Kymco MXU 500 User Manual
Issued: 03.09.2006
OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 500
OFF-ROAD
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. It 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.
A
SPECIAL MESSAGES
KYMCO provides many important safety messages both in this manual and on the
vehicle. For your safety and the safety of others, pay special attention to all
warnings preceded by this alert symbol . Failure to follow the warnings
contained in this manual can result in SERIOUS INJURY or DEATH.
WARNING
result 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.
B
Indicates a strong possibility that serious injury or death may
PREFACE
Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a
worldwide reputation for quality-in research, design, production and service.
For replacement parts and accessories, we recommend genuine KYMCO
products. They've been specially designed for your vehicle and manufactured to
meet KYMCO's demanding standards.
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:
WARNING
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 the right to make changes at any time without notice and without
incurring any obligation.
C
CONTENTS
Page Page
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
SAFETY INFORMATION
...................1
......................4
DESCRIPTION AND MACHINE
IDENTIFICATION
IDENTIFICATION NUMBER
RECORDS...........................................9
KEY IDENTIFICATION NUMBER............9
FRAME SERIAL NUMBER...................10
ENGINE SERIAL NUMBER..................10
PARTS LOCATION.............................11
..................................9
CONTROL FUNCTIONS....................16
IGNITION SWITCH..............................16
INSTRUMENTS AND INDICATOR........17
Multi-function display.......................19
HANDLEBAR SWITCHES....................26
Headlight dimmer switch..................26
Start button.....................................26
Engine stop switch...........................27
Passing signal switch.......................27
RIGHT HANDLEBAR SWITCH...........28
2WD/4WD select switch....................28
RECOIL STARTER..............................29
THROTTLE LEVER.............................30
SPEED LIMITER.................................31
(Cont'd)
D
Page Page
FRONT BRAKE LEVER.......................32
REAR BRAKE LEVER..........................32
BRAKE PEDAL...................................32
PARKING BRAKE...............................33
DRIVE SELECT LEVER.......................34
FUEL TANK CAP ................................35
FUEL VALVE......................................35
CHOKE KNOB....................................37
ACCELERATING PUMP LEVER .........38
SEAT..................................................39
FLAG POLE BRACKET.......................40
TRAILER HITCH.................................40
OWNER’S MANUAL STORAGE
COMPARTMENT.................................41
ACCESSORY SOCKET........................42
PRE-OPERATION CHECKS.............43
DRIVE SELECT LEVER ......................44
Drive select lever adjustment............46
FRONT AND REAR BRAKES................48
FUEL...............................................49
DRIVE SHAFT BOOTS........................50
ENGINE OIL ......................................51
FINAL GEAR OIL................................52
DIFFERENTIAL GEAR OIL..................52
THROTTLE LEVER.............................53
FITTINGS AND FASTENERS...............53
LIGHTS..............................................53
SWITCHES.........................................53
TIRES................................................54
How to measure tire pressure ..............55
Tire wear limit ....................................56
COOLANT..........................................56
(Cont'd)
E
Page Page
OPERATION........................................58
STARTING A COLD ENGINE...............58
Using the recoil starter......................61
STARTING A WARM ENGINE..............62
WARMING UP.....................................62
DRIVE SELECT LEVER OPERATION
AND REVERSE DRIVING ....................63
Shifting: neutral to high
and high to low .................................63
Shifting: neutral to reverse
and reverse to park...........................64
ENGINE BREAK-IN.............................65
PARKING..........................................66
Parking on a slope............................67
ACCESSORIES ..................................68
LOADING ...........................................69
RIDING YOUR ATV ............................71
GETTING TO KNOW YOUR ATV .........72
RIDE WITH CARE AND
JUDGEMENT......................................73
APPAREL...........................................75
PRE-OPERATION CHECKS................79
Speed limiter...................................80
LOADING AND ACCESSORIES..........81
Load Limits......................................81
Loading and operational guidelines...81
Accessories.....................................82
MODIFICATIONS................................83
No modifications..............................83
EXHAUST SYSTEM............................84
BE CAREFUL WHERE YOU RIDE........85
FOR OFF-ROAD USE ONLY.................90
DURING OPERATION.........................92
TURNING YOUR ATV ..........................94
SLIDING AND SKIDDING....................96
CLIMBING UPHILL.............................98
GOOD
(Cont'd)
F
Page
RIDING DOWNHILL.......................104
CROSSING A SLOPE.........................106
RIDING OVER ROUGH TERRAIN.......108
CROSSING THROUGH SHALLOW
WATER........................................109
PARKING....................................110
WHAT TO DO IF..................................111
WHAT TO DO....................................111
PERIODIC MAINTENANCE AND
ADJUSTMENT
TOOL KIT/
TOOL KIT COMPARTMENT.................113
PERIODIC MAINTENANCE/
LUBRICATION..................................115
ENGINE OIL
FINAL GEAR OIL...............................125
DIFFERENTIAL GEAR OIL.................127
SPARK PLUG INSPECTION..............129
SPARK ARRESTER...........................130
AIR FILTER CLEANING.....................132
AIR CLEANER HOUSING DRAIN
TUBE...............................................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
...................................113
......................................118
Page
(cont'd)
G
Page
COOLING SYSTEM INSPECTION......141
Engine overheating........................143
WHEEL REMOVAL............................144
WHEEL INSTALLATION.....................144
BATTERY..........................................146
Battery remove..............................147
Battery installation.........................147
FUSE REPLACEMENT......................148
HEADLIGHT BEAM ADJUSTMENT....149
DRIVE SHAFT BOOTS.......................149
CABLE INSPECTION AND
LUBRICATION..................................150
TROUBLESHOOTING .......................151
Troubleshooting chart...................152
Page
CLEANING AND STORAGE...........153
A. CLEANING ...................................153
B. STORAGE ....................................155
SPECIFICATIONS..................................157
NOISE REGULATION.............................161
MAINTENANCE RECORD.......................162
INDEX...................................................163
H
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) (USA only)
(B) (USA only)
(2)
(B) (A)
(4)(3)(1)
(7) (6)
1
(5)
(8)
(1)
WARNING
Never carry passenger
This carrier.
