direction press and release the passing signal switch and the headlight will wink to warn the coming vehicles RIGHT HANDLEBAR SWITCH 2WDI 4WD select switch This ATV is equipped with a 2WD 4WD select switch which permits a choice between the 2WD and 4WD drive modes Selecta drive mode that is suitable for your riding The 2WD
56. justment and lubrication are explained on the following pages A WARNING POTENTIAL HAZARD Servicing an engine while itis running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified 113 Have KYMCO dealer perform service if you are not familiar with machine service TOOL KIT TOOL KIT COMPARTMENT The tool kit is stored in the tool kit compartment under the seat 1 Tool kit Tool kit compartment The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work reguiring additional tools should be performed by your authorized KYMCO dealer MXU 500 version The tool kit includes the following items 1 Air pressure gauge 2 Spark plug wrench 10 12 mm wrench 4 Standard Phillips screwdriver 5 Screwdriver handle 6 3 6 Tool bag 5 4 3 2 1 The tools in the kit are sufficient to perform routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer MXU 500 IRS version The tool kit includes the following items 1 Air pressure gauge 2 Spark plug wrench A 3 10 14 mm wrench 4 Standard Phillips screwdriver 5 Screwdriver handle 6 Tool bag 7 Spark
57. l A arm Swing arm Dual A arm Coil spring Oil damper Coil spring Oil damper C D I A C magneto 12V 18AH MF Tubeless AT25X8 12 AT25X10 12 12V35W 35W X2 12V21W 5W X2 12V5WX2 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Some local laws and regulations prohibit 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 AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 161 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 asa reminder to you that the maintenance work is required It is not acceptable proof of maintenance work DATE MAINTENACE OF MONTH SERVICING DEALER REMARKS INTERVAL SERVICE NAME AND ADDRESS 150 km 1000 km 2000 km 3000 km 4000 km 6000 km 7000 km 8000 km 9000 km 10000 km 162
58. lide See pages 94 97 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See pages 98 103 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See pages 106 107 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See pages 108 110 Indicates astrong possibility that serious injury or death may result if instructions are not followed 112 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient condition possible Safety is an obligation of the machine owner The most important points of machine inspection ad
59. ly and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 58 62 to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components 31 With the engine idling return the starter knob to the closed position and shift the drive select lever into the forward position Then release the parking brake Apply the throttle slowly and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident DURING OPERATION Always keep your feet on the footboards during operation Otherwise your feet may contact the rear wheels _ DA A SP BEL seg E NS DOORS N 92 A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet 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 an
60. ly affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including aN sidewalks driveways parking lots and Cay N v streets sl 85 Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states itis illegal to operate ATVs on public streets roads and highways 86 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the machine to upset AA WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 8 A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery
61. mendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc 74 APPAREL A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Protective clothing Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident 19 Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket Long pants Do not operate after consuming alcohol or drugs Operator s performance capability is reduced by the influence of alcohol or drugs 76 A WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could res
62. n the fuel tank The fuel valve supplies fuel from the fuel tank to cap until it clicks the carburetor The fuel valve has three Insert the breather tube into the meter cover positions hole To refuel refer to page 49 1 Fuel tank cap 2 Breather tube 3 Meter cover hole 1 Fuel valve 35 OFF With the lever and A mark in this position fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever A mark in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever A mark to this position THEN FILL THE FUEL TANKAT THE FIRST OPPORTUNITY After refueling return the fuel valve lever to the ON position NOTE After refueling do not operate the ATV with the fuel valve in the RES position If you run out of fuel there will be no reserve supply OFF p a ROES CHOKE KNOB MXU 500 version only Starting a cold engine requires a richer air fuel mixture Aseparate starter circuit supplies this mixture Move in direction A to turn on the choke knob Move in direction B to turn off the choke knob Refer to starting a cold engine for proper operation See page 58 1 Fully open 2 Half open 3 Closed A ON position B OFF position 37 CAUTION Extended use of the choke may impair piston and cylinder wall lub
63. ng surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slippery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel A WARNING 106 POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Ou wb ES Un O Ou x N E Q Ou dam ur O Ta Be D Ou gt
64. not get soft water NOTE 1 If water is added have a KYMCO dealer check the antifreeze content of the coolant as soon as possible 2 The radiator fan operation is completely automatic It is switched on or off according to the coolant temperature in the radiator 142 Engine overheating A WARNING If your ATV overheat wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is low check the cooling system for leakage Ask a KYMCO Add coolant dealer to inspect See NOTE and repair the cooling system POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN Level is OK You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Should be serviced by your authorized KYMCO dealer when changing the coolant Restart the engine If the engine overheats again ask aKYMCO dealer to inspect and or repair the cooling system NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible 143 WHEEL REMOVAL WHEEL INSTALLATION 1 Elevate the wheel by placing a suitable s
65. onents Remember excessive noise WHAT CAN HAPPEN bothers everyone and creates a bad image for Improper installation of accessories or off road vehicles modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be 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 an authorized ATV dealer 83 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 A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burned A EE e A E EA HOW TO AVOID THE HAZARD Do not touch the hot exhaust system Do not park the machine in a place where others might be likely to touch it 84 BE CAREFUL WHERE YOU RIDE This machine is designed for off road use only Riding on paved surfaces can cause loss of control A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATV are designed for off road use only Paved surfaces may serious
66. perature below 5 C 40 F Position Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position Cold engine start ambient temperature above 25 C 80 F and warm engine start position 60 AMBIENT TEMP STARTER CHOKE POSITION 20 30 c 1 Fully open 3 Closed 2 Half open a Choke knob 7 Completely close the throttle lever and start the engine by pushing the start switch 8 The carburetor uses the automatic choke device in MXU 500 IRS version NOTE Using the recoil starter If the engine fails to start release the start The recoil starter is used to start the engine switch then push the start switch again when the battery is low Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt If the battery is discharged pull the recoil starter to start the engine 8 If the engine is started with the choke knob in position 1 the choke knob should be returned to position 2 to warm up the engine If the engine is started with the choke knob in position 2 keep the choke knob in this position to warm up the engine 9 Continue warming up the engine until it idles smoothly and return the choke knob to position 3 before riding 1 Recoil starter 61 To start the engine without the electric starter zech Follow steps 1 through 6 With the throttle closed g