Maximum load 45 Kg (100 lbs)：
(2)
WARNING
NEVER ride as a
passenger.
Passengers can cause a
loss of control, resulting
in SEVERE INJURY or
DEATH.
(4)
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
on
(3)
WARNING
Operating this ATV if you are under
the age of 16 increases your changes
of severe injury or death.
NEVER
under the age of 16.
operate this ATV if you are
(5)
WARNING
Never carry passenger
This carrier.
.
Maximum load 85 Kg (187 lbs)：
on
2
(6)
(7)
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, (0.25~0.32kgf/cm ), 3.5~4.5psi
REAR :
Never set tire pressure below recommended.
LOADING
Maximum Vehicle Load: 220 Kg. (485 lbs).
Including weight of operator, cargo and accessories.
25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi
2
2
(8)
WARNING
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner's manual for details.
MAXIMUM TOWING CAPACITY: 454kg (1000lbs)
TONGUE WEIGHT: 16kg (35 lbs)
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH.
ALWAYS USE AN
APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER operate :
Without proper training or instruction.
At speeds too fast for your skills or the
conditions.
On public roads-a collision can occur with
another vehicle.
With a passenger-passengers affect balance
and steering control.
ALWAYS :
Use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in
turns.
Avoid paved surfaces-pavement may seriously
affect handling and control.
READ OWNER'S MANUAL, FOLLOW ALL
INSTRUCTIONS AND WARNINGS.
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
3
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 precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
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 anATV with engine size greater than 90cc.
Never carry a passenger on an ATV.
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
4
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.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
Never attempt wheel, jump, or other stunt.
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.
5
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 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 theATV 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.
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.
6
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 flames, 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.
7
WARNING
POTENTIAL HAZARD
ON
Starting or running the engine in a closed
area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your machine in an area
with adequate ventilation.
8
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)
(1) Key identification number
9
FRAME SERIAL NUMBER
The frame serial number is stamped on the
front and rear of the frame.
(1)
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left
crankcase.
(1)
(1) Frame serial number
(1) Engine serial number
10
PARTS LOCATION
(01)(02)(02)(03)
(01) Rear brake lever
(02) Headlights/Position lights
(03) Front brake lever
11
(07) (05)
(06)(04) (04)
(04) Taillights/Brake lights
(05) 2WD/4WD select switch
(06) Instrument and indicators
Headlight dimmer switch
(07)
Starter button
Engine Stop Switch
(08) Spark arrester
(09) Trailer hitch
(10) Throttle lever
(08) (09)
(10)
12
(13)
(14) (11)(12)
(15)
(11) Reservoir water tank
(12) Front brake fluid reservoir
(13) Fuel valve
(14) Recoil starter
(15) Seat
Brake pedal fluid reservoir
(16)
(17) Seat lock lever
(18) Oil level inspection window
(16) (17)
(18)
13
(22)
(24) (25)
(19)(23) (20)(21)
(19)
Exhaust system
) Battery/Fuse
(20
(21) Tool kit
(22) Accelerating pump lever
(23) Rear brake fluid reservoir
(24) Accessory socket seat
(25)
Drive select lever
14
(29) (28)(30) (26)
(27)
(26 Right footpeg
)
(27) Owner’s manual storage
(28) Front cargo rack
(29) Ignition switch
(30) Left footpeg
(31) Rear cargo rack
(32) Fuel fill cap
(33) Choke knob
(34) Rear brake pedal
(35) Flag pole bracket
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
(32) (33) (34)(31)
(35)
15
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.
"“:
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.
ON
(1)
OFF
(2)
(1) Ignition switch (2) Key
16
INSTRUMENTS AND INDICATOR
2WD
4WD
AB
TRIPODO
mile
PM
MODE
km
P R N H L
SET
(10)
(6) (5)(8)(9)
(7)
(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 “N:
(9) Park indicator light “P”
(10)
Mode button
(4)
(1) Multi-function display
(1)
The display includes the following functions:
Speedometer
Odometer/Tripmeter
(2)
(3)
Digital clock
2WD/4WD indicator
Fuel gauge
(2) High beam indicator
The ignition switch is at the " " position, the
high beam indicator will light when the headlight
switch to select High beam ( ).
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, TRIP A
and TRIP B.
This button is also used to adjust the time
and reset the tripmeter.
(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.
(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 tripmeter.
18
Multi-function display
2WD
4WD
AB
TRIPODO
(4)
(1) Speedometer
(2) 2WD/4WD indicator
(3) Fuel gauge
(4) Odometer/Tripmeter
(5) Digital clock
mile
km
PM
(5)
(1)(2)(3)
(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.
2WD
4WD
AB
TRIPODO
mile
PM
MODE
km
P R N H L
SET
19
(2) 2WD/4WD indicator
Shows the drive mode is in the 2WD or 4WD.
2WD
4WD
(3) Fuel gauge
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
(3) flashes, fuel will be low and you should
refill the tank as soon as possible.
(2)
(3)
(3) Fuel indicator(1) Segment F
(2) Segment E
(1)
20
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