67. plug wrench B 8 Rear cushion adjuster 3 5 4 2 7 1 8 PERIODIC MAINTENANCE LUBRICATION eReplace Warm engine before draining eClean D H D Oil strainer eReplace if necessary Engine oil filter cartridge eReplace eCheck oil level oil leakage eReplace every 12 months eCheck oil level oil leakage eReplace every 12 months Final gear oil Differential gear oil Air filter element for engine and V belt compartment eClean More often in wet or dusty areas eReplace if necessary eCheck idle speed starter operation eAdjust if necessary eCheck breather hose for cracks or damage eReplace if necessary eCheck condition Spark plug eAdjust gap and clean eReplace if necessary eCheck fuel hose for cracks or damage eReplace if necessary eCheck valve clearance eAdjust if necessary Carburetor Cylinder head cover breather system Fuel line Valves 115 INITIAL EVERY vom 1 el 12 N eCheck operation and brake fluid Brake eReplace brake pad if necessary eCheck coolant leakage Coolant eReplace if necessary eReplace coolant every 24 months eCheck operation V belt eReplace if damage or excessive wear eCheck leakage Exhaust system eRetighten if necessary eReplace gasket if necessary Spark arrester E eCheck balance damage runout Wheels eReplace if necessary m eCheck bearing assembly for looseness damage Wheel bearings eReplace if damaged
68. quantity MXU 500 IRS Front gear case oil Periodic oil change 0 25 L 0 22 Imp qt 0 265 US qt Total amount 0 27 L 0 238 Imp qt 0 286 US qt THROTTLE LEVER LIGHTS Check to see that the throttle lever operates Check the headlight and taillight to make sure correctly It must open smoothly and spring back they are in working condition Repair as to idle position when released Repair as necessary for proper operation necessary for proper operation FITTINGS AND FASTENERS SWITCHES Always check the tightness of chassis fittings Check the operation of the headlight switch and fasteners before a ride Take the machine to engine stop switch and any other switches a KYMCO dealer or refer to the Service Manual Repair as necessary for proper operation for correct tightening torque 53 TIRES 2 The tires should be set to the recommended A WARNING pressure POTENTIAL HAZARD e Recommended tire pressure Operating this ATV with improper tires or Front 25 32 kpa 0 25 0 32 kgf cm with improper or uneven tire pressure oa PSI ME 00 Rear 25 32 kpa 0 25 0 32 kgf cm WHAT CAN HAPPEN Eps Front 32 38 kpa 0 32 0 38 kgf cm Use of improper tires on this ATV or 4 6 5 4 psi MXU 500 IRS operation of this ATV with improper or Rear 29 35 kpa 0 29 0 35 kgf cm uneven tire pressure may cause loss of 4 1 4 9 psi control increasing your risk of accident e Check and adjust tire pressures when the tires are cold HOW TO AVO
69. rasp the starter grip firmly then pull it out slowly until it seats lightly Pull the grip up briskly and fully After the engine starts allow the starter grip to return slowly NOTE Do not allow water enter the right case always put the recoil starter to original position and seal the hole 5 Follow steps 8 through 9 62 CAUTION See the engine break in section prior to operating engine for the first time STARTING A WARM ENGINE To start a warm engine refer to the Starting a cold engine section The choke knob should not be used The throttle should be opened slightly WARMING UP To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the choke knob turned off DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING CAUTION Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged NOTE Apply the rear brake and shift the shift lever 1 Drive select lever L Low into P position before turning off the engine H High N Neutral when parking the vehicle on an incline if you R Reverse P Park park on an incline with shiftlever in H Lor R position vehicle weight will make it difficult to
70. rial number is stamped on the left front and rear of the frame crankcase en 7 aa o OG e A Sex E iP gpm 1 Frame serial number 1 Engine serial number 10 PARTS LOCATION 03 02 02 01 01 Rear brake lever 02 Headlights Position lights 03 Front brake lever 11 04 07 06 05 04 4 Taillights Brake lights 5 2WD 4WD select switch and differential lock lever 6 Instrument and indicators 7 Headlight dimmer switch Starter button Engine Stop Switch Passing signal switch 08 Spark arrester 09 Trailer hitch MXU 500 version only 10 Throttle lever 0 0 0 0 MXU 500 IRS selectivity appurtenances 23 22 21 20 19 19 Exhaust system 20 Battery Fuse 21 Tool kit 22 Accelerating pump lever 23 Rear brake fluid reservoir 24 Accessory socket seat 25 Drive select lever 24 25 14 15 14 13 12 11 1 Reservoir water tank 2 Front brake fluid reservoir 3 Fuel valve 4 Recoil starter 5 Seat 6 Brake pedal fluid reservoir 7 Seat lock lever 8 Oil level inspection window 1 1 1 1 1 1 1 1 13 H 26 Right footpeg OV et nh 27 Owner s manual storage Ze Aa ip ee 28 Front cargo rack Zin L Gell 29 lgnition switch q LJo _ OLJO 2 Bas 30 Left footpeg L S A EHE 31 Rear cargo rack ISL BO 32 Fuel fill cap Jess N 33 Choke knob Dy 7 N 34 Rear brake ped
71. rication and shorten the life of the engine e Pushing the choke knob too hard to the OFF position may dislodge the choke cable boot If this happens water and dirt may enter the choke cable and cause corrosion If the choke is hard to actuate or feels like itis sticking check the cable boot The carburetor uses the automatic choke device in MXU 500 IRS version ACCELERATING PUMP LEVER The accelerating pump lever is on the carburetor right side under the seat Starting a cold engine start ambient temperature below 15 C 0 F requires a richer air fuel mixture When the pump lever is pressed the pump send the necessary amount of fuel to the fuel pipe for correcting fuel Refer to starting a cold engine for proper operation See page 59 38 1 Accelerating pump SEAT To install the seat align the tabs on the seat with To remove the seat pull the seat lock lever the grommets on the frame and press the seat upward and pull up the seat at the rear down until it locks 1 Seat lock lever 39 FLAG POLE BRACKET Flag poles are optional equipment available from your KYMCO dealer To mount a flag pole in the bracket to make you more visible NOTE Flag poles are required in some riding areas Check local regulations before riding 1 Flag pole bracket TRAILER HITCH The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball as specified by
72. rom the air cleaner holder 8 7 Remove the inner air cleaner 9 and air cleaner screen 10 from the air cleaner guide 11 8 Remove the air cleaner screen from the inner air cleaner 7 7 Outer air cleaner 8 Air cleaner holder 9 inner air cleaner 10 Air cleaner screen 11 1 11 Air cleaner guide 6 Screw washer 133 9 Gently wash the air cleaner in clean non 10 Soak the air cleaner an eduivalent gear oil flammable high flash point solvent such as SAE 80 90 until saturated then squeeze out kerosene not gasoline Allow the air cleaner the excess oil to dry throughly before applying oil Awet air cleaner will not fully absorb the oil NOTE The element should be wet but not dripping A WARNING CAUTION POTENTIAL HAZARD BE the air cleaner when squeezing out Using gasoline or low flash point solvents excess oil could damage the air cleaner for cleaning ATV parts 11 Reassemble by reversing the disassembly WHAT CAN HAPPEN sequence A fire or explosion could result HOW TO AVOID THE HAZARD Use only anonflammable or high flash point solvent to clean ATV parts 134 AIR CLEANER HOUSING DRAIN TUBE The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule Riding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the dra
73. rs 3 Lock nuts 2 Left side cover 4 Rod 46 4 Turn the rod clockwise or counterclockwise until the drive select lever 5 into the N position of the shift guide and tighten the locknuts 5 Drive select lever N Neutral 47 FRONT AND REAR BRAKES de 2 Make sure there is no brake fluid leakage Check operation of the levers and pedal They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a KYMCO dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear See page 138 140 A WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride 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 FUEL Fill the fuel tank when necessary and make sure Your KYMCO engine has been designed to use there is sufficient gasoline in the tank regular unleaded gasoline with a pump octane Check for leaks number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a
74. rt up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed 99 An obstacle a sharp drop or another vehicle or person could be on the other side ofthe hill If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill A WARNING When crossing the side of a hill POTENTIAL HAZARD Always follow proper procedures as Improperly crossing hills or turning on described in the Owner s Manual hills Avoid hills with excessively slippery or loose surfaces WHAT CAN HAPPEN Shift your weight to the uphill side of the Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible Y GER ders BE LISA T A Male O7 100 If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are
75. s or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in Your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes A WARNING POTENTIAL HAZARD Starting or running the engine ina 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 DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION NUMBER RECORDS Record the key identification number frame serial number engine serial number and model code information for assistance when order replacement parts KEY NO FRAME NO ENGINE NO MODEL CODE KEY IDENTIFICATION NUMBER The key identification number is stamped on the hang tag as shown in the following illustration 1 Key identification number FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the The engine se
76. se caution while descending a hill with loose or slippery surfaces Braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight downhill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear 104 A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn Always follow proper procedures for going down hills as described in this Owner s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible 105 CROSSING A SLOPE Traversing a slopi
77. se the engine is brand new you must not put an excessive load on it for the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a KYMCO dealer 65 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 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally PARKING When parking stop the engine and shift into the park position Turn the fuel valve to OFF and apply the parking brake The front brake lever has three locked position that allow itto be used as a parking brake To set the parking brake see page 33 1 Locke
78. ser off witha garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Dry the chain and lubricate it to prevent rust 153 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes A WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings B STORAGE Before storing your ATV for
79. sesse 151 Troubleshooting chart 152 Page CLEANING AND STORAGE 153 A CLEANING E 193 B STORAGE esse ee ge 155 SPECIFICATIONS osse SE RE De EE 157 NOISE REGULATION sis as ee ie 161 MAINTENANCE RECORD 162 Jg 163 LOCATION OF THE WARNING AND SPECIFICATION LABELS WARNING INFORMATION Anyone who rides the vehicle should read and understand this information before riding They contain important information for safe and proper operation of your ATV The labels should be considered as permanent parts of the vehicle If a label comes off or becomes hard to read contact your KYMCO dealer for replacements A US version only O KYMCO MODEL MXU 500 MXU 500 IRS 499 cc 4 Stroke TWC Emission Control KYMCO CARES ABOUT THE ENVIRONMENT 0 IS THE CLEANEST AND 10 THE LEAST CLEAN ALLOWED YOUR ATV IS A 3 2 OK Kwang Yang Motor Co Ltd Taiwan R O C KYMCO USA Inc Spartanburg SC 29307 USA 87522 LDB5 M30 B US version only VEHICLE EMISSION CONTROL INFORMATION ENGINE TUNEUP SPECIFICATIONS IGNITION TIMING NOT ADJUSTABLE IDLE SPEED 1500 100 rpm IN NEUTRAL ENGINE DISPLACEMENT 499 cc ENGINE FAMILY SKYMXO 49MXU PERMEATION FAMILY SKYMPP403B02 gKYMPp202B02 IDLE MIXTURE NOT ADJUSTABLE THIS VEHICLE IS CERTIFIED TO VALVE CLEARANCE 0 10 0 02 mm OPERATE ON GASOLINE THIS VEHICLE INTAKE amp EXHAUST CONFORMS TO US EPA REGULATI
80. side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual gt E AN 102 If the hill is not too steep and you have good footing you may be able to walk the ATV back down the hill 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 Stand with your body facing downhill beside the vehicle so you can reach the front brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the hill using the front brake lever to control speed 5 If you lose control of the ATV for your safety get away from the vehicle If the hill is too steep or too slippery or if you have any doubt whether you can safely walk the ATV back down the hill leave the vehicle where it is and get help If possible block the wheels so the vehicle Won t roll backwards lt HAN N 1 OR lt 103 RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engine compression braking effect select low range L and change to 4WD before beginning to descend the hill Improper braking may cause a loss of traction U
81. sult if instructions are not followed CAUTION Indicates a possibility that equipment or property damage could result if instructions are not followed Note Gives helpful information The Owner s Manual should be considered a permanent part of your ATV It should remain with the vehicle at all times and stay with the ATV if it is sold PREFACE Congratulations on your purchase of the KYMCO ATV KYMCO take pride ina 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 This manual will provide you with a good basic understanding of the features and operation of this machine This manual includes important safety information It provides information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a KYMCO dealer We wish you many years of safe and enjoyable riding While reading this manual remember Indicates a strong possibility that serious injury or death may result if instructions are not followed All information in this publication is based on the latest product information available at the time of approval for printing KWANG YANG MOTOR CO LTD Reserves
82. tand When reinstalling a wheel tighten the wheel under the frame nuts in acrisscross rather than a circular 2 Remove the nuts from the wheel pattern Be sure the tapered side of the wheel 3 Remove the wheel assembly nuts 1 face the wheel rim 2 Wheel nut torque MXU 500 Front 65 N m 6 5 kgf m 46 Ibf ft Rear 65 N m 6 5 kgf m 46 Ibf ft SE i E Wd l WM A Wheel nut torque MXU 500 IRS Front 55 N m 5 5 kgf m 39 6 Ibf ft Rear 55 N m 5 5 kgf m 39 6 Ibf ft Be sure the tapered side of the wheel nuts 1 face the wheel rim 2 1 Wheel nuts ok S OK 4 2 1 Wheel nut 2 Wheel rim 144 NOTE The arrow mark lt on the tire must point toward the rotating direction of the wheel A WARNING POTENTIAL HAZARD Installing wheels improperly WHAT CAN HAPPEN A wheel may come loose possibly leading to an accident HOW TO AVOID THE HAZARD Carefully follow the instructions in this Owner s Manual when installing 1 Arrow mark 145 BATTERY Your ATV battery is located in a compartment under the seat The battery is sealed so it is not necessary to check the electrolyte level or add distilled water If the battery seems weak see your authorized KYMCO dealer for information on recharging or replacement If you replace the battery choose one that is sealed and equivalent to the original Be sure to read and follow all safety precautions indicated on the
83. the oil in the rear gear box case when specified by the Maintenance Schedule Change the oil with the rear gear box warm and the ATV on level ground to assure complete and rapid draining Rear gear box oil replacement 1 Remove the two bolts 1 on the skid plate 2 right left side and two bolts 3 under the skid plate remove skid plate MXU 500 version 2 To drain the oil first place an oil drain pan under the oil drain plug 4 MXU 500 version 3 To drain the oil first place an oil drain pan under the oil drain plug 5 MXU 500 IRS version 1 Bolts on the skid plate 2 Skid plate 3 Bolts under the skid plate 5 Oil drain plug 125 3 Remove the oil filler cap 5 7 then 7 Install the skid plate remove the drain plug washer 4 After the oil has completely drained reinstall the drain plug washer CAUTION j i Be sure no foreign material enters the gear Tightening torque Drain plug 20 N m 2 kgf m 15 Ibf ft case 5 Fill the gear case with the recommended oil Recommended oil SAE 80 Oil quantity Periodic oil change MXU 500 MXU500 IRS 0 13L 0 114Imp 0 138USqt 0 23 L 0 20 Imp at 0 243 US qt Remove the oil level check bolt washer 6 8 7 Oil filler cap Make sure the oil level reaches the oil 8 Oil level check bolt washer level check hole 6 Install the oil filler cap and oil level check bolt Tightening torque Oil filler cap 14 7 N m 1 5 kgf m 11 Ibf ft Oil le
84. the trailer manufacturer To attach the ball and properly hook up a trailer follow the trailer manufacturer s instructions For load limits and operational guidelines see page 81 1 Trailer MXU 500 version only MXU 500 IRS has not this fittings If you need this accessories Please ask your dealers 0 OWNER S MANUAL STORAGE COMPARTMENT Your ATV provides storage for the owner s To open the compartment remove the lid 3 manual so you ll have it with you for easy The owner s manual should be stored in the reference Store your owner s manual 1 in the plastic bag storage compartment 2 at the right side of the front fender Be careful not to flood this area when washing yourATV 1 Owner s manual 3 Lid 2 Storage compartment 41 ACCESSORY SOCKET The accessory socket 1 is attached to the left side of the meter cover You can use the accessory socket to power a trouble light spotlight radio or cell phone etc CAUTION Do not plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket Be carful not to flood this accessory socket when washing yourATV To use the accessory socket i 2 Turn the ignition switch ON then start the engine Turn the headlights OFF 3 Open the accessory socket cap 2 and then insert the accessory power plug into the socket 42 Be sure the engine is on and the
85. ult in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV This machine is designed to carry operator only passengers prohibited A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV 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 The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers Ce Never carry passenger on the cargo racks A WARNING POTENTIAL HAZARD Carrying a passenger on the cargo racks 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 cargo racks The cargo racks Is to allow the operator to carry cargo It is not for carrying passengers 78 PRE OPERATION CHECKS Always perform the pre operation checks listed on page 43 before riding for safety and proper care of the machine A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect tour ATV each time you use it to make sure th
86. ur Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads or lining 109 Test your brakes after leaving the water Do not PARKING continue to ride your ATV without verifying that Always choose a level place to park After you have regained proper braking ability bringing your ATV to a stop hold the brakes while you shift into neutral 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 z we ad AG i V D 110 WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding technidues completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 92 93 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 94 95 111 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the S
87. ved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T200 LAA0CA US A5
88. vel check bolt 20 N m 2 kgf m 15 Ibf ft 5 Oil filler cap 6 Oil level check bolt washer 126 FRONT GEAR BOX OIL Change the oil in the front gear box when specified by the Maintenance Schedule Change the oil with the front gear box warm and the ATV on level ground to assure complete and rapid draining Front gear box oil replacement 1 To drain the oil first place an oil drain pan under the oil drain plug washer 1 2 Remove the oil filler bolt washer 2 MXU 500 IRS 1 Oil drain plug washer 2 Oil filler bol wahser 127 3 Remove the drain plug 4 After the oil has completely drained reinstall the drain plug washer Tightening torque Drain plug 32 N m 3 2 kgf m 23 Ibf ft 5 Fill the gear case with the recommended oil Recommended oil SAE 80 Oil quantity Periodic oil change MXU 500 IRS 0 3L 0 264Imp qt 0 318US qt 0 25 L 0 22 Imp at 0 265 US qt Remove the oil level check bolt washer 3 Make sure the oil level reaches the oil level check hole 6 Install the oil filler bolt washer and oil level check bolt washer Tightening torque Oil filler bolt 35 N m 3 5 kgf m 25 5 Ibf ft Oil level check bolt 10 N m 1 kgf m 7 2 Ibf ft 2 Oil level check bolt CAUTION Be sure no foreign material enters the gear case Imxu 500 IRS 3 Oil level check bolt 128 SPARK PLUG INSPECTION The spark plug is an important engine component and is easy
89. y oncea month A WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery WHAT CAN HAPPEN with the skin or breathing of fuel vapor Gases may explode and possibly cause injury KEEP OUT OF REACH OF CHILDREN HOW TO AVOID THE HAZARD Do not allow open flames or sparks near the battery 3 Remove the spark plug and pour one tablespoon 15 20 cc of clean engine oil into the cylinder Operate the starter for a few seconds to distribute the oil then reinstall the spark plug 5 Wash and dry the ATV and wax all painted surfaces 6 Inflate the tires to their recommended pressures 7 Place the ATV on blocks to raise all four tires off the ground 156 SPECIFICATIONS Dimension Overall length 2204 mm 88 12 in Overall width 1223 mm 48 92 in Overall height 1240 mm 49 6 in 1243 mm 49 72 in Seat height Bo7mm 34 28in 887 mm 35 48 in Wheel base 1293mm 51 72in 1297 mm 51 88 in Minimum ground clearance 235mm 9 4in 241 mm 9 64 in Basic weight With oil and full fuel tank 308kg 678lbs 334 kg 734 Ibs Engine Type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder Displacement 498 5 cc Bore x stroke 92X75 mm 3 68X3 in Compression ratio 10 5 1 Starting system Electric Recoil starter Lubrication system Wet sump 157 Engine oil transmission oil rear final gear case oil Type Engine oil classification Front gear box oil classification
90. your ability to see where you are going e Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier vehicle takes longer to stop e Avoid making sharp turns unless at very slow speeds e Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV Never carry passenger on the cargo racks 70 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Riding Your ATV A 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 section riding yourATV provides general ATV riding instructions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be

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